Engine data

Engine code Manufactured Capacity Power output Torque Bore Stroke Compression ratio CN Firing order Catalytic converter Exhaust gas recirculation Charging Charge air cooler

ltr kW at rpm Nm at rpm mm mm not less than

1Z 06.95 > 1.9 66/4000 202 1900 79.5 95.5 19.5: 1 45 1-3-4-2 yes yes yes yes

AHU 08.96 > 1.9 66/4000 202 1900 79.5 95.5 19.5: 1 45 1-3-4-2 yes yes yes yes

Engine code Valve timing At 1 mm valve lift and 0 mm valve clearance Inlet opens after TDC Inlet closes after BDC Exhaust opens before BDC Exhaust closes before TDC

1Z

AHU

16° 25° 28° 19°

16° 25° 28° 19°

CUT Removing and installing engine

Special tools and workshop equipment required Engine support bracket 10-222 A Lifting tackle 2024 A Special tool 3147 V.A.G 1202 A V.A.G 1306 Special tool Matra V/175

Removing Notes: The engine is lifted out without the gearbox. Catch drained-off coolant in a clean container for re-use or disposal. All cable ties which are opened or cut open when removing the engine must be replaced in the same position when installing the engine. - Obtain radio code on vehicles with coded radio. - With ignition switched off disconnect battery earth strap. Warning! Hot steam can escape when the cap on the expansion tank is opened. Cover the cap with a cloth, and open it carefully.

- Open cap on coolant expansion tank. - Remove noise insulation (two sections) -arrows-. - Place drip tray V.A.G 1306 below engine.

900058

Type 4A

Type description - Turn drain screw -arrow- on radiator anti-clockwise, if necessary fit drain hose to connection.

- To drain off remaining coolant, disconnect coolant hoses -arrows-.

900058

Type 4A

Type description - Slacken bolts 2 ... 6. - Slacken V-belt by loosening tensioning nut -1-. - Remove V-belt.

on left. . . Do not disconnect hydraulic connections. .Secure vane pump to body with wire to avoid overtensioning the hydraulic connections.900058 Type 4A .Move wiring clear.Installation position: behind front bumper.Unbolt vane pump for power steering and bracket (at rear) -arrows-. .Disconnect positive wire to fan motor at series resistance -arrow-. .

Unbolt earth wire -2. . .from longitudinal member.Unbolt torque reaction support from engine and cross member -arrows-.Disconnect bottom air hose -3. .Disconnect wiring-1-from alternator.from charge air cooler.900058 Type 4A Type description . .

900058 Type 4A Type description . Vehicles with automatic gearbox .Unscrew 3 torque converter nuts through starter opening using Matra V/175 15 mm A/F socket attachment (turn crankshaft 1/3 turn each time). counterhold crankshaft by applying spanner to central bolt on vibration damper. Note: Starter cables do not have to be disconnected. All models .Unscrew engine/gearbox securing bolts accessible from below .Unbolt starter from engine/gearbox and secure as necessary. Note: When loosening torque converter bolts.

.Remove engine cover panel -arrows-. .900058 Type 4A Type description .between lock carrier and air cleaner housing.Remove air intake pipe -arrow.

Unscrew earth connection to fan motor at earth point -arrow.Move wiring and hoses clear.Remove upper section of air cleaner housing with air mass meter. . .at front left of engine compartment. .Disconnect thin hose-6-from bottom of valve for exhaust gas recirculation -N18. . .Disconnect wires/unplug connectors as follows: 1 -Exhaust gas recirculation valve -N18 2 -Air mass meter -G70 4 -Charge pressure control solenoid valve -N75 5 -Intake manifold temperature sender -G72 .Disconnect vacuum hose from mechanical exhaust gas recirculation valve-3-. .900058 Type 4A Type description .Unbolt radiator fan cowl from radiator and lift out.Disconnect air hose from air mass meter. .

Do not disconnect hoses. .from air duct -1-. .Disconnect front exhaust pipe with catalytic converter from turbocharger.Remove air intake hose between charge air cooler and turbocharger. Vehicles with air conditioner: . .Remove air duct-1-between charge air cooler and intake manifold.Remove A/C compressor and secure to body with wire. Warning! The air conditioner refrigerant circuit must not be opened. All models . . Note: Secure the flange of the front exhaust pipe to the right suspension turret with wire. It is then not necessary to remove the front exhaust pipe. . .Remove ribbed belt => Page 13-11.Unscrew bolts securing turbocharger to catalytic converter -arrows-.900058 Type 4A Type description .Disconnect connector on A/C compressor. .Unbolt charge pressure control solenoid valve -2.Remove lower section of air cleaner housing.

Unplug connectors from glow plugs. .Unplug connector from speedometer sender -G22 on left of gearbox.Disconnect wires/unplug connectors as follows: 1 -Injection pump 2 -Injection pump 3 -Wiring for engine speed sender -G28 4 -Needle lift sender -G80 5 -Coolant temperature sender -G62 6 -Electronic thermo switch -F76 7 -Oil pressure switch -F1 8 -Oil temperature sender -G8 . . and move wire clear.900058 Type 4A Type description .

. and move wire clear. .Disconnect coolant hoses -arrows-.at injection pump and move clear to one side. Note: Use clean plugs to block off the pipes. . All models .Unscrew upper engine/gearbox securing bolts.900058 Type 4A Type description Vehicles with manual gearbox: .Disconnect diesel supply and return pipes -arrows. . Leave one bolt in place (hand-tight).Unplug connector for reversing light switch on gearbox.Remove hose with non-return valve from exhauster pump.

Position support bar 10-222 A on bolted flanges of wing panels -arrows-. . otherwise the pressure pipe for the clutch slave cylinder could be damaged (on manual gearbox).on left and right engine mounts.4A .Engage gearbox support 3147 in top right bolt hole in bell housing on gearbox. . as illustrated. Do not overtension. Note: Support bar must be positioned behind gas strut for bonnet. The illustration shows the engine removed. Notes: The height of the gearbox can be adjusted via the wing nut on the lifting hook. . and spindles must face forwards.Unscrew top nuts -arrow.

Note: Check that all hoses and other connections between engine and body have been detached.G 1202 A.Tighten spindle of support bar 10-222 A. . Note: To balance the centre of gravity of the engine. .Lift engine over studs of engine mounts. . position the hook attachments as shown in the illustration.Remove the last securing bolt..Secure torque converter in gearbox to prevent it falling out. Vehicles with automatic gearbox .Raise engine carefully and lift out.Attach lifting tackle 2024 A to engine and hook onto workshop crane V. . Warning The hook attachments and locating pins on the lifting tackle must be secured with locking pins (arrows in illustration). .A.

Attaching engine to engine stand Special tools and workshop equipment required Engine and gearbox support VW 540 Work sequence When working on the engine. secure it to the engine stand using engine bracket VW 540. .

In vehicles with automatic gearbox. . Install needle bearing if necessary => Page 13-53. . Remove corrosion and apply only a very thin coating of grease G 000 100 to the splines. Secure all hose connections with the correct hose clips (same as original equipment) => Parts catalogue . . . .To secure the torque converter on the drive plate only use the correct nuts as specified in the parts catalogue. renew seals.Check whether the two dowel sleeves for centring engine and gearbox are in the cylinder block.A needle bearing must be fitted in the crankshaft on vehicles with manual gearbox.Check that clutch plate is properly centred in vehicles with manual gearbox. no needle bearing must be fitted in the crankshaft. Do not grease guide sleeve. Vehicles with automatic gearbox . Remove needle bearing if necessary => Page 13-53. when doing this note the following: Notes: When performing repairs. gaskets. install if necessary.Clean input shaft splines and (in the case of used clutch plates) the hub splines. self-locking nuts and bolts which have a specified tightening angle. . Vehicles with manual gearbox .Check clutch release bearing for wear and renew if necessary.Push intermediate plate onto dowel sleeves.Installing Installation is carried out in the reverse order.

Allow stop for torque reaction support to rest on rubber buffer for torque reaction support under its own weight. Checking and changing ATF. . rotate torque converter and drive plate so that one hole and one stud are level with the aperture for the starter motor. Repair group 37.Tighten torque converter nuts with special tool Matra V/175.Fill up with coolant=> Page 19-7. If the torque converter has not been installed properly. .=> Parts catalogue .Before installing engine. Checking ATF level and topping up ATF=> All models . and tighten bolts.Check ATF level: => Automatic gearbox 01N. .Install ribbed belt =>Page 13-12. the distance will be about 13 mm. . the driver of the torque converter or the ATF pump will be severely damaged when the gearbox is attached to the engine. Checking position of torque converter If the torque converter has been installed correctly. If the torque converter is incorrectly inserted in the gearbox.Ensure that engine mounts are free of stress by shaking engine to align it before tightening engine mounts. distance-A -between the joint surface on the torque converter bellhousing and the bottom contact surface on the torque converter studs should be approx 23 mm. . .

. Electrical fault finding and Fitting locations . .Interrogate fault memory: => Diesel direct injection and glow plug system (4-cyl. Coolant must not be used again if it is dirty. enter anti-theft code for radio => Radio operating instructions The electronic control units can be damaged if a rapid charger is used to start the engine. . . Page 26-15. TDI).Connect EGR hoses and pipes => Diagram of vacuum hose connections.Notes: Drained-off coolant 1Z only be used again if the original may CUT cylinder head or cylinder block are re-installed.Close windows fully using electric window switches.After connecting battery.Set clock to correct time.Then operate all electric window switches again for at least one second in the "close" direction to activate the automatic one -touch function. . . . Repair group 01. Interrogating and erasing fault memory=> Note: Faults will have been stored in the memory because connectors have been unplugged.Stress-free alignment of exhaust system => Page 26-10.Electrical connections and routing: => Current flow diagrams. . . Page 21-2. . Therefore interrogate and erase fault memory after installing engine.Connect hoses and pipes for charge pressure control system => Diagram of connections.Check oil level before starting engine.

3. Do not use degreased parts. phosphated. 6 5. 11 7. Tolerance for tightening torques is ±15%. 9. 8 1). oiled. 1. or black-finished nuts and bolts. 4 2. 10 1)M8 Bolt M12 x 67 M12 x 90 M12 x 110 M10 x 45 Nm 65 65 65 45 bolt fitted up to approx.Tightening torques Notes: The tightening torques listed on this page apply only to lightly greased. Engine/gearbox mountings (manual gearbox) Item No. Additional lubricant such as engine or gearbox oil may be used. 07.96: tightening torque 25 Nm A: centering sleeves . but do not use graphite lubricant.

4. 1.Engine/gearbox mountings (automatics) Item No. 11 5 6 7 A: centering sleeves Component Bolts/nuts Nm 10 20 45 65 25 25 20 40 85 25 25 25 2 Bolt M10 x 45 M12 x 67 M12 x 110 M12 x 90 M10 x 60 Nm 45 65 65 65 45 M6 M8 M10 M12 Except for the following: Engine mount to subframe Engine support to engine mount Torque reaction support Drive plate to torque converter A/C compressor to compressor bracket Power steering pump to bracket Catalytic converter to turbocharger Hose clamps M8 M10 M10 x1 . 9. 8. 3. 10 2.

Dismantling and assembling engine Ribbed belt drive for alternator. Mark the direction of rotation before removing the ribbed belt. V-belt drive for coolant pump and vane pump Notes: The following illustration shows the belt drive on vehicles without air conditioner. Ensure that the belt is properly seated in the pulleys when installing. this can cause breakage. . If the belt rotates in the wrong direction when it is refitted.

. brace pulley with strap wrench (oil filter wrench) when loosening and tightening.1 . brace pulley with strap wrench (oil filter wrench) when loosening and tightening. 3 .Bolt Bolt with strength rating 8.V-belt For coolant pump For vane pump Check for wear Removing and installing => Page 13-9 2 .25 Nm If necessary.9: tighten to 35 Nm => Parts catalogue If necessary.8: tighten to 25 Nm Bolt with strength rating 10.

65 Nm If necessary. .Ribbed belt Check for wear Removing and installing => Page 13-11 6 .Tensioning roller For ribbed belt Removing and installing ribbed belt => Page 13-11 8 .4 . brace pulley with strap wrench (oil filter wrench) when loosening and tightening.Pulley For vibration damper V-belt version 5 .Cover cap Prise off with screwdriver 7 .

Loosen bolts on alternator (top and bottom) .Disconnect battery earth strap .Alternator Removing: .Remove ribbed belt .25 Nm 11 .Detach alternator and unscrew wiring connections To facilitate positioning of alternator.Pulley For alternator For ribbed belt 10 .9 . knock back bush for bottom retaining bolt on bracket slightly 12 .Lever For tensioning roller Engage flats on end of lever in tensioning element -Item 17- .

13 .Bracket For alternator 19 .10 Nm 17 .25 Nm 14 .Remove ribbed belt =>Page 13-11.25 Nm .25 Nm 16 . Engage on flats on lever for tensioning roller -Item 1218 .Tensioning element Removing: .Seal 15 .

Vibration damper For ribbed belt With pulley for V-belt Can only be installed in one position.Bolt Bolt with strength rating 8.8: tighten to 25 Nm Bolt with strength rating 10.Bracket For vane pump . Holes are off-set 21 .20 .9: tighten to 35 Nm => Parts catalogue 23 .Coolant pump Check that pump runs freely Removing and installing => Page 19-11 22 .

25 Nm .8: tighten to 25 Nm Bolt with strength rating 10.Rear bracket For vane pump 27 .Vane pump For power steering Removing and installing: => Running gear.25 Nm 26 .Bolt/nut Bolt with strength rating 8.9: tighten to 35 Nm Tighten nut to 25 Nm => Parts catalogue 25 . Assembly overview: Vane pump.24 . Front-wheel drive and four-wheel drive. Vehicles with 4-cylinder engine 28 . Repair Group 48.

Pulley For vane pump V-belt version 34 .Retainer 31 .25 Nm 32 .29 . brace pulley with strap wrench (oil filter wrench) when loosening and tightening.Bolt .Pulley For coolant pump V-belt version .25 Nm 36 . 35 .Frontbracket For vane pump 30 .25 Nm If necessary.25 Nm With tensioner nut 33 .

Ensure that the belt is properly seated in the pulleys when installing. .Ribbed belt drive for alternator. If the belt rotates in the wrong direction when it is refitted. this can cause breakage. V-belt drive for coolant pump and vane pump Notes: The following illustration shows the belt drive on vehicles without air conditioner. Mark the direction of rotation before removing the ribbed belt.

Bolt Bolt with strength rating 8. brace pulley with strap wrench (oil filter wrench) when loosening and tightening.8: tighten to 25 Nm Bolt with strength rating 10. .1 .V-belt For coolant pump For vane pump Check for wear Removing and installing => Page 13-9 2 .25 Nm If necessary. brace pulley with strap wrench (oil filter wrench) when loosening and tightening. 3 .9: tighten to 35 Nm => Parts catalogue If necessary.

Cover cap Prise off with screwdriver 7 .Pulley For vibration damper V-belt version 5 .65 Nm If necessary. .Ribbed belt Check for wear Removing and installing => Page 13-11 6 .4 . brace pulley with strap wrench (oil filter wrench) when loosening and tightening.Tensioning roller For ribbed belt Removing and installing ribbed belt => Page 13-11 8 .

25 Nm 11 . knock back bush for bottom retaining bolt on bracket slightly 12 .Detach alternator and unscrew wiring connections To facilitate positioning of alternator.Disconnect battery earth strap .9 .Loosen bolts on alternator (top and bottom) .Pulley For alternator For ribbed belt 10 .Lever For tensioning roller Engage flats on end of lever in tensioning element -Item 17- .Remove ribbed belt .Alternator Removing: .

13 .Bracket For alternator 19 .Tensioning element Removing: .25 Nm 14 .25 Nm 16 .Remove ribbed belt =>Page 13-11. Engage on flats on lever for tensioning roller -Item 1218 .Seal 15 .10 Nm 17 .25 Nm .

Bolt Bolt with strength rating 8.Bracket For vane pump .Coolant pump Check that pump runs freely Removing and installing => Page 19-11 22 .8: tighten to 25 Nm Bolt with strength rating 10.20 .9: tighten to 35 Nm => Parts catalogue 23 .Vibration damper For ribbed belt With pulley for V-belt Can only be installed in one position. Holes are off-set 21 .

Repair Group 48. Vehicles with 4-cylinder engine=> 28 .Vane pump For power steering Removing and installing: => Running gear.Bolt/nut Bolt with strength rating 8.Rear bracket For vane pump 27 .25 Nm 26 .9: tighten to 35 Nm Tighten nut to 25 Nm => Parts catalogue 25 . Assembly overview: Vane pump.8: tighten to 25 Nm Bolt with strength rating 10. Front-wheel drive and four-wheel drive.25 Nm .24 .

25 Nm 36 .25 Nm With tensioner nut 33 .29 .Pulley For vane pump V-belt version 34 .Pulley For coolant pump V-belt version . brace pulley with strap wrench (oil filter wrench) when loosening and tightening.25 Nm 32 .25 Nm If necessary.Frontbracket For vane pump 30 . 35 .Bolt .Retainer 31 .

Routing of belt=>Page 13-13 .Slacken V-belt by turning tensioner nut -1-. .Slacken bolts 2 .Tensioning V-belt=>Page 13-10.Removing and installing V-belt .Check that V-belt is properly seated. 6..Remove V-belt. . Installation is performed in the reverse order. . . ..

Check tension of V-belt: . .Tensioning V-belt .Press in the belt firmly with the thumb at a point half-way between the pulleys with the longest run of belt. 6.. Tightening torques Component Vane pump to bracket Vane pump to tensioning bar Nm 25 25 Belt yield (max..TIghten securing bolts on vane pump. .Slacken bolts 2 .) 2 mm 5 mm . The amount of yield should be as follows: V-belt for coolant pump and and vane pump New V-belt Used V-belt .Adjust belt tension with tensioner nut -1-.

.To slacken ribbed belt tensioning roller.Detach cover cap -Item 6-. .Remove V-belt=>Page 13-9. apply 17 mm socket with extension to central nut. . Page 13-3. it may break. If the belt rotates in the wrong direction when it is refitted. turn tensioning element in direction of arrow.Remove ribbed belt and release tensioning element. from tensioning roller. .To slacken ribbed belt. .Removing and installing ribbed belt Removing Note: Mark the direction of rotation with chalk or felt pen before removing the ribbed belt. .

Page 13-3. .Routing of belts=>Page 13-13 .Fit ribbed belt over crankshaft pulley and tensioning element.Start engine and check that belts run properly.Installing . .Install V-belt=>Page 13-9. for tensioning roller. .Fit ribbed belt over alternator pulley last. Release tensioning element. .Turn ribbed belt tensioning element in direction of arrow. . . Note: Ensure that the ribbed belt is properly seated in the pulleys when installing.Press on cover cap -Item 6-.

Routing of ribbed belt on vehicles without air conditioner.Routing of belts . .Routing of ribbed belt on vehicles with air conditioner. .

Toothed belt guard . engage carefully in bottom toothed belt guard 2 . 1 .Toothed belt drive Note: Mark the direction of rotation with chalk or felt pen before removing the toothed belt. this can result in breakage.Toothed belt Mark direction of rotation with chalk or felt pen before removing Check for wear Removing=>Page 13-20 Installing=>Page 13-26 . If a used belt rotates in the wrong direction when refitted.top When installing.

Page 13-18 5 .Camshaft sprocket Release from camshaft taper by tapping with a hammer (using a drift through toothed belt guard opening) 7 .Tensioning roller Checking semi-automatic toothed belt tensioning roller => Page 13-30 Position =>Fig.Toothed belt guard .45 Nm Counter-hold with 3036 to loosen and tighten 6 .rear .Idler roller 9 .1.3 .25 Nm 8 .10 Nm 10 .20 Nm 4 .

Crankshaft sprocket Contact surface between sprocket and crankshaft must be free of oil. Can only be installed in one position.25 Nm 13 .Injection pump sprocket Removing injection pump sprocket =>Fig. 2. Page 13-18 Check that Woodruff key is fitted correctly 16 .11 .Intermediate shaft sprocket Installation position =>Fig. . 3.Woodruff key Check proper seating 14 . Page 13-19 Check that Woodruff key is fitted correctly 15 .10 Nm 12 .

10 Nm 21 . unbolt vibration damper 22 .90 Nm + 1/4 turn (90 °) further Renew Do not use oil Use counter-hold tool 3099 or 3415 to loosen and tighten Bolting on counter-hold tool 3099 => Page 13-39 18 .45 Nm 20 .45 Nm Use counter-hold tool 3036 to loosen and tighten 19 .bottom To remove.Spreader clip .Toothed belt guard .17 .

The side of the sprocket with the lettering is at the rear. .900058 Type 4A Type description 1Z CUT Fig. Fig.2Installation position of intermediate shaft sprocket The wider rim -arrows.of the intermediate shaft sprocket is at the front.1Position of semi-automatic tensioning roller The retaining lug must fit in the opening in the rear toothed belt guard.

Apply tension to injection pump sprocket by tightening puller.Release arms of puller 3032 and apply puller. .Unscrew nut for injection pump sprocket.Release injection pump sprocket from taper of injection pump by lightly tapping spindle of puller (hold sprocket while doing this so it does not fall out).900058 Type 4A Type description 1Z CUT Fig. . .Align arms of puller with holes in injection pump sprocket and secure. .3Removing injection pump sprocket Toothed belt removed => Page 13-20 . .

Removing and installing toothed belt Special tools and workshop equipment required Mandrel 2064 Setting bar 2065 A Retainer 3036 Special tool Matra V/159 .

.900058 Type 4A Type description Removing .Remove engine cover panel -arrows-.Remove V-belt=>Page 13-9.Remove ribbed belt => Page 13-11. . .Unbolt pulley with vibration damper. .

.Remove top and bottom sections of toothed belt guard -arrows-. .

. Note: Turning crankshaft to TDC No. 1 cylinder with engine removed=> page 13-31.Remove cylinder head cover =>Page 15-8. .900058 Type 4A Type description . 1 cylinder -arrow.(vehicles with manual gearbox). 1 cylinder -arrow.Turn crankshaft to TDC No.Turn crankshaft to TDC No. .(vehicles with automatic gearbox).

at the other end between setting bar and cylinder head. turn camshaft so that one end of setting bar contacts cylinder head. of the same thickness. Now turn camshaft until setting bar contacts feeler gauge. Place a 2nd feeler gauge.Lock camshaft using setting bar 2065 A. Insert a feeler gauge corresponding to half the measured gap between setting bar and cylinder head.Centralize setting bar as follows: With setting bar in position.900058 Type 4A Type description . Using feeler gauge. . measure gap at other end of setting bar. .

Otherwise there is a risk of damage to valves and piston crowns. Notes: The position of the toothed belt must be set as described below. . injection pump sprocket and tensioning roller.Loosen tensioning roller. Installing (adjusting valve timing) Camshaft locked in position with setting bar. .Fit camshaft sprocket together with toothed belt and locate with securing bolt (camshaft sprocket can still turn). .Check again whether TDC mark on flywheel and reference mark are aligned. Injection pump locked in position with pin 2064. Counter-hold with 3036. Release camshaft sprocket from camshaft taper by tapping with a hammer (using a drift through rear toothed belt guard opening). .Lock injection pump sprocket with pin 2064. . . .Install idler wheel.Remove idler wheel. Never use the setting bar to hold the camshaft when loosening and tightening the bolt securing the camshaft sprocket.. The crankshaft must not be at TDC at any cylinder when the camshaft is turned.Loosen camshaft sprocket securing bolt 1/2 turn. even after repairs in which the belt is only taken off the camshaft sprocket. . .Fit toothed belt (check direction of rotation) on crankshaft sprocket.Mark direction of rotation of toothed belt with chalk or felt pen. . intermediate shaft sprocket.Take off toothed belt.

. Counter-hold with 3036.Remove pin 2064. . Matra V/159).Turn crankshaft two full revolutions in normal direction of rotation and set again to TDC No. . Note: On no account use the setting bar to hold the camshaft when loosening and tightening the bolt securing the camshaft sprocket. . slacken completely before re-tensioning.Using a suitable wrench (e. . .Tighten bolt securing camshaft sprocket to 45 Nm. .Check again whether TDC mark on flywheel and reference mark are aligned. Note: If the eccentric mounting is turned too far to the right (by mistake) .Remove setting bar.g. turn eccentric mounting on tensioning roller clockwise until notch aligns with raised portion (arrows). 1 cylinder. .Tighten lock nut on tensioning roller to 20 Nm.

8 10. .Install V-belt=>Page 13-9.Markings -arrows.should be in line.Re-tension toothed belt if necessary.Remove setting bar. repeat adjustment procedure. . . => Repair group 23. .Check whether injection pump sprocket can be locked with pin 2064. Servicing diesel direct injection system.=> => Dynamically checking and adjusting commencement of injection Tightening torques Component Toothed belt sprocket to camshaft Idler wheel to console Semi-automatic tensioning roller to cylinder block Bottom section of toothed belt guard to cylinder block Vibration damper with pulley to crankshaft 8.9 10 25 35 Nm 45 25 20 ..Check tension of toothed belt.Install ribbed belt =>Page 13-12.Check injection pump commencement of delivery (dynamic) => Diesel direct injection and glow plug system (4-cylinder TDI).Check position of camshaft with setting bar. Note: If the setting bar or pin do not fit in place.Remove pin 2064. . . . . .

. Notch and raised portion -arrows.Checking semi-automatic toothed belt tensioning roller Test requirements Toothed belt in position and tensioned.should be in line. . Test sequence . .Release thumb pressure on toothed belt.must move apart.Tension toothed belt with firm thumb pressure.Markings -arrows. The tensioning roller should move back to its initial position.

Turning crankshaft to TDC with engine removed Special tools and workshop equipment required Adjustment bar 2068 A for top dead centre Vehicles with manual gearbox Oil filter removed. .Fit TDC adjuster gauge 2068 A with screw as illustrated.Set adjuster gauge to 107 mm (the reference point is the left notch of the vernier -arrow-). . . . Vehicles with automatic gearbox Oil filter removed.Turn crankshaft until TDC marking "0" on flywheel coincides with end of adjuster gauge.

Turn crankshaft until TDC marking "0" on drive plate coincides with end of adjuster gauge.Fit TDC adjuster gauge 2068 A with screw as illustrated. .(the reference point is the left notch of the vernier -arrow-)..Set adjuster gauge to 99 mm -arrow. Note: TDC marking "0" is stamped into the cylinder block side of the drive plate. . .

Front-wheel drive.Intermediate shaft sprocket Installation position =>Fig. Servicing clutch=> 1 . Repair group 30.Removing and installing sealing flanges and flywheel/drive plate Note: For repairs to the clutch: => 5-Speed manual gearbox 012/01W.Oil seal To remove. Page 13-38 Check position of Woodruff key -Item 25- . remove sealing flange -Item 27Install with 10-203 Lightly oil sealing lip 2 . 1.

Front sealing flange Before fitting sump.3 .10 Nm 7 .Gasket Renew .45 Nm Use counter-hold 3036 to loosen and tighten 4 . apply a small amount of sealant "AMV 174 004 01"to sealing points between sealing flange and cylinder block 8 .25 Nm 5 .Oil seal Renewing => Page 13-39 Lightly oil sealing lip of oil seal 6 .

Bracket For exhauster 16 .Vacuum pump For brake servo 11 .20 Nm 15 .900058 Type 4A Type description MY 9 .Cylinder block Removing and installing crankshaft => Page 13-48 Dismantling and assembling pistons and conrods => Page 13-57 10 .10 Nm 14 .O ring Renew 12 .O ring Renew .Cover 13 .

Gasket Only install gasket if sealing flange has no sealing lip on cylinder block side 21 .Oil seal Renew 18 .10 Nm 19 .Flywheel/drive plate Removing and installing flywheel => Page 13-44 Removing and installing drive plate =>Page 13-45 .900058 Type 4A Type description MY 17 .Rear sealing flange With oil seal Only renew complete Lightly oil sealing lip of oil seal Before fitting sump. apply a small amount of sealant "AMV 174 004 01"to sealing points between sealing flange and cylinder block 20 .

Intermediate plate Must be located on dowel sleeves Do not damage orbend when assembling 24 .25 mm 25 .900058 Type 4A Type description MY 22 .Woodruff key Check that Woodruff key is fitted correctly 26 . 0.O ring Renew 27 .Intermediate shaft Axial clearance max.Sealing flange for intermediate shaft 28 .25 Nm .60 Nm + 1/4turn (90 °) further Renewing 23 .

The side of the sprocket with the lettering is at the rear.of the intermediate shaft sprocket is at the front. .1Installation position of intermediate shaft sprocket The wider rim -arrows.900058 Type 4A Type description 1Z CUT Fig.

pulley end Special tools and workshop equipment required Oil seal extractor 2085 Oil seal fitting tool 3083 Counter-hold tool (retainer) 3099 .Renewing crankshaft oil seal .

Screw cheese-head bolt from 3083 five or six turns into crankshaft before applying oil seal extractor. To do this counter -hold sprocket with 3099. .Remove V-belt=>Page 13-9. .Remove toothed belt => Page 13-20. . .Removing Engine in vehicle 4A . Note: Special tool 3415 can be used instead.Remove ribbed belt => Page 13-11.Remove crankshaft toothed belt sprocket. 3 mm) out of the outer part and lock with knurled screw.Unscrew inner part of the oil seal extractor 2085 two turns (approx. . .

.Clamp flats of oil seal extractor in vice. . exerting firm pressure. . . Remove oil seal with pliers.Lubricate threaded head of oil seal extractor.Loosen knurled screw and turn inner part against crankshaft until the oil seal is pulled out.Clean contact surface and sealing surface. Installing . screw it as far as possible into oil seal. place it in position and.Lightly oil sealing lip of oil seal. . .Place guide sleeve from 3083 onto crankshaft journal.900058 Type 4A Type description .Slide oil seal over guide sleeve.

Install ribbed belt =>Page 13-12.Install V-belt=>Page 13-9. and tighten bolts.Renew bolt for toothed belt sprocket. . Do not grease bolt for toothed belt sprocket. . Notes: Contact surface between toothed belt sprocket and crankshaft must be free of oil. .4A . .Install toothed belt (adjust valve timing) => Page 13-26.Allow stop for torque reaction support to rest on rubber buffer for torque reaction support under its own weight. Tightening torques Component Toothed belt sprocket to crankshaft Torque reaction support Nm 90 + 90°1)2) 20 40 M8 M10 1)Renew bolt 2)90° is a quarter turn . . .Install crankshaft sprocket and lock in position with retainer 3099.Press oil seal in onto stop using press sleeve and bolt from 3083.

Removing and installing flywheel/ drive plate Flywheel Special tools and workshop equipment required Counter-hold tool 10-201 Work sequence .Renew bolts.Reverse position of retainer 10-201 for loosening/tightening bolts. Tightening torque Component Flywheel to crankshaft 1)90°= Nm 60 + 90°1) 1/4turn . . .Mark position of flywheel relative to engine.

.Loosen securing bolts on drive plate. . Place two M10 hexagon nuts -1.Secure counter-hold tool VW 558 to the drive plate with a hexagon bolt M8x45.Mark position of drive plate relative to engine. .between counter-hold tool and drive plate.Drive plate 900058 Type 4A Type description Special tools and workshop equipment required Counter-hold tool VW 558 Hexagon bolt M8 x 45 and two M10 hexagon nuts Depth gauge Removing .

and packing plate -1. ..900058 Type 4A Type description Installing .. 28 mm If the specification is exceeded: .at three points and calculate average value.. . .Measure distance -a.Specified distance: 26 .must face towards torque converter.Insert at least 3 old securing bolts and tighten to 30 Nm.The lug -arrow.Locate drive plate with shim -2.

Fit new bolts and tighten. .Remove drive plate again and install without shim -2-.900058 Type 4A Type description . Tighten bolts to 30 Nm again.Measure distance again. Tightening torque Component Drive plate to crankshaft 1)90°= Nm 60 + 90°1) 1/4turn . If the specification is attained: .

Thrust washers For bearing 3 Different versions for cylinder block and bearing cap Note fixing arrangement 2 .Removing and installing crankshaft Note: Secure engine to engine bracket VW 540 on assembly stand when dismantling/assembling engine. 1 .Bearing shell Bearing shell with oil groove for cylinder block Do not interchange used bearing shells (mark with waterproof pen) .

..3 .Crankshaft Axial clearance new: 0.Bearing shell Bearing shell without oil groove for bearing cap Do not interchange used bearing shells (mark with waterproof pen) 5 .0.07.37 mm Check radial clearance with Plastigage New: 0.03.0.Thrust washers For bearing 3 bearing cap Different versions for cylinder block and bearing cap Note fixing arrangement .17 mm Do not rotate the crankshaft when checking the radial clearance Crankshaft dimensions => Page 13-56 4 .08 mm Wear limit: 0.17 mm Wear limit: 0...

tighten to 65 Nm but do not turn further 7 . Page 13-52 .6 .Bearing cap Bearing cap 1: Pulley end Bearing cap 3 with recesses for thrust washers Bearing shell retaining lugs (cylinder block/bearing cap) must be on the same side 8 .65 Nm + 1/4turn (90 °) further Renewing When measuring radial clearance of crankshaft.1.10 Nm + 1/4 turn (90 °) further Renew Always renew sender wheel if bolts have been unscrewed =>Fig.

Needle bearing Pulling out and driving in => Page 13-53 10 . Page 13-52 11 . Page 13-52 . 2.Sender wheel For engine speed sender (G28) Can only be installed in one position.9 .Fitted pin Checking projection from crankshaft=>Fig. 1. Holes are off-set Always renew sender wheel if securing bolts have been unscrewed Removing and installing =>Fig.

0 mm .out of crankshaft a =2.3. Notes: If the securing bolts are tightened a second time. Tightening torque Component Sender wheel to crankshaft 1)Renew Nm 10 + 90° 1)2) bolts 2)90° is a quarter turn Fig. The mounting holes are asymmetrically spaced.1Removing and installing sender wheel ..have been unscrewed..if securing bolts -1.(-arrows-) and the sender wheel will only fit loosely under the bolts. 2Checking dowel pin projection out of crankshaft Dowel pin projection -3. the seats for the countersunk bolt heads in the sender wheel will be distorted to such an extent that the bolt heads will come into direct contact with the crankshaft -3.5. so it is only possible to install the sender wheel in one position.4A 1Z CUT Fig.Always renew sender wheel -2.

Remove needle bearing if necessary.Removing and installing needle bearing in crankshaft Special tools and workshop equipment required Drift VW 207 C Special tool Kukko 21/1 (Item 1) and Kukko 22/1 (Item 4) Notes: A needle bearing must be fitted in the crankshaft on vehicles with manual gearbox. Install needle bearing if necessary. . The needle bearing must not be fitted in the crankshaft on vehicles with automatic gearbox.

Knock in with drift VW 207 C or centring mandrel 3176.Pull out needle bearing using Kukko 21/1 and Kukko 22/1. .Lettering on needle bearing must be visible when installed. . Installing .900058 Type 4A Type description Removing .

5 mm .4A Installation depth for needle bearing 1Z Distance a = 1.

022 1st undersize 53.042 -0.022 47.022 47.042 -0.022 -0. -0.042 -0.05 -0. Conrod journal dia.25 -0.00 .042 47.55 -0.Crankshaft dimensions (in mm) Honing dimension Main journal dia.022 2nd undersize 53.022 3rd undersize 53.042 -0.042 -0.50 -0.022 -0.022 Basic dimension 54.042 47.80 -0.75 -0.30 -0.042 -0.

.3 .Oil spray jet For piston cooling Version fitted>06. 1 .Dismantling and assembling pistons and conrods Note: Vehicles can be fitted with two different types of conrods: Conrods with fitted pin -item 8-: use conrod bolts without centring location.96 Apply sealant AMV 188 001 02 when installing 2 .96 With pressure relief valve (opens at 1. 1.6 bar) . Conrods without fitted pin: use conrod bolts with centring location(fitted bolts)..7 Nm Version fitted>06.

6 bar Do not apply locking fluid 4 .3 .. 27 Nm Version fitted 07.96>(phased in) opens at: 1.3 .08 mm Do not rotate crankshaft when checking radial clearance ..Pressure relief valve. 1.96>(phased in) 5 .37 mm Check radial clearance with Plastigage: Wear limit: 0.Oil spray jet For piston cooling Version fitted 07.Bearing shell Note installation position Do not interchange used bearing shells (mark with waterproof pen) Ensure retaining lugs fit tightly in recesses Axial clearance Wear limit: 0.

Bearing shell Note installation position Do not interchange used bearing shells (mark with waterproof pen) Ensure retaining lugs fit tightly in recesses Axial clearance Wear limit: 0. Page 13-64 Piston and cylinder dimensions =>Page 13-68 7 .08 mm Do not rotate crankshaft when checking radial clearance . 4.6 .Cylinder block Checking cylinder bores =>Fig.37 mm Check radial clearance with Plastigage: Wear limit: 0.

faces towards pulley end 10 . not in the bearing cap 9 .Fitted pin See note =>Page 13-57 The fitted pin must seat securely in the conrod.Conrod See note =>Page 13-57 Only renew as a set Mark cylinder number -AInstallation position: Marking -B.Piston pin If difficult to move.8 .Circlip 11 . 60 °C Remove and install with VW 222a . heat piston to approx.

Page 13-64 Mark installation position/cylinder number=> Fig.5. Page 13-65 Renew piston if there are cracks in piston skirt Arrow on piston crown points to pulley end Install using piston ring clamp Checking piston projection at TDC =>Page 13-66 Piston and cylinder dimensions =>Page 13-68 . 3.Piston With combustion chamber Checking=>Fig.12 .

2. 30 Nm + 1/4 turn (90 °) further See note =>Page 13-57 Renew Oil threads and contact surface To measure radial clearance use old bolts .Conrod bolt. Page 13-63 Checking ring-to-groove clearance =>Fig. 1. Page 13-63 14 .Piston ring Offset gaps by 120 ° Remove and install with piston ring pliers "TOP" must face towards piston crown Checking ring gap =>Fig.Conrod bearing cap Mark cylinder number -AInstallation position: Marking -B.13 .faces towards pulley end 15 .

25 0.0 1.0.0..15 ..0 1. 1Checking piston ring gap .06 Wear limit 0.0..08 0.20.Push ring squarely from above down to approx.0 Fig..25.05.Clean groove before checking clearance. Piston ring Dimensions in mm 1st compression ring 2nd compression ring Oil scraper ring New 0..09 0.... 2Checking ring to groove clearance .4A 1Z Fig.0.25 0. Piston ring Dimensions in mm 1st compression ring 2nd compression ring Oil scraper ring New 0.0.0..40 0.20. 15 mm from bottom end of cylinder..50 Wear limit 1.40 0.03...06.

Measure pistons approx.4A Fig.Deviation from nominal dimension not more than 0.04 mm . 10 mm from lower edge of skirt. . 3Checking piston . at 90° to the piston pin axis.

. .Deviation from nominal dimension not more than 0.4A 1Z Fig..and longitudinal -B.Take measurements at 3 positions in both lateral -A. 4Checking cylinder bores Special tools and workshop equipment required Internal dial gauge 50.directions.100 mm .10 mm .

allocation to cylinders is shown by a coloured marking on the piston crown.goes towards pulley end Note: On new pistons. Piston for cylinder 1 and 2: marked 1/2 Piston for cylinder 3 and 4: marked 3/4 Arrowon piston crown points to pulley end .goes towards flywheel end . .5Piston installation position andCUT piston/cylinder allocation .Mark installation position and cylinder number on inside of pistons (not on piston crown) with electric scriber or felt-tip pen.4A 1Z Fig.Pistons in cylinders 3 and 4: larger recess for inlet valve -arrows.Pistons in cylinders 1 and 2: larger recess for inlet valve -arrows.

Checking piston projection at TDC Special tools and workshop equipment required Special tool VW 382/7 Special tool VW 385/17 .

10 mm 1..4A The piston projection at TDC must be measured when MICLEF 1Z CUT installing new pistons or a short engine.. 1.01 mm ..11 mm . 1. Piston projection above top surface of cylinder block 0. 1.20 mm Gasket identification (No..see table below. of holes) 1 2 3 . Install the correct cylinder head gasket for the piston projection .91 mm .00 mm 1...

Installation position: marking "OBEN / TOP" or Part No. .4A 1Z Cylinder head gasket identification Part No. goes towards cylinder head. = arrow 1 Holes = arrow 2 Production code = arrow 3 (can be disregarded) Notes: If different values are measured at individual cylinders when checking piston projection. select the gasket for the highest value.

mm mm mm 79.97 Cylinder bore 79.47 79.51 79.Piston and cylinder dimensions Honing dimension Basic dimen.76 80. 1st oversize 2nd oversize Piston dia.01 .72 79.

The plastic protectors fitted to protect the open valves must only be removed immediately before fitting the cylinder head.Removing and installing cylinder head Notes: Cylinder heads which have cracks between the valve seats can continue to be used without reducing service life. When installing an exchange cylinder head with fitted camshaft. provided there are only small cracks not wider than 0. drain off all the old coolant and re-fill with new coolant. The cylinder head on a diesel engine must not be reworked.5 mm. Before applying sealant. When fitting a new cylinder head or cylinder head gasket. the contact surfaces between tappets and cams must be oiled after installing the head. check updated information: => Parts catalogue .

Page 15-6 Installing => Page 15-23 After replacing. 4. fill with fresh coolant 2 . Page 15-7 Fit projections into drill holes on cylinder head .25 Nm 3 .3and Fig.Lower sealing cone 5 .Cylinder head Removing => Page 15-13 Check for distortion =>Fig.Cylinder head cover gasket Renew if damaged or leaking Before fitting gasket apply AMV 174 004 01at sealing points =>Fig.1 . 1.Lifting eye 4 .

Cylinder head cover Removing and installing => Page 15-8 7 .Hose clip After fitting hose clip on hose.Upper sealing washer Renew if damaged 8 .10 Nm 10 .Cover cap 11 . engage in retaining tab on cylinder head cover .Gasket Renew if damaged or leaking 12 .Dished washer 9 .Fillercap 13 .Breather hose 14 .6 .

Cylinder head bolt Renew Note sequence when loosening => Page 15-22 Note sequence when tightening => Page 15-26 18 .Pressure regulating valve For crankcase breather 16 .Gasket Renew if damaged 17 .Coolant flange With coolant temperature sender .15 .10 Nm 20 .Injector pipes Tighten to 25 Nm Remove with 3035 Always remove pipework complete Do not alter shape 19 .

Coolant flange 23 .Return pipe To injection pump 26 .O ring Renew 22 .Cylinder head gasket Different thicknesses Note marking =>Fig. towards cylinder head After replacing. fill with fresh coolant .21 .Connector For needle lift sender -G80 25 . 2. Page 15-6 Renew => Removing cylinder head. from Page 15-13onwards Position: Marking "OBEN / TOP" or Part No.10 Nm 24 .

Use knife-edge straightedge and feeler gauge to measure at several points. permissible distortion: 0. .4A 1Z CUT Fig.Max. .1 mm Note: Reworking Diesel cylinder heads is not permissible. 1Checking cylinder head for distortion .

= arrow 1 Holes = arrow 2 Production code = arrow 3 (can be disregarded) Notes: Cylinder head gaskets of different thicknesses must be installed according to the amount of piston projection=>Page 13-66.4A 1Z CUT Fig. goes towards cylinder head. . install a new gasket with the same identification as the old one. When only the gasket is being replaced. Installation position: marking "OBEN / TOP" or Part No.2Cylinder head gasket identification Part No.

on upper sealing surface of cylinder head.Apply a small quantity of sealant "AMV 174 004 01" to sides of joints -arrows. 4Sealing sides of joint . 3Sealing sides of joint between CUT bearing cap and cylinder head .on upper sealing surface of cylinder head.4A 1Z Fig.Apply a small quantity of sealant "AMV 174 004 01" to sides of joints -arrows. Fig. .

Removing and installing cylinder head cover Removing . .Remove engine cover panel -arrows-.Slacken hose clamps -arrows.and disconnectcrankcase breather hoses from pressure control valve. .

and lower sealing cone -1-. . .Take off dished washer -5. .Pull off caps -7-. .Remove gasket -2.on cylinder head cover.Remove cylinder head cover -3-.and upper sealing washer -4-.Loosen nuts -6.. .

fit new cylinder head cover gasket. .on upper sealing surface on cylinder head.Apply a small quantity of sealant "AMV 174 004 01" to sides of joints -arrows.Installing Installation is carried out in the reverse order.Position cylinder head cover (with attached parts). upper sealing washer and sealing cone.Apply a small quantity of sealant "AMV 174 004 01" to sides of joints -arrows. . . Tightening torque Component Cylinder head cover to cylinder head Nm 10 . when doing this note the following: If damaged.on upper sealing surface on cylinder head.

Unscrew nuts -1. .Unscrew bolts -arrows-. .Removing and installing intake manifold Removing . .and remove heat shield.Remove intake manifold.Unscrew bolts -arrows-. Tightening torques Component Intake manifold to cylinder head Heat shield to exhaust manifold Mechanical exhaust gas recirculation valve to intake manifold Nm 25 25 25 . . Installing Installation is performed in the reverse order.Slacken hose clamp -1-.Remove turbocharger =>Page 21-29. .

A.Removing cylinder head Special tools and workshop equipment required Mandrel 2064 Setting bar 2065 A Open ring spanner 3035 Counterhold tool 3036 Guide pin 3070 V.G 1306 .

Obtain radio code on vehicles with coded radio.With ignition switched off disconnect battery earth strap. Warning! Hot steam can escape when the cap on the expansion tank is opened.Remove engine cover panel -arrows-. . . Cover the cap with a cloth. . . . and open it carefully.Work sequence Engine in vehicle Note: All cable ties which are released or cut open when removing must be fitted in the same position when installing.Open cap on coolant expansion tank.

..Disconnect thin hose -6. .Remove air intake pipe -arrow. .between lock carrier and air cleaner housing.from bottom of exhaust gas recirculation valve -N18.Disconnect vacuum hose from mechanical exhaust gas recirculation valve -3-. .Disconnect wires/unplug connectors as follows: 1 -Exhaust gas recirculation valve -N18 2 -Air mass meter -G70 4 -Charge pressure control solenoid valve -N75 5 -Intake manifold temperature sender -G72 .Detach air hose at air mass meter. .Move wiring and hoses clear.

from air pipe -1-.Unscrew charge pressure control solenoid valve -2. .Remove upper section of air cleaner housing together with air mass meter. Leave hoses connected. .Remove air intake hose between charge air cooler and turbocharger. . . It is then not necessary to remove front exhaust pipe. .Remove air pipe -1.Disconnect front exhaust pipe with catalytic converter from turbocharger.4A .Unscrew bolts securing turbocharger to catalytic converter -arrows-.between charge air cooler and intake manifold. . Note: Tie up flange of front exhaust pipe on right suspension turret with wire.

.Place a drip tray underneath..Detach oil return pipe from cylinder block -arrow-. . .Remove noise insulation (two sections -arrows-).Draincooling system=> Page 19-4 .

.between injectors and injection pump. .Remove cylinder head cover =>Page 15-8.Remove injector pipes.Unplug connectors from glow plugs. Use special spanner for injector pipes 3035. . .5-. .Disconnect coolant hoses -arrows.Disconnect coolant hose at rear of cylinder head -arrow-..on left side of cylinder head.Disconnect fuel return hose -1. . Note: Always remove complete set of injector pipes together.. .Disengage connector for engine speed sender from its retainer. .Disconnect connectors-2 . .

900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF .(vehicles with automatic gearbox).Turn crankshaft to TDC No. 1 cylinder -arrow.(vehicles with manual gearbox). 1 cylinder -arrow.Turn crankshaft to TDC No. MY Workshop Manual -7- . .

Lock camshaft with setting bar 2065 A.900058 Type 4A Type description Engine ID Gearbox ID 1Z CUT . MY User MICLEF Workshop Manual -8- . . .Remove toothed belt guard (upper) => Page 13-14.Unscrew 2 bolts -arrows.securing rear toothed belt guard on both sides of cylinder head.

. .Loosen tensioning roller. .Mark direction of rotation of toothed belt with chalk or felt pen. Counter-hold with 3036. .Lock injection pump sprocket with pin 2064.Take toothed belt off camshaft sprocket. Release camshaft sprocket from camshaft taper by tapping with a hammer (using a drift through rear toothed belt guard opening).Loosen camshaft sprocket securing bolt 1/2 turn. Note: On no account use the setting bar to hold the camshaft when loosening and tightening the bolt securing the camshaft sprocket.900058 Type 4A Type description Engine ID Gearbox ID 1Z CUT . .Remove toothed belt tensioning roller. .Remove camshaft sprocket. MY User MICLEF Workshop Manual -9- . .Remove idler wheel.

lift cylinder head up slightly and swivel out to the rear. MY Workshop Manual .10 - .Keep to specified sequence when loosening cylinder head bolts.900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF .With a second mechanic. .

turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated. When performing repairs. Remove new cylinder head gasket from packaging just before installation. If repairing. self-locking nuts and bolts which have a specified tightening angle. Handle gasket extremely carefully. Damaging the silicone layer or the indented area will lead to leaks. carefully remove any remains of gasket material from the cylinder head and cylinder block. Make sure that no long scores or scratches are made on the surfaces.900058 Type 4A Type description MY Engine ID 1Z Installing cylinder head Gearbox ID CUT User MICLEF Workshop Manual -1- Notes: Always renew cylinder head bolts when assembling. After working on the valve gear. Carefully remove any remaining emery and abrasive material. Installation is carried out in the reverse order. renew seals. No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block. when doing this note the following: . gaskets.

. Note: Illustration shows vehicle with manual gearbox... 1 before fitting cylinder head. .. It should be possible to insert setting bar 2065 A in camshaft .900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF . MY Workshop Manual -2- ...Turn crankshaft and camshaft to TDC of cylinder No. and TDC marking should be in line with reference edge.

900058 Type 4A Type description Engine ID Gearbox ID 1Z CUT . the new cylinder head gasket must be selected by measuring the piston projection at TDC => 13-66.Holes = arrow 2 . = arrow 1 .Part No.Production code = arrow 3 (can be disregarded) Notes: MY User MICLEF Workshop Manual -3- If the cylinder head gasket or the cylinder head has been replaced. If parts of the crankshaft drive have been replaced. .Check identification on cylinder head gasket: . select a new gasket according to the number of holes on the old gasket.

4th stage: 1/4 turn (90°) further Note: It is not necessary to tighten cylinder head bolts again later after repairs have been performed.Place cylinder head in position.Tighten using torque wrench: . .Check installation position of cylinder head gasket: the word "oben" (top) or the Part No. MY Workshop Manual -4- . . .2nd stage: 60 Nm .900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF . Note: Follow all instructions for removing and installing toothed belt =>Page 13-20.Screw in 8 cylinder head bolts and tighten by hand.Check that centring sleeve in cylinder block is fitted correctly. . screw guide pins 3070/9 from 3070 into the outer holes in the cylinder block.Install cylinder head cover =>Page 15-9. . should face towards the cylinder head.To centre. .TIghten with normal fixed wrench: .Place cylinder head gasket in position.Unscrew guide pins with removal tool from 3070 through bolt holes in cylinder head and install remaining cylinder head bolts. .1st stage: 40 Nm .3rd stage:1/4 turn (90°) further .Tighten cylinder head bolts in four stages in sequence shown as follows: .Install toothed belt (adjust valve timing) => Page 13-26. . .

1Z CUT . User MICLEF Workshop Manual -5- .After connecting battery. .Close windows fully using electric window switches. Tightening torques Component Catalytic converter to turbocharger Oil return pipe to cylinder block Injector pipes to injectors/ injection pump Idler wheel to console Toothed belt sprocket to camshaft Hose clamps Nm 25 30 25 25 45 2 .Set clock to correct time.900058 Type 4A Type description .Aligning exhaust system free of stress => MY Engine ID Gearbox ID Page 26-10.Fill cooling system with fresh coolant => Page 19-7. .Then operate all electric window switches again for at least one second in the "close" direction to activate the automatic one -touch function. enter anti-theft code for radio => Radio operating instructions .

A.900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF Checking compression pressure Workshop Manual -1- Special tools and workshop equipment required Special tool 3220 V.A.G 1763 V.G 1381/12 Requirements for test: .

. Note: Using the compression tester => Operating instructions .Remove all glow plugs using socket spanner 3220. 5 . .Operate starter until tester shows no further pressure increase.Remove engine cover panel -arrows-. . .900058 Type 4A Type description Engine ID Gearbox ID 1Z CUT Engine oil temperature not less than 30 °C Battery voltage not less than 12 V Test sequence .Check compressions with compression tester V.G 1381/12 in place of the glow plugs. .Disconnect connector to quantity adjuster on injection pump.A.A. Compression pressure: New Wear limit bar bar 25 .A..Interrogate and erase fault memory: .Screw in adapter V. 31 19 Permissible difference between cylinders bar max.G 1763.G 1381/V.Unplug connector for fuel cut-off valve on injection pump. MY User MICLEF Workshop Manual -2- .Install glow plugs with jointed spanner 3220 Tightening torque: 15 Nm. .

900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF => Diesel direct injection and glow plug system (4-cylinder TDI). Tightening torque Component Glow plugs in cylinder head Nm 15 MY Workshop Manual -3- . Interrogate and erase fault memory after checking compression. Interrogating and erasing fault memory=> Note: Faults will have been stored in the memory because connectors have been unplugged from the injection pump. => Repair group 01.

check updated information: => Parts catalogue . Before applying sealant. wait for about 30 minutes before starting the engine. otherwise the valves will contact the pistons. After installing the camshaft. The hydraulic tappets must be allowed to settle.900058 Type 4A Type description MY Engine ID Servicing valve gear 1Z Gearbox ID CUT User MICLEF Workshop Manual -1- Notes: Cylinder heads which have cracks between the valve seats can continue to be used without reducing service life. provided there are only small cracks not more than 0. Renew all gaskets and seals. After working on the valve gear. turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.5 mm wide.

Camshaft sprocket Take off toothed belt before removing and installing =>Page 13-20or 13-26 Drive off camshaft taper using hammer and drift through toothed belt guard openings .Cylinder head See note => Page 15-32 Checking valve guides =>Page 15-54 Reworking valve seats => Page 15-51 User MICLEF Workshop Manual -2- 2 . remove bearing cap and camshaft sprocket Removing and installing toothed belt =>Page 13-20and13-26 3 .900058 Type 4A Type description MY Engine ID Gearbox ID 1Z CUT 1 .Oil seal To remove and install.

45 Nm Counter-hold with 3036 to loosen and tighten 5 .3and Fig. Page 15-38 Installation sequence => Page 15-40.Bearing cap Installation position =>Fig.4. apply a thin coat of sealant "D 454 300 A2" to contact surfaces ApplyAMV 174 004 01at sealing points=>Fig. 1. removing and installing camshaft Before installing first bearing cap. Page 15-7 Workshop Manual -3- .20 Nm 6 .900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF 4 .

Hydraulic bucket tappet Checking => Page 15-46 Removing and installing => Page 15-48 Do not interchange Store with cam contact surface downwards Before installing check camshaft axial clearance => Page 15-39 Oil contact surface Workshop Manual -4- .900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF 7 .11 mm Run-out: max.Camshaft Checking axial clearance => 15-39 Removing and installing => Page 15-40 Check radial clearance with Plastigage Wear limit: 0. 0.01 mm 8 .

Valve cotters User MICLEF Workshop Manual -5- 10 .Upper valve spring plate 11 .Valve stem seal Renewing=> Page 15-48 14 .Valve guide Checking => Page 15-54 Renew cylinder head if wear limit is exceeded .Inner valve spring Removing and installing: with cylinder head removed: use 2037 with head installed: => Page 15-48 13 .Outer valve spring Removing and installing: with cylinder head removed: use 2037 with head installed: => Page 15-48 12 .900058 Type 4A Type description MY Engine ID Gearbox ID 1Z CUT 9 .

only lapping-in is permitted Valve dimensions =>Fig. Page 15-38 Workshop Manual -6- .900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF 15 .Valve Do not rework.Lower valve spring plate Use puller 3047 A to remove and install 16 . 2.

Before installing camshaft fit bearing caps and determine fitting position. 1Fitting position1Z camshaft bearing caps of User MICLEF Workshop Manual -7- Note offset.95 6. -aDia.900058 Type 4A Type description MY Engine ID Gearbox ID CUT Fig.943 96. Fig.85 45 .963 96. -bc α mm mm mm <° Inlet valve 35. 2Valve dimensions Note: Valves must not be reworked. Only lapping-in is permitted.85 45 Exhaust valve 31.45 6. Dimension Dia.

900058 Type 4A Type description MY Engine ID Gearbox ID 1Z Checking camshaft axial clearance CUT User MICLEF Workshop Manual -1- Special tools and workshop equipment required Special tool VW 387 Dial gauge .Wear limit: 0.15 mm .Perform measurement with bucket tappets removed and front and rear bearing caps fitted. .

.Remove toothed belt guard (upper) => Page 13-14.900058 Type 4A Type description MY Engine ID Gearbox ID 1Z Removing and installing camshaft CUT User MICLEF Workshop Manual -1- Special tools and workshop equipment required Mandrel 2064 Setting bar 2065 A Removing Cylinder head installed .

(vehicles with manual gearbox). 1 cylinder -arrow.900058 Type 4A Type description Engine ID Gearbox ID 1Z CUT .Turn crankshaft to TDC No.Remove cylinder head cover =>Page 15-8. . MY User MICLEF Workshop Manual -2- . 1 cylinder -arrow.Turn crankshaft to TDC No.(vehicles with automatic gearbox). .

Remove idler wheel. MY User MICLEF Workshop Manual -3- .Lock injection pump sprocket with pin 2064. Counter-hold with 3036. it can break. . Note: On no account use the setting bar to hold the camshaft when loosening and tightening the bolt securing the camshaft sprocket. .Loosen tensioning roller. .900058 Type 4A Type description Engine ID Gearbox ID 1Z CUT . .Lock camshaft with setting bar 2065 A.Take toothed belt off camshaft sprocket. . Note: If the belt runs in the wrong direction when it is refitted.Mark direction of rotation of toothed belt with chalk or felt pen.

otherwise the valves will contact the pistons. When installing the camshaft No.Check injection pump commencement of delivery (dynamic) MY Workshop Manual -4- . fit bearing caps and determine correct position. . Loosen bearing caps 2 and 4 alternately and diagonally. wait for about 30 minutes before starting the engine. .Install toothed belt (adjust valve timing) => Page 13-26.Loosen camshaft sprocket securing bolt 1/2 turn. .First remove bearing caps 1.Oil camshaft running surfaces. The hydraulic tappets must be allowed to settle.Install bearing caps 5. when doing this note the following: Notes: Renew camshaft oil seal. When installing the bearing cap note offset. After working on the valve gear. 3 and 5. . 1 cylinder cams must point upwards. . . After installing the camshaft. . Before installing camshaft. . 1 and 3 and also tighten to 20 Nm. turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated. Release camshaft sprocket from camshaft taper by tapping with a hammer (using a drift through rear toothed belt guard opening).Install cylinder head cover =>Page 15-9. Installing Installation is carried out in the reverse order. Notes: Follow all instructions for removing and installing toothed belt =>Page 13-20onwards.Tighten bearing caps 2 and 4 alternately and diagonally to 20 Nm.900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF .Remove camshaft sprocket.

1Z CUT MICLEF => Repair group 23. Servicing diesel direct injection system.900058 Type 4A Type description MY Engine ID Gearbox ID User => Diesel direct injection and glow plug system (4-cylinder TDI).=> => Dynamically checking and adjusting commencement of injection Tightening torque Component Bearing caps to cylinder head Nm 20 Workshop Manual -5- .

. Note: If the irregular valve noises stop but recur repeatedly during short journeys. 80 °C. Irregular valve noises when starting engine are normal.Start engine and run until coolant temperature reaches approx. . locate defective tappets as follows: .Determine play between cam and bucket tappet. If the hydraulic tappets are still noisy.Increase engine speed to about 2500 rpm for 2 minutes (perform road test if necessary).Remove cylinder head cover =>Page 15-8. . . The oil retention valve is located in the oil filter bracket.Rotate crankshaft until cams of cylinder to be checked are pointing upwards. a new oil retention valve must be fitted.900058 Type 4A Type description MY Engine ID Gearbox ID 1Z Checking hydraulic bucket tappets CUT User MICLEF Workshop Manual -1- Special tools and workshop equipment required Feeler gauge Wood or plastic wedge Notes: Hydraulic tappets cannot be adjusted or repaired. .

Notes: After installing the camshaft.20 mm feeler gauge can be inserted between camshaft and tappet. After working on the valve gear. MY Workshop Manual -2- . turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated. wait for about 30 minutes before starting the engine.Renewing tappets.Press tappet down with a wooden or plastic wedge. otherwise the valves will contact the pistons. Page 15-40. . => Removing camshaft.900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF . If an 0. The hydraulic tappets must be allowed to settle. renew tappet.

900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT Renewing valve stem seals MICLEF Workshop Manual -1- Special tools and workshop equipment required Valve lever VW 541/1A with thrust piece VW 541/5 Fitting tool 2036 Puller 3047 A Fitting tool 3129 Removing Cylinder head installed .Remove camshaft => Page 15-40. .

When doing this ensure that the tappets are not interchanged.Remove the bucket tappets and put them down with the contact surface downwards. Installing . MY Workshop Manual -2- . .Position fitting tool 2036 with shaft parallel to sealing edge of cylinder head cover. .Pull off valve stem seals with 3047 A. Tighten bolts to secure fitting tool. Note: The valves are supported by the piston crown.Remove valve springs with lever VW 541/1A. .900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF .Adjust shaft of fitting tool so that it is level with the studs for the bearing caps. .Set piston of respective cylinder to top dead centre (TDC).

turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.Insert valve stem seal in the tool 3129 and push it down carefully onto the valve guide. After working on the valve gear. . . otherwise the valves will contact the pistons. place plastic sleeve -A.Lightly oil sealing lip of valve stem seal.To prevent damage to the new valve stem seals -B-.Remove plastic sleeve. Notes: After installing the camshaft. The hydraulic tappets must be allowed to settle. wait for about 30 minutes before starting the engine.900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF .on valve stem. . MY Workshop Manual -3- .Install camshaft => Page 15-44. .

they must be refaced (reworked): Special tools and workshop equipment required Depth gauge Valve seat refacing tool Notes: When repairing engines with leaking valves. The valve guides must also be checked for wear. This is particularly important on high mileage engines =>Page 15-54.Insert valve and press it firmly against valve seat. the cylinder head must be replaced. Calculating max. it is not sufficient to reface the valve seats and renew the valves. Note: If the valve is to be renewed as part of a repair. permissible reworking dimension . Calculate the maximum permissible reworking dimension before reworking. The valve seats should only be reworked just enough to produce a perfect seating pattern. use a new valve for the calculation. measure again with a new valve. .900058 Type 4A Type description MY Engine ID 1Z Reworking valve seats Gearbox ID CUT User MICLEF Workshop Manual -1- Note: If a good seating pattern cannot be obtained by grinding the valve seats (lapping). If the maximum permissible reworking dimension is 0 mm or less than 0 mm. If it is still 0 mm or less than 0 mm.

between end of valve stem and upper edge of cylinder head. perm.Measure distance -a.1 mm Measured distance minus minimum dimension = max.6 mm = Valve seat angle . . = 35.5 mm 35.7 mm Reworking inlet valve seat a b 45 ° Note: The 30 ° lower valve seat chamfer is required for gas flow characteristics in the inlet port.900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF .and minimum dimension.8 mm Exhaust valve 36. rework dimension MY Workshop Manual -2- = 36.8 mm 0. Example: Measured distance Minimum dimension max.7 mm ш = 1. permissible reworking dimension.Calculate max. Minimum dimension: Inlet valve 35. permissible reworking dimension from measured distance -a.

7 mm = Valve seat angle Gearbox ID CUT User MICLEF Workshop Manual -3- .4 mm ш = 2.900058 Type 4A Type description MY Engine ID 1Z Reworking exhaust valve seat a b 45 ° = 31.

Due to the slight difference in stem diameters. ensure that only an inlet valve is used in the inlet guide and an exhaust valve in the exhaust guide. renew the cylinder head. If the wear limit is again exceeded. use a new valve for the calculation.900058 Type 4A Type description MY Engine ID 1Z Checking valve guides Gearbox ID CUT User MICLEF Workshop Manual -1- Special tools and workshop equipment required Special tool VW 387 Dial gauge .3 mm If the valve is to be renewed as part of a repair. repeat the measurement with new valves. Wear limit Notes: If the wear limit is exceeded. .Insert valve into valve guide until end of valve stem is flush with end of guide. Amount of sideways play: not more than 1.

The oil level must not be above the max. check updated information: => Parts catalogue Viscosity grades and oil specifications: => Maintenance Oil system capacity: => Binder "Emissions test" . mark .danger of damage to catalytic converter. the oil passages must be cleaned carefully. Before applying sealant.900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF Removing and installing parts of the lubrication system Workshop Manual -1- Notes: If large quantities of metal shavings or particles are found in the engine oil when repairing the engine. and the oil cooler renewed in order to prevent further damage occurring later.

Suction pipe Clean strainer if soiled .Oil drain plug.10 Nm 6 .18 Nm Tighten in stages and in diagonal sequence 4 . 30 Nm 2 .Gasket Renew Install dry Apply a small amount of sealant "AMV 174 004 01" only to sealing points between sealing flange and cylinder block (front and rear) 5 .900058 Type 4A Type description MY Engine ID 1Z Part I Gearbox ID CUT User MICLEF Workshop Manual -1- 1 .Gasket Renew 3 .

96 >(phased in) 9 .Gears Checking backlash =>Fig.900058 Type 4A Type description MY Engine ID Gearbox ID 1Z CUT 7 .6 bar Do not apply locking fluid Version fitted 07.96 >(phased in) Version fitted>06. 27 Nm opens at: 1. Page 17-8 . 2. 1.Pressure relief valve.Oil spray jet For piston cooling Version fitted 07..O ring Renew User MICLEF Workshop Manual -2- 8 . 1. Page 13-57 10 . Page 17-8 Checking axial clearance =>Fig.96 =>-Item 2-..3 .

7 bar 12 .6..10 Nm 13 . apply a small amount of sealant "AMV 174 004 01" to sealing points between sealing flange and cylinder block Workshop Manual -3- ..25 Nm 14 .Oil pump cover with pressure relief valve Opening pressure: 5.Sump Removing and installing => Page 17-9 Clean sealing surface before installing Before installing sump.7.900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF 11 .

8 mm from cylinder block). 16 .e.Engine/gearbox support Remove support in order to remove sump => Page 17-9 When installing engine/gearbox support with engine removed from vehicle.900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF 15 . ensure that support is positioned flush with intermediate plate at flywheel end (i.45 Nm Workshop Manual -4- . engine/ gearbox support should protrude 0.

900058 Type 4A Type description MY Engine ID 1Z Part II Gearbox ID CUT User MICLEF Workshop Manual -1- 1 .25 Nm 5 .Oil filter Observe change intervals => Maintenance manual Loosen with strap wrench Observe installation instructions on oil filter 2 .25 Nm 3 .Gasket Renew .Oil filter bracket 6 .Oil cooler See note => Page 17-1 Coolant hose connection diagram =>Page 19-2 4 .

Seal If seal is leaking. 11 .0.Seal If seal is leaking. 9 .O ring Renew Engage in projections on oil cooler Workshop Manual -2- .25 Nm Grey Checking => Page 17-15 8 .9 bar oil pressure switch -F1 . cut open and renew.Oil temperature sender -G8 -10 Nm 10 .900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF 7 . cut open and renew.

1Checking oil pump backlash CUT New: 0.20 mm User MICLEF Workshop Manual -3- Fig.15 mm . 2Checking oil pump axial clearance Wear limit: 0.900058 Type 4A Type description MY Engine ID Gearbox ID 1Z Fig.05 mm Wear limit: 0.

.900058 Type 4A Type description MY Engine ID 1Z Removing and installing sump Gearbox ID CUT User MICLEF Workshop Manual -1- Special tools and workshop equipment required Workshop crane V. .G 1202 A Drip tray Sealant AMV174 004 01 Removing .Remove noise insulation (two sections.Drain engine oil. -arrows-).A.

900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF .for starter cable from subframe. MY Workshop Manual -2- .A.Support subframe with workshop crane V. Note: The subframe should be detached and lowered only at the front. . otherwise it will be necessary to check wheel alignment.Unscrew front subframe bolts -1.Unscrew retaining clamps -arrows.and -2-.G 1202 A. .

G 1202 A. MY Workshop Manual -3- . ...900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF . . 8.A.Lower subframe slowly using workshop crane V.Take off engine/gearbox support.Unbolt and remove sump: if necessary loosen it by striking lightly with a rubber hammer.from engine/gearbox support.Unscrew bolts -1 . when doing this note the following: . Installing Installation is carried out in the reverse order.

.Lightly coat the sealing points for the sump between sealing flange and cylinder block (at front and rear) using AMV 174 004 01. Servicing front suspension.Tighten bolts securing sump to cylinder block in diagonal sequence and in two stages.Fill up with engine oil and check oil level. Tightening torques .900058 Type 4A Type description MY Notes: Engine ID 1Z Gearbox ID CUT User MICLEF Workshop Manual -4- Renew seals and gaskets. In other words. When installing the engine and gearbox support -3. .Installsubframe => Running gear. . . tightening to 18 Nm at second stage. => Repair group 40. the engine/gearbox support should protrude by 0.with the engine removed from the vehicle.Clean sealing surfaces before installing sump.8 mm (distance a) from cylinder block -2-.=> => Removing and installing subframe . make sure that the support is positioned flush with the intermediate plate -1. Front-wheel drive and four-wheel drive.at the flywheel end.

1 2. 7 6 8 1)Vehicles User MICLEF Nm 45 45 45 45 45 Workshop Manual -5- Bolt M10 x 28 M10 x 45 M10 x 95 M10 x 50 M10 x 65 up to approx.96: M8 bolt.900058 Type 4A Type description MY Engine ID Gearbox ID Attachments of engine/gearbox support 1Z CUT Item No. use only correct type (same as original equipment) => Parts catalogue . 5 1) 3. 07. 4. tightening torque 25 Nm Nm 18 30 Component Sump to cylinder block1) Oil drain plug 1)Special bolts.

when doing this note the following: . Installing Installation is carried out in the reverse order. Tightening torque Component Oil pump to cylinder block Nm 25 .900058 Type 4A Type description MY Engine ID Gearbox ID 1Z Removing and installing oil pump CUT User MICLEF Workshop Manual -1- Removing .Loosen bolts -arrows-.Remove sump => Page 17-9. .Take off oil pump. .Installing sump => Page 17-12.

A.G 1594 A Requirements for test: Oil level ok. Oil pressure warning lamp -K3 must come on when ignition is .A.A.G 1527 B V.900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF Testing oil pressure and oil pressure switch Workshop Manual -1- Special tools and workshop equipment required V.G 1342 V.

75.Connect voltage tester V.G 1527 B to oil pressure switch and positive side of battery (+) using test leads from V.of tester to earth (-).G 1342. renew oil pressure switch. renew oil pressure switch. Workshop Manual -2- .A.Disconnect wire from oil pressure switch.A. If test lamp does not light up..Test lamp should light up at 0.Screw oil pressure switch -2. so watch the tester and the test lamp while starting the engine. 80 °C Testing warning lamp The oil pressure warning lamp lights up when the ignition is switched on ("terminal 15 on") with the engine not running (this does not apply to vehicles with auto-check system).Test lamp should not light up .A.Start engine Note: The switching point of the oil pressure switch can be reached when the engine is cranked on the starter motor. .If test lamp lights up.05 bar. . . .Unscrew oil pressure switch and screw in oil pressure tester V. A.Connect brown wire -1.intoV.1. Testing oil pressure switch . . . .900058 Type 4A Type description switched on.G 1342.G 1594 A. Engine oil temperature approx.Disconnect wire from oil pressure switch.. MY Engine ID Gearbox ID User 1Z CUT MICLEF In vehicles with auto-check system the "OK" display must appear (call up symbol). Testing oil pressure .

A.intoV.Oil pressure at 2000 rpm: at least 2.Start engine (engine oil temperature at least 80°C).Screw oil pressure switch -2. renew oil pump => Page 17-14.G 1342. . MY Workshop Manual -3- .Unscrew oil pressure switch and screw in oil pressure tester V. .A. .G 1342.900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF .0 bar .Oil pressure at higher engine speeds: max.0 bar If the specifications are not obtained: .Pressure relief valve or oil pump defective. 7.

except in extremely cold climates.900058 Type 4A Type description MY Engine oil Engine ID 1Z Gearbox ID CUT User MICLEF Workshop Manual -1- A high-quality multigrade oil is put in at the factory: this can be used all year round. Viscosity grades and oil specifications Viscosity grades and oil specifications: => Maintenance .

.(grooved area on dipstick) after topping up. Note: The oil level must not be above marking -a. wipe off with a clean cloth and insert it again as far as it will go. Markings on oil dipstick: a -Do not top up oil. wait a few minutes to allow the oil to flow back into the sump. b -Oil can be topped up.900058 Type 4A Type description MY Checking oil level Engine ID 1Z Gearbox ID CUT User MICLEF Workshop Manual -1- Requirements for test: Engine oil temperature at least 60 °C Vehicle must be level (horizontal) After switching off the engine. It is sufficient if the oil level is somewhere in area -b.on the dipstick. The oil level may rise as far as area -aafter topping up. Test sequence .Pull out the dipstick again and read off the oil level. . c -Oil must be topped up.Pull out the dipstick.

900058

Type 4A

Type description

MY Engine ID Gearbox ID 1Z CUT Removing and installing parts of cooling system

User MICLEF

Workshop Manual -1-

Warning! Hot steam can escape when the cap on the expansion tank is opened. Cover the cap with a cloth, and open it carefully.

Notes: When the engine is warm the cooling system is under pressure. If necessary release pressure before commencing repair work. Secure all hose connections with the correct hose clips (same as original equipment) => Parts catalogue V.A.G 1921 pliers are recommended when installing spring -type clips. Renew all gaskets and seals. The arrow markings on the coolant pipes and on the ends of the hoses must be aligned with each other.

900058

Type 4A

Type description

MY

Engine ID Gearbox ID 1Z CUT Parts of cooling system

User MICLEF

Workshop Manual -1-

Diagram of coolant hose connections 1 - Radiator Removing and installing => Page 19-18 After replacing, fill system with fresh coolant 2 - Return pipe To expansion tank 3 - Expansion tank 4 - Fillercap With pressure relief valve Testing pressure relief valve =>Page 19-23 5 - Oil cooler Removing and installing =>Page 17-6, item 3

900058

Type 4A

Type description

MY

Engine ID Gearbox ID User 1Z CUT MICLEF 6 - Return pipe From heat exchanger (for heater) 7 - Heating system heat exchanger After replacing, fill system with fresh coolant 8 - Supply pipe To heat exchanger 9 - Coolant pump/coolant thermostat Removing and installing coolant pump =>Page 19-11 Check for ease of movement Removing and installing coolant thermostat =>Page 19-16 Checking =>Page 19-17

Workshop Manual -2-

900058

Type 4A

Type description

MY Engine ID Gearbox ID 1Z Draining and filling cooling system CUT

User MICLEF

Workshop Manual -1-

Special tools and workshop equipment required Drip tray V.A.G 1306

Special tool T10007 (for coolant additive G 012 A8 D) Draining Note: Catch drained-off coolant in a clean container for re-use or disposal. Warning! Hot steam can escape when the cap on the expansion tank is opened. Cover the cap with a cloth, and open it carefully.

- Open cap on coolant expansion tank.

900058

Type 4A

Type description

Engine ID Gearbox ID User 1Z CUT MICLEF - Remove front section of noise insulation -lower arrows-.

MY

Workshop Manual -2-

- Place drip tray V.A.G 1306 below engine. - Turn drain screw -arrow- on radiator anti-clockwise, if necessary fit drain hose to connection.

If greater frost protection is required in very cold climates. disconnect coolant hoses -arrows-. G 011 A8 C and G 012 A8 D (and coolant additives marked "meeting specification TL VW 774 C" or "meeting specification TL VW 774 D") prevent frost and corrosion damage.96 onwards. This should remove very nearly all of the old coolant. the coolant improves engine reliability under heavy loads. The anti-freeze ratio must be at least 40 %.900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF . Protection against frost must be assured down to about -25 °C (in countries with arctic climate downto about -35 °C). but only up to 60 % (this gives frost protection to about -40 °C). fill it with clean water and run the engine for about 2 minutes. stop scaling and at the same time raise the boiling point of the coolant. Filling Notes: The cooling system is filled all year round with a mixture of water and coolant additive (combined anti-freeze and corrosion protection agent). Because of its high boiling point. For these reasons the cooling system must be filled all year round with the correct anti-freeze and anti-corrosion additive. this means G 012 A8 D has been mixed with another type of coolant. flush out the cooling system and put in fresh coolant. Only coolant additive G 012 A8 D (red) is used in vehicles from 07. The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. as otherwise frost . To flush the system. particularly in countries with tropical climates. Coolant additive G 011 A8 C (green) is used in vehicles up to 06. the amount of G 012 A8 D can be increased. Caution The two different coolant additives G MY Workshop Manual -3- If the fluid in the expansion tank is brown.96.To drain off remaining coolant. In this case.

mark.900058 Type 4A Type description protection is reducedEngineand cooling effectiveness User MY again ID Gearbox ID is also reduced. If radiator.25 ltr. .Stop engine. . and open it carefully.5 litres (may vary according to equipment fitted on vehicle) . and max. .Check coolant level and top-up if necessary. cylinder head or cylinder head gasket is replaced. 1Z CUT MICLEF Only use clean tap water for mixing coolant. mark on expansion tank.Close drain screw on radiator. When the engine is at normal operating temperature. heat exchanger. . Recommended mixture ratios: Anti-freeze protection down to -25 °C -35 °C 1)Cooling Workshop Manual -4- Anti-freeze concentration 40 % 50 % G 012A8 D 1) 2. 3. . between the min. when the engine is cold.35 ltr.Fit expansion tank cap. Warning! Hot steam can escape when the cap on the expansion tank is opened. . do not reuse old coolant.60 ltr.90 ltr. 3.Then run engine at idling speed until bottom hose on radiator becomes hot.Fill up with coolant to max.Start engine. Cover the cap with a cloth. the coolant level must be on the max. marks. system capacity: 6. . Water 1) 3. Special tool T10007 must be used for testing the anti-freeze concentration if the cooling system contains coolant additive G012 A8 D.

Remove V-belt.. .900058 Type 4A Type description MY Engine ID Gearbox ID 1Z CUT Removing and installing coolant pump User MICLEF Workshop Manual -1- Removing .Slacken bolts 2 . . .. .Slacken V-belt by turning tensioning nut -1-. 6.Draincooling system=> Page 19-4.

Secure vane pump to body with wire to reduce load on connections. . Do not disconnect hydraulic connections.900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF . . MY Workshop Manual -2- .Disconnect coolant hoses from coolant pump and thermostat housing -arrows-.Unbolt vane pump for power steering complete with rear bracket -arrows-.

3-. . .Detach bracket for engine cover panel below injection pump -2-.Unbolt bracket for vane pump-1 . MY User MICLEF Workshop Manual -3- .900058 Type 4A Type description Engine ID Gearbox ID 1Z CUT ..Remove engine cover panel -arrows-..

..Install V-belt =>Page 13-9.Unbolt bearing housing -1.Unbolt coolant pump housing from toothed belt guard -4-. when doing this note the following: . 3-. .from pump housing -4-.900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF . Tightening torques Component Bearing housing to pump housing Pump housing to toothed belt guard Vane pump bracket to cylinder block Bracket for engine cover panel Hose clamps Nm 10 10 25 25 2 . . MY Workshop Manual -4- . . Installing Installation is carried out in the reverse order. .Remove coolant pump.Fill up with coolant=> Page 19-7.Clean sealing surfaces on both sections of housing.Unbolt support for injection pump console -1 .Insert hammer-head bolt in drilling in coolant pump.Renew gasket and O-ring.. .

900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF Removing and installing. checking coolant thermostat Workshop Manual -1- Removing .. .. . 6.Slacken V-belt by turning tensioning nut -1-.Slacken bolts 2 .Drain cooling system=> Page 19-4 .

Engine ID 1Z Gearbox ID CUT User MICLEF Workshop Manual -2- . .Unbolt vane pump for power steering complete with rear bracket -arrows-. Do not disconnect hydraulic connections.Secure vane pump to body with wire to reduce load on connections.Remove V-belt. .900058 Type 4A Type description MY .

O-ring -2.Heat thermostat in water bath. . Starts to open approx. Installing . Tightening torques Component Connection to pump housing Hose clamps Testing coolant thermostat .and coolant thermostat -1-. .Unscrew bolts -4.900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF . 8 mm be tested .and remove connection -3-.Insert coolant thermostat.Install V-belt =>Page 13-9. 102 °C1) Opening travel min.Fill up with coolant=> Page 19-7. 87 °C 1)cannot MY Workshop Manual -3- Nm 10 2 Fully open approx. .Clean and smooth down sealing surface for O-ring as required.

Drain coolant from drain plug on radiator=> Page 19-4 . Repair group 37. ensure that the pipes and hoses are not stretched. kinked or bent.900058 Type 4A Type description MY Engine ID 1Z Removing and installing radiator Gearbox ID CUT User MICLEF Workshop Manual -1- Removing .Unplug connector -1. . Front bumper=> .Remove front bumper.Disconnect both coolant hoses at bottom of radiator -arrows-.from radiator fan thermoswitch -F54. .Remove securing bolts for condenser. Removing and installing ATF pipes Vehicles with air conditioner: Warning! The air conditioner refrigerant circuit must not be opened. Repair group 63.Pull condenser out of its bracket.Removing ATF pipes/hoses from radiator: => Automatic gearbox 01N. . => General body repairs. pivot towards the side and . Note: To prevent damage to the condenser and refrigerant pipes/ hoses.=> => Dismantling and assembling gearbox. Vehicles with automatic gearbox . .Disconnect coolant hose at top left of radiator.

Remove securing screw -arrow A. . MY All models Engine ID 1Z Gearbox ID CUT User MICLEF Workshop Manual -2- .900058 Type 4A Type description secure with wire.and pull out headlight trim in direction indicated by arrow.

.Detach air cowls from radiator -1.(left and right).and -3.900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF .Remove screw securing bracket -2.for headlight trim on housing. MY Workshop Manual -3- .

900058

Type 4A

Type description

Engine ID Gearbox ID 1Z CUT - Unscrew nuts -2- on bonded rubber mountings.

MY

User MICLEF

Workshop Manual -4-

- Pull radiator forwards out of bracket for bonded rubber mounting at the bottom ... - ... and pull downwards out of top bracket -arrow- (if necessary, unscrew bolt -1- on radiator support). Installing Installation is carried out in the reverse order, when doing this note the following: - Fill up with coolant=> Page 19-7. Tightening torque Component Radiator to front end Condenser to radiator Hose clamps Nm 10 20 10 2

M6 M8

900058

Type 4A

Type description

MY Engine ID Gearbox ID 1Z Checking cooling system for leaks CUT

User MICLEF

Workshop Manual -1-

Special tools and workshop equipment required V.A.G 1274 with V.A.G 1274/1 Test requirement: Engine at operating temperature. Test sequence

900058

Type 4A

Type description

MY

Engine ID 1Z

Gearbox ID CUT

User MICLEF

Workshop Manual -2-

Warning! Hot steam can escape when opening cap on expansion tank: Cover cap with a cloth and open carefully.

- Open cap on coolant expansion tank. - Attach tester V.A.G 1274 with adapter V.A.G 1274/1 to expansion tank. - Using hand pump on tester, build up a pressure of approx. 1.0 bar. - If pressure is not maintained, trace leak and rectify fault. Testing pressure relief valve in filler cap.

900058

Type 4A

Type description

Engine ID Gearbox ID User 1Z CUT MICLEF - Fit tester V.A.G 1274 with adapter V.A.G 1274/1 onto filler cap. - Operate hand pump. - Pressure relief valve must open at 1.2 ... 1.5 bar.

MY

Workshop Manual -3-

900058

Type 4A

Type description

MY Engine ID Fuel supply system 1Z

Gearbox ID CUT

User MICLEF

Workshop Manual -1-

Safety precautions when working on the fuel supply system

When removing and installing the fuel gauge sender from a full or partly full fuel tank, note the following points: The fuel tank must not be more than2/3full. If necessary, drain the tank according to instructions: => Page 20-6. Before commencing work, switch on exhaust extraction system and place an extraction hose close to the sender opening in the fuel tank to extract escapingfumes. 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.

Drain the fuel tank before removal from the vehicle in order to reduce weight. If necessary, drain the tank according to instructions: => Page 20-6.

Drain the fuel tank before removal from the vehicle in order to reduce weight. switch on exhaust extraction system and place an extraction hose close to the sender opening in the fuel tank to extract escapingfumes.900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF Safety precautions when working on the fuel supply system Workshop Manual -1- When removing and installing the fuel gauge sender from a full or partly full fuel tank. If necessary. Avoid skin contact with fuel. Wear fuel-resistant gloves. drain the tank according to instructions: => Page 20-6. note the following points: The fuel tank must not be more than2/3full. drain the tank according to instructions: => Page 20-6. If necessary. Before commencing work. 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. .

Do not move vehicle unless absolutely necessary. Also ensure that no Diesel fuel runs onto the coolant hoses.900058 Type 4A Type description MY Engine ID 1Z Rules for cleanliness Gearbox ID CUT User MICLEF Workshop Manual -1- When working on the fuel supply/injection system. Place parts that have been removed on a clean surface and cover them over. pay careful attention to the following "basic rules": Thoroughly clean all unions and the adjacent areas before disconnecting. . Affected hoses must be replaced. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored loose (e. If necessary hoses must be cleaned immediately. Do not use fluffy cloths! Carefully cover over or seal opened components if the repair cannot be completed immediately.). When the system is open: Do not work with compressed air. in tool boxes etc.g.

Securing strap For fuel tank 2 .Fuel tank Removing and installing => Page 20-7 3 . 1 .Vent pipe . => Parts catalogue Always renew gaskets and seals when performing repairs.900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF Overview of components: fuel tank with attachments Workshop Manual -1- Notes: All hose connections must be secured with hose clips (same as original parts).

Oval head screw 9 .Overflow hose 8 .Fuel gauge sender -G Testing => Page 20-10 Removing and installing => Page 20-13 Internal dia. 60 Nm Remove and install with spanner 3217 11 .Clamp User MICLEF Workshop Manual -2- 10 .900058 Type 4A Type description MY Engine ID Gearbox ID 1Z CUT 4 .Union nut.Filler pipe 7 . of supply pipe: 8 mm Internal dia. of return pipe: 6 mm .Hose for filler pipe 5 .Filler pipe insert With non-return flap 6 .

20 Nm .Clamping washer 14 .Heat shield For fuel tank Ensure proper seating on rubber plugs Engage on retaining pins on fuel tank and secure with clamping washer 15 .Collar nut .900058 Type 4A Type description MY Engine ID 1Z 12 .Seal Gearbox ID CUT User MICLEF Workshop Manual -3- 13 .

900058 Type 4A Type description MY Draining fuel tank Engine ID 1Z Gearbox ID CUT User MICLEF Workshop Manual -1- Observe safety precautions=> Page 20-1.Drain tank as far as possible via fuel filler neck. .Remove filler cap from fuel tank filler neck. Observe rules for cleanliness => Page 20-2.G 1433 A Work sequence . Special tools and workshop equipment required Fuel extractor V. .A.

from fuel gauge sender.G 1383 A Removing .900058 Type 4A Type description MY Engine ID 1Z Removing and installing fuel tank Gearbox ID CUT User MICLEF Workshop Manual -1- Observe safety precautions=> Page 20-1. .A. .and supply pipe -3.G 1433 A => Page 20-6.Release and unplug connector -1-. . . Special tools and workshop equipment required Engine/gearbox jack V.Disconnect return pipe -2. Observe rules for cleanliness => Page 20-2.Drain fuel tank if necessary using fuel extractor V.A. Note: The fuel tank must be empty when it is removed from the vehicle in order to reduce weight.Detach cover for fuel gauge sender unit under floor trim in luggage compartment.

when doing this note the following: Notes: .Remove screw -arrow. . .Loosen nuts on securing straps. . .on filler neck.Clean area around tank filler neck.A. . . .Remove rear right wheel housing liner. .Mark the correct positions of the securing straps.Release hose clamp on lower connecting hose between fuel tank and fuel filler pipe -arrow-.900058 Type 4A Type description MY Engine ID 1Z Gearbox ID CUT User MICLEF Workshop Manual -2- .Disconnect overflow hose from filler neck. Installing Installation is carried out in the reverse order. .G 1383 A below vehicle to support tank.Lower fuel tank (2nd mechanic required).Detach overflow hose from bracket. .Position engine/gearbox jack V. Note: The lower connecting hose must remain on the hose connection on the tank.Pull off filler pipe and remove from vehicle.

Position fuel tank and securing straps on underside of vehicle using engine/gearbox jack V.900058 Type 4A Type description MY Engine ID Gearbox ID User Secure all hose connections with the correct hose clips (same 1Z CUT MICLEF as original equipment) => Parts catalogue Always renew sealing rings and gaskets when assembling. . Tightening torque Component Securing straps for fuel tank to body Nm 20 Workshop Manual -3- . .G 1383 A.A.Transfer heat shield from old tank to new tank.

A.G 1526 A Adapter set V. Repair group 90. Identification of contacts on multi-pin connectors in dash panel insert=> .A. Servicing dash panel insert.G 1594 A Note: Testing signal from fuel gauge sender: => Electrical system.900058 Type 4A Type description MY Engine ID Checking fuel gauge1Z sender -G Gearbox ID CUT User MICLEF Workshop Manual -1- Special tools and workshop equipment required Hand-held multimeter V.

Notes: In order to test the maximum and minimum values for "tank full" and "tank empty".Release connector -1. .and -3.Measure resistance at contacts -2. . When the sender is removed from the tank the float travel is greater. remove the fuel gauge sender -G => Page 20-13and move the float all the way to its top or bottom position. . so the resistance readings will differ slightly from those given in the table.900058 Type 4A Type description MY Work sequence Engine ID 1Z Gearbox ID CUT User MICLEF Workshop Manual -2- . the resistance should be somewhere between the specified values for "tank full" and "tank empty".Detach cover for fuel gauge sender under floor trim in luggage compartment.and unplug.on flange: Sender unit Fuel gauge sender -G Tank full Tank empty 58 Ω 550 Ω According to the amount of fuel in the tank.If the resistance is 0 Ωor ∞ Ω. this means there is a short circuit or an open circuit in the wiring in the tank. .

Observe rules for cleanliness => Page 20-2.A. Removing .900058 Type 4A Type description MY Engine ID Gearbox ID 1Z Removing and installing fuel gauge CUT sender User MICLEF Workshop Manual -1- Special tools and workshop equipment required Union nut spanner 3217 Hose clamp pliers V.G 1275 Observe safety precautions=> Page 20-1.

.900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF .Detach cover for fuel gauge sender under floor trim in luggage compartment. .and supply pipe -3. MY Workshop Manual -2- . .Release and unplug connector -1-.Disconnect fuel return pipe -2. when doing this note the following: Note: Secure all hose connections with the correct hose clips (same as original parts) => Parts catalogue .Fit new seal for fuel gauge sender (dry) in opening in fuel tank.Remove union nut with spanner 3217. Installing Installation is carried out in the reverse order.from fuel gauge sender. .Take out fuel gauge sender and seal from opening in fuel tank.

Note: Ensure that fuel pipes are securely seated. . Note: Hold guide for hose in position when tightening union nut. . note correct installation position: .Notch -2.Connect pipes and plug in the connector.900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF .Tighten union nut with spanner 3217 (60 Nm).Insert fuel gauge sender in fuel tank. MY Workshop Manual -3- .on flange must be aligned with marking on fuel tank -1-.

100 cm3 fluid to drain Loosen vent screw in order to drain water 2 .900058 Type 4A Type description MY Engine ID Gearbox ID 1Z Servicing fuelCUT filter User MICLEF Workshop Manual -1- Notes: All hose connections must be secured with hose clips (same as original parts). renewing => Maintenance booklet 1 .Water drain plug Loosen and allow approx.Seal Renew if damaged . Draining water from fuel filter. => Parts List Always renew seals and gaskets.

Supply pipe From fuel tank 6 .Return pipe From injection pump Workshop Manual -2- .Seal Renew if damaged 5 .Fuel filter Loosen with strap wrench Lightly lubricate seals with diesel before installing Fill with clean fuel before installing Tighten by hand 4 .O-Ring Renew 8 .Supply pipe To injection pump 7 .900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF 3 .

10 Nm Loosen in order to drain water 15 .900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF 9 .Control valve Installation position: arrow points towards fuel tank 10 .Fuel filter flange Workshop Manual -3- .5 Nm 12 .Seal 16 .Return pipe To fuel tank 13 .Vent screw .Non-return valve Installation position: arrow points towards fuel tank 14 .Retainer plate 11 .

Heat shield 19 .900058 Type 4A Type description MY Engine ID 1Z 17 .10 Nm .Bracket 21 .Insert Gearbox ID CUT User MICLEF Workshop Manual -4- 18 .10 Nm 20 .

A.A.G 1390 Bleeder container V.A.G 1390/1 .G 1318/10 Hand-operated vacuum pump V.900058 Type 4A Type description MY Engine ID Gearbox ID 1Z Bleeding fuel CUT system User MICLEF Workshop Manual -1- Special tools and workshop equipment required Hose clamps 3094 Adapter V.

A.A.G 1390 and bleeder container V.Screw adapter V.A.900058 Type 4A Type description MY Work sequence Engine ID 1Z Gearbox ID CUT User MICLEF Workshop Manual -2- .G 1318/10 into return connection on injection pump. Note: . .Connect hand vacuum pump V.G 1390/1 to adapter.

900058

Type 4A

Type description

MY Engine ID Gearbox ID User 1Z CUT MICLEF At temperatures below + 15 °C the control valve for fuel pre -heating opens the passage from the fuel return hose to the filter. If this is the case, clamp off the return hoses on both sides of the control valve using hose clamps 3094. - Operate hand vacuum pump until fuel flows free of bubbles. Important: Empty the bleeder container it becomes completely full. No fuel must be allowed to enter the hand vacuum pump.

Workshop Manual -3-

- Reconnect return pipe to injection pump (25 Nm). Note: Replace seals. - Remove hose clamps 3094 from return hose. - Start the engine and check fuel system for leaks (visual check).

900058

Type 4A

Type description

MY Engine ID 1Z Checking fuel system for leaks

Gearbox ID CUT

User MICLEF

Workshop Manual -1-

Special tools and workshop equipment required Hose clamps 3094

Cooling system tester V.A.G 1274 with adapterV.A.G 1274/2 A Leaks in the fuel system may result in the following: Foam build-up or air bubbles in the supply pipe Loss of power, misfiring Starting problems Work sequence

900058

Type 4A

Type description

Engine ID Gearbox ID User 1Z CUT MICLEF - Attach adapter 1274/2 to cooling system tester V.A.G 1274. - Unscrew return pipe from injection pump and connect hose from adapter V.A.G 1274/2 in its place.

MY

Workshop Manual -2-

900058

Type 4A

Type description

Engine ID Gearbox ID 1Z CUT - Fit hose clamps 3094 at the following points: - On supply hose downstream of fuel filter - On return hose downstream of fuel filter - On return hose from injection pump

MY

User MICLEF

Workshop Manual -3-

- Use hand pump on tester to create a pressure of between 1.0 and 1.5 bar. - If the pressure constantly drops, locate leak and eliminate fault. Note: By moving the hose clamps from the filter to the fuel tank connections it is also possible to test the fuel hoses.

900058

Type 4A

Type description

MY

Engine ID Gearbox ID User 1Z CUT MICLEF Servicing accelerator linkage

Workshop Manual -1-

1 - Bush 2 - Circlip 3 - Accelerator pedal 4 - Torsion spring 5 - 10 Nm 6 - Spring washer 7 - Cable cam 8 - Square nut 9 - Mounting 10 - Accelerator position sender -G79 Installing and adjusting => Page 20-35 11 - 10 Nm

A.G 1551/1 Accelerator position sender -G79 is located on the accelerator pedal.A.A. .Remove cover from additional relay carrier I on left of plenum chamber.G 1594 A V. Its function is to tell the control unit what position the pedal is in.900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT Testing accelerator position MICLEF sender -G79 Workshop Manual -1- Special tools and workshop equipment required V.G 1598/18 VAS 5051 withVAS 5051/1andVAS 5051/2 or V.G 1551 with V.A.G 1526 A V. .A.

Rapid data transfer Enter address word XX HELP When this display appears: .A. connect fault reader V. . Note: The following description refers only to the diagnostic procedure using fault reader V.Switch on ignition.Rapid data transfer 1) 2 . . connect black connector to black diagnostic connection.G .SELF DIAGNOSIS 1 .A. The warning lamp in key should light up. testing and information system VAS 5051 with diagnostic cable VAS 5051/1 and diagnostic adapterVAS 5051/2.Press keys 0 and 1 for address word "Engine electronics" and .Switch on fault reader printer with the print key.Connect white connector to white diagnostic connection (blue connector is not used). .Press key 1 for "Rapid data transfer".Flash code output 1) HELP Indicated in display 1)appears alternately .A. .900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF . When using vehicle diagnostic.G 1551/1.G 1551 using diagnostic cable V.With the ignition switched off. Alternatively.Connect up vehicle diagnostic.A.G 1551. MY Workshop Manual -2- V. follow the instructions in the operating manual for the equipment. testing and information system VAS 5051.

⇒ Indicated on display: Read measured value block 2 0 rpm 100 % 0 0 0 18.0 % (accelerator not depressed) .Switch off ignition. On vehicles with an automatic gearbox the kickdown switch pressure point must be distinctly felt before the full throttle stop position is reached.Press ⇒ key twice to advance the programme sequence.4 5C ⇒ Indicated on display: .. Rapid data transfer Select function XX HELP When this display appears: .900058 028906021A Coding 00000 1.G 1551 will show the control unit WSC 00000 identification. Read measured value block Enter display group number XXX Q When this display appears: . . as in thisexample.Specification: 0 1 0 (accelerator not depressed) 0 0 0 (accelerator depressed) . .0 % 0 1 0 18. .If the specifications for the initial and/or final readouts are not obtained. MY Engine ID 1Z Gearbox ID CUT User MICLEF Workshop Manual -3- D . adjust accelerator position sender -G79 => Page 20-35.4 5C . Read measured value block 2 0 rpm 0.Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.Check display in display zone 2 (accelerator pedal position).Press accelerator pedal down slowly. ⇒ The display on fault reader V.Check display in display zone 3.Unplug connector for accelerator position sender -G79 (located . 0 and 2 for "Display group number 002" and confirm entry with Q key.Specification: 0.A. .Press keys 0. . If the display does not change or only changes irregularly: .Specification: The value in display zone 2 should increase steadily to 100 % (accelerator fully depressed).9l Type 4A R4 EDC Type description SG confirm entry with Q key.

5 V If the specification is obtained: .900058 Type 4A Type description in footwell on accelerator pedal).Check the wiring.. Testing voltage supply . .G 1594 A: Accelerator Not depressed Not depressed Not depressed Depressed 5 + 6 1) Not depressed Fully depressed 1)Only on vehicles with automatic gearbox.If the specifications are not obtained..8 .. .A.2 kΩ ∞Ω ∞Ω 0.8 .G 1526 to resistance measuring range and connect to the following contacts on connector for accelerator position sender -G79 using test leads from V..8 .4 kΩ 0..4 kΩ 0. 1.Specification: approx...Set hand-held multimeter V. MY Engine ID 1Z Gearbox ID CUT User MICLEF Workshop Manual -4- . Testing wiring Contacts 1+3 2+3 4+6 Specification 0.G 1526 to voltage measuring range (20 V direct current) and connect it to contacts 2 and 3 on connector.8 .2 kΩ .A. .. 1. renew accelerator position sender -G79. 1.Switch on ignition. 1.Set hand-held multimeter V.A.

A.Rectify any open/short circuit as necessary.Remove storage compartment (shelf) on driver's side. 46 62 .900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF . .G 1598/18 Socket 15 57 55 65 1.A. Removing driver's side shelf=> . Repair group 70. => General body repairs. Test box V.(the control unit -2.Test for open circuit and short to positive or earth in the following wiring connections: Connector Contact 1 2 3 4 6 5 1) 1)Only on vehicles with automatic gearbox.Unplug connector for accelerator position sender -G79 (located in footwell on accelerator pedal). 24.With the ignition switched off. .remains disconnected). Dash panel.G 1598/18 to connector -1. MY Workshop Manual -5- . connect test box V.

Turn the cable cam anticlockwise slightly and pull the accelerator pedal until it touches the stop on the bracket.onto stud on accelerator pedal -3(pedal is already in position).Remove the full-throttle stop. . .by tightening the nut and counterholding with an open-ended spanner (AF 17) on the flats of the cable cam. .Install the pre-assembled throttle mechanism in the vehicle and adjust as follows: .Turn accelerator position sender -10. . . Special tools and workshop equipment required Setting jig 3226 Work sequence . .Fit eye from cable cam -7.The eye must be properly seated in the slot on the cable cam.The cable cam must be able to turn freely on the shaft of the accelerator position sender.Secure the cable cam in its new position on accelerator position sender -10.and tighten bolts to secure in position.900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z MICLEF Installing and adjusting accelerator CUT position sender -G79 Workshop Manual -1- Note: To renew accelerator position sender -G79.anticlockwise as far as possible in slots in bracket -9. . first remove the accelerator pedal.

Tighten bolts to secure accelerator position sender in this position.900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF . . .Slacken bolts securing accelerator position sender and turn sender so that accelerator pedal rests against setting jig without exerting pressure.Pull apart the setting jig and lock it in position with the pin -arrow-. .Remove setting jig and install full-throttle stop. MY Workshop Manual -2- .The threaded section of the setting jig must be screwed in as far as it will go. . .Push together setting jig 3226 and screw it in the hole instead of the full-throttle stop.

seals. Secure all hose connections with the correct hose clips (same as original equipment) => Parts catalogue Charge air system must be free of leaks. replace gaskets. When performing repairs.900058 Type 4A Type description MY Engine ID Gearbox ID 1Z CUT Charge air system with turbocharger User MICLEF Workshop Manual -1- Notes: Observe rules for cleanliness => Page 21-21. . self-locking nuts and stretch bolts which have to be tightened to a specified angle.

Charge air cooler .Pressure unit For charge pressure control Testing =>Page 21-12 3 .900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF Diagram of connections for charge pressure control system Workshop Manual -1- 1 .Control unit with intake manifold pressure sender -G71 2 .Pressure connection on turbocharger Pressure supply for charge pressure control 4 .Solenoid valve for charge pressure control -N75 Position: front left of engine compartment Testing =>Page 21-14 5 .

Final control diagnosis=> No leaks in intake or exhaust system No faults in engine or injection system.g compression pressure. => Repair group 01. If test equipment is operated from the front passenger seat. Requirements for test: Fault memory has been interrogated => Diesel direct injection and glow plug system (4-cylinder TDI). injectors or commencement of injection. Coolant temperature at least 80 °C . the occupant could be injured by the passenger's airbag in an accident.900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF Checking turbocharger and charge pressure control system Workshop Manual -1- Safety notes Note the following points if test equipment has to be used during a road test: Warning Test equipment must always be secured on the rear seat and operated from the rear seat by a second person. => Repair group 01. e. Interrogating and erasing fault memory=> Final control diagnosis has been performed => Diesel direct injection and glow plug system (4-cylinder TDI.

Special tools and workshop equipment required Turbocharger tester V.A.Connect measuring hose from turbocharger tester V.900058 Type 4A Type description MY Engine ID 1Z Checking charge pressure Gearbox ID CUT User MICLEF Workshop Manual -1- To isolate the cause of the fault.G 1397 A VAS 5051 with VAS 5051/1and VAS 5051/2 or V.G 1551/1 Test sequence .A.A.A. first check the turbocharger on its own (without charge pressure control).G 1551 with V. Testing charge pressure without charge pressure control: . .Route measuring hose under rear edge of bonnet and into passenger compartment via right-hand window.G 1397/ A to connecting pipe and secure with a hose clamp -arrow-. then check the charge pressure with charge pressure control.

Connect measuring hose to connection -I-. Observe safety notes => Page 21-3. The decimal point in the display flashes to indicate that the value is being stored.900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF . Pressing memory key M on turbocharger tester will store the last measured value until memory key M is pressed again or tester is switched off.(absolute pressure). . . If the battery voltage of the turbocharger tester drops below the minimum level. otherwise measurements will not be correct. Notes: Hose connections must be completely airtight.Read measured value block. Display Group 011 => Diesel direct injection and glow plug system (4-cylinder TDI).Switch on turbocharger tester and set measuring range selector switch to position -I. Ensure that measuring hose is not pinched at bonnet or side window.at charge pressure control solenoid valve.Unplug connector -arrow. MY Workshop Manual -2- . . an arrow will appear at the top left of the display.

G 1397/A. 1.Press PRINT key on V.750 bar MY Workshop Manual -3- Read measured value block 11 840 rpm 938 mbar 978 mbar 92 % ⇒ Read measured value block 11 3040 rpm 1846 mbar 1693 mbar 39 % ⇒ Specification for display zone 3 on V. .G 1551: 1550 .G 1551 and the memory key -M.G 1397 A simultaneously at approx..G 1551 is used to check whether the charge pressure is being registered by the control unit. and watch rev counter. 1750 mbar Note: The charge pressure should bemeasured with turbocharger tester V.G 1397/A: 1. . Reading measured value block=> Indicated on display: ...A. 3000 rpm..550 .A.Measure the charge pressure at full throttle. repeat charge .Accelerate from 1500 rpm at full throttle in third gear (or with selector lever at position 2).A. Specifications: Specification for V. A. .If the measured charge pressure is OK.on V.A..A. Fault reader V.900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF => Repair group 01.

=> Diesel direct injection and glow plug system (4-cylinder TDI).900058 Type 4A Type description pressure measurement with ID MY Engine charge pressure control active Gearbox ID User =>Page 21-10.Erase fault memory. Note: A fault was stored in the fault memory when the connector for charge pressure control solenoid valve -N75 was disconnected. .Connect connector to charge pressure control solenoid valve -N75. => Repair group 01. leaking.Read measured value block. Testing charge pressure with charge pressure control: . 1Z CUT MICLEF If the charge pressure is not attained: Leak between turbocharger and intake manifold Fault in linkage or pressureunit for charge pressure control.Measure the charge pressure at full throttle. Checking => Page 21-12 Turbocharger defective (turbine jammed by foreign body) If the charge pressure is exceeded: Hose connections for charge pressure control loose. or blocked Charge pressure control solenoid valve blocked Actuating mechanism (linkage or shaft) of bypass valve does not move easily or is sticking (valve does not open). . Reading measured value block=> Workshop Manual -4- Read measured value block 11 840 rpm 938 mbar 978 mbar 92 % ⇒ Indicated on display: . . Display Group 011.Accelerate from 1500 rpm at full throttle in third gear (or with .

.G 1397/A: 1.800 .Press PRINT key on V.. User MY Engine ID Gearbox ID 1Z CUT MICLEF . and watch rev counter..050 bar Workshop Manual -5- Read measured value block 11 3090 rpm 1866 mbar 1917 mbar 62 % ⇒ Specification for display zone 3 on V. Specifications: Specification for V.G 1551 and the memory key -M.on V.G 1551: 1800 . 2.A. 2050 mbar If the charge pressure is not attained: Electrical fault in charge pressure control solenoid valve Charge pressure control solenoid valve -N75 is jammed in the open position If the charge pressure is exceeded: Charge pressure control solenoid valve -N75 is jamming at times in the closed position Charge pressure has been increased as a result of tuning . 3000 rpm.A.G 1397 A simultaneously at approx.900058 Type 4A Type description selector lever at position 2).A.. A.

Remove air intake pipe -arrow. . .on charge pressure control solenoid valve.Unplug connector -arrow.900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF Testing linkage and pressure unit for charge pressure control valve Workshop Manual -1- Test requirement: Coolant temperature at least 80 °C Test sequence .between lock carrier and air cleaner housing.

. MY Workshop Manual -2- .Check charge pressure control valve lever -1.for ease of movement. even though the lever is free to move: . install new turbocharger. If the operating rod does not move. If the operating rod does not move: .Operating rod -2.Erase fault memory. If lever has seized due to corrosion. .900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF .for charge pressure control valve should move. Note: A fault was stored in the fault memory when the connector for charge pressure control solenoid valve -N75 was disconnected.Start the engine and increase to maximum rpm briefly by operating throttle.Renew pressure unit for charge pressure control valve -3-.

G 1594 A V.A.900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF Testing charge pressure control valve -N75 Workshop Manual -1- Special tools and workshop equipment required V.Switch off ignition. .A.G 1598/18 Testing internal resistance .A.G 1526 A V.

Testing voltage supply MY Workshop Manual -2- .. . .Renew charge pressure control solenoid valve -N75.Connect multimeter (voltage test range) between contact 2 and earth. battery voltage If the specification is not obtained: .Specification: 25 . .Switch on ignition.900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF . Electrical fault finding and Fitting locations Testing control signal wiring .Connect multimeter to valve (resistance measurement range) .Switch off ignition..Test wiring for open circuit and short to positive or earth: => Current flow diagrams.Pull connector off charge pressure control solenoid valve -N75. 45 Ω If the specification is not obtained: .Specification: approx. .

900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF . Removing and installing A-pillar trim and Removing and installing inner sill panel trim=> . cut open the perforated seam on the left with a knife. Trims.Remove screws on cover for electronics box -arrows-. (If necessary. ) MY Workshop Manual -3- . Repair group 70.Pull back floor covering at front of right-hand footwell. . => General body repairs. .Remove lower section of right-hand A-pillar trim and also right -hand sill panel trim around front door.Carefully detach upper and lower sections of cover.

900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF .(the control unit -2. .With the ignition switched off.G 1598/18 to connector -1. .Remove screws (arrows -1. MY Workshop Manual -4- .remains disconnected).Disengage retainer clip and unplug control unit connector. .and -2-).Pull out cross-piece (arrow -3-) together with attached components.A.Take out engine control unit. Note: Always make sure that the ignition is switched off before unplugging or fitting the connector for the diesel direct injection system control unit. connect test box V. .

900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF .=> => Renewing control unit for engine electronics Test box V. . fit a new engine control unit: => Diesel direct injection and glow plug system (4-cylinder TDI). => Repair group 23.G 1598/18 Socket 47 MY Workshop Manual -5- .If the wiring is OK.Rectify any open/short circuit as necessary.Test for open circuit and short to positive or earth in the following wiring connections: Connector Contact 1 .A. Servicing diesel direct injection system.

G 1551/1 Test sequence . Display Group 010.Testing intake manifold pressure sender The intake manifold pressure sender is located in the diesel direct injection system control unit. .Fit a new engine control unit: => Diesel direct injection and glow plug system (4-cylinder TDI).0 % ⇒ .Check displays in display zones 2 and 3. => Repair group 01. Tolerance: ± 30 mbar If the specification is not obtained: . MICLEF => Repair group 23. If the specification is still not obtained: . Servicing diesel direct injection system.A.Read measured value block. Reading measured value block=> Indicated on display: Read measured value block 10 0 mg/H 1027 mbar 1013 mbar 0. => Diesel direct injection and glow plug system (4-cylinder TDI).=> => Renewing control unit for engine electronics .A.G 1551 with V.Disconnect pressure hose from engine control unit. Special tools and workshop equipment required VAS 5051 with VAS 5051/1and VAS 5051/2 or V.Specification: The pressures should be the same.

Place parts that have been removed on a clean surface and cover them over. Carefully cover over or seal opened components if the repair cannot be completed immediately.). .g. in tool boxes etc. pay careful attention to the following "5 rules": Thoroughly clean all unions and the adjacent areas before disconnecting. When the system is open: Do not work with compressed air if this can be avoided. Do not move vehicle unless absolutely necessary. Do not use fluffy cloths. Only install clean components: Only unpack replacement parts immediately prior to installation.900058 Type 4A Type description MY Engine ID 1Z Rules for cleanliness Gearbox ID CUT User MICLEF Workshop Manual -1- When working on theturbocharger. Do not use parts that have been stored loose (e.

10 Nm Lock nut for operating rod -Item 6Adjusting=>Page 21-27 5 .Bracket 3 .Pressure unit For charge pressure control 2 .900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF Removing and installing turbocharger .Securing clip 6 .overview Workshop Manual -1- 1 .10 Nm 4 .Operating rod For charge pressure control valve Adjusting=>Page 21-27 .

10 Nm Install with locking fluid D 000 600 A2 8 .Banjo bolt.25 Nm Renew 10 .Gasket Renew 9 . 25 Nm Workshop Manual -2- .25 Nm 11 .900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF 7 .Oil supply pipe From cylinder head to turbocharger Tighten union nut to 25 Nm 12 .

25 Nm .Cap For charge pressure test connection Secure with hose clamp 17 .900058 Type 4A Type description MY Engine ID Gearbox ID 1Z CUT 13 .Intake manifold Removing and installing => Page 15-11 16 .Exhaust manifold With connection for exhaust gas recirculation 15 .From charge air cooler 19 .Gasket Renew 18 .Seals Renew User MICLEF Workshop Manual -3- 14 .

Turbocharger Checking => Page 21-3onwards Removing and installing => Page 21-29 Fill with engine oil at connection for oil supply pipe 26 .25 Nm Renew 23 .Gasket Renew Note installation position 22 .Heat shield 24 .25 Nm Renew 25 .900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF 20 .From air cleaner Workshop Manual -4- .30 Nm Renew Coat threads and bolt head seating surface with high -temperature lubricant "G 052 112 A3" 21 .

From solenoid valve for charge pressure control -N75 Diagram of connections =>Page 21-2 Workshop Manual -5- .Banjo bolt.Seal Renew 32 .To solenoid valve for charge pressure control -N75 Diagram of connections =>Page 21-2 28 .900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF 27 .40 Nm 29 .Oil return pipe To cylinder block 31 .Seal Renew 30 .To charge air cooler 34 . 30 Nm 33 .

in towards pressure unit onto stop and hold.Remove turbocharger => Page 21-29. . Installing . .Unscrew bolts -2-. . .off. (Lever lies against stop with no play).Unclip securing clip -4-. .Tighten lock nut -1-. . . .lock nut -1-. screw in operating rod 8 full turns (rod shortens).for pressure unit -6 -. .900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF Removing and installing pressure unit for charge pressure control valve Workshop Manual -1- Removing .Loosen operating rod -3. . .Pivot charge pressure control valve lever -5. install on turbocharger and tighten to 10 Nm.Adjust rod length -3.Take pressure unit -6.From this position.Install turbocharger => Page 21-32.so that the rod eye will fit easily on lever pin -5-.Apply locking fluid D 000 600 A2 to bolts -2.Fit operating rod on to lever and install securing clip -4-.

Vehicles with air conditioner: .Place a drip tray underneath.Remove noise insulation (two sections.Detach oil return pipe from cylinder block -arrow-. -arrows-). . .900058 Type 4A Type description MY Engine ID Gearbox ID 1Z CUT Removing and installing turbocharger User MICLEF Workshop Manual -1- Removing .Remove ribbed belt => Page 13-11. .

900058 Type 4A Type description MY Engine ID 1Z Gearbox ID CUT User MICLEF Workshop Manual -2- Warning! The air conditioner refrigerant circuit must not be opened. .Remove front air intake hose from turbocharger.Disconnect wires/unplug connectors as follows: 1 -Exhaust gas recirculation valve -N18 2 -Air mass meter -G70 4 -Charge pressure control solenoid valve -N75 5 -Intake manifold temperature sender -G72 .Remove air intake pipe -arrow. .from bottom of exhaust gas recirculation valve -N18. . . All models . .Remove A/C compressor and secure to body with wire.between lock carrier and air cleaner housing.Move wiring and hoses clear. . .Remove upper section of air cleaner housing together with air mass meter. .Disconnect thin hose -6.Detach air hose at air mass meter.Disconnect vacuum hose from mechanical exhaust gas recirculation valve -3-.

Unscrew nuts -1.Check oil level => Page 17-19. Installing Installation is carried out in the reverse order.Unscrew oil supply pipe -3. .900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF . .Disconnect hose -6.Remove air intake hose -5.Unscrew bolts securing turbocharger to exhaust manifold and remove turbocharger.Unbolt bracket -2. Secure all hose connections with the correct hose clips (same as original equipment) => Parts catalogue Always renew seals. .between turbocharger and charge air cooler. let engine idle for about one minute after installing turbocharger and do not increase engine speed immediately.securing turbocharger to catalytic converter.from pressure unit for charge pressure control.Disconnect hose -4.from turbocharger. Fill turbocharger with engine oil at connection for oil supply pipe. Charge air system must be free of leaks. . when doing this note the following: Notes: Apply high-temperature paste G 052 112 A3 to threads and bolt head contact surfaces of turbocharger bolts. Tightening torques MY Workshop Manual -3- . To ensure adequate lubrication of turbocharger. . . gaskets and self-locking nuts.at turbocharger. .for oil supply pipe from exhaust manifold.

900058 Type 4A Type description MY Engine ID 1Z Component Turbocharger to exhaust manifold Turbocharger to catalytic converter Oil return pipe to cylinder block Oil supply pipe to turbocharger Hose clamps Gearbox ID CUT User MICLEF Nm 30 25 30 25 2 Workshop Manual -4- .

900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF Removing and installing parts of charge air cooling system Workshop Manual -1- Notes: Secure all hose connections with the correct hose clips (same as original equipment) => Parts Catalogue Charge air system must be free of leaks. 1 .Rubber grommet For front retaining bracket .Front retaining bracket 5 .20 Nm 3 .Air ducting 2 .Washer 4 .

20 Nm 8 .20 Nm With shoulder 9 .Air intake hose Between turbocharger and charge air cooler (intercooler) Workshop Manual -2- .Charge air cooler (intercooler) Removing and installing => Page 21-37 7 .Air intake hose Between intake manifold and charge air cooler (intercooler) 12 .Rear retaining bracket 11 .900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF 6 .Rubber grommet For rear retaining bracket 10 .Cheese head bolt .

Vacuum pipe To engine control unit In engine wiring harness Must not be lengthened or shortened When renewing. use same length and inside diameter => Parts List 14 .Self-tapping screw Workshop Manual -3- .900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF 13 .

between lock carrier and air cleaner housing.900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF Removing and installing charge air cooler (intercooler) Workshop Manual -1- Removing .Remove front bumper.Move wiring and hoses clear.Disconnect wires/unplug connectors as follows: 1 -Exhaust gas recirculation valve -N18 2 -Air mass meter -G70 4 -Charge pressure control solenoid valve -N75 5 -Intake manifold temperature sender -G72 . Front bumper=> . . .Disconnect vacuum hose from mechanical exhaust gas recirculation valve -3-.Remove upper section of air cleaner housing together with air mass meter. .Remove air intake pipe -arrow.from bottom of exhaust gas recirculation valve -N18. . => General body repairs.Disconnect thin hose -6. Repair group 63. .Detach air hose at air mass meter. .

MY User MICLEF Workshop Manual -2- . .between charge air cooler and intake manifold. .Remove air intake hose between turbocharger and charge air cooler.Remove front air intake hose from turbocharger.Remove lower section of air cleaner housing.Remove air duct -1.Unscrew rear bolt -arrow-.900058 Type 4A Type description Engine ID Gearbox ID 1Z CUT . . .

Take out charge air cooler from underneath. . Installing Installation is carried out in the reverse order.900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF . Tightening torques Component Charge air cooler to retaining bracket Hose clamps Nm 20 2 .Pull charge air cooler out of rubber mountings at the front -arrows-.Disengage air ducting from charge air cooler.Remove front section of noise insulation -lower arrows-. MY Workshop Manual -3- . .

1. If necessary.2. Removing and installing floor cross member =>Fig. After installing exhaust system.3. loosen clamp and align silencers and exhaust pipe so that sufficient clearance is maintained to the bodywork at all points and the mountings are evenly loaded. and that it has sufficient clearance from the bodywork. Page 26-4and Fig. 90°=>Fig. Page 26-4.900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT Removing and installing parts of exhaust system MICLEF Workshop Manual -1- Notes: Always renew seals. . otherwise it may be damaged. Page26-5. gaskets and self-locking nuts. After working on the exhaust system ensure that the system is not under stress. knock back retaining tabs on exhaust mountings approx. Do not bend the flexible connection (de-coupling element) in the exhaust system more than 10 °.

Clamp User MICLEF Workshop Manual -2- 3 .25 Nm Renew 2 .Seal Can be damaged by knocks.Clamp 5 .900058 Type 4A Type description MY Engine ID Gearbox ID 1Z CUT 1 .40 Nm .Rear silencer Aligning exhaust system free of stress => Page 26-10 6 . do not drop on the floor 4 .Front silencer Aligning exhaust system free of stress => Page 26-10 7 .

900058

Type 4A

Type description

MY

Engine ID Gearbox ID User 1Z CUT MICLEF 8 - Clamp Align exhaust system so it is free of stress before tightening clamp => Page 26-10. Installation position: bolted connection on the right Position of bolts => Fig.4 Tighten bolted connections evenly. 9 - Catalytic converter With flexible connection (de -coupling element) Do not bend flexible connection more than10°- otherwise it can be damaged Protect from damage by knocks and impact Removing and installing => Page 26-8 10 - Gasket Renew 11 - 25 Nm Renew

Workshop Manual -3-

900058

Type 4A

Type description

MY Engine ID Gearbox ID User 1Z CUT Fig.1Bending back retaining tabs on front exhaust MICLEF mountings Front and rear silencers - After installing exhaust system, knock back retaining tabs -arrows- approx. 90°. - Maintain a clearance (distance -a-) between mounting ring and retaining tab. - Distance a = 2 mm

Workshop Manual -4-

Fig.2Bending back retaining tabs on rear exhaust mountings Rear silencer - After installing exhaust system, knock back retaining tabs -arrows- approx. 90°.

900058

Type 4A

Type description

MY Engine ID Gearbox ID User 1Z CUT Fig.3Removing and installing floor cross member MICLEF Tightening torque: 20 Nm

Workshop Manual -5-

Fig.4Installation position of clamp - Fit clamp in horizontal position. - Bolted connection faces right

900058

Type 4A

Type description

MY Engine ID Gearbox ID 1Z CUT Removing and installing exhaust manifold

User MICLEF

Workshop Manual -1-

Removing - Remove turbocharger=>Page 21-29. - Unbolt heat shield. - Unbolt exhaust gas recirculation pipe. - Unscrew all nuts -arrows- on exhaust manifold. - Remove washers and take off exhaust manifold. Installing Installation is carried out in the reverse order, when doing this note the following: Note: Fit new gaskets and self-locking nuts. - Install turbocharger=>Pages 21-32. Tightening torques Component Exhaust manifold to cylinder head Heat shield to exhaust manifold Exhaust gas recirculation pipe to exhaust manifold Nm 25 25 25

900058

Type 4A

Type description

MY Engine ID Gearbox ID User 1Z CUT MICLEF Removing and installing front exhaust pipe with catalytic converter Removing Note: Do not bend the flexible connection (de-coupling element) in the exhaust system more than 10 °, otherwise it may be damaged. - Unscrew bolts securing turbocharger to catalytic converter -arrows-. - Disconnect front exhaust pipe with catalytic converter from turbocharger.

Workshop Manual -1-

- Remove noise insulation (2 sections) -arrows-. - Slacken clamp on exhaust system. - Slide the clamp towards the rear and remove the exhaust pipe. Installing Installation is carried out in the reverse order, when doing this note the following: Note: Fit new gaskets and self-locking nuts. - Aligning exhaust system free of stress => Page 26-10. MY Tightening torques Component Catalytic converter to turbocharger Clamp for exhaust pipe Nm 25 40

Align tailpipes so that distance -a. . Aligning tailpipes . .. 10 mm.Tighten bolted connections on clamp evenly to 40 Nm. .is the same on both sides.900058 Type 4A Type description MY Engine ID Gearbox ID 1Z CUT Stress-free alignment of exhaust system User MICLEF Workshop Manual -1- The exhaust system must be aligned when cold..Push exhaust system towards front of vehicle -arrow. . Page 26-3.Slacken bolted connections on clamp -Item 8-.so that rear mounting of rear silencer is pre-loaded by amount a = 7 .

Start engine and run at idling speed. etc.Listen for noise at the connection points (cylinder head/ manifold. manifold/turbocharger.Plug tailpipes (e.900058 Type 4A Type description MY Engine ID Gearbox ID 1Z Checking exhaust system for leaks CUT User MICLEF Workshop Manual -1- .) to locate any leaks. .Rectify any leaks that are found. . . .g. with rags or stoppers) until check is completed. turbocharger/catalytic converter.

900058 Type 4A Type description MY Engine ID 1Z Exhaust gas recirculation system Gearbox ID CUT User MICLEF Workshop Manual -1- Notes: The exhaust gas recirculationsystem is activated by the diesel direct injection system control unit -J248 via the exhaust gas recirculation valve -N18 and themechanical exhaust gas recirculation valve. gaskets and self-locking nuts. Secure all hose connections with the correct hose clips (same as original equipment) => Parts catalogue Always renew seals. The tapered plunger in the mechanical exhaust gas recirculation valve gives an opening of variable cross-section for different amounts of valve travel. . All required valve positions can beachieved by means of pulsed control.

Exhaust gas recirculation valve Checking => Page 26-16 4 .900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF Removing and installing parts of exhaust gas recirculation system Workshop Manual -1- 1 .Intake manifold 2 .25 Nm 5 .Gasket Renew 6 .25 Nm .Gasket Renew 3 .

then tighten stress free 8 . just nip all bolts (parts must be just free to move).Exhaust manifold Removing and installing => Page 26-6 Workshop Manual -2- .Gasket Renew 10 .25 Nm 9 .900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF 7 .Exhaust gas recirculation pipe When installing.

Vacuum pump (exhauster) For brake servo 4 .Vacuum connection 3 .900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF Diagram of vacuum hose connections Workshop Manual -1- 1 .Brake servo 2 .Air cleaner 7 .Exhaust gas recirculation valve -N18 6 .Breather pipe To air cleaner .Mechanical exhaust gas recirculation valve 5 .

Note: Watch the diaphragm rod through the opening -arrow-. .900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF Checking mechanical exhaust gas recirculation valve Workshop Manual -1- Special tools and workshop equipment required V. .Connect hand vacuum pump V.The diaphragm rod should move towards the vacuum connection.A.G 1390 Test sequence .Pull hose of hand vacuum pump off exhaust gas recirculation valve.The valve must be clearly heard to close. . .G 1390 to valve.Operate pump. The diaphragm rod should move towards the intake manifold.Pull vacuum hose off mechanical exhaust gas recirculation valve. .A. .

The more exhaust gas recirculated. the weaker the signal from the air mass meter.G 1551 with V.900058 Type 4A Type description MY Engine ID Testing exhaust gas 1Z recirculation Gearbox ID CUT User MICLEF Workshop Manual -1- The function of the exhaust gas recirculation system is tested by checking the mass of air inducted.Read measured value block.A. => Repair group 01. Display Group 001: => Diesel direct injection and glow plug system (4-cylinder TDI).G 1551/1 Test requirement: Coolant temperature at least 80 °C Test sequence . Reading measured value block=> .A. Special tools and workshop equipment required VAS 5051 with VAS 5051/1and VAS 5051/2 or V. If exhaust gas is being recirculated. a smaller quantity of fresh air is registered by the air mass meter.

then allow the engine to continue running at idling speed.. .. Display Group 003.Read measured value block.370 > 370 mg/ mg/H H Constant 425 mg/H Note: If display zone 3 shows a constant value of 425 mg/H.370 230. check the air mass meter: .370 mg/H mg/H > 370 mg/ > 370 mg/ H H Possible cause of fault Indicated on display: Okay Engine too cold Electrical equipment on Temperature of intake manifold too high Injection pump too lean Unmetered air Too much EGR Too little EGR or none at all Fixed substitute value caused by open circuit in wiring to air mass meter or implausible air mass signal 230.Specification: at least 80 °C .. Display zone 2 (spec. .3 5C ⇒ MY Engine ID 1Z Gearbox ID CUT User MICLEF Workshop Manual -2- Read measured value block 1 840 rpm 6.Check display in display zone 4 (coolant temperature).900058 Type 4A Type description 1.Observe displays in display zones 2 and 3.) 3 (actual) 230...370 < 230 mg/ mg/H H 230.480 V 87.Wait until the coolant has reached the specified temperature before continuing with the test..Briefly depress the accelerator pedal. Read measured value block 3 840 rpm 272 mg/H " 268 mg/H 54 % . ...5 mg/H Indicated on display: .

⇒ Indicated on display: If the valve does not click: . MY Engine ID Gearbox ID User 1Z CUT MICLEF => Repair group 23. => Repair group 01. Final control diagnosis=> Workshop Manual -3- Final control diagnosis Exhaust gas recirculation valve -N18 The valve shouldclick. If the valve clicks: . If vacuum hose connections are OK: . .Check vacuum hose connections => Page 26-15.Check mechanical exhaust gas recirculation valve => Page 26-16.=> => Testing air mass meter -G70 If the specifications are not obtained: .Test exhaust gas recirculation valve -N18 => Page 26-21.Start final control diagnosis and activate exhaust gas recirculation valve -N18: => Diesel direct injection and glow plug system (4-cylinder TDI).900058 Type 4A Type description => Diesel direct injection and glow plug system (4-cylinder TDI). Testing exhaust gas recirculation.

Unplug connector from exhaust gas recirculation valve.900058 Type 4A Type description MY Engine ID Gearbox ID User 1Z CUT MICLEF Checking exhaust gas recirculation valve -N18 Workshop Manual -1- Special tools and workshop equipment required V.G 1526 A V. .A.A.G 1598/18 Testing internal resistance .G 1594 A V. .A.Switch off ignition.

=> Current flow diagrams. .Connect multimeter to valve (resistance measurement range) .. Testing voltage supply .Fit new exhaust gas recirculation valve -N18. and at upper end of tolerance at engine operating temperature. . 20 Ω Note: The resistance will be at lower end of tolerance at room temperature.Switch on ignition.Connect multimeter (voltage measurement range) between contact 1 and earth..Switch off ignition. . Electrical fault finding and Fitting locations Testing control signal wiring .900058 Type 4A Type description MY Engine ID 1Z Gearbox ID CUT User MICLEF Workshop Manual -2- .Test wiring for open circuit and short to positive or earth.Specification: 14 . If the specification is not attained: .Specification: approx. battery voltage If the specification is not obtained: .

Carefully detach upper and lower sections of cover.Remove screws on cover for electronics box -arrows-. . ) MY Workshop Manual -3- . => General body repairs. Trims. Removing and installing A-pillar trim and Removing and installing inner sill panel trim=> .Remove lower section of right-hand A-pillar trim and also right -hand sill panel trim around front door. cut open the perforated seam on the left with a knife. (If necessary.Pull back floor covering at front of right-hand footwell. . Repair group 70.900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF .

MY Workshop Manual -4- . . .Disengage retainer clip and unplug control unit connector. .Remove screws (arrows -1. connect test box V.G 1598/18 to connector -1.With the ignition switched off.(the control unit -2.Pull out cross-piece (arrow -3-) together with attached components. Note: Always make sure that the ignition is switched off before unplugging or fitting the connector for the diesel direct injection system control unit.Take out engine control unit.and -2-).remains disconnected).A. .900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF .

Rectify any open/short circuit as necessary. Renewing control unit for engine electronics=> Test box V.A.If the wiring is OK.Test for open circuit and short to positive or earth in the following wiring connections: Connector Contact 2 . fit a new engine control unit: => Diesel direct injection and glow plug system (4-cylinder TDI).900058 Type 4A Type description Engine ID Gearbox ID User 1Z CUT MICLEF . . => Repair group 23. Servicing diesel direct injection system.G 1598/18 Socket 25 MY Workshop Manual -5- .

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