4 Cyl Diesel Engine With Distributor Pump

Service
Workshop Manual
Ibiza 2002 ➤
Córdoba 2003 ➤
4 cyl. diesel engine with distributor pump
Engine ID ASY
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList 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 system
20 - Fuel supply system
23 - Mixture preparation, Injection
26 - Exhaust system
28 - Ignition system
Ibiza 2002 ➤ , Córdoba 2003 ➤
4 cyl. diesel engine with distributor pump - Edition 01.03
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1 Engine: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Dismantling: notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Engine: securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Installing: notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5 Engine brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.6 Vehicles with air conditioning: additional indications and assembly work . . . . . . . . . . . . . . 9
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Engine: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Ribbed belt-V: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Checking semi-automatic toothed belt tensioning roller: checking . . . . . . . . . . . . . . . . . . . . 17
2 Sealing flanges and engine flywheel/: removing and installing . . . . . . . . . . . . . . . . . . . . . . 19
2.1 Crankshaft oil seal belt pulley end: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2 Sealing flange, pulley side: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3 Crankshaft: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4 Piston and conrod: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1 Position of piston at TDC: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1 Cylinder head: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.1 Toothed belt: removing, installing and tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.2 Cylinder head: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.3 Compression ratio: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2 Valve gear: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.1 Valve seats: reworking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.2 Valve guides: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.3 Valve guides: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.4 Valve stem seals: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.5 Camshaft: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.6 Hydraulic plungers: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.7 Camshaft oil seal: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1 Lubrication system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.1 Sump: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.2 Oil pressure and oil pressure switch: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.3 Oil pump: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1 Cooling system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.1 Cooling system components, body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.2 Cooling system components, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.3 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Contents i
1.4 Coolant: draining and filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

1.5 Coolant pump: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.6 Radiator: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.7 Coolant thermostat: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.8 Radiator fans V7 and V35 : checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.9 Cooling system water tightness: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

1 Fuel supply system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.1 Fuel tank with accessory parts: removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.2 Fuel filter: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.3 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 90
1.4 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.5 Fuel tank: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.6 Fuel gauge sender unit: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.7 Fuel gauge sender: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.8 Accelerator mechanism: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.9 Accelerator pedal position sender: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
23 - Mixture preparation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

1 Direct diesel injection system: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.3 Fitting locations overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.4 Intake manifold: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.5 Air cleaner: dismantling and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.6 Injection pump: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.7 Injection pump: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.8 Beginning of injection: check and adjust dynamically . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.9 Injectors: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.10 Injectors: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.11 O-ring for injection corrector cover: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2 Components and functions: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.1 Checking cables and components with test box V.A.G 1598/31 . . . . . . . . . . . . . . . . . . . . 120
2.2 Relay for the diesel direct injection system J322 : checking . . . . . . . . . . . . . . . . . . . . . . . . 121
2.3 Engine speed sender: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2.4 Coolant temperature sender: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.5 Intake manifold temperature sender: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.6 Fuel temperature sender: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.7 Slide travel sender and dosifier: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.8 Needle movement sender: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
2.9 Regulation margin for injection corrector: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.10 Fuel cut-off valve: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.11 Motor for flap in intake manifold: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3 Additional signals: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.1 Speed signal: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.2 Signals from/to air conditioning system: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.3 Brake light and brake pedal switches: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3.4 Clutch pedal sender: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3.5 Activation and deactivation of GRA speed regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3.6 Speed regulator (GRA): checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3.7 Data bus: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
4 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4.1 Supply voltage for engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4.2 Engine control unit: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
ii Contents
4.3 Engine control unit: encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

4.4 Engine control unit: adapting to electronic immobiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4.5 Engine control unit fault memory: consulting and clearing . . . . . . . . . . . . . . . . . . . . . . . . . . 156
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

1 Exhaust system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.1 Exhaust system: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
2.1 Parts of exhaust gas recirculation system: removing and installing . . . . . . . . . . . . . . . . . . 161
2.2 Diagrams of the vacuum hoses' connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2.3 Mechanical exhaust gas recirculation valve: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2.4 Exhaust gas recirculation: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

1 Preheating system: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.1 Pre-heating elements: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Contents iii
iv Contents
00 – Technical data
1 Technical data
1.1 Engine number

The engine number (“engine code” and “serial number” ) are en‐
graved on the engine block next to the engine/gearbox joint.
Additionally there is a sticker on the toothed belt guard with “En‐
gine code” and “Serial number” .
The engine code is also included on the vehicle-data plate.
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.
1.2 Engine data

Engine code ASY
Emissions fulfil EU3 Standard
Displacement ltrs. 1,896
Power kW a 1/min 47/4000
Torque Nm a 1/min 125/11600-2800
Bore ∅ mm 79,5
Stroke 95,5
Compression ratio 19,5
Cetane index min. 49
Firing order 1-3-4-2
Catalytic converter Yes
Exhaust gas recirculation Yes
Supercharging No
Intercooler No
1. Technical data 1
10 – Removing and installing engine

1 Engine: removing and installing
Special tools and workshop

equipment required
♦ Lifting tackle -T20127-
♦ Support flanges -T20082-
♦ Engine support -Ar-2204A-
♦ Engine bracket -T10012-
♦ Workshop crane -V.A.G
1202 A-
♦ Drip tray -V.A.G 1306-
2 Rep. Gr. 10 - Removing and installing engine

♦ Torque spanner -SAT

8010-
♦ Engine and gearbox sup‐
port -SAT 1001-
♦ Pliers for spring-type clips -
T20029-
♦ Step ladder
♦ Bolt M10 X 25 / 8.8
♦ Cable tie
1.1 Dismantling: notes

– The engine is removed downwards together with the gearbox.
Caution
When doing any repair work, especially in the engine compart‐

ment, due to the cramped conditions, pay attention to the
following:
Route all sorts of pipes (e.g. for fuel, hydraulics, activated
charcoal filter system, coolant, refrigerant, brake fluid and vac‐
uum pipes and hoses) and electrical wiring so that the original
positions are restored on reassembly.
Ensure sufficient clearance from all moving or hot components.
– All cable ties which are opened or cut open when removing
engine, must be replaced in the same position when re-instal‐
ling.
1. Engine: removing and installing 3

– Remove engine cover in the -direction of the arrow- .
Note!
To carry out this work it will be necessary to disconnect battery

earth strap. The vehicle should be checked for a fitted radio. If
necessary obtain radio anti-theft code first.
– With the ignition switched off disconnect battery earth strap.

– Open the expansion tank sealing cap to release pressure in
cooling system.
– Remove battery and battery retainer. ⇒ Rep. Gr. 27

– Remove the flexible hose which connects the air filter to the
intake hose.
– Remove air cleaner ⇒ page 105 .
– Remove lower engine protection: ⇒ General body repairs-as‐

sembly work; Rep. Gr. 50 ; General body repairs, front Sound‐
proofing, (diesel engine) General assembly overview
– Remove right-hand drive shaft and disconnect left-hand drive
shaft at gearbox: ⇒ Running gear, axles, steering; Rep. Gr.
40 ; Front wheel suspension: repair Drive shafts: removing and
installing
– Raise the articulated left-hand driveshaft and secure the driv‐
eshaft to the roll bar.
– Remove the front exhaust along with the catalytic converter
⇒ page 158 , Exhaust system: dismantling and assembling
– Drain coolant ⇒ page 74
– Remove coolant hoses from engine using assembly tool for
springtype clamps -T20029- .
– Remove lower coolant hose from radiator -arrow- .

– Furthermore, the front coolant hose should be removed from

the oil radiator -arrow- and the rest of the coolant emptied.
– Disconnect all electric wires from gearbox, compressor, alter‐
nator and starter and leave to one side.
– Remove interconnecting, coolant, vacuum and intake hoses
on engine.
– Remove hydraulic clutch slave cylinder: removal ⇒ 5-speed
manual gearbox 02T; Rep. Gr. 30 ; Clutch control: repairing
General assembly diagram -hydraulics
– Disconnect selector mechanism from gearbox: ⇒ 5-speed
manual gearbox 02T; Rep. Gr. 34 ; Gear change mechanism:
repairing
Caution
The fuel and the pipes may be very hot (danger of burns)
Fuel system is under pressure. Before opening the system,
place a cloth around the connection and depressurise, releas‐
ing with care.
Use protective glasses and gloves for all fuel system assembly
work!
– Uncouple fuel feed and return pipes-arrows- from the injector

pump.
– Seal the pipes so that the fuel system is not contaminated by
dirt etc.
– Observe rules for cleanliness ⇒ page 90 .
– Pull off/disconnect all other electrical connections as neces‐
sary from engine and lay to one side.
– Unbolt pendulum support -arrows- .
1.1.1 Vehicles with air conditioning:

– Remove ribbed belt ⇒ page 15 .
– Observe additional information and removal work
⇒ page 9 .
– Remove the alternator.

1.1.2 Continued for all vehicles

– Place engine bracket -T10012- on the engine/gearbox jack -
SAT 1001A- .
– Secure the -T 10012- engine carrier to engine block with nut
and M10 X 25/8.8 bolt, tightening to about 40 Nm.
– Lift the engine and gearbox slightly with the -SAT 1001A- jack.
– Unbolt from the engine bracket, engine side, from its securing
point on the engine bracket -arrows A- , from above.
Note!
To remove securing bolts use a ladder.
– Unbolt from the engine bracket, gearbox side, from its secur‐
ing point on the gearbox bracket -arrows A- , from above.
– Carefully lower the engine and gearbox.
Note!
Engine and gearbox must be guided carefully when lowering to

prevent damage to the bodywork.
1.2 Engine: securing engine to assembly

stand
For assembly work secure engine to assembly stand with engine
support -Ar-2204 A- together with the flanges -T20082- .
1.2.1 Work sequence

– Remove gearbox

– Attach lifting tackle -T20127- as follows and lift off engine from
engine/gearbox jack -SAT 1001A- with workshop crane.
Caution
Secure hooks and locating pins with locking pins.
– Support the engine with the engine support -Ar-2204 A- and

flanges -T20082-
1.3 Installing: notes

Installation is carried out in the reverse sequence, when doing this
note the following:
– Check clutch release bearing for wear, renew if necessary.
– Lightly grease clutch release bearing, release bearing guide
sleeve and input shaft splines with -G 000 100- .
– Check whether the dowel sleeves for centralising engine/gear‐
box are in the cylinder block, install if necessary.
– Check that the intermediate plate is correctly positioned and
that the adjusting sleeves are in their housing -arrows- .
– When installing the assembly, ensure sufficient clearance to
drive shafts.
Note!
Engine support tightening torques ⇒ page 8
– Align the engine bracket assembly by jerking it so as to leave

it without tension; if necessary, release the engine bracket
from the bodywork as well.
– Fit gearbox control and, if necessary, adjust control cable: ⇒
5-speed manual gearbox 02T; Rep. Gr. 34 ; Gear change
mechanism: Repairing Drive mechanism cables: removing
and installing
– Remove hydraulic clutch slave cylinder: fitting ⇒ 5-speed
manual gearbox 02T; Rep. Gr. 30 ; Clutch control: repairing
General assembly diagram -hydraulics
– Fit the coolant hoses and the vacuum hoses.

1.3.1 Vehicles with air conditioning

– Installing air conditioner compressor: ⇒ Heating, Air condi‐
tioning; Rep. Gr. 87 ; Compressor bracket: removing and
installing
– Fit the alternator.
1.3.2 Continued for all vehicles

– Install ribbed belt ⇒ page 15 .
– Electrical connections and routing: ⇒ Electrical system; Rep.
Gr. 97
– Install the front exhaust along with the catalytic converter
– Fill with coolant ⇒ page 74
– Fit the lower, left and right protective cover for the engine: ⇒
General body repairs-assembly work; Rep. Gr. 50 ; General
body repairs, front Soundproofing, (diesel engine) General
assembly overview
– Carry out a test drive and consult the fault memory; Fault
memory for engine control unit: consulting and clearing ⇒ -
VAS 5051- Vehicle self-diagnosis , ⇒ page 156
1.4 Tightening torques

Bolted joint Tightening tor‐
ques
Bolts, nuts M6 10 Nm
M7 15 Nm
M8 25 Nm
M10 40 Nm
M 12 60 Nm
Deviating from above
Engine to gearbox connecting bolts M10 45 Nm
Engine to gearbox connecting bolts M12 80 Nm

Driveshafts to flanged shafts 40 Nm
Exhaust pipe to manifold 40 Nm
Note!
Engine support tightening torques ⇒ page 8
1.5 Engine brackets
1.5.1 Tightening torques
Note!
The assembly mounting securing bolts are stretch bolts and must
be replaced.

Engine bracket, engine

11) = 20 Nm + 1/4 turn (90 °)
21) = 30 Nm + 1/4 turn (90 °)
1) Replace bolts
Engine brackets, gearbox

12) = 50 Nm + 1/4 turn (90 °)
22) = 40 Nm + 1/4 turn (90 °)
2) Replace bolts
Pendulum support
Note!
Position the bolts -1- in the support coils, in such a way that be‐
tween the gearbox and the sub-frame the distance is minimum.
Engine brackets, gearbox

13) = 30 Nm + 1/4 turn (90 °)
23) = 40 Nm + 1/4 turn (90 °)
3) Replace bolts
1.6 Vehicles with air conditioning: additional

indications and assembly work
Caution
The coolant circuit for the air conditioning should not be

opened. To avoid damaging the condenser and the hoses/
sleeves of the coolant take care not to kink, stretch or bend
them too much.
Note!
To prevent damage to condenser and refrigerant pipes/hoses,

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

the refrigerant circuit:
– Remove the clip/s from the cooling agent hose/s.


– Partially separate air conditioner compressor: ⇒ Heating, Air
conditioning; Rep. Gr. 87 ; Compressor bracket: removing and
installing
– Secure air conditioner compressor to towing eye so that the
refrigerant hoses/pipes are not under tension.
Note!
To prevent damage to bumper protect with adhesive tape.

13 – Crankshaft group
1 Engine: dismantling and assembling
Note!
If when repairing an engine, metal shavings or large quantities of small metal particles - caused, for example,
by partial seizure of crankshaft and conrod bearings - are found in engine oil, to prevent consequential damage,
apart from thoroughly cleaning oil passages, it is necessary to replace the oil cooler.
Repairing the injectors

⇒ Rep. Gr. 23 ; Injectors: repairing
I ⇒ page 11
II ⇒ page 13
III ⇒ page 14
Part I
1. Engine: dismantling and assembling 11

1 - 120 Nm + 1/4 turn (90 °)

❑ Renew
❑ Counter hold with -
T20018 A- to loosen and
tighten
❑ The thread and the col‐
lar must not be lubrica‐
ted
❑ Retightening can be
done in several stages.
2 - 40 Nm + 1/4 turn (90°)
❑ Renew
3 - 15 Nm
4 - Toothed belt guard - lower
part
5 - Toothed belt guard - centre
section
6 - 10 Nm
❑ Renew
7 - 45 Nm
8 - Engine bracket
9 - Toothed belt guard - upper
part
10 - Toothed belt
❑ Mark D.O.R. before re‐
moving
❑ Check for wear
❑ Do not kink
❑ Removing, installing
and tensioning
⇒ page 34
11 - Securing bolts for the injection pump spindle
❑ 25 Nm
12 - 25 Nm
❑ Tensioning toothed belt ⇒ page 34 , Toothed belt: removing, installing and tensioning
13 - Bolt for idler roller
❑ 20 Nm
14 - 45 Nm
❑ Counter hold with -T20018 A- to loosen and tighten
15 - Camshaft sprocket
❑ Remove ⇒ page 34 , Toothed belt: removing, installing and tensioning
❑ Use extractor -T20119-
16 - Tension roller
❑ Installation position ⇒ page 15
❑ Checking semi-automatic toothed belt tensioning roller ⇒ page 17
17 - Idler roller
18 - Injection pump spindle
19 - 10 Nm
❑ Renew
12 Rep. Gr. 13 - Crankshaft group

20 - 30 Nm
21 - Rear toothed belt guard
22 - Coolant pump
❑ Removing and installing ⇒ page 78
23 - Main drive toothed belt idler roller
❑ Remove for the removal for the coolant pump
24 - Crankshaft toothed belt- sprocket
❑ The contact surface between the crankshaft toothed sprocket and the crankshaft should be clean and
free of grease.
❑ Assembly position: The cut down areas in the toothed belt sprocket and the crankshaft should coincide.
25 - 30 Nm
26 - Socket
27 - Tighten bolt
28 - Injection pump
❑ Removal and installation ⇒ page 109
❑ The central bolt should never be loosened
29 - Compact bracket
❑ Different in vehicles with and without air conditioning
30 - 45 Nm
Part II
Note!
♦ Before installing the ribbed belt mark the direction of rotation. Incorrect installation of a previously used belt
could produce serious damage.
♦ When fitting a toothed belt special care should be taken when seating it in the pulleys.

1 - 10 Nm + 1/4 turn (90 °)

2 - Belt pulley/vibration damper
❑ Can only be installed in
one position -holes are
off-set
3 - 25 Nm
4 - Tensioning device for rib‐
bed belt
❑ Turn with open-end
spanner to slacken rib‐
bed belt ⇒ page 15
5 - Compact bracket
❑ During fitting, remember
the adjusting sleeves for
centring.
❑ For injection pump and
alternator
6 - 45 Nm
7 - Alternator
❑ To join the alternator to
the support more easily,
slightly retract the threa‐
ded bushes for the se‐
curing bolts
8 - 25 Nm
9 - Ribbed belt
❑ Mark D.O.R. before re‐
moving
❑ Check for wear
❑ Do not kink
❑ Dismantling and fitting
⇒ page 15
Part III
Note!
♦ Before installing the ribbed belt mark the direction of rotation. Incorrect installation of a previously used belt
could produce serious damage.
♦ When fitting a toothed belt special care should be taken when seating it in the pulleys.

1 - 10 Nm + 1/4 turn (90 °)

2 - Belt pulley/vibration damper
❑ Can only be installed in
one position -holes are
off-set
3 - 25 Nm
4 - Alternator
❑ To join the alternator to
the support more easily,
slightly retract the threa‐
ded bushes for the se‐
curing bolts
5 - Tensioning device for rib‐
bed belt
6 - Compact bracket
❑ During fitting, remember
the adjusting sleeves for
centring.
❑ If the vehicle is fitted
with additional equip‐
ment, include the air
conditioning compres‐
sor
7 - 45 Nm
8 - 25 Nm
9 - 25 Nm
10 - Air conditioner compres‐
sor
11 - Adjusting bushes for the
air conditioning compressor
❑ Fitted onto the bracket
⇒ Item 6 (page 15)
12 - Ribbed belt
❑ Removal and installation ⇒ page 15
Fitting position for the semi-automatic tensioning roller

– The retaining part -arrow- of the tensioning roller should fit into
the groove on the rear cover of the ribbed belt.
1.1 Ribbed belt-V: removing and installing

Special tools and workshop equipment required

♦ Locking pin -T10060-
♦ Ribbed belt loosening tool -T20126-
1.1.1 Removing ribbed belt
Note!
Before removing the ribbed belt mark the direction of rotation.

When installing the belt, ensure it is correctly seated on the pulley.
– Remove lower engine protection: ⇒ General body repairs-as‐

– Mark direction of rotation of ribbed belt.
1.1.2 Vehicles without air conditioning com‐

pressor
– Turn tensioning device in direction of arrow to relieve tension
on ribbed belt.
– Lock tensioning element using mandrel -T10060- .
– Remove ribbed belt.

1.1.3 Vehicles with air conditioning compres‐

sor
– Turn tensioning device in direction of arrow with tool -T20126-
to relieve tension on ribbed belt.
– Lock tensioning element using mandrel -T10060- .

– Remove ribbed belt.
1.1.4 Installing ribbed belt

– Install in reverse order.
Note!
♦ Ensure, before installing ribbed-belt, that all ancillaries (alter‐

nator, air conditioner compressor, injector pump) are secured
tightly.
♦ When fitting the ribbed belt check belt rotation direction and
that the belt is seated correctly in the belt pulleys.
♦ For vehicles without air conditioning, put ribbed belt over al‐
ternator last.
♦ For vehicles with air conditioning, put ribbed belt over air con‐
ditioning compressor last.
After completing repairs always:

– Start engine and check how belt is running.
1.2 Checking semi-automatic toothed belt

tensioning roller: checking
1.2.1 Test conditions

• Toothed belt fitted and tensioned

1.2.2 Checking process

– Press the toothed belt firmly with thumb. The groove and the
projection -arrow- should move.
– Release tension on toothed belt. The tensioning roller should
return to its original position (the notch and the lug coincide
again).
– If the groove and the lug do not coincide, loosen the tensioning
roller and adjust the tension on the toothed belt ⇒ page 34 ,
Toothed belt: removing, installing and tensioning.
– If the tension on the toothed belt has been changed:
– Check and if necessary adjust dynamically the beginning of
injection ⇒ page 113 , Components and functions: adapting

2 Sealing flanges and engine flywheel/: removing and installing
Note!
Servicing clutch (vehicles with front wheel drive): ⇒ 5 speed manual gearbox 02T; Rep. Gr. 30 ; Clutch: repairing
1 - Cylinder block
❑ Crankshaft: removing
and installing
⇒ page 164
❑ Piston and conrod: dis‐
mantling and assem‐
bling ⇒ page 164
2 - 60 Nm + 1/4 turn (90°)
❑ Renew
❑ Retightening can be
done in several stages.
3 - Flywheel
❑ Fitting is only possible in
one position -transposi‐
tion of pins
❑ To remove and fit fly‐
wheel, immobilise with
tool -T20075A- ,
⇒ page 20
4 - Intermediate plate
❑ Must be located on dow‐
el sleeves
❑ Do not damage/bend
when assembling
⇒ page 20
5 - 15 Nm
6 - Sealing flange with oil seal
❑ Only renew complete
❑ Do not additionally oil or
grease the oil seal seal‐
ing lip
❑ Before installing, re‐
move oil remains from
crankshaft journal with a clean cloth.
❑ Use protective sleeve supplied when installing
❑ Remove protective sleeve first after sealing flange has been slid onto crankshaft journal
7 - Oil seal
❑ Do not additionally oil or grease the oil seal sealing lip
❑ Before installing, remove oil remains from crankshaft journal with a clean cloth
❑ Renew crankshaft oilseal - pulley end ⇒ page 21
8 - Front sealing flange
❑ Must be located on dowel sleeves
❑ Assemble with silicone sealant -D 176 404 A2- ⇒ page 23
2. Sealing flanges and engine flywheel/: removing and installing 19

Immobilising the flywheel

– To fit and remove the flywheel, fit retaining tool -T20075A- ,
operating it as shown in the drawing.
Installing intermediate plate

– Fit intermediate plate onto sealing flange and slide onto dowel
sleeves -arrows- .

2.1 Crankshaft oil seal belt pulley end: replace

equipment required
♦ Counter support -T20018A-
8010-
♦ oil seal extractor -T20143-
♦ Plungers - fit seal -T20081/
B-
2.1.1 Removing
– Remove front right wheel housing:
– Remove ribbed belt ⇒ page 167
– Remove toothed belt ⇒ page 165 .
– Remove crankshaft toothed belt sprocket. To do this immobi‐
lize the sprocket with counter support -T20018A-

– Fit seal extractor -T20143- , as shown in the figure, introducing

the end of the tool between the shaft and the seal and look for
a support point for the other end, lever until the seal works free
and take care not to damage the seal.
2.1.2 Fitting
Note!
Gradual introduction of PTFE oil seals (identifying characteristics:

no annular spring, wider sealing lip). The lip of this seal must not
be lubricated with oil or grease. A radial shaft seal of older design
(with annular spring) may be replaced with a PTFE oil seal, but
not vice versa.
– Before installing, remove oil traces from crankshaft journal

with a clean cloth.
– Fit the seal onto guide sleeve -T20081B/6- and fit the unit on
the camshaft stub.
– Use fitting tool -T20081B/1- and press guide sleeve-oil seal
set as far as it will go. For this use the old camshaft sprocket
securing bolt.
– Install crankshaft toothed belt sprocket and lock with counter-

hold -T20018A- .
Note!
Thread and shoulder must be free of oil and grease.
Installing toothed belt and adjusting valve timing ⇒ page 34


2.2 Sealing flange, pulley side: removing and installing

equipment required
♦ Counter support -T20018A-
♦ Plungers - fit seal -
T20081B-
8010-
♦ Hand drill with plastic brush
insert
♦ Flat scraper
♦ Silicone sealant -D 176 404
A2-

2.2.1 Removing
– Remove ribbed belt ⇒ page 167
– Remove toothed belt ⇒ page 165 .
– Remove crankshaft toothed belt sprocket. To do this immobi‐
lize the sprocket with counter support -T20018A- .
Note!
When fitting tool -T20018A- , fit two washers between the toothed
belt sprocket and the tool.
– Drain engine oil.

– Remove sump ⇒ page 167 .
– Unbolt front sealing flange.
– Remove sealing flange. If necessary, release by gently tap‐
ping with a rubber mallet.
– Remove sealant residue on cylinder block with a flat scraper.
– Remove sealant remains on sealing flange with a rotating

plastic brush (wear protective glasses).
– Clean sealing surface, must be free of oil and grease.
2.2.2 Fitting
Note!
♦ Note the use by date of the sealant.

♦ Sump must be installed within 5 minutes of applying silicone
sealing compound.
– Cut off tube nozzle at forward marking (nozzle approx.:). ap‐

prox. 3 mm).
Note!
♦ The sealing bead must not be thicker otherwise sealer could

enter the sump and block the strainer in the shaft support cover
and could drip onto the sealing surface of the crankshaft oil‐
seal.
♦ Before applying sealing bead, clean the oil seal with a clean
rag.

– Apply silicone sealing compound, as shown, to clean sealing

flange surface.
♦ Thickness of sealant bead: 2 ... 3 mm
– Fit sealing flange immediately and lightly tighten all bolts.
Note!
Use guide sleeve -T20081B/6- to fit sealing flange with the oil seal
already installed.
– Tighten sealing flange securing bolts using alternate se‐

quence. Tightening torques: 15 Nm
– Install sump ⇒ page 167 .
Note!
After installing sump the sealant must be allowed to dry for ap‐
prox. 30 minutes before engine oil is added 30 minutes. After this
time has passed, the sump may be filled.
– Install crankshaft toothed belt sprocket. To do this immobilize

the sprocket with counter support -T20018B- . Tightening tor‐
ques: 120 Nm + 1/4 turn (90 °)
– Install ribbed belt ⇒ page 167

3 Crankshaft: removing and installing
1 - Bearing shells 1, 2, 4 and 5

❑ For bearing caps with‐
out oil groove
❑ For cylinder block with
oil groove
❑ Do not mix up used
bearing shells (mark
them)
2 - 65 Nm + 1/4 turn (90 °)
❑ Renew
❑ To measure radial play
tighten to 65 Nm, but do
not re-tighten
3 - Bearing caps
❑ Bearing cap 1: Pulley
end
❑ Bearing cap 3 with re‐
cesses for thrust wash‐
ers
❑ Bearing shell retaining
lugs (cylinder block/
bearing cap) must be on
the same side
4 - Bearing shell 3
❑ For bearing cap without
oil groove
❑ For cylinder block with
oil groove
5 - Thrust washer
❑ For bearing cap 3
❑ Note fixing arrangement
6 - Sender wheel
❑ For engine speed send‐
er -G28-
7 - 10 Nm + 1/4 turn (90 °)
❑ Renew
8 - Pin
❑ Check the pin lug above the crankshaft ⇒ page 15
9 - Crankshaft
❑ Axial clearance, new: 0.07...0.17 mm Wear limit: 0.37 mm
❑ Check radial clearance with Plastigage New: 0.03...0.08 mm Wear limit: 0.17 mm
❑ Do not rotate the crankshaft when checking the radial clearance
❑ Crankshaft dimensions ⇒ page 27
10 - Thrust washer
❑ For engine block, bearing 3

Check the pin lug above the crankshaft

♦ Depth gauge
Checking process
– Check the pin lug above the crankshaft -a- with the aid of a
depth gauge with the sender wheel -1- removed.
1 - Sender wheel
2 - Securing screw
3 - Pin lug: a = 2.5...3.0 mm
3.1 Crankshaft dimensions

(Dimensions in mm)
Honing dimen‐ Conrod journal ∅ Conrod journal ∅
sions bearings
Basic -0,022 -0,022
dimension 54,00 47,80
-0,042 -0,042
1st undersize -0,022 -0,022
53,75 47,55
-0,042 -0,042
2nd undersize -0,022 -0,022
53,50 47,30
-0,042 -0,042
3rd undersize -0,022 -0,022
53,25 47,05
-0,042 -0,042
3. Crankshaft: removing and installing 27

4 Piston and conrod: dismantling and assembling
1 - Piston rings
❑ Offset gaps by 120 °
❑ Remove and install with
piston ring pliers
❑ “TOP” faces towards
piston crown
❑ Checking ring gap
⇒ page 29
❑ Checking ring to groove
clearance ⇒ page 29
2 - Piston
❑ With combustion cham‐
ber
❑ Mark installation posi‐
tion and cylinder num‐
ber
❑ Fitting position and pis‐
ton/cylinder corre‐
spondence
⇒ page 30
❑ Arrow on piston crown
points to pulley end
❑ Install using piston ring
clamp
❑ If the piston pin is
cracked, replace the
piston
❑ Check position at TDC
⇒ page 30
3 - Piston pin
❑ If difficult to remove,
heat piston to 60 °C
❑ Remove and install with
-T20019-
4 - Safety washer
5 - Conrod
❑ Only renew as a set
❑ Mark correspondence of cylinder -A- with a coloured pencil
❑ Assembly position: Marking -B- faces towards pulley end
6 - Pin
❑ The pins should house firmly in the bearing and not in the cap
7 - Halfshell bearing
❑ Note the fitting position.
❑ Do not interchange used bearing shells
❑ Observe right positioning onto attachment flanges
❑ Axial clearance Wear limit: 0.37 mm
❑ Check radial clearance with Plastigage: Wear limit: 0.08 mm Do not rotate crankshaft when checking
radial clearance
8 - Cylinder block
❑ Checking cylinder bores ⇒ page 30

❑ Piston and cylinder dimensions ⇒ page 31

9 - Conrod bearing caps
10 - Oil spray jet
❑ For piston cooling
11 - 25 Nm
❑ Fit without sealer
12 - Conrod bolt,
❑ 30 Nm + 1/4 turn (90 °)
❑ Renew
❑ Oil threads and contact surface
❑ To measure the radial play used the old bolt
Checking piston ring play

♦ Feeler gauge
Checking process
– Push ring squarely from above down to approx. 15 mm from
bottom end of cylinder. 15 mm from the edge of the cylinder.
Piston ring New Wear limit
Dimensions in mm
1st Compression ring 0,25...0,40 1,0
Oil scraper ring 0,25...0,50 1,0
Checking ring to groove clearance

♦ Feeler gauge
4. Piston and conrod: dismantling and assembling 29

Checking process
Clean groove before checking.
Piston ring New Wear limit
Dimensions in mm
2nd Compression ring 0,05...0,08 0,25
Oil scraper ring 0,03...0,06 0,15
Checking cylinder bore diameters

♦ Internal dial gauge 50...100 mm
Checking process
– Take measurements at right angles -A- and -B- at 3 positions.
Deviation from specification max. 0.10 mm
Note!
Measuring the cylinder bores must not be done when the cylinder
block is mounted on a repair stand with adapter bracket -
Ar-2204A- , as incorrect measurements would then be possible.
Assembly position of pistons and piston/cylinder correspondence

Pistons in cylinders 1 and 2:
Large cut-out for inlet valve facing towards the flywheel -arrows-
Pistons in cylinders 3 and 4:
Large cut-out for inlet valve facing towards the pulley -arrows-
Note!
♦ New pistons have the numbers of the corresponding cylinders

stamped on the crown.
♦ Pistons for cylinders 1 and 2: Numbers ½
♦ Pistons for cylinders 3 and 4: Numbers ¾
4.1 Position of piston at TDC: checking


♦ Measurement bridge -T20026-

On fitting new pistons or on a lightened engine, piston position at
TDC must be checked. Depending on the projection of the pis‐
tons, the cylinder head gasket must be chosen according to the
following table:
Note!
To measure piston at TDC, turn engine clockwise.
Piston projection Identification

Grooves/holes
0.91 mm. 1.00 mm 1
1.01 mm. 1.10 mm 2
1.11 mm. 1.20 mm 3
4.1.2 Identification of the cylinder head gasket

♦ Spare part number = arrow -1-
♦ Administration code = arrow -2- (not relevant!)
♦ Holes = arrow -3-
Note!
If the piston projections differ, choose the correct gasket accord‐

ing to the maximum projection.
4.2 Piston and cylinder dimensions

Honing dimensions Piston ∅ Cylinder bore∅
Basic dimension. mm 79,47 79,51
1st oversize mm 79,72 79,76
2nd oversize mm 79,97 80,01
4. Piston and conrod: dismantling and assembling 31

15 – Cylinder head, Valve gear

1 Cylinder head: removing and instal‐
ling
Note!
♦ When installing an exchange cylinder head with camshaft in‐

stalled, all the contact surfaces between the plungers and the
cams must be oiled before installing the cylinder head cover.
♦ The plastic packing pieces for protecting open valves must not
be removed until immediately before fitting the cylinder head.
♦ If the cylinder head is replaced, all the coolant in the system
must also be renewed.
♦ The cylinder heads must not be reworked in diesel engines
Checking compression ⇒ page 45 .
1 - Cylinder head gasket

❑ Renew
❑ Note identification
⇒ page 34
❑ If replaced, renew all the
coolant
2 - 20 Nm
3 - Cylinder head
❑ Check for distortion
⇒ page 33
❑ Removing and installing
⇒ page 40
❑ If replaced, renew all the
coolant
4 - Lifting eye
5 - 8 Nm
❑ For the engine casing
6 - Cylinder head bolt
❑ Renew
❑ Note the loosening and
tightening sequence
⇒ page 40 , cylinder
head: removing and in‐
stalling
7 - Oil deflector
8 - Cylinder head cover
❑ With vulcanised gasket
9 - Sealing sleeve
❑ Renew if damaged
10 - Cap
❑ Renew seal if damaged
32 Rep. Gr. 15 - Cylinder head, Valve gear

11 - Vent tube
12 - Clip
13 - Pressure regulator valve
❑ To ventilate engine block
14 - Gasket
15 - 10 Nm
16 - Injection hoses
❑ Tighten to 25 Nm
❑ Remove with spanner -U-40072-
❑ Always remove the complete set of hoses
❑ Do not change the bends
17 - Support
❑ For the engine casing
18 - 20 Nm
19 - Vacuum pump
❑ For break servo amplifier
20 - 20 Nm
21 - Gasket
❑ Renew
Checking cylinder head for distortion

♦ Straight edge
♦ Feeler gauge
Checking process
Max. permissible distortion: 0.1 mm
1. Cylinder head: removing and installing 33

Note!
Diesel cylinder heads cannot be ground.
Identification of the cylinder head gasket

♦ Spare part number = arrow -1-
♦ Administration code = arrow -2- (not relevant!)
♦ Holes = arrow -3-
Note!
Different thickness cylinder head gaskets will be used depending

on the degree of projection of the pistons. When replacing the
gasket, do so with one of the same type.
1.1 Toothed belt: removing, installing and tensioning

equipment required
♦ Holding tool -T20018A-
♦ Straight edge adjuster -
T20038- 4)

♦ Camshaft wheel extractor -
T20119-
♦ Pin wrench -U-30009A-
♦ Engine support cross mem‐
ber -U-30025E-
4) If it is not, cut with saw according to figures in drawing


♦ Ribbed belt loosening tool -
T20126-
♦ adjusting tool -U-20010-
♦ Torque wrench -SAT 8010-
1.1.1 Dismantling
– Remove coolant expansion tank (coolant hoses remain con‐
nected).
– Remove upper part of toothed belt guard.
– Remove the cylinder head cover
– Remove the vacuum pump for the brake servo amplifier.

– Remove lower engine protection.
– Fit the engine cross member -U-30025E- as shown in the fig‐

ure.
– Fit support in the lifting eye on the cylinder head and slightly
tighten the engine.
Note!
♦ When dismounting the support element from the assembly,

the engine should be supported by the support cross member
-U-30025E- .
♦ The engine support should not be removed until the assembly
support element has been removed.
♦ To loosen the engine bracket bolts it is necessary to lift the
engine slightly with the support device.
– Remove securing bolts A and B in the unions of: drive train

group fastener/engine support, drive train group fastener/
bodywork and support of the drive train group fastener/body‐
work -arrows- , and dismount completely the fastening ele‐
ment of the drive train group.
– Dismount from the block the engine support.
– Remove toothed belt central guard.
– Turn crankshaft to TDS No.1 cylinder.

– The mark on the fly wheel -1- should line up with that of the
gearbox -2- .
Note!
To do this the mark on the flywheel should be looked at in a ver‐

tical position from the tapered surface of the gear box -A- .
Engine removed:

– Thread adjusting tool -U-20010- as shown.

– Calibrate the adjusting tool to 39 mm. The right groove of the
vernier -arrow A- is the reference point.
– Turn the crankshaft until the TDS mark on the flywheel coin‐
cides with the point on the adjusting tool -arrow B- .
– Immobilize camshaft with adjusting ruler -T20038- , as indica‐

ted in the figure.
– Centre the adjusting ruler as described as follows: Once cam‐
shaft is immobilized, turn it until one end of the ruler is sup‐
ported on the cylinder head. Measure the play that results on
the other extreme of the ruler with a feeler gauge. Insert a
feeler gauge half the previous size between the adjusting ruler
and the cylinder head. Next, turn camshaft so that the ruler
rests on the feeler gauge. Insert a second feeler gauge of the
same size in the other extreme, between the ruler and the cyl‐
inder head.
– Immobilize injection pump wheel with tool -T20102- .

– Loosen the bolts -1- which secure the injection pump wheel.
– Remove vibration damper/belt pulley.
– Remove lower toothed belt guard.
– Mark D.O.R. of toothed belt.
– Loosen tensioning roller
– Remove toothed belt.
1.1.2 Installation
– Check to see if TDC mark on fly wheel and the reference mark
coincide.
– Loosen camshaft wheel securing bolt by 1 turn. To loosen the
securing bolt, immobilize the camshaft wheel with retaining
tool -T20018A- .
Note!
The adjusting ruler -T20038- should never be used as a retaining

tool to loosen and secure the camshaft wheel. Use retaining tool
-T20018A- .

– Use extractor -T20119- to separate the camshaft wheel from

its cone.
– Place toothed belt on the crankshaft wheel, idler roller, injec‐
tion pump wheel, coolant pump wheel and the tensioning roller
(observe turning direction).
– Position the injector pump wheel in such a way that it is centred
on the coil openings.
– Place the camshaft sprocket along with the toothed belt and
secure with fixing bolt (the camshaft sprocket can still move).
– Tension toothed belt. For this turn pin wrench -U-30009 A-

clockwise by the excentric until the groove and the protuber‐
ance -arrows- face each other...
Note!
If the excentric has been turned too far, the tensioning roller will
have to be completely slackened and tightened again. The ex‐
centric should not be turned in the opposite direction and if so,
only when it has been turned too far.
– Tighten fixing nut on tensioning roller Tightening torques: 25

Nm
– Check to see if TDS mark on fly wheel and the reference mark
coincide.

Note!
Make sure that the tensioning roller is correctly housed in the rear
toothed belt protector -arrow- .
– Re-check the TDC mark on the flywheel.

– Tighten the bolt that secures the camshaft (immobilize the
sprocket with tool -T20018A- ). Tightening torques: 45 Nm
– Tighten the bolts which secure the injection pump wheel Tight‐
ening torques: 25 Nm
– Remove the adjusting ruler -T20038- from camshaft.
– Withdraw locking pin -T20102- .
– Turn the crankshaft two turns in the direction of engine rotation
until cylinder 1 TDC is again reached.
– Check the following points: • The TDS mark on the fly wheel •
The adjusting ruler -T20038- on the camshaft • The locking pin
-T20102- in the injection pump sprocket. • Tensioning roller
adjuster (groove/projection)
– If the groove and the projection or the groove and the arrow
do not coincide, tighten the tensioning roller and tighten the
securing bolt to torque 25 Nm.
– Turn the crankshaft two turns in the direction of engine rotation
until cylinder 1 TDC is again reached.
– Repeat the check.
– Fit engine mounting to cylinder block. Tightening torques: 45
Nm
Note!
All the bolts of the engine bracket must be tightened to the speci‐
fied torque before fitting the engine bracket assembly.
– Engine mounting, engine. Tightening torque ⇒ page 8 .

– Fit vacuum pump. Tightening torques: 20 Nm
– Fit the toothed belt guard and the damper/belt pulley.
– Fit lower engine protection.
– Fit the upper toothed belt cover and the engine cover.
memory for engine control unit: consulting and erasing. ⇒ -
VAS 5051- vehicle self-diagnosis , ⇒ page 156

1.2 Cylinder head: removing and installing

equipment required
♦ Engine support tool (distri‐
bution side) -T10014-
T20029-
♦ Cylinder head centring tool
-T20049-
T20119-
♦ Engine and gearbox sup‐
port cross member -
U-30025E-

♦ Torque spanner -SAT 8010-
♦ Injector nut spanner -U-40072-
1.2.1 Prerequisites
• The engine must be no more than warm to touch.
• The pistons can not be positioned at TDC.
1.2.2 Removing
Note!


– All cable ties which are opened or cut open when removing
engine, must be replaced in the same position when installing
engine.

– Remove the front exhaust along with the catalytic converter
– Drain coolant ⇒ page 74 .
– Remove the hoses from the injectors.

Note!
♦ To loosen the injector hoses, use the injector nut spanner -

U-40072- .
♦ Always remove the complete set of hoses.
♦ Do not change the shape of the hoses.
– Cover the openings with a clean cloth.

– Extract the return pipes from the injectors/injector pump.
– Extract the plug connection bar from the pre-heating plugs.
– Separate the cylinder head vacuum hoses and leave them to
one side.
– Pull off/disconnect all other electrical connections as neces‐
sary from engine and lay to one side.
– Remove connector for the intake manifold flap -1- .

– Remove air intake hose -2- from the intake manifold flap.
– Remove the pressure regulating valve -3- with the breather
hose connected .
– Unscrew the intake manifold securing bolts -4- .

– Remove the coolant hose-5- and the vacuum pipe -6- .
– Unscrew the coolant connecting piece -2- -arrows- and sepa‐

rate the coolant hose -1- from the distributor.
– Remove ribbed belt and cylinder head cover upper protector.
– Remove the vacuum pump for the brake servo amplifier.

– Fit the cross member -U-30025E- and maintain the engine in

the fitting position with a spindle -B- .
Note!
Both lifting eyes are situated in the cylinder head and due to this
an additional support should be fixed to the engine block to sup‐
port the engine.

– Remove the toothed belt from the camshaft wheel and remove
the camshaft wheel. ⇒ page 34 , Toothed belt: removing, in‐
stalling and tensioning.
– Remove the engine support from the block ⇒ page 34 , Tooth‐
ed belt: removing, installing and tensioning.
– Secure the tool -T10014- to the front threaded orifice of the

engine bracket, situated on top of the coolant pump
– Lift engine using second spindle -A- until spindle -B- is freed.
– Remove main roller of the toothed belt.
– Unscrew the securing bolts from the toothed belt guard to the
rear of the cylinder head.
– Loosen socket head bolts in the sequence given and then re‐
move completely.
– Carefully lift cylinder head off.
1.2.3 Fitting
Note!
♦ Always replace the cylinder head securing bolts.

♦ If repaired, carefully remove gasket remains from engine block
and cylinder head. Avoid making scratches or grooves. If abra‐
sive paper is used it must be at least 100 grade.
♦ Carefully remove all traces of abrasive particles.
♦ Only remove the new cylinder head gasket from its packing
immediately before installing.
♦ Handle the new gasket with extreme care. If the layer of sili‐
cone and the grooved area are damaged there is a possibility
of leakage.

– Place a clean cloth in cylinders so that no dirt or emery cloth

particles can get in between cylinder wall and piston.
– Also prevent dirt and emery cloth particles from getting into the
coolant.
– Carefully remove metal particles, emery remains and cloths.
– Check that the two adjusting sleeves are well fitted to the en‐
gine block -1- to guide the cylinder head.
– Before fitting the cylinder head, locate crankshaft at TDC.
– Turn crankshaft in opposite direction to engine rotation until
the pistons are almost uniformly under TDC.
– Fit cylinder head gasket.
– Fit the cylinder head, point all the studs and tighten them by
hand.
– Tighten the cylinder head in four stages as indicated below:

– 1. Previous tightening with torque wrench: I stage = 40 Nm II
stage = 60 Nm
– 2. Retighten with a rigid wrench: III stage = 1/4 turn (90 °) IV
stage = 1/4 turn (90 °)
Note!
It is not necessary to retighten the cylinder head bolts after re‐

pairs.
The rest of the assembly is basically a reverse of the dismantling

sequence.
– Once the cylinder head has been secured, turn the camshaft
so that the cams for cylinder 1 point uniformly upwards. Before
fitting the toothed belt, turn the crankshaft in engine rotation
direction until they are in TDC position.
– Place the camshaft sprocket along with the toothed belt and
secure with fixing bolt (the camshaft sprocket can still move).
Installing toothed belt and adjusting valve timing ⇒ page 34 ,
Toothed belt: removing, installing and tensioning
– Install the engine support in the block ⇒ page 34 , Toothed
belt: removing, installing and tensioning. Tightening torques:
45 Nm
Note!
All the bolts of the engine bracket must be tightened to the speci‐
fied torque before fitting the engine bracket assembly.
– Fit vacuum pump.

– Install the front exhaust along with the catalytic converter
Filling with new coolant ⇒ page 74 .
memory for engine control unit: consulting and erasing. ⇒ -
VAS 5051- vehicle self-diagnosis , ⇒ page 156

1.3 Compression ratio: checking

equipment required
♦ Spanner -U-40082- for pre‐
heating spark plugs
8010-
♦ Adapter -V.A.G 1381/12-
♦ Compression tester -V.A.G
1763-

• Engine oil temperature must be at least 30 °C

– Uncouple the 10-pin connector from the injector pump.
– Remove all the pre-heating plugs with articulated spanner -
U-40082-

– Fit adapter -V.A.G. 1381/12- to pre-heater plug locations.

– Check compression with compression tester -V.A.G 1763- or
-V.A.G 1381- .
Note!
Using the compression tester ⇒ Operating instructions .
– Operate starter until tester shows no further pressure in‐

crease.
Compression pressure:
New: 25...31 bar Wear limit: 19 bar
Permissible difference between all cylinders: 5 bar
– Fit all the pre-heating plugs with articulated spanner -U-40082-
Tightening torques: 15 Nm.
– Consulting fault memory; Interrogating and erasing fault mem‐
ory of engine control unit. ⇒ -VAS 5051- vehicle self-diagno‐
sis , ⇒ page 156
Note!
On uncoupling the connectors to the injector pump, faults will me

recorded. Thus, it is necessary to consult the fault memory and
erase if necessary.

2 Valve gear: repairing
Note!
Cylinder heads with cracks between valve seats are still useable as long as the cracks are no more than 0.5
mm wide.
1 - Bearing cap
❑ Installation position
⇒ page 48
❑ Note the loosening and
tightening sequence
⇒ page 55 , Camshaft:
removing and installing
❑ For the installation apply
sealer -AMV 174 004
02- to the contact surfa‐
ces of bearing cap 1
2 - 20 Nm
3 - Camshaft
❑ Checking axial clear‐
ance ⇒ page 48
⇒ page 55
❑ Checking radial clear‐
ance with plastigage
Wear limit: 0.11 mm
❑ Runout: max. 0.05 mm
❑ Identification and valve
timing ⇒ page 49
4 - Hydraulic plunger
❑ Before installing check
camshaft axial clear‐
ance ⇒ page 48
❑ Checking ⇒ page 57
❑ Do not interchange
❑ With hydraulic valve
clearance compensa‐
tion
❑ Place with contact sur‐
face downwards
❑ Oil contact surface
5 - Valve cotters
6 - Valve spring plate
7 - Valve spring
❑ Removing and installing: Cylinder head removed: with -T20034B/1- installed: ⇒ page 53 , renewing
valve stem seals
8 - Valve stem seal
❑ Renew ⇒ page 53
9 - Valve guide
2. Valve gear: repairing 47

10 - Oil seal
❑ To remove and fit, the bearing cap and the toothed belt have to be removed
❑ Do not additionally oil or grease the oil seal sealing lip.
❑ Toothed belt: removing, installing and tensioning ⇒ page 34
❑ Before fitting remove oil traces from crankshaft journal with a clean cloth.
11 - Cylinder head
❑ See note ⇒ page 47
❑ Rework valve seats ⇒ page 49
12 - Valves
❑ Valve dimensions ⇒ page 49
❑ Do not rework, only grinding is permitted
Check camshaft axial play

♦ Universal dial gauge bracket -T20020-
♦ Dial gauge
Checking process
Measure with the hydraulic followers removed and with the first
and last bearing caps fitted.
Wear limit: max. 0.15 mm
Fitting position of camshaft bearing caps
Observe excentricity. Before installing the camshaft fit the bearing
caps and determine the fitting position.

Valve dimensions
Note!
Valves must not be reworked. Only lapping-in is permitted.
Dim. Inlet valve Exhaust valve

∅a mm 35,95 31,45
∅b mm 6,963 6,943
c mm 96,55 96,35
α ∠° 45 45
Camshaft identification, valve timing

Identification
♦ Basic cam diameters: a = ∅ 38 mm
♦ Identification by means of numbers and letters stamped be‐
tween the inlet camshaft and the exhaust camshaft:
Cylinder 1 -arrow A- 38E
Cylinder 2 -arrow B- DE
Valve timing with 1 mm valve lift
Inlet after TDC 11°
Inlet closing after BDC 25°
Exhaust opening before BDC 40°
Exhaust closing before TDC 10°
2.1 Valve seats: reworking

♦ Depth gauge
♦ Valve seat refacing tool
Note!
♦ Do not machine the valves. They may only be reworked.

♦ When repairing engines with leaking valves, it is not always
sufficient to reface or renew valve seats and valves. It is also
necessary to check the valve guides for wear. This particularly
important on high mileage engines.
♦ The valve seats should only be reworked just enough to pro‐
duce a perfect seating pattern. The maximum permissible
reworking dimension must be calculated before reworking
commences. If the reworking dimension is exceeded, the func‐
tion of the hydraulic tappets can no longer be guaranteed and
the cylinder head should be renewed.
2.1.1 Work sequence

Calculate the max. permissible reworking dimension
– 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.
– Calculate max. permissible reworking dimension from meas‐
ured distance -a- and minimum dimension.
Minimum dimensions: Inlet valve 35.8 mm Exhaust valve 36.1
mm
Measured distance minus minimum dimension = max. permissi‐
ble reworking dimension.
Example:
- Measured distance 36,5 mm
Minimum dimension 35,8 mm
= max. perm. rework dimension 0,7 mm
2.1.2 Reworking inlet valve seat: reworking

a = ∅ 35.7 mm
b = 1.6 mm
45 ° = Valve seat angle
Note!
The angling of 30° of the valve seat is indispensable to avoid inlet

turbulence.
2.1.3 Exhaust valve seat: reworking

a = ∅ 31.4 mm
b = 2.7 mm
45 ° = Valve seat angle
2.2 Valve guides: checking


♦ Universal dial gauge bracket -T20020-
♦ Dial gauge

– Fit a new valve in the guide. The end of the valve stem should
be flush with the guide. Due to the slight difference in stem
dimensions, ensure that only an inlet valve is used in the inlet
guide and an exhaust valve in the exhaust guide.
– Determine rock. Wear limit: max. 1.3 mm
If rock tolerance is exceeded:
– If the rock exceeds the wear limit, the cylinder head should be
replaced.
2.3 Valve guides: replace

♦ Valve guide plunger -T20035-
♦ Manual reamer -T20066- and cutting fluid

2.3.1 Removing
– Clean and check cylinder head. Cylinder heads whose valve
seat inserts cannot be reworked, or cylinder heads that have
surpassed the minimum dimension are not suitable for valve
guide replacement.
– Remove worn valve guides with tool -T20035- from camshaft
side (valve guides with shoulder -only for spares- from the
combustion chamber side).
2.3.2 Fitting
– Coat the new valve guides with oil and press with tool -T20035-
into cold cylinder head from the camshaft side until the shoul‐
der makes contact.
Note!
When the shoulder of the guide makes contact, the pressure must
not exceed 1.0 t otherwise shoulder may break off.
– Ream the valve guide with manual reamer -T20066- . Always

use cutting fluid.
– Rework valve seats ⇒ page 49

2.4 Valve stem seals: replace

equipment required
♦ Valve removal/fitting tool -
T20034B-
♦ Guide seal extractor -
T20058-
♦ Tool for fitting valve guide
seals -T20039-
♦ Pressure element -
T20034- / ∅ 35
2.4.1 Removing
(with cylinder head in place)
– Remove camshaft ⇒ page 55
– Remove the plungers and place them on the contact surface
face down, making sure you do not interchange them.
– Take corresponding piston to TDC.

– Use valve removal/fitting tool -T20034B- and adjust mountings

to height of studs.
– Remove valve springs with tool -T20034B- and pressure tool
-T20034- / ∅ 35
Note!
Valves rest on piston crown.
– Remove valve stem seals with tool -T20058-
2.4.2 Fitting
– To avoid damage of valve seals, place the plastic sleeve over
valve stem (this sleeve is included with the spare).
– Install the new valve seal in tool -T20039- .
– Oil valve stem seal sealing lip and press carefully onto the
valve guide.

2.5 Camshaft: removing and installing

equipment required
T20038- 5)

T20119-
♦ Feeler gauge
♦ Sealant -AMV 174 004 01-
5) If it is not, cut with saw according to figures in drawing

2.5.1 Removing
– Remove ribbed belt, vacuum pump and cylinder head cover
upper protector.
stalling and tensioning
Note!
It is not necessary to remove the damper/belt pulley nor the lower/

central protective covers for the toothed belt.
– Loosen camshaft sprocket securing bolt by 1 turn. To loosen

the securing bolt, immobilize the camshaft wheel with counter
support -T20018A- .
Note!
The adjusting rule -T20038- should never be used as a retaining

tool to loosen and secure the camshaft wheel. Use counter sup‐
port -T20018A- .
– Separate the camshaft sprocket using extractor -T20119- .

– Remove the camshaft wheel.
– First remove bearing caps 5, 1 and 3. Loosen alternately and
diagonally bearing caps 2 and 4.

2.5.2 Fitting
Note!
♦ On fitting camshaft, cams for cylinder 1 must point upwards.

♦ When fitting the bearing caps observe the hole offset. Before
fitting, position the bearing caps and determine the fitting po‐
sition.
– Lubricate the camshaft contact surfaces.

– Fit the camshaft in the cylinder head.
– Tighten bearing caps 2 and 4 alternately and diagonally to
Tightening torques: 20 Nm
– Spread a little sealant -AMV 174 004 01- on the contact sur‐
face of bearing caps 1 and 5.
– Install bearing caps 5, 1 and 3 and also tighten to Tightening
torques: 20 Nm
– Position bearing cap 5, tapping it gently, in the front side of the
camshaft.
Note!
Remove the excess sealant from bearing caps 1 and 5. There

should not be any sealant on the sealing surface of the cylinder
head/cylinder head cover.
– Immobilize camshaft with adjusting rule -T20038- .

– The adjusting tool should be centred as follows: Once cam‐
shaft is immobilized, turn it until one end of the ruler touches
the cylinder head. Measure the play that results on the other
extreme of the ruler with a feeler gauge. Insert a feeler gauge
with the play reduced halfway between rule and cylinder head.
Next, turn camshaft so that the rule rests on the feeler gauge.
Insert a second feeler gauge of the same size in the other ex‐
treme, between the rule and the cylinder head.
Installing toothed belt and adjusting valve timing ⇒ page 34 ,
Toothed belt: removing, installing and tensioning
– Fit ribbed belt, vacuum pump and cylinder head cover upper
protector.
Note!
After fitting new plungers do not start the engine for approx. 30
minutes. Hydraulic compensation elements must be allowed to
settle (or else the valves could touch the piston).
2.6 Hydraulic plungers: checking

♦ Feeler gauge
♦ Wooden or plastic wedge

Note!
♦ The hydraulic plungers should always be replaced in their en‐

tirety (they cannot be adjusted or repaired individually)
♦ Unusual noises from the valves during starting are normal.

• Engine oil temperature must be at least 80 °C.

– Start up the engine and make it turn until the radiator fan has
switched on once.
– Increase speed to approx. 2,500/min for 2 minutes.
If the hydraulic plungers continue to make a noise, check to see
which one/s is/are faulty as follows:
– Remove protective engine cover and cylinder head cover.
– Turn the crankshaft clockwise until the plunger cams to be
checked are up.
– Check the play between cams and hydraulic plungers.
– If play is greater than 0.1 mm, replace the plunger. If play is
less than 0.1 mm or if there is no play, proceed with the check
as follows:
– Press the plunger slightly downwards with a wooden or plastic
wedge. If it is not possible to insert a 0.1 mm thick feeler gauge
between the camshaft and the plunger the plunger should be
replaced.
Note!
After fitting new plungers do not start the engine for approx. 30
minutes. Hydraulic compensation elements must be allowed to
settle (or else the valves could touch the piston).
2.7 Camshaft oil seal: removing and instal‐

ling
♦ Oil seal plunger -T20031B-
♦ M12X65 bolt

♦ Torque spanners -SAT 8010-
2.7.1 Removing
stalling and tensioning.
– Remove bearing cap 1 from the camshaft without damaging
the support surface.
– Remove camshaft oil seal.
2.7.2 Fitting
Note!
♦ The lip of this seal must not be lubricated with oil or grease.
♦ Remove the excess sealant from bearing cap 1. There should
not be any sealant on the sealing surface of the cylinder head/
cylinder head cover.
– Spread a little sealant -AMV 174 004 01- on the contact sur‐
face of bearing cap 1.
– Fit camshaft bearing cap 1 ⇒ Item 1 (page 47) Tightening tor‐
ques: 20 Nm
– Remove the remaining oil from the camshaft journal.
– Fit the seal into guide sleeve -T20081B/2- and fit the unit onto
camshaft journal.
– Use fitting tool -T20081B/1- and press guide sleeve-oil seal
set as far as it will go. Use the camshaft sprocket securing bolt.
– Separate guide sleeve -T20081B/2- .
– Toothed belt, installing and tensioning ⇒ page 34
sequence.

17 – Lubrication
1 Lubrication system components: re‐
moving and installing
Note!
♦ If when repairing an engine, metal shavings or large quantities

of small metal particles - caused, for example, by partial seiz‐
ure of crankshaft and conrod bearings - are found in engine
oil, to prevent consequential damage, apart from thoroughly
cleaning oil passages, it is necessary to renew the oil cooler.
♦ The oil level must not be above the max. mark - danger of
damaging catalytic converter!
Checking oil pressure and oil pressure switch ⇒ page 67 .

Oil capacity:
without oil filter 3.8 ltr. with oil filter 4.3 ltrs.
Engine oil specifications:
Only use engine oil according to standard VW 505 00 or 505 01.
The oil has to be changed every 12 months or every 15,000 kil‐
ometres and the service interval indicator has to be programmed
accordingly. Procedure:
⇒ Maintenance ; Booklet ; Maintenance
Engine oil specifications for long service intervals:
In engines developed for long service intervals use engine oil to
standard VW 506 00 or 506 01.
Part I
Part II, Oil filter bracket: dismantling ⇒ page 62
60 Rep. Gr. 17 - Lubrication

1 - Oil pump
❑ With 12 bar relief valve
❑ Before assembly, check
that the two centering
sleeves of: oil pump/cyl‐
inder block
❑ If scoring is found on the
sliding surfaces and
gears: replace
⇒ page 69 ; Oil pump:
removing and installing
2 - Oil pump gear
❑ Take note of assembly
position
❑ It can only be inserted
into one position on the
oil pump spindle
3 - 25 Nm
4 - Chain for oil pump
5 - Sealing flange
❑ with oilseal
❑ Assemble with silicone
sealant -D 176 404 A2-
⇒ page 23
⇒ page 23
❑ Do not additionally oil or
grease the oil seal seal‐
ing lip
❑ Before installing, re‐
move oil remains from
crankshaft journal with a
clean cloth
❑ Must be located on dowel sleeves
❑ Renew crankshaft oilseal - pulley end ⇒ page 21
6 - 15 Nm
7 - Chain tensioner with tensioning plate 15 Nm
❑ On assembling, pretension the spring and hook it
8 - Sprocket
9 - Dipstick
❑ The oil level must not go above the max. mark!
❑ Markings ⇒ page 62
10 - Funnel
❑ Pull off to extract oil
11 - Guide tube
12 - Oil spray jet
❑ To cool the pistons
❑ Note fitting position: Turn the oil injector anti-clockwise until it is stopped by the engine block and tighten
it in this position
13 - Pressure relief valve
❑ 25 Nm
❑ It opens at 0.25...0.32 bar pressure
1. Lubrication system components: removing and installing 61

❑ Fit without sealer

14 - O-ring
❑ Renew
15 - Suction pipe
❑ Clean filter if soiled
16 - Baffle plate
17 - Sump
❑ Clean sealing surface before installing
❑ Assemble with silicone sealant -D 176 404 A2- ⇒ page 64
18 - Oil drain screw, 30 Nm
❑ If the sealing ring is leaking, nip open and replace the o-ring
Dipstick level marks

1 - Max. mark
2 - Min. mark
a - Area above hatched field up to max. mark: do not add oil
b - Oil level within hatched field: can be topped up with engine oil
c - Area from min. mark up to hatched field: fill with max. 0.5 ltr.
of engine oil
Part II

1 - Plug
❑ 25 Nm
2 - Gasket
❑ Renew
3 - Oil cooler
❑ Ensure clearance to ad‐
jacent components
❑ See note ⇒ page 60
4 - Gasket
❑ Renew
❑ Hold with tabs provided
on the oil cooler
5 - Plug
❑ 25 Nm
❑ With o-ring
❑ Do not loosen
6 - Oil pressure switch -F1-
❑ 20 Nm
❑ 0.7 bar switch: brown
❑ If the sealing ring is leak‐
ing, nip open and re‐
place the o-ring
❑ Checking ⇒ page 67 ;
Oil pressure and oil
pressure switch: check‐
ing
7 - Oil filter bracket
❑ With integrated relief
valve (0.5 bar)
8 - 15 Nm + 1/4 turn (90 °)
❑ Renew
❑ First fit the top left and bottom right bolts and then tighten the four bolts diagonally.
9 - Gasket
❑ Renew
10 - O- ring
❑ Renew
11 - Plug
❑ 25 Nm
❑ Do not loosen
12 - Cover
❑ 25 Nm
13 - O-ring
❑ Renew
14 - Oil filter element
❑ Replace the O-rings
❑ Take note of assembly position: top = top
15 - O-ring
❑ Renew

1.1 Sump: removing and installing

♦ Sump bolt spanner set -U-40051 A-
♦ Hand drill with plastic brush

♦ Silicone sealant -D 176 404 A2-
♦ Flat scraper
♦ Torque spanners -SAT 8010- (5 - 50 Nm)
1.1.1 Dismantling
– Remove lower engine protection. ⇒ General body repairs-as‐
– Drain engine oil.
Note!
Observe disposal regulations!
– Remove sump.
– Loosen the sump by gently tapping it with a rubber hammer.
– Remove sealant residue on cylinder block with a flat scraper.

– Remove sealant residue on the sump with a rotating brush,

e.g. a hand drill with a plastic brush (wear protective goggles).
– Clean sealing surface, must be free of oil and grease.
1.1.2 Installation
Note!
♦ Note the use by date of the sealant.

♦ Sump must be installed within 5 minutes of applying silicone
sealing compound.
– Cut off tube nozzle at forward marking (nozzle approx.:). ap‐

prox. 3 mm).
– Apply silicone sealing compound, as shown, to clean sump
sealing surface. Sealing compound bead must be:
♦ 2 - 3 mm thick
♦ and run on inside of bolt holes -arrows- .
Note!
The sealing compound bead must not be thicker, otherwise ex‐

cess sealing compound will enter the sump and may block the oil
suction pipe strainer.

– Apply silicone sealing compound to clean sump sealing sur‐

face, as shown in the illustration. (observe the location of the
bead of sealing compound on engine block in the figure.)
– Install sump immediately and tighten all sump bolts lightly.
Note!
Thread the bolts on the flywheel side using tool -U-40051 A- .
– Tighten the bolts which secure the oil sump alternately with
tool -U-40051 A- , to tightening torque 15Nm.
– Tighten sump bolts to gear box to 45 Nm.
Note!
After installing sump the sealant must be allowed to dry for ap‐
prox. 30 minutes before engine oil is added 30 minutes. After this
time has passed, the sump may be filled.

sequence.

1.2 Oil pressure and oil pressure switch: checking

equipment required
♦ Oil pressure tester -V.A.G
1342-
♦ Diode test lamp -V.A.G
1527 B-
♦ Adapter set -V.A.G 1594 C-
Note!
♦ Buzzer function warning low oil pressure

♦ The oil pressure switch is open when there is no pressure and
it closes on reaching the switching pressure.
Low oil pressure warning comes into action in approx. 10 seconds

after switching on the ignition.
Low oil pressure warning comes into action with a delay of approx.
3 seconds.
Warning ends with a delay of aprox. 5 seconds.

Note!
♦ Checking the warning lamp

♦ After switching on the ignition and with the engine stopped, the
oil pressure warning should light up for approx. 3 seconds and
then go out. Checking is interrupted if the engine is on.
Note!
Activation of the optical oil pressure warning lamp (warning lamp

in flashing mode) and three warning buzzes will occur in the fol‐
lowing circumstances.
• “Ignition on” , engine off, oil pressure switch closed

• Engine revolutions greater than 1500 R.P.M., oil pressure
switch open
Note!
♦ Engine revolutions greater than 5,000 R.P.M., warning lamp

stays on even when oil pressure switch is closed. At less than
5,000 rpm warning lamp goes out again.
♦ If the oil pressure switch is open for only 0.3- 3.0 seconds at
an engine speed greater than 1,500 rpm., the dash panel pro‐
cessor will memorise it. If this happens three times while
engine is in operation, the oil pressure warning will be imme‐
diately activated and will not turn off even at less than 1,500
rpm. Elimination of the oil pressure warning will happen when
the oil pressure switch has been closed for more than 5 sec‐
onds above 1,500 rpm. or ignition is turned off.
1.2.1 Check conditions

• Engine oil level OK, checking ⇒ page 62
• The oil pressure warning lamp -K3- must light up for approx.
3 seconds with the ignition switched on.
• Engine oil temperature at least 80 °C (radiator fan must have
run once)


– Remove 7.0 bar oil pressure switch -F1- and screw into tester.
– Screw tester into the oil filter bracket, in place of the oil pres‐
sure switch.
– Connect brown wire of tester to earth (-).
– Connect diode testing lamp -V.A.G 1527 B- to battery positive
(+) and the oil pressure switch -F1- with auxiliary cables from
-V.A.G 1594 A- . The LED should not light-up.
– If the LED lights up, renew 0.7 bar oil pressure switch -F1- .
If the LED does not light up:
– Start engine and run at high speed: a 0.55...0.85 bar pressure
the LED should light up, if not renew oil pressure switch.
– Increase engine speed further. At 2,000 RPM and an oil tem‐
perature of 80 °C, the oil pressure should be 2.0 bar.
If the specifications are not attained:
– Rectify mechanical damage, e.g. bracket damage.
– Replace the oil filter support along with the discharge valve or
the oil pump.
At higher engine speeds the oil pressure must not exceed 7.0 bar
If the specification is exceeded:
– Check oil galleries.
– If necessary, replace oil filter bracket with pressure relief valve.
1.3 Oil pump: removing and installing
1.3.1 Removing
– Remove sump ⇒ page 64
– Removing baffle panel.
– Unscrew bolt -2- .
– Remove axle sprocket from the oil pump.
– Remove bolts -1- and -3- and remove oil pump.
1.3.2 Installation
Install in reverse order
Note!
Fit the sockets to the upper part of the oil pump.

19 – Cooling system
1 Cooling system components: remov‐
ing and installing
Caution

following:
Note!
♦ When the engine is hot the cooling system is under pressure.

If necessary release pressure before commencing repair
work.
♦ Hose connections are secured with spring-type clips. When
repairing, only use spring-type clips.
♦ To fit spring type clips use pliers -T20029- .
♦ Coolant hoses should be stress-free when installing, so that
they do not come into contact with other components (observe
markings on coolant connection and hose).
Perform cooling system leakage test with cooling system tester -

V.A.G 1274- and adapters -V.A.G 1274/8- and -V.A.G 1274/9- .
Parts of cooling system, body side ⇒ page 71 .
Parts of cooling system, engine side ⇒ page 72 .
Coolant hose connection diagram ⇒ page 73 .
Draining and filling with coolant ⇒ page 74
Notes on coolant mixture ratios ⇒ page 74 , Coolant: draining
and filling
70 Rep. Gr. 19 - Cooling system

1.1 Cooling system components, body side
1 - Radiator
⇒ page 80
❑ After replacing, renew
all coolant
2 - O-ring
❑ Renew
3 - Upper coolant hose
❑ Secured to radiator with
retaining clip
❑ Coolant hose connec‐
tion diagram
⇒ page 73
4 - Cap
❑ Check with cooling sys‐
tem tester -V.A.G 1274-
and adapter -V.A.G
1274/9- ⇒ page 84
❑ Test pressure 1.4...1.6
bar
5 - Connector
6 - Double bolt
❑ 10 Nm
7 - Air duct
8 - 5 Nm
9 - 5 Nm
10 - Expansion tank
❑ Carry out leak test of
cooling system with
cooling system tester -
V.A.G 1274- and adapt‐
er -V.A.G 1274/8-
❑ Observe markings ⇒ page 74 , Coolant: draining and filling
11 - Securing clip
❑ For fan cable
❑ Check for secure seating
12 - Additional fan
❑ Only vehicles with optional equipment
13 - Fan screen
14 - Radiator fan
15 - Lower coolant hose
❑ Secured to radiator with retaining clip
❑ Coolant hose connection diagram ⇒ page 73
16 - Support
❑ To connect to fan terminal
17 - Termoswitch -F18-
❑ 35 Nm
❑ For electric fan
1. Cooling system components: removing and installing 71

❑ Switching temperatures: 1atspeed on: 92...97 °C off: 84...91 °C 2atspeed on: 99...105 °C off: 91...98 °C
18 - Lower radiator support
❑ For radiator
❑ Note that there are different versions
19 - 5 Nm
20 - Upper radiator support
❑ For radiator
❑ Note that there are different versions
1.2 Cooling system components, engine side
1 - Upper coolant pipe

❑ Secured on intake mani‐
fold
2 - 10 Nm
3 - Connection
❑ For heat exchanger
4 - Connection
❑ In cylinder head
5 - Distributor
6 - To top of radiator
❑ Coolant hose connec‐
tion diagram
⇒ page 73
7 - 15 Nm
8 - Coolant temperature send‐
er -G62-
❑ With coolant tempera‐
ture gauge sender -G2-
❑ For engine control unit
❑ If necessary release
pressure in cooling sys‐
tem before removing
9 - Securing clip
❑ Check for secure seat‐
ing
10 - O-ring
❑ Renew
11 - Oil seal
❑ Renew
ing
12 - Coolant pipe
13 - To bottom of expansion tank

14 - Goes to the bottom of radiator

15 - Thermostat housing
16 - Coolant thermostat
❑ Checking: heat the thermostat in water
❑ Opening commences approx. 86 °C
❑ Opening lift min. 7 mm
17 - Oil cooler
18 - Coolant pump
❑ Check for ease of movement
❑ If damaged or leaking renew complete Only renew complete
19 - Distributor
20 - To expansion tank
1.3 Coolant hose connection diagram
1 - Radiator
2 - Oil cooler
3 - Thermostat
4 - Coolant pump
5 - Cylinder head/cylinder
block
6 - Expansion tank
7 - Upper coolant pipe
8 - Connection
❑ In cylinder head
9 - Heating system heat ex‐
changer
10 - Connection
❑ For heat exchanger
11 - Coolant pipe
12 - Quick release coupling

1.4 Coolant: draining and filling

equipment required
♦ Refractometer -T10007-
T20029-
1.4.1 Empty
– Open cap on coolant expansion tank.
Caution
Steam can be released when removing the cap from the ex‐
pansion tank. Cover cap with a cloth and open carefully.

– To drain coolant from radiator remove drain plug -arrow- from

radiator.
– Furthermore, the flexible hose for the coolant has to be un‐

coupled from the oil cooler-arrow- in order to empty what
remains of the coolant in the engine, use pliers for spring type
clips -T20029-
Note!
Observe disposal regulations!

1.4.2 Filling
Note!
♦ Only use antifreeze additive G 12 according to specification

TL VW 774 F. Identification: purple colour.
♦ The purple G 12 (TL VW 774 F standard) may be mixed with
the previously used red G 12 antifreeze additive.
♦ On no account must G 12 be mixed with other antifreeze ad‐
ditives.
♦ If the fluid in expansion tank is brown, G 12 has been mixed
with other antifreeze additives. In this case the coolant must
be changed.
♦ G 12 and anti-freeze additives marked “In accordance with TL
VW 774 F” prevent frost and corrosion damage, scaling and
also raise the boiling point of coolant. For this reason, the sys‐
tem must be filled all year round with recommended anti-
freeze and anti-corrosive additives.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy work loads, particularly in countries with
tropical climates.
♦ The anti-freeze protection should be guaranteed to approx.
-25 °C (in countries with arctic weather up to approx. -35 °C).
♦ Coolant concentration must not be reduced by adding water,
even in warmer seasons or in warmer countries. The anti-
freeze additive/coolant ratio 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). With a greater concentration en‐
gine cooling and anti-freeze properties are diminished.
♦ Never reuse used coolant. the radiator, the heat exchanger,
the cylinder head or the cylinder head gasket.
Recommended mixture ratios:

Frost protection Anti-freeze G 126) Water6)
to amount.
-25 °C 40 % 2.0 ltr. 3.0 ltr.
-35 °C 50 % 2.5 ltr. 2.5 ltr.
6) The quantity of coolant can vary depending upon the vehicle specifications.
– Close the coolant drain plug.

– Fit the flexible coolant hose in the oil cooler and secure it with
a spring-type clamp.
– Fill with coolant up to max. mark on expansion tank.

– Close expansion tank cap.
– Run engine until radiator fan cuts in.
– Check coolant level and top up if necessary. When the engine
is at normal operating temperature, the coolant level must be
on the MAX., marking and between the MIN. and MAX. mark‐
ing when the engine is cold.
– Install lower engine cover:

1.5 Coolant pump: removing and installing

equipment required
♦ Pliers -T20029- for spring-
type clips
8010-
Note!
♦ Always renew seals and gaskets.

♦ The lower part of the toothed belt guard need not be removed.
♦ The toothed belt should be left in position on the crankshaft
sprocket.
♦ Cover toothed belt with a cloth to protect it from coolant before
removing coolant pump.

1.5.1 Removing
– Remove lower engine protection:
– Remove upper and centre parts of toothed belt guard
⇒ page 34 , Removing, installing and tensioning toothed belt
– Remove the toothed belt from the camshaft wheel and from
the coolant pump ⇒ page 34 , Toothed belt: removing, instal‐
ling and tensioning
– Remove fixing bolt -1- from the idler roller-2- and remove the
idler roller.
– Unscrew coolant pump securing bolts -3- and remove coolant
pump-4- .
1.5.2 Fitting
Installation is carried out in the reverse sequence, when doing this
note the following:
– Clean the sealing surface for the O-ring.
– Moisten the new O-ring -5- with coolant.
– Insert coolant pump -4- into cylinder block and tighten securing
bolts -3- . Tightening torques: 15 Nm
– Replace the securing bolt -1- for the idler roller -2- and fit the
idler roller. Tightening torques: 40 Nm + 1/4 turn (90 °)

1.6 Radiator: removing and installing

equipment required
8010-
type clips
♦ Lock carrier centraliser -
T20070-
1.6.1 Removing
– Removing the front bumper: ⇒ Body repairs-outside assembly
work; Rep. Gr. 63 ; Front bumper: removing and installing
– Remove coolant hoses from radiator.
– Pull connectors off thermoswitch and radiator fan.

– Bring lock carrier into service position: ⇒ General Body Re‐

pairs, exterior; Rep. Gr. 50 ; General Body Repairs, front Lock
carrier service position
– Loosen radiator securing bolts and remove radiator down‐
wards together with fan.
Vehicles with air conditioning:
Caution
The air conditioning refrigerant circuit must not be opened.
Note!
To prevent damage to condenser and refrigerant pipes/hoses,

ensure that pipes and hoses are not stretched, kinked or bent.
– Remove the clip/s from the cooling agent hose/s.

– Unbolt condenser from radiator and secure to lock carrier.
Continued for all vehicles:
– Remove radiator duct and the electric fans.
– Loosen radiator securing bolts and remove radiator together
with fan
1.6.2 Fitting
Installation is carried out in the reverse order. When doing this
note the following:

1.7 Coolant thermostat: removing and installing

equipment required
8010-
type clips
1.7.1 Removing
– Remove engine cover in the -direction of the arrow-.
Note!
Always renew seals and gaskets.

– Pull coolant hose off connector -2- .

– Unbolt securing bolts -1- from connecting flange -2- and re‐
move connecting flange -2- with coolant thermostat-4- .
– Turn coolant thermostat -4- 1/4 of a turn (90°) to the left and
remove from the connector -2- .
1.7.2 Fitting
Installation is carried out in the reverse order. When doing this
note the following:
– Clean the sealing surface for the O-ring.
– Moisten new O ring -3- with coolant and fit it to the connector.
– Fit the coolant thermostat -4- onto the connector -2- and turn
1/4 of a turn (90 °) to the right.
Note!
The brace on the thermostat must be almost vertical.
– Loosen connecting flange -2- with thermostat- 4- in the engine

block.
– Tighten securing bolts -1- . Tightening torques: 15 Nm
1.8 Radiator fans -V7- and -V35- : checking

♦ -V.A.G 1594 A- or auxiliary measuring set -V.A.G 1594 C-
♦ Current flow diagrams


• The basic fuses should present no problems.
• Radiator fan thermoswitch -F18- , OK.

– Remove 3 pin connector from radiator fan thermoswitch -
F18- .
– Bridge connector contacts -1- and -2- of connector terminal
using auxiliary cables from -V.A.G 1594 A- or -V.A.G 1594 C- .
Radiator fans -V7- and -V35- should begin to run at speed 1.
– Switch ignition on.
– Bridge connector contacts -2- and -3- of connector terminal
using auxiliary cables from -V.A.G 1594 A- or -V.A.G 1594 C- .
Radiator fans -V7- and -V35- should begin to run at speed 2.
If fans do not run at 1st or 2nd speeds:
– Locate and rectify open circuit using current flow diagram:
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations .
If no wiring fault is detected:
– Replace radiator fans -V7- or -V35- .
1.9 Cooling system water tightness: check‐

ing
♦ Coolant system tester -SAT 1274-

• Engine at service temperature
Caution
Steam can be released when removing the cap from the ex‐
pansion tank. The cap should be covered with a cloth and
opened carefully
– Open cap on coolant expansion tank.

– Fit tester -SAT 1274- with adaptor -V.A.G 1274/8- in expan‐
sion tank .

– With the tester hand pump, a pressure of 1 bar should be cre‐

ated.
– If the pressure is low the leak will have to be detected in the
installation and the fault eliminated.
1.9.3 Checking the pressure relief valve in the

locking cap
– Fit tester -SAT 1274- with adaptor -V.A.G 1274/9- in locking
cap.
– With the tester hand pump, a pressure of 1.5 bar should be
created.
– Operate hand pump. The pressure relief valve should open at
1.4...1.6 bar

20 – Fuel supply system

1 Fuel supply system components: re‐
moving and installing
Note!
♦ Hose connections are secured with either spring-type or

clamptype clips.
♦ Always replace clamp-type clips with spring-type clips.
♦ For fitting the spring-type clips, assembly tool -T20029- is rec‐
ommended.
Observe safety precautions ⇒ page 90 .

Observe rules for cleanliness ⇒ page 90 .
Removing and installing fuel tank with attachments
⇒ page 87 .
Repairing the fuel filter ⇒ page 89 .
Repairing the accelerator control ⇒ page 96 .
86 Rep. Gr. 20 - Fuel supply system

1.1 Fuel tank with accessory parts: removal and installation
1 - Cap
2 - Securing screw
3 - Tank flap unit
⇒ General external
body-assembly work;
Rep. Gr. 55 ; Fuel tank
flap unit
4 - Gravity/overflow valve
❑ To remove, release
locking lug and unclip
valve upwards out of fill‐
er neck
❑ Check valve for through
flow Valve vertical:
open, valve tilted 45 °:
closed
5 - Earth connection
ing
6 - 10 Nm
7 - Vent pipe
❑ Clipped onto top of fuel
tank
ing
8 - Securing screw
❑ 25 Nm
9 - Fuel tank
❑ Support with engine and
gearbox jack -SAT
1001- when removing
10 - Securing strap
11 - Fuel delivery unit
❑ Note fitting position of flange on fuel tank ⇒ page 88
❑ With fuel gauge sender -G-
❑ Removing and fitting the fuel level sender ⇒ page 95
❑ Clean filter if soiled
12 - O- ring
❑ Coat with fuel when installing
13 - Union nut
❑ Remove and install with -U-40055A-
14 - Supply pipe/hose
❑ To fuel filter ⇒ Item 6 (page 89)
❑ Black
❑ Clipped to the fuel tank
1. Fuel supply system components: removing and installing 87


❑ To uncouple from sealing flange press unlocking keys on connecting element
15 - Return pipe
❑ From fuel filter ⇒ Item 5 (page 89)
❑ Blue or with blue marking
❑ Clipped to the fuel tank
❑ To uncouple from sealing flange press unlocking keys on connecting element
16 - Vent valve
❑ To remove valve unclip sideways out of support
❑ Before installing, unscrew cap
17 - O-ring
Fitting position of fuel delivery unit flange

Marking on flange must align with the marking on fuel tank
-arrows- .
Blue or blue marked return pipe -1- to connection with identifica‐
tion R.
Black supply pipe -2- to connection with identification V.
Note!
After installing fuel delivery unit flange, check that the supply, re‐
turn and breather pipes are still clipped onto the fuel tank.
Checking vent valve

Lever in rest position: closed
Lever pushed in direction of arrow: open
Note!
Before installing vent valve remove fuel tank cap.

1.2 Fuel filter: repairing
1 - Return pipe
❑ From the injection pump
❑ Blue or with blue mark‐
ing
ing
❑ Towards the injection
pump
❑ White or white mark
ing
3 - Securing clip
ing
4 - Regulating valve
❑ Assembly position: Ar‐
row pointing to petrol
tank
❑ To change the filter, re‐
move the securing clip
and the regulating valve
with the fuel pipes con‐
nected
❑ Less than +15 °C: Flow
to filter, open
❑ More than +31 °C: flow
to filter, closed
5 - Return pipe
❑ To fuel tank
❑ Blue or with blue mark‐
ing
❑ From fuel tank
❑ White or white mark
7 - Fuel filter
❑ Fill with diesel fuel before fitting
❑ Direction of flow indicated by arrows
❑ Do not mistake unions
8 - Gasket
9 - Water drain screw
❑ To ventilate, remove the securing clip and the regulating valve with the fuel pipes connected
❑ Open and let about 100 cm³of fluid come out (collect it)
10 - 25 Nm
11 - Fuel filter bracket

12 - Cartridge
Removing and fitting fuel filter

– Remove the regulating valve with the fuel pipes connected
(remove the securing clip).
– Press the fixing lugs -arrows- on the plastic element outwards.
– Remove the fuel filter upwards.
Note!
The fuel filter can only be fitted in one position.
1.3 Safety precautions when working on the

fuel supply system
Caution

following:
Caution
ing with care.
work!
On removing and fitting the fuel level sender from a full or almost
full fuel tank, observe the following:
♦ Before commencing work, switch on exhaust extraction sys‐
tem and place an extraction hose close to the sender opening
in the fuel tank to extract escaping fuel fumes. If no exhaust
extraction system is available, a radial fan (as long as motor
is not in air flow) with a displacement greater than 15 m³/h can
be used.
♦ Avoid skin contact with fuel, wear fuel-resistant gloves!
1.4 Rules for cleanliness

When working on the fuel supply/injection system the following “6
rules of cleanliness” must be observed:
♦ Thoroughly clean all unions and the adjacent areas before
disconnecting.

♦ Place parts that have been removed on a clean surface and

cover them. Use lint-free cloths!
♦ If repairs cannot be completed in one session, all parts and
components that are left open should be covered or stored
with the greatest of care.
♦ Only install clean components: Only unpack replacement
parts immediately prior to installation. Do not use parts that
have been stored loose (e.g. in tool boxes etc.).
♦ When the system is open: Do not work with compressed air if
this can be avoided. Do not move vehicle unless absolutely
necessary.
♦ Furthermore, check that no diesel leaks onto the coolant hose
pipes. If necessary, immediately clean the hose pipes. The
affected hose pipes should be replaced.
1.5 Fuel tank: removing and installing

♦ Engine and gearbox jack -SAT 1001 A-
1.5.1 Removing
Note!


– Fold rear seat bench forwards.

– Remove the fuel level sender cover -1- and remove the flange
connector -3- upwards.
– Open fuel flap.
– Empty the fuel tank.
– Remove rear right wheel housing liner: ⇒ Body-work external
installation work; Rep. Gr. 66
– Remove all rear exhaust system brackets. Then lower the ex‐
haust system a little, hanging it from the body with wire.
– Remove the heat shield to the left of the fuel tank.

– Remove rear axle: ⇒ Running gear, axles, steering, front
wheel and four wheel drive; Rep. Gr. 42 ; Rear axle: Rear
axle: removing and installing
– Uncouple the supply hose (black) -1- and the return hose
(blue) -2- in the fuel tank (press the unblocking mechanism on
the quick connector).
– Remove securing bolts on filler neck -arrows- .

– Remove the securing screws from the strap on the fuel tank
and support it with engine/gearbox jack -SAT 1001A- .
– Remove the fuel filler from the rubber bowl.
– Lower fuel tank.
1.5.2 Fitting
Install in reverse order but note following:
♦ Breather and fuel hoses are to be installed kink-free.
♦ Ensure fuel hoses are seated securely.
♦ Do not interchange supply and return hose (return hose blue
or blue markings, supply hose black).
♦ Clip supply and return pipe onto fuel tank.
Note!
After installing fuel gauge sender, check that the supply, return
and breather pipes are still clipped onto the fuel tank.
1.6 Fuel gauge sender unit: removing and

installing
♦ Ring nut spanner -U-40055 A-

1.6.1 Removing
– First check whether a coded radio is fitted. If this is the case
consult the anti-theft coding.
– Fold rear seat bench forwards and remove the cover -1- , the
dust sleeve -2- may remain in place.
– Remove the supply hose (black) -5- and return hose (blue)
from the quick connector, by pressing the unblocking mecha‐
nism.
– Uncouple the double-contact connector -3- and remove the
sender unit flange.
Caution
ing with care.
work!
– Place spanner -U-40055 A- on nut and unscrew it from the

flange.
– Pull fuel delivery unit and seal out of the opening in fuel tank.
Note!
If the delivery unit is to be renewed then drain old delivery unit

before disposal.
1.6.2 Fitting
– Installing the fuel delivery unit is carried out in the reverse or‐
der.

Note!
♦ Do not bend fuel sender when installing.

♦ Insert seal for flange or fuel delivery unit dry into opening of
fuel tank.
♦ Moisten seal with fuel only when installing flange or fuel de‐
livery unit.
♦ Ensure fuel hoses are seated securely.
♦ After installing fuel delivery unit, check that the supply, return
and vent pipes are still clipped onto fuel tank.
♦ Note installation position of fuel delivery unit flange: The mark‐
ing on flange must align with marking on fuel tank -arrows- .
Note assembly position:

♦ The marking on the flange must align with marking on fuel tank
-arrows- .
♦ Connect the supply hose (black) -1- to the connection marked
V.
♦ Connect the return hose (blue) -2- to the connection marked
R.
1.7 Fuel gauge sender: removing and in‐

stalling
1.7.1 Removing
– Removing fuel delivery unit ⇒ page 93 .
– Release and pull off the terminals for wires -3- and-4- .
– Lift retaining tabs -1- and -2- with a screwdriver and disconnect
fuel gauge sender downwards -arrow- .
1.7.2 Fitting
– Insert fuel gauge sender in the guides on the fuel delivery unit
and push up until it engages.

1.8 Accelerator mechanism: repairing
1 - Support
2 - Connector
❑ Black, 6-pin
3 - Accelerator pedal position
sender -G79- -
❑ Not adjustable
❑ The accelerator pedal
position transmits the
position of the pedal on
to the engine control unit
❑ Remove footwell cover
on driver's side to re‐
move sender
4 - 10 Nm

1.9 Accelerator pedal position sender: checking

equipment required
♦ Hand multimeter -V.A.G
1526-
♦ Fault reader -V.A.G 1551-
or vehicle system tester -
V.A.G 1552- with cable -
V.A.G 1551/3B-
♦ Auxiliary measuring set -
V.A.G 1594 A-
♦ Test box -V.A.G 1598/31-
♦ Current flow diagram

• The fuses must be OK.
• Battery voltage at least 11.5 V
• All electric consumers, e.g.: lights and rear window heater
must be switched off.
• If the vehicle is equipped with air conditioning, this must be
switched off.

– Connect fault reader -V.A.G 1551- ( -V.A.G 1552- ) and select
engine electronics control unit with the “Address code” 01. The
ignition must be switched on:

Indicated on display: Rapid data transfer HELP

Select function XX
– Press keys 0 and 8 for the function “Read measured value

block” and confirm entry with Q key.
Indicated on display: Read measured value block
Input display group number XXX
– Press keys 0 , 0 and 2 for “Display group number 2” and

confirm entry with Q key.
Read measured value block 2→
0/min 0.0 % 0 1 0 18.4 °C
– Check the indication of the accelerator pedal position in field

2, without pedal being pressed. Specification: 0,0 %
– Also check the idling switch indicator in field 3. The central digit
should be 1. Display: 0 1 0
Read measured value block 2→
0/min 100.0 % 0 0 0 18.4 °C
– Slowly press the accelerator pedal to its limit, observing fields

2 and 3.
♦ Display field 2: The value of the accelerator pedal position
should rise continously. Value of accelerator in full throttle po‐
sition: 100,0 %
♦ Display field 3: The central digit should change to 0. Display:
000
– Press → key.
– Press keys 0 and 6 for the “End data transfer” function and
confirm input with the Q key.
– Switch off ignition.
If the specification is not obtained:
– Remove cover in footwell (driver's side).
– Replace the accelerator pedal position sender -G79-
⇒ Item 3 (page 96) .
If the indication does not vary or only varies irregularly:
– Check accelerator pedal position sender wiring as follows:
– Connect test box -V.A.G 1598/31- to control unit wiring har‐
ness without connecting the engine control unit.
– Remove cover in footwell (driver's side).
– Disconnect 6-pin connector for accelerator pedal position
sender.

– Check wiring between test box socket and connector for open
circuit for breaks, using current flow diagram: Contact 2+sock‐
et 12 Contact 3+socket 50 Contact 4+socket 69 Contact 5
+socket 70 Contact 6+ socket 51 Wire resistance: 1,5 Ω Max.
– Additionally check wires for shorts to one another, to vehicle
earth or to battery positive. Specification: ∞ Ω
– Replace the accelerator pedal position sender -G79-
⇒ Item 3 (page 96) .
If the specifications are still not attained:
– Replace the injection system and diesel pre-heating control
unit ⇒ Rep. Gr. 23 ; Engine control unit: replace, code and
adapt, Engine control unit: replace

23 – Mixture preparation, Injection

1 Direct diesel injection system: repair‐
ing
The direct diesel injection and ignition system control unit is
equipped with a fault memory. Before carrying out work or repairs
and for finding faults, the fault memory for the engine control unit
has to be consulted: consulting and erasing. -VAS 5051- , Vehicle
self-diagnosis, ⇒ page 156
Safety precautions ⇒ page 100
Rules for cleanliness ⇒ page 90
1.1 Safety precautions
Caution

following:
To prevent injuries to persons and/or damage to the injection and

ignition pre-heating system, the following must be observed:
♦ The ignition must be switched off before connecting or dis‐
connecting injection or ignition system wiring or tester cables.
♦ If the engine is to be turned at starter speed, without starting,
eg: for compression pressure test, the 10-pin connector of the
ignition coil must be disconnected from the injector pump.
♦ If there is a radio with an anti-theft code, the code should be
consulted before disconnecting the battery.
♦ The battery can be connected and disconnected only with ig‐
nition switched off; if not, the direct diesel injection control unit
could be damaged.
Observe the following if test and measuring instruments are re‐
quired during a test drive:
♦ Test and measuring instruments must be secured to rear seat
and operated by a 2nd person from this location.
Caution
Secure fault reader to rear seat and operate from this position.
If test and measuring instruments are operated from front pas‐

senger's seat and the vehicle is involved in an accident, there is
a possibility that the person sitting in this seat may receive serious
injuries if the airbag is triggered
100 Rep. Gr. 23 - Mixture preparation, Injection

1.2 Rules for cleanliness

When working on the fuel supply/injection system, pay careful at‐
tention to the following “rules on cleanliness” :
♦ Thoroughly clean all unions and the adjacent areas before
disconnecting.
♦ Place parts that have been removed on a clean surface and
cover them. Use lint-free cloths!
♦ If repairs cannot be completed in one session, all parts and
components that are left open should be covered or stored
with the greatest of care.
♦ Only install clean components: Only unpack replacement
parts immediately prior to installation. Do not use parts that
have been stored loose (e.g. in tool boxes etc.).
♦ When the system is open: Do not work with compressed air if
this can be avoided. Do not move vehicle unless absolutely
necessary.
♦ Furthermore, check that no diesel leaks onto the coolant hose
pipes. If necessary, immediately clean the hose pipes. The
affected hose pipes should be replaced.
1.3 Fitting locations overview

The components from A to G do not appear in the breakdown.
A - Relay for the Diesel direct injection system -J322-
♦ In the relay bracket ⇒ page 20
♦ Checking ⇒ page 121
B - Glow plug relay -J52-
♦ Checking; -VAS 5051- ; Vehicle selfdiagnosis ⇒ page 156
C - Relay for high heating power -J359-
D - Relay for high heating power -J360-
E - Accelerator pedal position sender -G79- -
♦ In footwell, accelerator pedal ⇒ page 103
♦ Checking ⇒ page 97 ⇒ Rep. Gr. 20 ; Fuel supply system
components: removing and installing Accelerator mechanism:
repairing
F - Brake light switch -F- brake pedal switch -F47-
♦ In footwell, brake pedal ⇒ page 103
G - Clutch pedal switch -F36-
♦ In footwell, in clutch pedal ⇒ page 103
1. Direct diesel injection system: repairing 101

1 - Exhaust gas recirculation

valve -N18-
❑ Checking; -VAS 5051- ;
Vehicle selfdiagnosis
⇒ page 156
2 - Mechanical exhaust gas re‐
circulation valve
⇒ Rep. Gr. 26 ; Exhaust
gas recirculation system
3 - Injector with needle move‐
ment sender -G80-
❑ Checking; ⇒ page 134
4 - Inlet manifold flap motor -
V157-
5 - Temperature sender in in‐
take manifold -G72-
6 - Air cleaner
❑ Dismantling and assem‐
bly Air cleaner
⇒ page 105
❑ Removal and installa‐
tion ⇒ page 105
7 - Direct diesel injection con‐
trol unit -J248- -
❑ With altitude sender -
F96-
❑ Encode ⇒ page 155
❑ Checking the diesel direct injection system voltage supply -J248- ⇒ page 153
8 - Coolant temperature sender -G62-
❑ Black
❑ With coolant temperature gauge sender -G2-
❑ If necessary release pressure in cooling system before removing
9 - Connector
❑ 2-pin, brown
❑ For the needle movement sender -G80- -
10 - Connector
❑ 3-pin, grey
❑ For engine speed sender -G28-
11 - Connector
❑ 10-pin, black
❑ For the fuel temperature sender -G81- -
❑ For the dosifier -N146-
❑ For the slide travel sender -G149-

❑ For the injection start valve -N108-

❑ For the fuel cut-off valve -N109-
12 - Fuel cut-off valve -N109-
13 - Injection start valve -N108-
❑ With flap on intake manifold
14 - Injection pump dosifier mechanism
❑ With dosage servomechanism
❑ With fuel temperature sender -G81-
❑ With dosifier -N146-
❑ With slide travel sender -G149-
15 - Fuel filter
Relay bracket
1 - Relay for the diesel direct injection system -J322- ; item 10,
(109)
2 - Glow plug relay -J52- ; item 3, (103)
3 - Relay for high heating power -J360- ; item 14, (100)
4 - Relay for low heating power -J360- ; item; 15, (53)
Components on the pedal assembly bracket

1 - Clutch pedal switch -F36-
2 - Brake light switch -F- and brake pedal switch -F47-
3 - Accelerator pedal position sender -G79-

1.4 Intake manifold: removing and installing
1 - 25 Nm
2 - 10 Nm
3 - Securing clip
4 - O-ring
❑ Renew
5 - Motor for flap in intake
manifold -V157-
6 - 10 Nm
7 - Connection for bleeding
crankcase
8 - 20 Nm
9 - Gasket
❑ Renew
10 - Intake manifold
11 - Gasket
❑ Renew
12 - Mechanical exhaust gas
recirculation valve
❑ Checking ⇒ Rep. Gr.
26 ; Exhaust system
components

1.5 Air cleaner: dismantling and assembly
1 - Flexible air hose

❑ To intake manifold
❑ Note assembly position
2 - Flexible clamp
3 - 2 Nm
4 - Air cleaner upper part
5 - Filter element
6 - Air cleaner lower part
7 - 2 Nm
8 - Air duct
❑ To front panel
9 - Connection for bleeding
hose
10 - Securing clip
❑ Check for correct seat‐
ing
11 - Intake manifold tempera‐
ture sender -G72-
12 - O-ring
Air cleaner: removal and installation
1.5.1 Removing
– Remove spring-type mounting -1- in the flexible air hose and
separate it from the air cleaner.
– Loosen the bleeding hose -2- and uncouple the connector for
the intake manifold temperature sender.
– Remove air filter conduit -4- for the air cleaner.

– Remove the securing bolt -5- on the air cleaner Tightening

torques: 5 Nm
– Carefully separate the air cleaner by pulling it upwards.
1.5.2 Fitting
Note!
Make sure that the stops on the bottom part of the air cleaner are
correctly seated (front and back).
– Install the air cleaner in reverse order.
Note!
When fitting the mark on the flexible hose should be located

-arrows- .
1.6 Injection pump: repairing

♦ Observe safety precautions ⇒ page 90
♦ Removing and installing the fuel pump: ⇒ page 109
♦ Check and adjust dynamically the beginning of injection
⇒ page 113 , Components and functions: adapting

♦ Always replace seals and O rings
1 - Securing bolts for the injec‐

tion pump spindle
❑ 25 Nm
❑ Look at the two models
that exist: ⇒ page 108
2 - Injection pump spindle
⇒ page 109 ,Injection
pump: removing and in‐
stalling
3 - Tighten bolt
❑ For hub
❑ Can not by loosened un‐
der any circumstances.
If it is, the basic setting
of the injection pump will
be knocked out of
phase; this can not be
adjusted with the tools
available in the work‐
shop.
4 - Connection
❑ 25 Nm
❑ For fuel supply pipe
❑ From fuel filter
5 - Oil seal
❑ Renew
6 - Fuel cut-off valve -N109-
❑ 40 Nm
❑ Checking -VAS 5051- ,
Vehicle selfdiagnosis
⇒ page 156
7 - Connection
❑ For return pipe
8 - Return pipe
❑ Towards the regulating valve/fuel filter
9 - 25 Nm
10 - Injection hoses
❑ Tighten to 25 Nm
❑ Remove with tool -U-40072-
❑ Always remove the complete set of hoses
❑ Do not change the bends
11 - Connection
❑ 45 Nm
❑ With pressure valve
12 - 25 Nm
13 - Injector
❑ Dismantling and fitting ⇒ page 116

❑ For cyl. 3 with needle movement sender -G80-

14 - 20 Nm
15 - Support flange
16 - Round washer
17 - Insulation gasket
❑ Renew
18 - 10 Nm
19 - Injection start valve -N108-
❑ -VAS 5051- , Vehicle self-diagnosis ⇒ page 156
20 - O-ring
❑ Renew
21 - Filter
22 - 30 Nm
23 - Bush
❑ With bolt
24 - Console
❑ For injection pump and alternator
❑ Different in vehicles with and without air conditioning
❑ Removal and installation: ⇒ Rep. Gr. 13 ; Engine: dismantling and assembling
25 - 30 Nm
1.6.1 Securing bolts models for the injection

pump spindle
1.6.2 Type A: Securing bolts with recess in the

thread and pins -arrows a-
♦ Part No. for securing bolts: -N 907 134 01-
♦ Part No. for the injection pump spindle: -038 130 111 A-
♦ Tightening torque: 20 Nm
♦ Replace fixing bolts.
Note!
♦ After checking beginning of injection, retighten the fixing bolts

90° (1/4 turn).
♦ The fixing bolts -A- should only be used once, as they are ex‐
panding bolts .

1.6.3 Type B: Securing bolts without recess in

the thread and pin
♦ Part No. for securing bolts: -N 903 285 04-
♦ Part No. for the injection pump spindle: -038 130 111 B-
♦ Tightening torque: 25 Nm
♦ The fixing bolts do not have to be replaced.
1.7 Injection pump: removing and installing

equipment required
♦ Adapter -1318/10-
♦ Hand vacuum pump -SAT
1390-
T20038- 7)

T20119-
7) If it is not, cut with saw according to figures in drawing.

♦ Adjusting tool -U-20010- for

TDC
♦ Open ring spanner -
U-40072-
♦ Feeler gauge
1.7.1 Dismantling
– Loosen the toothed belt and remove it from the camshaft
wheel and the injector pump ⇒ page 34 , Toothed belt: remov‐
ing, installing and tensioning.
Note!
It is not necessary to remove the damper/belt pulley nor the lower

protective cover for the toothed belt.
– Remove all the fuel pipes from the pump.
Note!
♦ To loosen the injector hoses, use ring spanner -U-40072- .

♦ Do not change the shape of the hoses.
– Cover the openings with a clean cloth.

– Uncouple the 10-pin connector towards the injector pump and

separate the connector from its support .
– Loosen the bolts which secure the injection pump wheel-1- .
Note!
The bolt -2- on the hub should never be loosened. If it is, the basic
setting of the injection pump will be knocked out of phase; this
can not be adjusted with the tools available in the workshop.
– Remove securing bolts from the compact bracket -1- .
– Remove the bolt which secures the rear support -arrow- .

– Remove the injection pump.
1.7.2 Installation
– Place the injector pump in the compact support and first se‐
cure the bolt to the rear support with the fixing nut.

– Fit the fixing bolts -1- and tighten them to tightening torque 30
Nm.
– Screw the injection pump wheel to the bush, without tighten‐

ing, using the fixing bolts -1- .
– Immobilize injection pump wheel with locking pin -T20102- .
– Centre the injection pump wheel on the coil openings.
– Loosen camshaft wheel securing bolt by 1 turn. To loosen the
securing bolt, immobilize the camshaft wheel with retaining
tool -T20018A- .
Note!
The adjusting ruler -T20038- should never be used as a retaining

tool to loosen and secure the camshaft wheel. Use retaining tool
-T20018A- .
– Use extractor -T20119- to separate the camshaft wheel from

its cone.
– Remove the camshaft wheel.
– Check to see if TDC mark on fly wheel and the reference mark
coincide.
– Place the toothed belt on the injector pump wheel and the ten‐
sioning roller.
– Insert the camshaft sprocket in the toothed belt and secure the
camshaft sprocket in such a way that it can still turn.
– Tighten the toothed belt ⇒ page 34 .
– Couple the injector tubes, the fuel pipes and all the electrical
cables.

Fill the injector pump with petrol as follows.

– Screw on adaptor -V.A.G 1318/10- to the return opening on
the injector pump.
– Couple the adaptor to the manual vacuum pump -V.A.G 1390-
with the help of a clear plastic hose approx. 1 m in length.
– Work the manual vacuum pump -V.A.G 1390- until fuel comes
out of the return hose. The fuel should not reach the vacuum
pump.
– Remove the adaptor and couple the return fuel hose.
1.8 Beginning of injection: check and adjust

dynamically
Note!
♦ The dynamic checking and testing of the start of injection are

only possible in function 04 “Engine basic setting” .
♦ The start of the injection should always be checked and be
adjusted if necessary, after replacing the toothed belt and after
having loosened the bolted joints on the injector pump or the
toothed belt wheel.

♦ Fault reader -V.A.G 1551- or vehicle system tester -V.A.G
1552- with cable -V.A.G 1551/3B-

1.8.1 Conditions for testing and adjusting

• Engine mechanical basic setting, correct
• V-belt tension, correct
1.8.2 Work sequence

– Connect fault reader -V.A.G 1551- ( -V.A.G 1552- ). Start en‐
gine and select “Address code” 01 to select engine control unit.
Select function XX
– Press keys 0 and 4 for the function “Begin basic setting” and
confirm entry with the Q key.
Indicated on display: Basic setting
– Press key 0 three times for “Display group number 0” and

Indicated on display: (1...10 = display fields) System in basic setting 0 →
43 79 0 22 19 199 73 156 131 255
– Check the coolant liquid temperature indicated in display field

7. Value indicated between 72 ÷ 75 corresponding to a tem‐
perature of approx. 85° C.
Do not continue with the check until the coolant temperature has
been reached.
Beginning of injection, display zone 2, depends on the fuel tem‐
perature, display zone 9. A - Display zone 2, beginning of injec‐
tion. B - Display zone 9, fuel temperature. C - The tolerance range
for the beginning of injection.
Data readings example:
The numeric value 90 in the display zone 9 -B- , corresponds in
display zone 2 -A- to a range of 25...78.
Note!
If when checking the beginning of the injection is within the range

indicated -C- , a new adjustment is not necessary. After repairs,
such as the removal or installation of the injector pump or the
adjustment of the distribution times, the beginning of the injection
should be adjusted to the average value (traced line) of the tol‐
erance range -C- .
– Press → key.
– Press keys 0 and 6 for the “End output” function and confirm
input with the Q key.
If the beginning of the injection is outside the range, it will need
to be adjusted as follows:
– Remove upper part of toothed belt guard.

– Loosen the two fixing screws -1- on the injector pump wheel.
– To hold the pump shaft, a ring spanner e/c 22 will have to be
used on the hub bolt -2- .
– Loosen the third fixing bolt on the injector pump wheel and
gently offset the injector pump shaft by turning. To the left =
delays the beginning of injection. To the right = advances the
beginning of injection.
Note!
The bolt -2 on the hub should never be loosened. If it is, the basic
setting of the injection pump will be knocked out of phase; this
can not be adjusted with the tools available in the workshop.

thread and pins -arrows-
– Tighten the new securing bolts for the injection pump spindle.
Note!
♦ After the dynamic checking of the beginning of the injection,

the fixing bolts should be tightened 1/4 of a turn (90°) more.
♦ The fixing bolts should only be used once, as they are ex‐
panding bolts.
1.8.4 Type B: Securing bolts without recess in

the thread and pin
– Tighten the securing bolts for the injection pump spindle.
Note!
The fixing bolts are not replaced.
1.8.5 Continuation for all versions:

– Observe value in display field 2 and if necessary, repeat the
adjustment until the value indicated stays within the average
value of the specifications -C- .

thread and pins -arrows-
– Tighten 1/4 turn (90°) the new securing bolts for the injection
pump spindle.

1.8.7 Continuation for all versions:

– Press → key.
– Installing toothed belt guard upper section
– Install engine cover.
1.9 Injectors: removing and installing

equipment required
♦ Open ring spanner -
U-40072-
8010-
♦ Extractor -T10055A-
♦ Adaptor -T10055/1-

Note!
♦ Faulty injectors produce the following faults:

♦ Faulty ignition
♦ Knocking in one or more cylinders
♦ Engine overheating
♦ Reduction in power
♦ Excessive black exhaust fumes
♦ Increased fuel consumption
♦ Blue smoke when starting in the cold
Faulty injectors can be located by loosening the ring nuts on the

injector hoses after the other whilst the engine is idling quickly. If
the engine speed remains constant after loosening a ring nut this
is a sign that the injector is defective.
1.9.1 Removing
– Undo the injection pipes with torque spanner -U-40072- .
Note!
Always remove the complete set of hoses. Do not bend the hoses.
– If necessary, loosen the hollow bolt for the return hose (injector
cyl. 3).
– Loosen the fixing bolt, remove the support flange and pull out
the injector.
Note!
To extract the clipped injectors, use extractor -T10055- with adap‐

tor -T10055/1-
– Screw extractor -T10055- with adaptor -T10055/1- on to the

injector.
– Carefully remove the injector from its seating in the cylinder
head (upwards) by softly tapping.

1.9.2 Fitting
Note!
Always replace the insulation gasket between the cylinder head

and the gasket.
– Fit the injectors.

– Make sure the cylinder head supports are correctly seated.
– Fit the support flange and tighten the fixing bolt.
Tightening torques:
Injection tubes = 25 Nm
Bolt for support flange = 20 Nm
1.10 Injectors: checking

This engine is fitted with double-springed injectors; therefore, the
fuel in injected in two phases.
If these injectors become faulty they must be replaced as it is not
possible to adjust the pressure or repair them.
♦ Injector tester -V.A.G 1322- with pressure hose -V.A.G
1322/2-

• Pressure tester connected
1.10.2 Check the pressure of the flow
Caution
When checking the injectors, be careful that the fuel flow does
not spray over your hands as due to the high pressure the fuel
can penetrate the skin causing serious injury.
– Removing injectors ⇒ page 116

– Connect the injector to the injector tester.

– Press the lever of the pump slowly downwards. As the injection
begins, read the pressure of the flow. If the reading is different
from that of the specification, replace the injector.
Specifications (positive pressure): New injectors: 220...230 bar
Wear limit: 190 bar
1.10.3 Checking for leaks

– Press the lever on the pump gently downwards and keep the
pressure at approx. 150 bar for 10 seconds. There should not
be any fuel leaks from the injector.
– If there are leaks, replace the injector.
1.11 O-ring for injection corrector cover: re‐

place
– Place a clean cloth below the injector pump.
– Extract the fixing bolts from the cover -1- with a commercial
angular screwdriver for Torx screws, for example: -Hazet
2115-T30-
– Remove the cover -2- and clean it.
– Replace the O-ring -3- and fit the cover with the old washers
-4- .

2 Components and functions: checking
2.1 Checking cables and components with

test box -V.A.G 1598/31-
♦ Test Box -V.A.G 1598/31-
Note!
♦ Test box -V.A.G 1598/31- is designed so that it can connect

simultaneously to the wiring harness, to the engine control unit
and to the unit itself.
♦ This has the advantage that the engine control unit continues
to function fully with the test box connected (e.g. measuring
signals while the engine is running).
♦ The need to additionally connect the control unit to the test box
is indicated in the corresponding test processes.
♦ The connector contact number and the test box -V.A.G
1598/31- connection number coincide.
Caution
To avoid destroying the electronic components, before con‐

necting the measuring cable, the corresponding measuring
range must be chosen and the testing conditions adhered to.

– Loosen the fixing of the connectors and separate the connec‐
tors from the engine control unit.
– Connect the test box -V.A.G 1598/31- to both the wiring har‐
ness connectors. The earth clip in the test box should be
connected to the battery negative.
– Carry out the test as described in the corresponding test pro‐
cesses.

2.2 Relay for the diesel direct injection system -J322- : checking
The voltage supply for the injection system comes for the relay
for the direct diesel injection system -J322- .

equipment required
1526 A- or multimeter -
V.A.G 1715-
♦ -V.A.G 1594 A- or auxiliary
measuring set -V.A.G 1594
C-
♦ Test box -V.A.G 1598/31-
2.2.1 Fitting location

the relay for the direct diesel injection system -J322- is situated
in the relay bracket on the driver's side to the left, socket 10
Check conditions:
• Battery voltage correct (at least 11.5 V)
• The fuses in the battery fuse holder should work perfectly

Checking functioning:
2. Components and functions: checking 121

– Removing the lower part of the dash panel, driver's side ⇒

General body repairs; Rep. Gr. 70 ;
– Switch on ignition.
Relay for the diesel direct injection system -J322- should operate.
Note!
Due to the engine noise it is not possible to hear the sound of the
relay and it is better to check it by feel.
If the relay does not operate:
2.2.3 Checking the operation

ness. The engine control unit remains disconnected.
– Measure the voltage with manual multimeter -V.A.G 1526 A-
between the following sockets: 18 and 4 Specification: approx.
0V
The relay should operate.
The relay operates but not in the test:
– Renew engine control unit -J248- ⇒ page 154
If the relay does not operate:
– Extract the relay for the diesel direct injection system -J322-
from the relay bracket socket.
– Connect the manual multimetre -V.A.G 1526 A- in contact 2

and earth to measure voltage. Specification: battery voltage
– Check cables for brake, open circuit and transfer resistances
at contact points, using current flow diagram.
If the specification is obtained:
– Check wiring for open circuit between test box and relay brack‐
et position 10 using current flow diagram. Contact 9 + socket
18 Wire resistance: 1,5 Ω Max.
– Check the cables for short circuit, using current flow diagram
Specification: ∞ Ω
– Replace the relay for the Diesel direct injection system -J322-
2.3 Engine speed sender: checking

The engine speed sender -G28- is a speed and reference mark
sender. The engine stops if the sender gets damaged.


♦ Test box -V.A.G 1598/31-
♦ Hand multimeter -V.A.G 1526 A- or multimeter -V.A.G 1715-

– Disconnect the grey connector for the engine speed sender -
G28- .
– Connect multimeter -V.A.G 1526 A- (resistance measure‐

ment) to contacts 1 and 2 of connector -2- , using measuring
cable -V.A.G 1594 C- . Specification: 1.0...1.6 kΩ
– Replace engine speed sender -G28- . ⇒ Rep. Gr. 13 ; Engine:
dismantling and assembling


– Check wiring between test box and 3-pin connector for open
circuit using current flow diagram. Contact 1+socket 102 Con‐
tact 2+socket 110 Contact 3+socket 86 Wire resistance: 1,5
Ω Max.
– Check 3-pin connector cables for short circuit, using current
flow diagram Specification: ∞ Ω
– Replace diesel direct injection control unit -J248-
⇒ page 154 .
2.4 Coolant temperature sender: checking

equipment required
V.A.G 1551/3B-
♦ Test box -V.A.G 1598/31-
V.A.G 1715-
C-

Select function XX


Enter number group values XXX

Read measured value block 1 →
900/min 3.8 mg 1,720 V 76.2 °C
– Indicated on display:
– Consult coolant temperature value in display field 4. The value
should increase uniformly and without interruption.
– In the case of a fault, replacement values are displayed for the
fuel temperature or the value -4.5 °C.
– If no realistic value is given in field 4 or if replacement values
are displayed for the fuel temperature or 5.4 °C, the coolant
temperature sender and the wiring to the sender should be
checked as follows:
– Press → key.
– Extract the connector -1- for the coolant temperature sender -
G62- Components' fitting locations, ⇒ page 101 .
– Connect the manual multimetre between the two contacts of
the sender -2- for the coolant temperature -G62- .
Specification: see diagram

Scale A shows resistance values for temperature range 0...50 °
C, and scale B the values for temperature range 50...100 °C.
Examples:
♦ 30 °C corresponds to a resistance of 1,500...2,000 Ω
♦ 80 °C corresponds to a resistance of 275...375 Ω
– Renew coolant temperature sender -G62- .


– Check the wiring between test box and 2-pin connector for
open circuit using current flow diagram. Contact 1+socket 112
Contact 2+socket 104 Wire resistance: 1,5 Ω Max.
⇒ page 154 .

2.5 Intake manifold temperature sender: checking

equipment required
V.A.G 1551/3B-
♦ Test box -V.A.G 1598/31-
V.A.G 1715-
C-

Select function XX


15,4°C 15.9°C 16.7°C
– Indicated on display:

– Check the temperature value of the intake manifold which is

displayed in display field 3: The temperature should be approx.
the ambient temperature.
– If a realistic reading is not given in field 3 or if a replacement
temperature of 136.8 °C is given, the intake manifold temper‐
ature sender -G72- - should be checked along with the wiring
leading to the switch as follows:
– Press → key.
– Extract the intake manifold temperature sender switch -G72- ,
Components' fitting locations, ⇒ page 101 .
– Connect the manual multimetre between the contacts of the
intake manifold sender -G72- .

Examples:
♦ 30 °C corresponds to a resistance of 1.500...2.000 Ω
♦ 80°C corresponds to a resistance of 275...375 Ω
– Replace the intake manifold temperature sender -G72- .


– Check wiring for open circuit between test box and connector
using current flow diagram. Contact 1+socket 73 Contact 2
+socket 51 Wire resistance: 1,5 Ω Max.
⇒ page 154 .
2.6 Fuel temperature sender: checking

♦ Test box -V.A.G 1598/31-

Select function XX


Indicated on display: Read measured value block 7 →
15.4 °C 15.9 °C 16.7 °C
– Check the temperature value for the fuel which is displayed in

display field 1. The temperature should be approx. the ambient
temperature.
– If there is a fault, a constant fuel temperature of -5.4 °C will
appear.
– If a realistic reading is not given in field 1 or if a replacement
temperature of -5.4 °C is given, the fuel temperature sender
should be checked along with the wiring leading to the switch
as follows:
– Press → key.

– Uncouple the 10-pin connector for the fuel temperature sender

(connector to the fuel measuring system servomechanism of
the injector pump).
– Measure the resistance between contacts 4 + 7 of connector.

Examples:
♦ 30 °C corresponds to a resistance of 1.500...2.000 Ω
♦ 80°C corresponds to a resistance of 275...375 Ω
– Replace injector pump ⇒ page 109
– Interrogate fault memory, repair faults and then erase fault
memory. -VAS 5051- ; Vehicle self-diagnosis, fault memory:
consulting and clearing ⇒ page 156

⇒ page 154 .

2.7 Slide travel sender and dosifier: check‐

ing
2.7.1 Functioning
The dosifier is an electromagnetic change-over regulator which
is controlled through the control unit via a specific proportion of
the period. The excentric shaft of the dosifier displaces the slide
travel on the high pressure piston and therefore defining the in‐
jection throughflow. The slide travel sender transmits the position
of the dosifier to the control unit -N146- , which means that the
amount injected is indicated.
♦ Test box -V.A.G 1598/31-


• Fuse no. 40 should work properly
• Relay for the diesel direct injection system -J322- should op‐
erate correctly, checking ⇒ page 121

Select function XX



900/min 6.5 mg/H 1,680 V 87.3 °C
– Check coolant temperature in the display field 4. Specification:

85 °C min.
Do not continue with the check until the coolant temperature has
been reached.
900/min 6.5 mg/H 1,680 V 87.3 °C
– Check display in display field 3 ( slide travel sender voltage).

Specification: 1.500...2.100 V
– Press → key.
– If the specification is not reached, check the slide travel sender
and dosifier as follows:
2.7.4 Check the slide travel sender -G149-

– Uncouple the 10-pin connector for the slide travel sender (con‐
nector to the fuel measuring system servomechanism of the
injector pump).
– Measure the resistance between contacts 1+ 2 and 2 + 3 of
connector -2- . Specification: 4,9...7,5 Ω


-1- , using current flow diagram. Contact 1 + socket 108 Con‐
tact 2 + socket 106 Contact 3 + socket 99 Wire resistance: 1,5
Ω Max.
⇒ page 154 .
2.7.5 Check the dosifier -N146-

– Remove 10-pin connector -2- (connector to the fuel measuring
system servomechanism of the injector pump).
– Test resistance between contacts 5 and 6 of connector -2- .
Specification: 0,5...2,5 Ω

using current flow diagram. Contact 5 + socket 2 Contact 6 +
socket 116 and 121 Wire resistance: 1,5 Ω Max.
⇒ page 154 .

2.8 Needle movement sender: checking
2.8.1 Functioning
The signal of the needle movement sender is required to deter‐
mine the beginning of injection. If there is a fault, the system
adopts the operative control mode for the beginning of injection
(according to load and engine speed).. Usually the system regu‐
lates the beginning of injection (according to load, engine speed
and temperature).
♦ Test box -V.A.G 1598/31-

– Remove upper engine cover.
– Uncouple double connector -1- for the needle movement
sender -G80- -.
– Measure resistance between contacts of connector -2- . Spec‐

ification: 80...120 Ω
Note!
The resistance value of the needle movement sender -G80- refers

to a temperature of 20 °C. The resistance rises along with the
temperature.

– Replace the injector cyl. 3 with the needle movement sender
-G80- ⇒ Item 13 (page 107)


using current flow diagram. Contact 1 + socket 109 Contact 2
+ socket 101 Wire resistance: 1,5 Ω Max.
⇒ page 154 .
2.9 Regulation margin for injection corrector: checking

Functioning
Checking the regulation margin of the injection corrector is carried
out in function 4 (basic setting). Proceeding as such, the begin‐
ning of injection valve is timed in such a way that in measured

value block 4 the extreme positions of the advance and retarda‐

tion of the corrector can be consulted in display field 3.

equipment required
V.A.G 1551/3B-
♦ Test box -V.A.G 1598/31-
V.A.G 1715-
C-

Select function XX
– Press keys 0 and 4 for the function “Introduction of basic set‐

ting” and confirm entry with the Q key.
Indicated on display: Begin basic setting

– Observe figure displayed in display field 2: Specification: ad‐
vance
System in basic setting 4 →
900/min advance 7.9°v.OT 66 %

– Indicated on display: Specification in display zone 3: 7,0...9,0°

a TDC
After 10 seconds the injection corrector moves to the retardation
position.
System in basic setting 4 →
900/min Retardation 3.9°v.OT 74 %
– Indicated on display: Specification in display zone 3: 3,0...5,0°

a TDC
– Press → key.
– Checking the beginning of injection valve -N108-
⇒ page 137
2.9.2 Check the beginning of injection valve -

N108- as follows:
– Uncouple the 10-pin connector for the beginning of injection
sender (connector to the fuel measuring system servome‐
chanism of the injector pump).
– Measure resistance between contacts 9+10 of connector -2- .
Specification: 12,0...20,0 Ω
– Replace beginning of injection valve -N108-
⇒ Item 19 (page 108)


using current flow diagram. Contact 9 + socket 114 Contact
10 + socket 2 Wire resistance: 1,5 Ω Max.
⇒ page 153 .
2.10 Fuel cut-off valve: checking

♦ Diode test lamp -V.A.G 1527 B-
♦ Test box -V.A.G 1598/31-

– Checking the fuel cut-off valve -N109- is carried out with the
final control diagnosis -VAS 5051- : Vehicle self-diagnosis
⇒ page 156
Only if the engine does not stop:
– Extract the fuel cut-off valve -N109- and eliminate possible
metal particles or dirt.
– Repeat the final control diagnosis and if the engine continues
to run, check the fuel cut-off valve as follows:
The fuel cut-off valve -N109- should activate briefly.
If the valve does activate:
– Uncouple the 10-pin connector -arrows- from the injector
pump.
– Connect diode test lamp -V.A.G 1527 B- between contact 8 of
the connector -1- and vehicle earth. The LED should flash
If the LED does not flash:


using current flow diagram. Contact 8 + socket 120 Wire re‐
sistance: 1,5 Ω Max.
⇒ page 154 .

2.11 Motor for flap in intake manifold: checking

equipment required
V.A.G 1551/3B-
♦ Test box -V.A.G 1598/31-
V.A.G 1715-
C-

• Fuse no. 14 should work properly
• Relay for the diesel direct injection system -J322- should op‐
erate correctly, checking ⇒ page 121



Select function XX
– Press keys 0 and 3 for the function “Final control diagnosis” .

Indicated on display: Rapid data transfer Q
03-Final control diagnosis
– Confirm entry with Q key.

– Continue to press key → until the following message appears.
Indicated on display: Final control diagnosis →
Motor for flap in intake manifold -V157
When the motor for flap in intake manifold is activated, the com‐
bustion noise changes (the servomotor opens and closes the flap
on the intake manifold).
If you do not notice any change in the combustion noise:
– Proceed with final control diagnosis until completed.

– Extract the connector for the motor for the intake manifold flap
-V175- .
– Measure the supply voltage for the motor for the intake mani‐
fold flap in contact 4 of the connector and vehicle earth.
Specification: approx battery voltage

– Check wiring between test box socket and connector for open
circuit for breaks, using current flow diagram: Contact 1 +
socket 4 and 5 Contact 2 + socket 81 Contact 3 + socket 75
Wire resistance: 1,5 Ω Max.
⇒ page 153 .

3 Additional signals: checking
3.1 Speed signal: checking

equipment required
V.A.G 1551/3B-
♦ Test box -V.A.G 1598/31-
V.A.G 1715-
♦ Auxiliary measurement kit -
V.A.G 1594 A- or -V.A.G
1594 C-
• Speedometer OK, checking: ⇒ VAS 5051, Electrical system;

Rep. Gr. 01 ; Self-diagnosis of dash panel insert Final control
diagnosis
Note!
To check the speed signal, the vehicle must be driven. To do this

a second person is necessary.
Caution
Secure fault reader to rear seat and operate from this position.
3. Additional signals: checking 143


Select function XX


– Carry out a test drive and compare the display reading (a sec‐
ond person is required) with the speedometer reading.
Specification, display zone 1: approx. driven speed Read measured value block 6 →
0 km/h 0 0 0 000000 255
If no speed is displayed:
– Press → key.
– Connect multimeter to measure voltage between test box
sockets 4/5+20.
– Raise front left side of vehicle.
– Rotate front wheel and observe voltage display. Specification:
between 0 and at least 4 Volt fluctuating
Note!
If necessary, hold the front right wheel to prevent it from turning.
If the display does not fluctuate:

– Check wiring from contact 20 of engine control unit connector
to dash insert panel for open circuit or short. ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations
3.2 Signals from/to air conditioning system:

checking
The air conditioning is connected to the direct diesel system con‐
trol unit -J248- via the data Bus. All the signals from the air
conditioning that enter and leave the engine control unit are trans‐
mitted via the data Bus.
Checking is carried out with the help of air conditioning measured
value groups and the direct diesel system control unit -J248-


• Air conditioner functioning OK.
• There should not be any fault registered in the data bus ⇒
Electrical system; Rep. Gr. 90 ; Self-diagnosis of Gateway
• Vehicle at room temperature (warmer than +15 °C)

Select function XX


Indicated on display: (1...4 = display fields) Read measured value block 2 →
– Observe value in field 3. The air conditioner should not be

switched on.
Specification: 0 1 0 (air conditioner signal) Read measured value block 2 →
1 2 0 1 0 4
– Switch on air conditioning system. According to the type of air

conditioner fitted, the AC button has to be pressed in a manual
heater or the button “Auto” in the case of an automatic heater
(Climatronic).
– Select lowest temperature and highest blower speed. The
compressor should work.
– Observe reading in display field 3.
Specification: X 1 1 (air conditioner signal) Read measured value block 2 →
1 2 0 1 1 4
Specification: 1 X X (high idling speed)

Meaning if display = 1
x x x Engine operating mode
1 Air conditioner compressor switched on
1 Idling switch closed
1 Idling speed raised due to activation of air conditioning
– Disconnecting the air conditioning.

– Press C key.
01000000
– Observe value in field 4. The air conditioner should not be

switched on. Specification: 010000
– Switch on air conditioning system. According to the type of air
conditioner fitted, the AC button has to be pressed in a manual

heater or the button “Auto” in the case of an automatic heater

(Climatronic).
11100000
– Observe reading in display field 4. Specification: 111000

If the value is not obtained:
– Checking the air conditioning ⇒ Heating; air conditioning; Rep.
Gr. 01 ; Self-diagnosis
– Checking the data bus ⇒ Electric system; Rep. Gr. 90 ; Data
bus ⇒ -VAS 5051- Vehicle self-diagnosis
3.3 Brake light and brake pedal switches:

checking
As the injection system works with a accelerator pedal sender
(potentiometer), which could be faulty, for security reasons the
supply to the engine is cut off on braking. Due to this, the control
unit needs the signal from the brake light sender -F- , and also
from the brake pedal sender -F47- . This means that if the brake
pedal is pressed whilst the accelerator is constantly pressed, the
supply to the engine is immediately cut off and the engine goes
to idle. If the switches are incorrectly adjusted, involuntary cut offs
in the fuel supply could occur.
♦ Test box -V.A.G 1598/31-

Select function XX


– Observe figure displayed in display field 2.
Specification: 0 0 0 Read measured value block 6 →
0 km/h 0 0 0 0.0 % 255
– Slowly press brake.

Specification: 0 1 1 The two figures should change at the same Read measured value block 6 →
time from 0 to 1. 0 km/h 0 1 1 0.0 % 255
♦ Central figure = brake pedal switch

♦ Right-hand figure = brake light switch
– Allow brake pedal to return slowly to its resting position.

The two figures should change again from 0 to 1. Read measured value block 6 →
0 km/h 0 0 0 0.0 % 255
– Press → key.
If one or both of the figures do not change:
– Check the switches or the wiring that leads to the switches:
cations
If the value is not obtained:
– Remove the shelf on driver's side: ⇒ General body repairs-
assembly work, interior; Rep. Gr. 68 ; Dash panel driver's side
shelf : removal
– Pull the connector off brake light/brake pedal switch.
– Connect the multimeter to measure resistance between con‐
tacts 1 and 4. Specification: ∞ Ω (no continuity)
– Depress the brake pedal. Specification: 0 approx. 0 Ω
– Connect the multimeter to measure resistance between con‐
tacts 2 and 3. Specification: 0 approx. 0 Ω
– Depress the brake pedal. Specification: ∞ Ω (no continuity)
– Replace the brake light/brake pedal switch.
If the specifications are obtained:
– Connect multimeter to measure voltage between contact 1

and earth. Specification: at least 11.5 V
– Connect the multimeter to measure voltage between contact
2 and earth. Specification: at least 11.5 V
– Check wiring between 4-pin connector, contact 1 and fuse 26
for open circuit using current flow diagram for any short cir‐
cuits. ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
Fitting locations


earth or to battery positive.
– Renew engine control unit ⇒ page 154
3.4 Clutch pedal sender: checking

The clutch pedal switch -F36- informs the control unit about the
clutch status. On pressing the clutch the amount injected is re‐
duced briefly. This prevents the engine from jerking.
♦ Fault reader -V.A.G 1551- (or vehicle system tester -V.A.G
1552- ) with cable -V.A.G 1551/3B-
♦ Test box -V.A.G 1598/31-

– Connect fault reader -V.A.G 1551- ( -V.A.G 1552- ). With ig‐
nition turned on select “Address code” 01 to select engine
control unit.
Select function XX


– Observe figure displayed in display field 2. Specification: 0 0
0
0 km/h 0 0 0 0.0 % 255

– Depress the clutch pedal. The left-hand digit should change to

1. Specification: 1 0 0
0 km/h 1 0 0 0.0 % 255
– Allow clutch pedal to return slowly to its resting position.

The left figure should change again from 1 to 0.
– Press → key.
– Extract the clutch pedal switch Components' fitting locations,
⇒ page 101 .
– Test resistance in switch's contacts. Specification Without de‐
pressing clutch: 1,5 Ω Max. Clutch depressed: ∞ Ω (no con‐
tinuity)
– Renew clutch pedal switch -F36- .
– Connect multimeter to measure voltage between contact 2

and earth. Specification: at least 11.5 V
Fitting locations


using current flow diagram. Contact 3 + socket 66 Wire resist‐
ance: 1,5 Ω Max.
3.5 Activation and deactivation of GRA

speed regulator
1552- ) with cable -V.A.G 1551/3B-

• Interrogate fault memory
3.5.2 Work sequence

– Connect fault reader -V.A.G 1551- ( -V.A.G 1552- ) and select
engine electronics control unit with the “Address code” 01. The
ignition must be switched on.
If “G00SG” is indicated, the cruise control system is activated.
– Press → key.
– Press keys 1 and 1 for function “Login procedure” and con‐
firm entry with Q key.
– Enter corresponding code number according to table:
Code number Speed regulating system
11463 Activation of speed regulating system
16167 Deactivation of speed regulating system
– Confirm entry with Q key.
After activating the speed regulating system, the functioning of
this has to be checked in a test drive.
3.6 Speed regulator (GRA): checking

The CCS -except for the control switch- does not have its own
components. All the functions are carried out by the direct diesel
injection system -J248- .


3.6.1 Test sequence

Indicated on the display: Rapid data transfer HELP
Select function XX

Indicated on the display: Read measured value block
Enter value group number XXX

– Observe the information in field 4.
Specification: Read measured value block 6 →
0 km/h 0 0 0 000000 0
0 = Cruise control deactivated

1 = Cruise control activated
– Activate cruise control system ⇒ -VAS 5051- Vehicle self-di‐
agnosis
– Observe the information in field 3.
Indicated on the display: Read measured value block 6 →
0 km/h 0 0 0 000000 0
Conditions for testing. Display zone 3

Switch B engaged in “OFF” 000000
Switch B engaged in “ON” 000011
Switch A flashing in 001011
“RES” (Switch B engaged in
“ON” )
Switch A flashing in 000111
“SET” (Switch B engaged in
“ON” )
– Press the → key.
entry with Q key.
– Switch ignition off.
– Check the wiring to CCS switch for open or short circuits.
cations

3.7 Data bus: checking
3.7.1 Functioning
Data bus compatible control units are connected together via two
data bus wires twisted together (CAN high and CAN low) and ex‐
change information (messages). Information not available in the
data bus will be recognised as a fault by the engine control unit
as well as other CAN data bus control units.
The CAN data bus requires a matching resistor of 66 Ω for each
one to function fault free. This matching resistor is located in the
engine control unit.
♦ Test box -V.A.G 1598/31-

• A fault has been recognised by the CAN data bus self-diag‐
nosis -VAS 5051- ; Vehicle self-diagnosis, ⇒ page 156
• The coding of all the control units should be correct.

– Unlock the engine control unit connectors and pull them off.
– Connect test box -V.A.G 1598/31- to engine control unit. The
engine control unit wiring harness is not connected.
– Check centralized matching resistor in engine control unit.
– To do this, measure resistance between sockets 6 +7 of the
test box. Specification: 60...72 Ω
3.7.4 If the resistance measurement is out‐

side the specified range:
3.7.5 If the resistance value is within the

specified range:
– Check wiring to the individual data bus components for open
circuit, short to positive and earth using current flow diagram:
cations

4 Engine control unit
4.1 Supply voltage for engine control unit

1552- ) with cable -V.A.G 1551/3B-
♦ Test box -V.A.G 1598/31-

• Fuses no. 17 and 40 should work correctly
• Alternator working correctly
• The fuses in the battery fuse holder should work correctly
4.1.2 Work sequence

electronics control unit.
Select function XX


– Observe the reading in field 3.
Indicated on display: Specification: Battery voltage at least 11.5 Read measured value block 12 →
V. 11111111 0, 0 0 14.1 V 28.5°C
– Press → key.
If the displayed value oscillates or does not reach battery voltage:
4. Engine control unit 153


– Measure supply voltage using multimeter -V.A.G 1526 A- and
test leads from -V.A.G 1594 C- between the test box sockets.
1 + 4 and 5, 2 + 4 and 5, 37 + 4 and 5 Specification: approx.
0V
– Again measure the voltage between connections: 1 + 4 and 5,
2 + 4 and 5, 37 + 4 and 5 Specification: approx. battery voltage
11.5 V
– Checking the relay for the Diesel direct injection system -J322-
⇒ page 121 ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations
– Check cables for brake, open circuit and transfer resistances
at contact points, using current flow diagram.
If no wiring or relay fault is detected:
4.2 Engine control unit: replace

1552- ) with cable -V.A.G 1551/3B-
4.2.1 Removing
– First print out the control unit identification and thereby the
previous control unit coding as follows:
In the fault reader -V.A.G. 1551- display, the control unit identifi‐ 038906012EM 1.9l R4 EDC G00SG 3919 →
cation is displayed; for example: Code 00002 WSC 00000
– Print out the control unit identification by pressing the fault

reader print button.
– Press → key.
– Release connectors from control unit and detach them.

– Separate the control lugs -arrow- and remove the engine con‐
trol unit from the engine in a forward direction.
4.2.2 Fitting
– Place the new control unit into the retaining frame.
– Install control unit connector and lock.
– Check the previous coding and code the new control unit
⇒ page 155
– Adapt engine control unit to electronic immobiliser
⇒ page 156
– Interrogate the fault memory of the new engine control unit and
erase the fault memory if necessary -VAS 5051- ;
⇒ page 150
– Carry out a test drive.
– To finish, interrogate the fault memory of the new engine con‐
trol unit -J248- again -VAS 5051- ; Vehicle self-diagnosis,
⇒ page 150
4.3 Engine control unit: encoding

The control unit must be recoded if the relevant vehicle coding is
not displayed or the control unit has been renewed, as follows:
1552- ) with cable -V.A.G 1551/3B-
4.3.1 Work sequence

Select function XX
– Press keys 0 and 7 for the function “Code control unit” and
Indicated on display: Coding control unit Q
Enter code xxxxx (0-32000)
– Enter the relevant code number for this vehicle and confirm
with Q key.
In the fault reader -V.A.G. 1551- display, the control unit identifi‐ 038906012EM 1.9l R4 EDC G00SG 3919 →
cation is displayed; for example: Coding variations of engine Code 00002 WSC 00000
control unit ⇒ page 156
Indicated on display when a unauthorised code number has been
entered.
– Press → key.

Note!
♦ On disconnecting and reconnecting the ignition the code that

has been introduced is activated. If the ignition is not connec‐
ted and disconnected after having introduced the valid code,
the fault “control unit, incorrect code” , can not be erased.
♦ Engine running faults (gear change jerks, load change jerks,
etc.)
♦ Increased fuel consumption
♦ Increased exhaust gas emissions
♦ Faults stored in fault memory which are not actually present
♦ On vehicles with front-wheel drive the traction control system
does not function (TCS warning lamp lights up)
♦ Reduced gearbox life
♦ Certain functions will not be performed (Lambda regulation,
activation of the activated charcoal filter system, etc.)
4.3.2 Coding variations of engine control unit

Engine control Variation Equipment Code
unit Part No. number
-038 906 012 Without AC With airbag 00005
CD-
With airbag 00002
and ABS
-038 906 012 With air condition‐ With airbag 00005
EM- ing
With airbag 00002
and ABS
4.4 Engine control unit: adapting to elec‐

tronic immobiliser
⇒ Electrical self-diagnosis system; Rep. Gr. 01 ; Immobiliser
selfdiagnosis Adapting after changing engine control unit
4.5 Engine control unit fault memory: con‐

sulting and clearing

♦ Vehicle Diagnosis, Testing and Information System -VAS

5051-
♦ Diagnosis cable -VAS 5051/1 or VAS 5051/3-
4.5.1 Work sequence

– Fit the Vehicle Diagnosis, Testing and Information System -
VAS 5051- as follows:
– Fit connector on diagnosis cable -VAS 5051/1 or VAS 5051/3-
to the diagnosis connection.
– Start engine and run at idling speed.
Only when engine does not start:
4.5.2 Select operating mode:

– Press button on display for “Vehicle self diagnosis” .
4.5.3 Select vehicle system:

– Press keys “01 - Engine electronics” on the display"
The control unit identification and the coding will appear on the
display.
4.5.4 Select diagnostic function

– Key in “02 - Interrogate fault memory” If there is no fault stored
in the engine control unit, “0 faults detected” will appear on the
display. If there are faults stored in the engine control unit, they
will be displayed as a list
– Press key ⇐ .
– Key in “05 - Erase fault memory” .
– Key in"06 - End data transfer.

26 – Exhaust system
1 Exhaust system components: remov‐
ing and installing
Note!
♦ After working on the exhaust system ensure that the system

is not under stress, and that it has sufficient clearance from
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 supports are evenly
loaded.
♦ Renew self-locking nuts.
1.1 Exhaust system: dismantling and assembling
1 - Gasket
❑ Renew
2 - Exhaust manifold
❑ With connection for ex‐
haust gas recirculation
⇒ page 161
❑ To remove, the intake
manifold has to be re‐
moved
3 - Washer
4 - 25 Nm
❑ Renew
❑ Grease thread with -G
052 112 A3-
5 - Front exhaust pipe with cat‐
alyst
6 - Retaining ring
7 - Cross member
8 - 23 Nm
9 - Double clamp
❑ Note assembly position:
Bolts downwards and in
a horizontal position
⇒ page 20
10 - 40 Nm
11 - Suspension element
❑ Note assembly position
⇒ page 103
12 - Suspension element
❑ Note assembly position ⇒ page 103
13 - Separating point
❑ For repair cases
158 Rep. Gr. 26 - Exhaust system

❑ Marked by three impressions on circumference of exhaust pipe

❑ As standard, front and main silencers come as a single component. In cases of repair the rear silencer
and exhaust are supplied individually and with a double clamp for connecting.
❑ Cut the exhaust pipe perpendicularly at the indicated point with tool -U-40075- ⇒ page 159 .
14 - To front silencer
❑ Can be replaced individually ⇒ page 159
❑ Note installation position ⇒ page 103
15 - 40 Nm
❑ Renew
❑ Apply insulation paste to the thread -G 052 112 A3-
Fitting position of double clamp
1.1.1 Conditions
• The exhaust system should be cold.
1.1.2 Work sequence

– The distance -a- between the double clamp and the mark
should be approx. 5 mm.
Installation position of mounting
1.1.3 Work sequence

– Fit the rear silencer -1- so that the dimension -b- is 3...7 mm.
Cutting point on exhaust pipe
1. Exhaust system components: removing and installing 159

♦ Exhaust pipe cutting tool with chain saw -U-40075-
1.1.4 Work sequence

– Cut exhaust pipe at right angles at separating point as indica‐
ted by the -arrow 1- , use tool -U-40075- .
– When installing fit repair type double clamp -4- , position it at
side markings arrows -2- and -3- . Tightening torques: 40 Nm

2 Exhaust gas recirculation system
Note!
♦ The activation of the exhaust gas recirculation system comes

from the direct diesel injection control unit -J248- through the
exhaust gas recirculation valve -N18- , to the mechanical ex‐
haust gas recirculation valve.
♦ Checking the exhaust gas recirculation valve -N18- : ⇒ -VAS
5051- Vehicle self-diagnosis
♦ The mechanical exhaust gas recirculation valve with the cone
shaped plunger allows different opening sections by means of
different valve lifts.
♦ Pulsed control makes every conceivable valve position possi‐
ble.
♦ Renew self-locking nuts.
2.1 Parts of exhaust gas recirculation system: removing and installing
1 - Intake manifold
2 - Gasket
❑ Renew
3 - Exh. gas recirculation valve
4 - 25 Nm
5 - Securing clip
6 - 10 Nm
7 - 20 Nm
❑ Renew
8 - Connecting pipe
9 - Exhaust manifold
2. Exhaust gas recirculation system 161

2.2 Diagrams of the vacuum hoses' connections
1 - Exh. gas recirculation valve

2 - Exhaust gas recirculation
valve -N18-
3 - Goes to the air filter
4 - To the brake servo
5 - Non-return valve
6 - Vacuum pump
2.3 Mechanical exhaust gas recirculation

valve: checking
♦ Hand vacuum pump -V.A.G 1390-


– Disassembling the engine casing.
– Remove the vacuum hose from the mechanical exhaust gas
recirculation valve.
– Fit to the -V.A.G 1390- manual vacuum pump valve.
– Operate pump. The membrane must move in the direction of
the connection of the vacuum (check by touching from below).
– Remove the manual vacuum pump hose from the exhaust gas
recirculation valve. The closing of the valve should be audible
(the membrane moves in the direction of the exhaust mani‐
fold).
2.4 Exhaust gas recirculation: checking

equipment required
V.A.G 1551/3B-
1526-
♦ Auxiliary measuring set -
V.A.G 1594 A-
♦ Test box -V.A.G 1598/31-


• The fuses must be OK.
• Engine oil temperature at least 80 °C (radiator fan must have
run once)
• There must be no leaks on the inlet and exhaust sides.
• Engine/injection system without faults.
• No faults must be stored in fault memory: ⇒ -VAS 5051- Ve‐
hicle self-diagnosis Fault memory Fault memory: interrogat‐
ing , ⇒ page 156

Select function XX
– Press keys 0 and 4 for the function “Begin basic setting” and
Indicated on display: Start basic adjustment

Indicated on display: System in basic setting 3 →
900/min EGR inact XXX mg/H XX %
The message in display field 2 must oscillate every 10 seconds

between “EGR activ” and “EGR inact” .
The values in field 4 should oscillate in the following way:
Display field 2: EGR inactiv.
Specification in display zone 4: 0...5 %
Display field 2: EGR activ.
Specification in display zone 4: 95...100 %
– Initiate final control diagnosis and activate the EGR valve -
N18- : -VAS 5051- ; Vehicle self-diagnosis, ⇒ page 156
Indicated on display: Final control diagnosis →
Exhaust gas recirculation valve -N18
The valve should activate.

If the valve does not activate:
– Test exhaust gas recirculation valve -N18- ⇒ page 165
If the valve activates:
– Check vacuum hoses ⇒ page 162 .
If the vacuum hose is correct:
– Test mechanical exhaust gas recirculation valve
⇒ page 162 .

2.4.3 Checking the exhaust gas recirculation

valve -N18-
– Press → key.
– Remove connector 1 from exhaust gas recirculation valve 2.
– Measure resistance between the valve contacts. Specifica‐
tion: 14,0...20,0 Ω
Note!
At ambient temperature the resistance is in the lower tolerance

field and when the engine has reached running temperature it is
in the higher.

– Replace exhaust gas recirculation valve -N18-
– Measure the supply voltage of the valve between contact 1 of
the connector and earth Specification: approx battery voltage
using current flow diagram. Contact 1+sockets 1+2 Contact 2
⇒ page 164

28 – Ignition system
1 Preheating system: checking
♦ Hand multimeter -V.A.G 1526 A-
♦ Adapter set -V.A.G. 1594 C-
Check conditions:
• Ignition off
• Direct diesel injection control unit -J248- , correct
• The fuses in the battery fuse holder should work correctly.
Checking process
– Extract the fuel temperature sender switch -G62- Compo‐
nents' fitting locations, ⇒ page 164 .
166 Rep. Gr. 28 - Ignition system

Note!
On removing the connector “engine cold” is simulated. When ig‐

nition is connected, the corresponding preheating process will be
carried out.
– Extract the connections from pre-heating elements.

– Connect multimeter to measure voltage between a pre-heat‐
ing element contact and vehicle earth.
– Switch on ignition. It should indicate for 20 seconds approx.
battery voltage
– If no voltage is present:
– Interrogate the fault memory of the new engine control unit and
erase the fault memory if necessary -VAS 5051- , Vehicle self-
diagnosis, ⇒ page 167
1.1 Pre-heating elements: checking

♦ Adapter set -V.A.G 1594 C-
♦ Diode test lamp -V.A.G 1527 B-
♦ Pre-heating element spanner -U-40082-
1.1.1 Check conditions:

• Strap fuse 176 for pre-heating elements in fuse holder/battery,
correct

– Unclip connectors from pre-heating elements.
– Connect diode lamp cable to battery positive (+) with the help
of aux. clamps from the adapter set.
– Apply check point of diode lamp to each pre-heating element.
The LED lights up: element OK The LED does not light up:
replace element
– Install and remove pre-heating elements with tool -U-40082- .
Tightening torques: 15 Nm.
1. Preheating system: checking 167

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Service

Service Department. Technical Information

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1.4 Coolant: draining and filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

23 - Mixture preparation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

4.3 Engine control unit: encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

1.1 Engine number

1.2 Engine data

10 – Removing and installing engine

Special tools and workshop

2 Rep. Gr. 10 - Removing and installing engine

♦ Torque spanner -SAT

1.1 Dismantling: notes

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

1. Engine: removing and installing 3

– Remove engine cover in the -direction of the arrow- .

To carry out this work it will be necessary to disconnect battery

– With the ignition switched off disconnect battery earth strap.

– Remove battery and battery retainer. ⇒ Rep. Gr. 27

– Remove lower engine protection: ⇒ General body repairs-as‐

– Remove lower coolant hose from radiator -arrow- .

4 Rep. Gr. 10 - Removing and installing engine

– Furthermore, the front coolant hose should be removed from

– Uncouple fuel feed and return pipes-arrows- from the injector

– Unbolt pendulum support -arrows- .

1.1.1 Vehicles with air conditioning:

1. Engine: removing and installing 5

1.1.2 Continued for all vehicles

To remove securing bolts use a ladder.

Engine and gearbox must be guided carefully when lowering to

1.2 Engine: securing engine to assembly

1.2.1 Work sequence

6 Rep. Gr. 10 - Removing and installing engine

Secure hooks and locating pins with locking pins.

– Support the engine with the engine support -Ar-2204 A- and

1.3 Installing: notes

Engine support tightening torques ⇒ page 8

– Align the engine bracket assembly by jerking it so as to leave

1. Engine: removing and installing 7

1.3.1 Vehicles with air conditioning

1.3.2 Continued for all vehicles

1.4 Tightening torques

Engine to gearbox connecting bolts M12 80 Nm

Engine support tightening torques ⇒ page 8

1.5 Engine brackets

1.5.1 Tightening torques

8 Rep. Gr. 10 - Removing and installing engine

Engine bracket, engine

Engine brackets, gearbox

Engine brackets, gearbox

1.6 Vehicles with air conditioning: additional

The coolant circuit for the air conditioning should not be

To prevent damage to condenser and refrigerant pipes/hoses,

To facilitate removing and installing the engine without opening

1. Engine: removing and installing 9

– Remove ribbed belt ⇒ page 15 .