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2 5+eurovan+motor PDF
2 5+eurovan+motor PDF
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The engine number ("Code letters" and "Serial
number") is located between cylinders 1 and 3
on the cylinder block.
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1)
195 Nm when 95 RON premium unleaded fuel is used.
2)
Optional with RON 95 unleaded.
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Cable tie
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- Unscrew left and right mounting screws -1-.
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- Bolt engine stand 3227 with 20 Nm (15 ft lb)
to cylinder block
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- Remove transmission.
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- Attach engine support bracket VW 540 and
secure to engine stand to carry out repairs.
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Engine to M12 80 Nm
transmission
59 ft lb
M10 60 Nm
44 ft lb
M8 20 Nm
15 ft lb
Console to M10 x 65 Nm
transmission 60
48 ft lb
M10 x 45 Nm
28
33 ft lb
Engine to M10 65 Nm
transmission
48 ft lb
Drive shaft to 55 Nm
flanged shaft
41 ft lb
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Crankshaft oil seal (pulley end), replacing
Crankshaft dimensions in millimeters
Drive plate, removing and installing
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Piston and cylinder, dimensions
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I Page 13-2
II Page 13-5
IV Page 13-12
3DUW,
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Removing and
installing ribbed
belt tensioning
device Page
13-26
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20 Nm (15 ft lb)
20 Nm (15 ft lb)
+ 1/4 turn (90 )
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Loosen and
tighten using
3419 Counter-
hold Page 13-
17
Screw length: 65
mm
Tightening
torque: 460 Nm
(340 ft lb)
Torque: 160 Nm
(118 ft lb) + 1/2
turn (180 )
further
2 x 90
additional turns
can be
performed in
stages.
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Damper and
sprocket can
only be installed
in one position
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09.91
for power
steering pump
Check tension
using thumb
Deflection: new
and used V-belts
approx. 5 mm
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For Generator
Check tension
using thumb:
max. deflection:
Checking V-belt
tension: vehicles
with toothed rack
tensioner Page
13-24
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Damper and
sprocket can
only be installed
in one position
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Mark direction of
rotation before
removing
Remove and
install with 3299
lever Page 13-
14 , Figs. 1 and 2
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Tensioning roller
mounting nut, 15
Nm (11 ft lb)
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Removing,
installing,
tensioning
toothed belt
Page 13-17
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Observe steel
type marking on
bolt head:
8.8 = 85 Nm (63 ft
lb)
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tighten using
3036 counter-
hold
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Removing and
installing Page
13-17
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Note position
when installing
toothed belt
Page 13-17
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To remove: take
off vibration
damper if
necessary
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To remove: take
off vibration
damper if
necessary
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Mark direction of
rotation before
removing
Do not kink
Removing and
installing Page
13-17
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Observe steel
type marking on
bolt head:
8.8 = 85 Nm (63 ft
lb)
Loosen and
tighten using
3036 counter-
hold
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Note position
when installing
toothed belt
Page 13-17
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Without
elongated holes
If damaged and
leaking, replace
assembly
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If leaking and
damaged replace
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Breather hose
secured with
bracket to oil
filler pipe item -2-
Make sure
sufficient
clearance to
throttle valve
housing
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Replace if
damaged
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damaged
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damaged
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Sequence when
loosening and
tightening
Page 15-7
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Installing:
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Replace if
damaged
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Replace
If replaced;
completely
replace coolant
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Yellow, 4-pin
-F95- Checking:
Page 19-20
ECT switch,
checking:
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Removing and
installing Page
15-7
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Always replace
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Installation
position
determined by
fitted pin
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Replace if
damaged
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Disassembly and
assembly:
cylinder block,
crankshaft and
flywheel Page
13-30
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Replace
Do not attach
with adhesive,
make sure
positioned
correctly
Remove and
install using
socket 3249
With flywheel
installed: turn
flywheel so
recess aligns
with bolts
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Mounted to
cylinder head
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Tighten by hand
Note instructions
on filter when
installing
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Coat contact
area to flange,
outside seal with
AMV 188 100 02
Make sure
clearance to
adjacent
components
See note Page
13-1
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3299 Lever
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Ring wrench 3355
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Engine removed:
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Engine cold
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20 Nm (15 ft lb)
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It must be possible to turn the toothed belt 90
with the thumb and forefinger between camshaft
and intermediate shaft sprockets.
20 Nm (15 ft lb)
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Specification:
30 Nm (22 ft lb)
35 Nm (26 ft lb)
25 Nm (18 ft lb)
Specifications:
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3299 Lever
Wooden wedge
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20 Nm (15 ft lb)
- Unscrew 2 mounting bolts -arrows- from
transmission support on sub-frame.
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Engine mount center bolt 65 Nm
48 ft lb
Drive shaft to flange shaft 55 Nm
41 ft lb
Transmission mount to sub- 45 Nm
frame
33 ft lb
Tensioner device bracket and 40 Nm
engine mount to cylinder block
30 ft lb
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Always replace
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Bearing cap 1:
Pulley end
Bearing cap 6:
flywheel end
Bearing shell
retaining lugs
cylinder
block/bearing
cap must be on
the same side
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Note fixing
arrangement
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For cylinder
block with oil
groove
127
$33/,&$%/(
Replace
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Can be replaced
with engine
installed; by first
removing the
transmission
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To remove and
install flywheel
counter-hold with
3067
Removing and
installing drive
plate (for
vehicles with
automatic
transmission)
Page 13-36
Replace
Turning 90
further can be
carried out in
several stages.
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Always replace
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For cylinder
block
Note installation
arrangement
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Axial clearance:
Check radial
clearance using
Plastigage
New: 0.016 to
0.075 mm
Do not rotate
crankshaft when
checking radial
clearance
Crankshaft
dimensions
Page 13-35
&\OLQGHUEORFN
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For cylinder
block with oil
groove
Do not
interchange used
bearing shells
(mark)
2LOSXPS
Only Replace
complete
When installing
note coupling
ring (item 23 ) on
crankshaft
Disassembling
and assembling
Page 17-1
M6 = 10 Nm (7 ft
lb)
2LOVHDO
Replace Page
13-34
2LOSXPS
FRXSOLQJULQJ
Break open to
pull off
Heat new
coupling ring to
200 C
(maximum)
before installing
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Basic -0.022 -0.022
-0.042 -0.042
-0.022 -0.022
-0.042 -0.042
-0.022 -0.022
-0.042 -0.042
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A - To loosen
B - To tighten
,QVWDOOLQJGULYHSODWH
- Locate drive plate and packing plate with
recesses -1-.
30 Nm (22 ft lb)
30 Nm (22 ft lb)
When Replacing drive plate, note
transmission version:
Version -A-:
Version -B-:
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GLVDVVHPEOLQJ
DQGDVVHPEOLQJ
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Offset gaps by
120
Remove and
install using
piston ring pliers
"TOP" faces
toward piston
crown
Checking ring
gap Fig. 1
Checking ring to
groove clearance
Fig. 2
3LVWRQ
Checking Fig.
3
Mark installation
position and
cylinder number
Arrow on piston
crown points to
pulley end
Install using
piston ring clamp
3LVWRQSLQ
If difficult to
remove, heat
piston to 60 C
Remove and
install using VW
222a
&LUFOLS
&RQQHFWLQJURG
Only replace as
a set
Mark cylinder
number -A-
Installation
position:
:ULVWSLQ
%HDULQJVKHOO
Note installation
position
Do not
interchange used
bearing shells
Axial clearance
New: 0.05...0.31
mm
Check radial
clearance with
Plastigage:
New: 0.01...0.06
mm
Do not rotate
crankshaft when
checking radial
clearance
&\OLQGHUEORFN
Checking
cylinder bores
Fig. 4
Piston and
cylinder
dimensions
Page 13-46
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EHDULQJFDS
Installation
position:
&RQQHFWLQJURG
EROW1PIW
OE WXUQ
IXUWKHU
Always replace
To measure
radial clearance
use old bolts and
tighten to 30 Nm
(22 ft lb) do not
turn further
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6SHFLDOWRROVWHVWHUVDQGDX[LOLDU\LWHPV
Feeler gauge
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Dimensions in mm
Compression rings 0.20 to 0.40 1.0
Oil scraper ring 0.25 to 0.50 1.0
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Feeler gauge
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Dimensions in mm
Compression rings 0.02 to 0.05 0.15
Oil scraper ring 0.02 to 0.05 0.15
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15 - Engine - Cylinder head, Valvetrain
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Cylinder head, removing and installing
Compression, checking
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Valve seats, reworking
Hydraulic lifters, checking
Camshaft, removing and installing
Camshaft oil seal, removing and installing
Valve guides, checking
Valve guides, replacing
Valve stem seals, replacing
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Compression checking
Page 15-10
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Breather hose
secured to oil
filler tube (item -
2-) with retainer
Make sure
sufficient
clearance to
throttle body
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6HDOLQJULQJ
Replace if
damaged
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Replace
complete if
damaged or
leaking
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Replace if
damaged
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No longer
available as a
spare part,
replace valve
cover assembly if
leaking
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tightening
sequence
Page 15-7
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distortion Page
15-6 , Fig. 1
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installing Page
15-7
Valve gear,
servicing Page
15-11
After replacing,
completely
replace the
coolant
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position
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completely
replace the
coolant
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Page 13-17
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lb)
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loosen and
tighten
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Removing and
installing Page
13-17
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when installing
the toothed belt
Page 13-17
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cylinder head
loosen mount
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cylinder head bolts
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position Page
15-15 Fig. 2
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sequence
Page 15-24
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clearance
Page 15-15 , Fig.
1
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installing Page
15-24
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clearance with
plastigage
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0.01 mm
Identification and
valve timing
Page 15-16 , Fig.
3
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interchange
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valve clearance
compensation
Checking Page
15-23
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check camshaft
axial clearance
Page 15-15 ,
Fig. 1
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surface
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chamfer
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installing: with
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removed: use
2037 with
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installed: Page
15-31
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Page 15-31
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install with
3047A puller
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15-29
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Page 15-30
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with collar
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dimensions
Fig. 4
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Page 15-27
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dimension:
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= 132.6 mm
Reworking valve
seats Page 15-
19
See notes
Page 15-1 and
Page 15-11
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UHSDLUHG
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7HVWVHTXHQFH
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20 Nm (15 ft lb)
20 Nm (15 ft lb)
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WKHSUHVVXUHPXVWQRWH[FHHGWRQRWKHUZLVH
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VAG 1202 or VAG 1556/2 Workshop crane
3047A Puller
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and right and unclip spreader clips from the
radiator bracket.
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Part I
Part II
Oil pressure and oil pressure switch, checking
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FUDQNVKDIWDQGFRQQHFWLQJURGEHDULQJVDUH
IRXQGLQWKHHQJLQHRLOWRSUHYHQW
FRQVHTXHQWLDOGDPDJHWKRURXJKO\FOHDQRLO
SDVVDJHVUHSODFHWKHRLOFRROHU
7KHRLOOHYHOPXVWQRWEHDERYHWKHPD[
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II Page 13-5
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installing and
tensioning
toothed belt
Page 13-17
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tighten using
3419 counterhold
Page 13-17
Screw length: 65
mm
Tightening
torque 460 Nm
(340 ft lb)
Tightening
torque 160 Nm
(118 ft lb) + 1/2
turn (2 x 90 )
further
90 additional
turn can be
carried out in
several stages.
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10.91
Vibration damper
and crankshaft
toothed belt
sprocket can
only be installed
in one position
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10.91
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rotation before
removing
Remove/install
with 3299 lever
Page 13-14
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20 Nm (15 ft lb)
20 Nm + 1/4 turn
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to remove;
remove vibration
damper if
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installing and
tensioning
toothed belt
Page 13-17
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Observe steel
type marking on
bolt head:
8.8 = 85 Nm (63 ft
lb)
Loosen and
tighten with 3036
counter-hold
7RRWKHGEHOW
Removing and
installing Page
13-17
&DPVKDIW
VSURFNHW
Note position
when removing
and installing
toothed belt
Page 13-17
7RRWKHGEHOW
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To remove, take
off vibration
damper if
necessary
2LOSXPSKRXVLQJ
When installing;
note coupling
ring on
crankshaft
Page 17-10 ,
item 12
Only replace as
an assembly
2LOSXPSGULYH
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Identification
mark "D" points
in direction of
end plate
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YDOYH
40 Nm (30 ft lb)
Opening
pressure: 5.3 to
6.3 bar
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Replacing
Page 13-34
&UDQNVKDIW
VSURFNHW
,GOHUZKHHO
9EHOW
09.91
for generator
Check tension
using thumb:
Max. deflection:
New V-belt
approx. 2 mm
Used V-belt
approx. 5 mm
Check V-belt
tension on
vehicles with
toothed rack
tensioner Page
13-24
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09.91
Installing
vibration damper
and crankshaft
toothed belt
sprocket only
possible in one
position
9EHOW
09.91
for power
steering pump
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using thumb
Deflection: approx.
5 mm
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Breather hose
secured with
retainer to oil
filler pipe item -2-
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sufficient
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throttle valve
housing
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25 Nm (18 ft lb)
Checking Page
17-14
If sealing ring
leaking; nip open
and replace.
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install with
commercial type
multi-point key 8
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25 Nm (18 ft lb)
White
Wire: Yellow
Checking Page
17-14
2LOSDQJDVNHW
Replace
Do not stick-on,
make sure
positioned
correctly
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Heat new
coupling ring to
200 C max.
before fitting
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Always replace
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install with 3249
socket
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installed: Turn
flywheel so that
the recess aligns
with bolt
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6HDO
Always replace
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50 Nm (37 ft lb)
Replace if
leaking. See
Parts Catalog for
correct
application. In
some cases, seal
and drain plug
are combined; do
not interchange
with separate
seal and drain
plug.
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Loosen with
sockets 2067
Tighten by hand
Observe
installation
instructions on oil
filter
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for dipstick
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Coat contact
area to flange,
outside the seal,
with AMV 188
100 02
Make sure
clearance to
adjacent
components
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70 Nm (52 ft lb)
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Installation
position fixed by
installed pins
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Cap. difference
between min.
and max. mark:
1.5 liter. (1.6 qts)
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Vehicles 01.96 :
Page 19-7
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Attached at
radiator:
Vertically 4
screws,
horizontally 4
rivets or 4
screws -arrows-
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Removing and
installing Page
19-18
After replacing,
completely
replace coolant
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Always replace
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25 Nm (18 ft lb)
Switching
temperatures:
1st speed
on: 84 to 89 C
off: 76 to 83 C
2nd speed
on: 90 to 95 C
off: 82 to 89 C
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Checking:
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temperature below
25 C) shut-off
ring (item - 13 -)
closed
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to top of radiator
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cooling system
tester and VAG
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Test pressure
1.3 to 1.5 bar
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35 Nm (26 ft lb)
Switching
temperatures:
1st speed
on: 84 to 89 C
off: 76 to 83 C
2nd speed
on: 90 to 95 C
off: 82 to 89 C
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19-18
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19-18
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Vehicles 07.96
Page 19-11 ,
item - 9 -
to throttle valve
control module
Vehicles 08.96
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Test pressure
1.3 to 1.5 bar
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Removing and
installing Page
19-18
After replacing,
completely
replace engine
coolant
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damper (if
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Observe steel
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bolt head:
8.8 = 85 Nm (63 ft
lb)
Counter-hold
with 3036 to
loosen and
tighten
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Note position
when installing
toothed belt
Page 13-17
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to remove, take
off vibration
damper, if
necessary
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installing Page
17-1
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Vehicles 12.95
Page 19-5 , item
- 16 -
Vehicles 01.96
07.96 Page 19-5
, item - 16 -
Vehicles 08.96
To throttle valve
control module
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Replace if
damaged
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Replace
complete if
damaged or
leaking
09.91 with
elongated holes:
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toothed belt:
loosen slightly
and turn with
screwdriver
Page 13-17
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10.91
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installing Page
13-17
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Blue, 2-pin
Checking:
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/LWHU&\O9(QJLQH
0HFKDQLFDO(QJLQH
&RGHV$$)$&8
5HSDLU*URXS
&RQQHFWRU
%UDQFK
FRQQHFWLRQ
WRKHDWH[FKDQJHU
WRRLOFRROHU
3DJHLWHP
WRUHJXODWLQJ
YDOYHKHDW
H[FKDQJHU
&RRODQWSLSH
Secured to
starter
WRFRRODQW
H[SDQVLRQWDQN
Vehicles 12.95
Page 19-5 , item
- 17 -
Vehicles 01.96
Page 19-8 , item
- 14 -
WRWRSRIUDGLDWRU
Vehicles 12.95
Page 19-6 , item
- 25 -
Vehicles 01.96
Page 19-9 , item
- 22 -
6HDOLQJULQJ
Replace
'UDLQVFUHZ
10 Nm (7 ft lb)
Draining coolant
Page 19-16
$IWHUUXQFRRODQW
SXPS9
Checking:
Page 19-20
5HWDLQHU
for After-run
coolant pump
WRERWWRPRI
UDGLDWRU
Vehicles 12.95
Page 19-5 , Item
22
Vehicles 01.96
Page 19-9 , item
- 19 -
&RQQHFWLQJKRVH
&RRODQW
WKHUPRVWDW
Checking: heat-
up thermostat in
water
Opening begins
approx. 87 C
Closes at
approx. approx.
102 C
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WKHUPDOVZLWFK
)ZLWK(QJLQH
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7HPSHUDWXUH
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Yellow, 4-pin
Checking -F95-:
Page 19-20
:LULQJGLDJUDPV
(OHFWULFDO
7URXEOHVKRRWLQJDQG
&RPSRQHQW/RFDWLRQV
ELQGHU
5HWDLQLQJFOLS
&RROLQJV\VWHPGUDLQLQJDQGILOOLQJ
6SHFLDOWRROVWHVWHUVDQGDX[LOLDU\LWHPV
VAG 1921 spring clip pliers
'UDLQLQJ
5HSDLU0DQXDO%RG\([WHULRU5HSDLU*URXS
- Drain coolant:
or
)LOOLQJ
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7KHFRROLQJV\VWHPLVILOOHG\HDUURXQGZLWKD
PL[WXUHRIZDWHUDQWLIUHH]HDQG*FRUURVLRQ
SURWHFWLRQDJHQW*SOXVFRRODQWDGGLWLYHV
PDUNHGDVEHLQJLQDFFRUGDQFHZLWK7/9:
&SUHYHQWIUHH]LQJDQGFRUURVLRQGDPDJH
WKHIRUPDWLRQRIFKDONUDLVHVWKHFRRODQWERLOLQJ
SRLQW)RUWKHVHUHDVRQVWKHFRROLQJV\VWHP
PXVWEHILOOHG\HDUURXQGZLWKDQWLIUHH]HDQG
*'XHWRWKHKLJKHUERLOLQJSRLQWWKH
GHVFULEHGFRRODQWPL[WXUHDLGVRSHUDWLRQDO
HIILFLHQF\ZKHQWKHHQJLQHLVRSHUDWLQJXQGHU
KLJKORDGVSDUWLFXODUO\LQWURSLFDOFOLPDWHV
,IUDGLDWRUKHDWH[FKDQJHUF\OLQGHUKHDGRU
F\OLQGHUKHDGJDVNHWKDVEHHQUHSODFHGGRQRW
UHXVHROGFRRODQW
Recommended mixture ratios:
)UHH]H $QWLIUHH]H
*
:DWHU
SURWHFWLRQGRZQ DPRXQW
WR
-25 C 40 % 4.6 6.9 ltr.
ltr.
-35 C 50 % 5.75 ltr.
5.75
ltr.
1)
Amount of anti-freeze must not exceed 60 %;
freeze protection and cooling effect will decrease if
anti-freeze quantity is too high.
2)
Coolant quantity can vary depending upon vehicle
equipment.
5DGLDWRUDQGUDGLDWRUIDQUHPRYLQJDQG
LQVWDOOLQJ
6SHFLDOWRROVWHVWHUVDQGDX[LOLDU\LWHPV
5HPRYLQJ
9HKLFOHV
5HSDLU0DQXDO%RG\([WHULRU5HSDLU*URXS
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5HSDLU0DQXDO%RG\([WHULRU5HSDLU*URXS
9HKLFOHV
&RQWLQXDWLRQIRUDOOYHKLFOHV
,QVWDOOLQJ
Installation is carried out in the reverse order of
removal, when doing this note the following:
5HSDLU0DQXDO(OHFWULFDO(TXLSPHQW5HSDLU
*URXS
0DLQWHQDQFH
$IWHUUXQ&RRODQW7KHUPDOVZLWFK(QJLQH
&RRODQW7HPSHUDWXUHVHQVRUFKHFNLQJ
6SHFLDOWRROVWHVWHUVDQGDX[LOLDU\LWHPV
Fluke 83 multimeter
Wiring diagram
7HVWVHTXHQFH
:LULQJGLDJUDPV(OHFWULFDO:LULQJ'LDJUDPV
7URXEOHVKRRWLQJ &RPSRQHQW/RFDWLRQVELQGHU
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Specifications:
20 - Fuel Supply
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Fuel supply system components, removing and installing
Fuel delivery unit, removing and installing
Fuel supply system, safety precautions
Rules for cleanliness
Fuel delivery unit, removing and installing
Fuel delivery unit, disassembling and assembling
Fuel pump, checking
Delivery rate, checking
Fuel pump check valve, checking
Fuel tank, removing and installing
Accelerator mechanism, servicing
Accelerator cable, adjusting
Evaporative emissions (EVAP) system, servicing
Evaporative emissions (EVAP) system control, checking
)XHOVXSSO\V\VWHP
FRPSRQHQWVUHPRYLQJDQG
LQVWDOOLQJ
:$51,1*
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DUHDWKDWFDQLJQLWHIXHO
1RWHV
+RVHFRQQHFWLRQVDUHVHFXUHGZLWKHLWKHU
VFUHZVSULQJRUFODPSW\SHFOLSV
$OZD\VUHSODFHFODPSW\SHFOLSVZLWKVFUHZ
RUVSULQJW\SHFOLSV
)XHOKRVHVLQHQJLQHFRPSDUWPHQWPXVWRQO\
EHVHFXUHGZLWKVSULQJW\SHFOLSV7KHXVHRI
FODPSRUVFUHZW\SHFOLSVLVQRWSHUPLVVLEOH
)RULQVWDOOLQJWKHVSULQJW\SHFOLSV
FRPPHUFLDOO\DYDLODEOHSOLHUVHJ+D]HW
DUHUHFRPPHQGHG
$IWHUDOOZRUNRQWKHIXHOGHOLYHU\XQLWRUWKH
IXHOJDXJHPDNHVXUHWKDWWKHVXSSO\UHWXUQ
KRVHVGRQRWWRXFKWKHIXHOWDQNWUDQVIHURI
SXPSQRLVHV
)XHOVXSSO\V\VWHP
FRPSRQHQWV
UHPRYLQJDQG
LQVWDOOLQJ
6XSSO\OLQH
Black
To fuel
manifold/cold
start valve
junction
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,QMHFWLRQ ,JQLWLRQ
5HSDLU*URXS
5HWXUQKRVHOLQH
Blue or blue
markings
From fuel
manifold
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,QMHFWLRQ ,JQLWLRQ
5HSDLU*URXS
%UDFNHW
)XHOILOWHU
Installed position:
Arrow points in
direction of flow
&ROODUQXW
Remove and
install with 3217
wrench
)XHOWDQN
Removing and
installing Page
20-21
)ODQJH
Note installed
position on fuel
tank Fig. 1
Removing and
installing fuel
delivery unit
Page 20-11
Has additional
fuel line
connection, for
vehicles with
additional heater
6HFXULQJVWUDS
%UDFNHW
For securing
straps
2YHUIORZKRVH
&DS
5HWDLQLQJULQJ
5XEEHUFXS
9HQWOLQH
On vehicles
without EVAP
sys.
%UHDWKHUOLQH
On vehicles with
EVAP system
To EVAP
canister T piece
Page 20-26 ,
item - 9 -
)LJ )XHOGHOLYHU\XQLWIODQJH,QVWDOOHG
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&RQQHFWRU
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Note installing
position on fuel
tank Page 20-4
, Fig. 1
Note
identification for
supply and return
hose on
underside
Has additional
fuel line
connection for
vehicles with
additional heater
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From fuel
manifold
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,QMHFWLRQ ,JQLWLRQ
5HSDLU*URXS
6XSSO\
To fuel manifold
Page 20-2 ,
item - 5 -
6HDOLQJULQJ
6XSSO\KRVH
5HWXUQKRVH
)XHOJDXJH
VHQVRU
Removing and
installing Page
20-11
8SSHUVXSSRUW
ULQJ
Unclip with
screwdriver
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Unclip with
screwdriver
2ULQJ
Replace if
damaged
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6HDOLQJULQJ
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When installing
pull into housing
upper section -
item. 10 -
)XHOSXPS
Checking fuel
pump Page
20-15
5XEEHUPRXQWLQJ
Note installation
position
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When installing
pull into housing
lower section -
item 18 -
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Unclip with
screwdriver
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UHPRYLQJIURPKRVHFRQQHFWLRQZUDSDFORWK
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SUHVVXUHE\FDUHIXOO\SXOOLQJKRVHRII
FRQQHFWLRQ
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DUHDWKDWFDQLJQLWHIXHO
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LQVWDOOLQJ
6SHFLDOWRROVWHVWHUVDQGDX[LOLDU\LWHPV
&$87,21
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EHIRUHGLVFRQQHFWLQJEDWWHU\JURXQGFDEOH
5HPRYLQJ
:$51,1*
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WKDWFDQLJQLWHIXHO
- Disconnect connector and supply and return
lines from fuel delivery unit flange.
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2QYHKLFOHVZLWKDGGLWLRQDOKHDWHUSXOORIIIXHOOLQH
EHWZHHQVXSSO\DQGUHWXUQOLQH
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WKDWWKHIXHOJDXJHVHQVRULVQRWEHQWDQG
SRLQWVDSSUR[ IRUZDUG
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1RWHLQVWDOOHGSRVLWLRQRIIXHOGHOLYHU\XQLW
IODQJH0DUNRQIODQJHPXVWDOLJQZLWKPDUNRQ
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DVVHPEOLQJ
9HKLFOHV
:$51,1*
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WKDWFDQLJQLWHIXHO
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UHWXUQKRVHRQXQGHUVLGHRIIODQJH
- Unclip upper retaining ring -1- and bayonet ring
-2- (on housing lower part) using screwdriver.
1RWH
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KRXVLQJVHFWLRQZLWKIXHO
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DUURZVLQWRWKHXSSHUDQGORZHUKRXVLQJ
VHFWLRQVDQGVHFXUHDWWKHWRSZLWKDUHWDLQLQJ
ULQJDQGWKHERWWRPZLWKDED\RQHW
)XHOSXPSFKHFNLQJ
6SHFLDOWRROVWHVWHUVDQGDX[LOLDU\LWHPV
7HVWFRQGLWLRQV
Fuse 18 OK.
7HVWVHTXHQFH
- Switch ON ignition.
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Minimum delivery cm3/30 seconds
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Voltage at fuel pump with engine stationary and
pump running (approx. 2 Volts less than battery
voltage).
Example:
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,QVWDOOLQJ
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Vehicles 08.96
Throttle valve
control
5HWDLQHU
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Adjusting Page
20-24
Removing:
Detach
accelerator cable
at accelerator
pedal, support
bracket and
throttle valve
housing. Break
off spreader clips
from inside
vehicle (do not
reuse damaged
cable) and pull
cable out into
engine
compartment.
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6HFXULQJFOLS
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Fluke 83 multimeter
Distance piece 11 mm
- Fully open throttle valve by pulling on the
outer cable and fix in this position with the
retainer -arrow-.
Specification:
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Checking Page
20-27
When engine is
warm, valve is
pulsed via ECM
Note installed
position: Arrow
points in
direction of flow
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Installed location:
Front left wheel
housing
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9HQWOLQH
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Oxygen sensor and Oxygen sensor control
OK, checking
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If voltage supply OK
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QHFHVVDU\ORRVHQ
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PXIIOHUDQGIURQW
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VXIILFLHQWFOHDUDQFHLV
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I Page 26-2
II Page 26-4
3DUW,
:DUPDLU
FROOHFWRUSODWH
5HWDLQHU
+RVH
To air intake
connection on Air
Cleaner housing
M8 - 25 Nm (18 ft
lb)
M10 - 40 Nm (30 ft
lb)
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Vehicles 09.91
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Always replace
2[\JHQVHQVRU
50 Nm (37 ft lb)
Only grease
threads with
"G5"; "G5" must
not get into slots
on sensor body
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5HSDLU*URXS
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AAF engine:
2 piece with
intermediate and
corrugated pipes
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07.94
Additionally
secured to intake
manifold
3OXJ
Make sure it is
tight and leak
free
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M8 - 25 Nm (18 ft
lb)
M10 - 40 Nm (30 ft
lb)
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5HDUPXIIOHU
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Align exhaust
system
longitudinally at
the clamps, so
that the
dimensions
(items -3- and -4-
) are maintained
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diameter: 11 mm
Dimensions:
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FRQWURORIWKH(QJLQH&RQWURO0RGXOH(&0
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*URXS
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AAF engine:
2-piece with
intermediate and
corrugated pipes
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07.94
3OXJ
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VHQVRU*
20 Nm (15 ft lb)
With 2-pin
connector
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,QMHFWLRQ ,JQLWLRQ
5HSDLU*URXS
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Checking Page
26-10
(*59DFXXP
5HJXODWRU
VROHQRLGYDOYH
1
Two-way valve
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,QMHFWLRQ ,JQLWLRQ
5HSDLU*URXS
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for intake
manifold vacuum
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34 Nm (25 ft lb)
In intake
manifold
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Always replace
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30 Nm (22 ft lb)
(*5YDOYH
Checking Page
26-10
In intake
manifold
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Always replace
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1
Two-way valve
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6SHFLDOWRROVWHVWHUVDQGDX[LOLDU\LWHPV
US 8012 Hand vacuum pump
7HVWFRQGLWLRQV
7HVWVHTXHQFH
9HKLFOHV
9HKLFOHV
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5HSDLU*URXS
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Make sure
seated tightly
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Make sure
seated tightly
&RPELYDOYH
Checking Page
26-15
*DVNHW
Always replace
&RQQHFWLQJSLSH
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Always replace
6HFRQGDU\$LU
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Checking Page
26-19
SLQKDUQHVV
FRQQHFWRU
9DFXXPKRVH
to brake servo
check valve
connection
&KHFNYDOYH
%UDFNHW
Secondary Air
Injection pump
item -17- and
Secondary Air
Injection solenoid
valve, item -11-
6HFRQGDU\$LU
,QMHFWLRQSXPS
Checking Page
26-16
,QWDNHKRVH
7R$LU&OHDQHU
on intake hose
connection
$LUFKDQQHO
in cylinder head
%UDFNHW
for combi-valve
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7HVWVHTXHQFH
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7HVWVHTXHQFH
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