2.8 Tdi VW Agk-Ata

Service
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LT 1997 ➤
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4-cyl. diesel engine, mechanics
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Engine ID AGK ATA
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Edition 11.1998
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
LT 1997 ➤ olksw
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Repair Group
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00 - Technical data
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10 - Removing and installing engine
13 - Crankshaft group
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15 - Cylinder head, Valve gear
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17 - Lubrication
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19 - Cooling system
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20 - Fuel supply system
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21 - Charging
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Technical information should always be available to the foremen and mechanics, because their careful
and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In
addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course,
be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg K0050006220

LT 1997 ➤
4-cyl. diesel engine, mechanics - Edition 11.1998
Contents
olkswagen AG
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00 - Technical data . . . . . . . . . . . . . . . . . .Vo.lk.sw.a.g . . . . . . . . . . . .do. e.s n.o.t g. . . . . . . . . . . . . .1
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1 Technical data . . . . . . . . . . . . . .ris.e.d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.an.te. . . . . . . . . . . . .1
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1.1 Technical data . . . . . . . . . . .a.uth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .or.a . . . . . . . . . .1
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1.2 Engine number and cylinders 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
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1.3 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
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10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
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Removing and installing the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
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1.1 Removing and installing the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
hole
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1.2 Notes on removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
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1.3 Securing engine to mounting trestle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
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1.4 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.5 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
rrectness of i
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
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1 Dismantling and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

1.1 Dismantling and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
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1.2 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

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1.3 Removing and installing ribbed V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
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1.4 Removing and installing tensioning device for ribbed V-belt . . . . . . . . . . . . . . . . . . . . . . . .27
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2 Removing and installing drive gears and dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . .29
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2.1 Removing and installing drive gears and dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . .29
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2.2 Check drive gear wheels and adjust if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
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2.3 Replace crankshaft gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
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2.4 Replacing needle bearing of dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
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2.5 Renewing sealing ring for crankshaft (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
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2.6 Renewing sealing ring for crankshaft (flywheel end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
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3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

3.1 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
4 Dismantling and assembling piston and connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
4.1 Dismantling and assembling piston and connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
4.2 Cylinder dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
1.1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
1.2 Checking compression pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
2 Overhauling valve train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
2.1 Overhauling valve train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
2.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
2.3 Removing and installing rocker arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
2.4 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
2.5 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
2.6 Checking and adjusting valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
1 Removing and installing lubricating system components . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
1.1 Removing and installing lubricating system components . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
1.2 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

1 Removing and installing cooling system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Contents i
LT 1997 ➤
1.1 Removing and installing cooling system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

1.2 Cooling system components, radiator end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
1.3 Cooling system components, engine end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
1.4 Draining off and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
1.5 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
1.6 Removing and installing viscous fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

1 Removing and installing fuel system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
1.1 Removing and installing fuel system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
1.2 Removing and installing fuel tank and add-on components . . . . . . . . . . . . . . . . . . . . . . . . . .110
1.3 Safety measures when working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
1.4 Cleanliness rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
1.5 Removing and installing the fuel tank . .A.G.. V. o. lk. s.w.a.ge. n.A.G. d. . . . . . . . . . . . . . . . . . . . . . . . . . . .114
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1.6 Removing and installing fuel level olkswgauge . . . . . . . . . . . . . .s.no. t.g.u . . . . . . . . . . . . . . . . . . . . . .117
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1.7 Servicing throttle controlsris.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.n.te. . . . . . . . . . . . . . . . . . .119
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21 - Charging . . . . . . . . . . s. . . .
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1 Charge-air system with exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
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1.1 Charge-air system with exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
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1.2 Removing and installing turbocharger and add-on components . . . . . . . . . . . . . . . . . . . . . .122
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1.3 Removing and installing charge-air cooler components . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
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1.4 Cleanliness rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
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1.5 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
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1.6 Checking turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
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1 Removing and installing exhaust system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
1.1 Removing and installing exhaust system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
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ii Contents
LT 1997 ➤
00 - Technical data
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1.1 - Technical data or eo
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1.2 - Engine number and cylinder 1
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-> The engine number (consisting of "engine code letter" and "serial number") is positioned on the left-hand
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-> The arrow on cylinder 1 is at the flywheel end. The cylinders are numbered from the power-discharging end
(flywheel).
1.3 - Engine data
Code letter AGK ATA

Date of production 04.97 ä 01.99 ▸
Displacement l 2.8 2,8
Output kW at rpm 92/3500 96/3500
1.1 - Technical data 1

LT 1997 ➤
Code letter AGK ATA

Torque Nm at rpm 280/2200 300/2000...2500
Bore ø mm 93.0 93,0
Stroke mm 103.0 103,0
Compression ratio 19 19
Cetane number min. 45 45
Firing order 1-3-4-2 1-3-4-2
Catalytic converter - AG. Volkswagen AG -
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2 00 - Technical data
LT 1997 ➤
10 - Removing and installing engine
1 - Removing and installing the engine

1.1 - Removing and installing the engine
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Special tools, factory equipment, test and measuring instruments and accessories required
◆ V.A.G 1202 A workshop crane

◆ 3448 suspension device
◆ VW 785/ 1B holder
◆ 3444 engine holder
◆ VW 313 clamp
◆ V.A.G 1383 A engine/gearbox lifter
1.1 - Removing and installing the engine 3

LT 1997 ➤
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◆ V.A.G 1306 collecting tray

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◆ V.A.G 1921 Pliers for spring band clamps

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◆ V.A.G 1331 torque wrench (5...50 Nm)

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◆ Grease G 000 100
◆ Cable ties
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◆ Lashing straps
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◆ The vehicle is secured by means of 4 lashing straps.

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◆ If there is no workshop crane V.A.G 12-02 A available (500 kg load capacity), the engine can also be removed rig ht
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4 10 - Removing and installing engine

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1.2 - Notes uonthorisremoving tee
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- Check first whether there is a code-protected radio is fitted to the vehicle. If so, request details of the anti-
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- The engine is removed to the front, together with the gearbox.
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- All cable ties which are disconnected or cut to allow the engine to be removed should be refastened or
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refitted at the same point when the engine is installed again.
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- Pull off coolant hoses with pliers for spring band clips V.A.G 1921.
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Procedure
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- Disconnect the battery's earth strap with the ignition turned off.
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- Remove the cover on the inspection window:
=> General Body Repairs External; Repair group 50; Removing cover of service opening Removing cover of
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- Drain off coolant => Page 104 .

- Remove front lid:
=> General Body Repairs External; Repair group 55; Bonnet Bonnet
- -> Remove the torx screws -arrows- which retain the coolant equalising tank and set the equalising tank
together with the spacer -1- to one side.
- Remove steps on right and left:
=> General Body Repairs External; Repair group 63; Front bumper Front bumper
- Remove front bumper:
- -> Remove the torx screws -arrows- and set down the cooling pipe for the power steering to one side.
- Remove the catch plate and add-on components:
1.2 - Notes on removing 5

LT 1997 ➤
=> General Body Repairs External; Repair group 50; Lock carrier plate wiht attached parts - removing and
installing Lock carrier plate wiht attached parts - removing and installing
- Remove the radiator => Page 106 .
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- -> Release the hose clips -1- and pull the hose -arrow- off the oil separator.
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- Remove the complete hoses.
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- -> Pull the coolant hoses -arrows- off the coolant pump.
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- Disconnect the coolant hoses from the engine. t. C rig
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- Remove the coolant equalising tank together with the spacer and the coolant hoses. yri
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- Disengage the accelerator cable on the injection pump and set down to one side.
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- -> Remove the retaining screws -arrows- for the vane pump for power steering and take off vane pump -1-.
The hoses remain connected up.

AG. Volkswagen AG d
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- -> Pull the underpressure hose -arrow- off the vacuum pump.
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- Pull the fuel supply and return lines off the injection pump.
- Pull off/disconnect all electrical lines from the engine, starter motor and alternator and lift out.
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Caution:
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If you only have a workshop crane with a load capacity of 300
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Removing engine with gearbox

- Remove shift lever from gearbox:
=> 5-Speed Manual Gearbox 000.1 and 000.2; Repair group 34; Removing and installing gearshift lever Re‐
moving and installing gearshift lever
- -> Unscrew the electrical lead -1- from the switch -2- for reversing lights (F4).
- -> Remove the sensor -1- for the speedometer (G22).

- Unscrew the earth lead from the gearbox.
- Remove the front end of the exhaust pipe => Page 131 .
- Remove clutch slave cylinder and lead on gearbox:

LT 1997 ➤
=> 5-Speed Manual Gearbox 000.1 and 000.2; Repair group 34; Removing and installing gearbox Removing
and installing gearbox
- Unscrew propeller shaft on gearbox flange:
=> Repair group 39; stripping down and assembling intermediate propeller shaft stripping down and assembling
intermediate propeller shaft
- Support the gearbox with the aid of transmission hoist V.A.G 1383 A.
- -> Remove the retaining screws -arrows- for the engine/gearbox cross-member and take out the cross-
member.
- Carefully set down the engine and gearbox.
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Removing engine without gearbox
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- -> Support the gearbox with retaining device VW 785/1B.

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- Remove the bolts holding the engine and gearbox together.

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- -> Engage suspending device 3448 and lift the assembly slightly with the workshop crane.
thi
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- Remove the retaining screws for the engine mounts on the left and right inside the engine compartment.
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LT 1997 ➤
Note:
When lifting out, the assembly must be guided carefully so as to prevent damage to the unit and the steering
gear.
- Raise the assembly and pullenitAG

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1.3 - Securingau engine to mounting
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When performing all assembly work, the engine should be secured with engine retainer 3444 to mounting trestle
VW 313.
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Procedure
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- Disconnect the gearbox.

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1.4 - Notes on installing
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Procedure
Install in the reverse order of removal, observing the following points:
- Check declutching bearing for wear and renew if necessary.

- Lightly grease declutching bearing, guide sleeve for declutching bearing and teeth on drive shaft with G 000
100 grease.
- Check whether dowels for centring the engine/gearbox in the cylinder block are fitted, and add if necessary:
=> 5-Speed Manual Gearbox 000.1 and 000.2; Repair group 34; Servicing gearbox housing Servicing gearbox
housing
- When installing the assembly, check that there is sufficient clearance in relation to the steering gear
- Insert retaining screws for engine mounts on right and left by hand until just before the limit position.
- Raise gearbox with gearbox hoist V.A.G 1383 A.
- Secure engine/gearbox cross-member at rear and mount gearbox to gearbox mounting:
- Shake the engine and gearbox mounting to release any stresses.
- Tighten retaining screws for engine mounts on right and left.

- Install clutch slave cylinder in gearbox together with line:

LT 1997 ➤
- Fit propeller shaft on gearbox flange:
=> Repair group 39; stripping down and assembling intermediate propeller shaft stripping down and assembling
intermediate propeller shaft
- Remove exhaust pipe to the front => Page 131 .

- Screw earth lead onto gearbox.
- Install fan housing:
=> Heater, air conditioner; Repair group 80; Servicing fan housing Servicing fan housing
- Install gearbox shift lever:
=> 5-Speed Manual Gearbox 000.1 and 000.2; Repair group 34; Removing and installing gearshift lever Re‐
moving and installing gearshift lever
- Install inspection window cover:
=> General Body Repairs External; Repair group 50; removing cover of service opening removing cover of
service opening
- Install vane pump for power steering.

- Install radiator => Page 106 . n AG. Volkswagen AG do
- Install catch plate with add-on components:
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=> General Body Repairs External;thoris
Repair group 50; Lock carrier plate with
nte
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installing Lock carrier plates awith attached parts - removing and installing
u ra
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nl
- Install steps on right and left:

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- Install front bumper:

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es, in part or in w
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nform
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- -> Install coolant equalising tank with coolant hoses.
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When installing the coolant equalising tank, ensure that the spacer is also fitted.
- Connections for coolant hoses => Page 96 , removing and installing cooling system components
- Fit front lid:
=> General Body Repairs External; Repair group 55; Bonnet Bonnet

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4-cyl. diesel
auth engine, mechanics - Edition 11.1998e or a
ss c
- Electrical connections and installation:
ce
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nl
pt
du
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=> Current flow diagrams, electrical fault finding and fitting locations
erm
ab
ility
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- Add coolant => Page 104 .
wit
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h re
hole
- Check headlight settings and adjust if necessary:
spec
es, in part or in w
t to the co
=> Manual of correct repair procedures
rrectness of i
1.5 - Tightening torques
l purpos
Engine to gearbox M10 55 Nm
nf
ercia
o
Retaining screw for engine mounts M12 85 Nm
rm
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Propeller shaft to gearbox flange M10 70 Nm
om
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c
Vane pump for power steering to engine M8 30 Nm

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1.4 - Notes on installing 11

AG. Volkswagen AG d
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LT 1997 ➤ Vol
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4-cyl. diesel engine, mechanics - risEdition
ed 11.1998 ara
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13 - Crankshaft group s au ra
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1 - Dismantling and
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1.1 - Dismantling and
t to the co
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1.2 - Dismantling and assembling engine
Notes:
◆ If large quantities of metal chips and abrasion caused by seizing, such as crankshaft and conrod bearing
damage, is found in the engine oil, the oil cooler must be renewed and the oil channels thoroughly cleaned
to prevent subsequent damage.
12 13 - Crankshaft group
LT 1997 ➤
◆ Defective injectors can lead to heavy engine knocking and indicate bearing damage. In the case of com‐
plaints, run the engine at idle and loose the union nuts on the injection lines consecutively. If the knocking
disappears after loosening a union nut, this indicates a defective injector.
AG. Volkswagen AG d
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mer
atio
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I =>Page 14 yri
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II => Page 17
AG.
III =>Page 19
IV =>Page 13-10
1.2 - Dismantling and assembling engine 13

LT 1997 ➤
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Part I
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nl
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1 Belt pulley
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ab
2 Ribbed V-belt
ility
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◆ Mark running direction before removing

, is n
h re
◆ Check for wear

hole
spec
◆ Removing and installing

es, in part or in w
=> Page 13-14

t to the co
3 30 Nm
4 Tensioner for ribbed V-belt
rrectness of i

=> Page 13-16
l purpos
5 20 Nm + additional1/8turn
(45°)
nform
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◆ Renew
6 Bracket
m
at
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◆ For alternator
n
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or
7 Guide sleeve
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AG. Volkswagen AG d
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h e
aut 4-cyl. dieselorengine,
ac mechanics - Edition 11.1998
ss
ce
le
un
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an
d
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rm
ab
pe
ility
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spec
es, in part or in w
t to the co
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8 Dowel sleeve
9 Idler pulley
10 20 Nm + additional 1/4 turn
(90 °)
◆ Renew
11 Dust cap
12 Belt pulley (two-piece)
◆ Back
◆ For vacuum pump
13 Shim(s)
◆ For adjusting V-belt tension
14 V-belt
◆ For vacuum pump
15 Belt pulley (two-piece)
◆ Front
◆ For vacuum pump

LT 1997 ➤
AG. Volkswagen AG d
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un
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an
d
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pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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do
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cum
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Cop py
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rig ht
py by
co Vo
by lksw
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Prote AG.
16 25 Nm
(90 °)
◆ Renew
18 Dust cap
19 10 Nm
20 Belt pulley
◆ For vacuum pump
21 Vibration damper with ribbed V-belt pulley
◆ Watch fixing when mounting
◆ Brace with spanner 3447 to remove and install bolts of vibration damper
22 Dowel sleeve
23 15 Nm
◆ Fit with AMV 188 001
LT 1997 ➤
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byV ua
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t to the co
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f inform
mer
atio
om
n
c
i
or
n thi
te
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cum
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pyri by
Vo
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by
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Prote AG.
Part II
1 35 Nm
2 Washer
3 Spacer bush
4 35 Nm
5 Tensioning element for tensioner
◆ Removing and installing tensioner for ribbed V-belt
=> Page 13-16
◆ Ensure proper installation position: "TOP" marking
6 30 Nm
7 Bracket
◆ For ribbed V-belt tensioner
8 Relay lever
9 Bracket
◆ For viscous fan

LT 1997 ➤
AG. Volkswagen AG d
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aut ra
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spec
es, in part or in w
t to the co
rrectness of i
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(45 °)
◆ Renew nform
ercia
11 Bush
12 Sealing ring
m
a
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tio
◆ Renew if damaged
n in
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13 Halter
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◆ For tensioner
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14 Tensioner
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(90 °)
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◆ Renew co Vo
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16 Dust cap
agen
Prote AG.

(45 °)
◆ Renew
18 35 Nm
LT 1997 ➤
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cial p
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Part III
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1 Cylinder head cover
t. rig
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2 Cap cop Vo
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3 Seal Prote AG.
4 15 Nm
5 Bush
6 Cover gasket
7 Cylinder head bolt
◆ Observe order when loosening and tightening
=>Page 15-7, Removing and installing cylinder head

LT 1997 ➤
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rrectness of i
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8 Injection lines
◆ Tighten with 30 Nm on injectors
nf
ercia
◆ Tighten with 27 Nm on injection pump

or
◆ Do not change shape of bends

m
m
atio
◆ Always remove entire set of lines

om
n in
c
9 10 Nm
or
thi
e
10 Bracket
t
sd
iva
o
r
◆ Always use bracket (Item 10) with M8 x 30 bolt (Item 11) (renew if necessary) when renewing injection
rp
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lines
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11 20 Nm t. Cop py
rig
12 Dowel sleeve
gh ht
pyri by
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13 Cylinder block
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Prote AG.
◆ Removing and installing drive gears and two-part flywheel => Page 13-18
◆ Removing and installing crankshaft => Page 13-46
◆ Dismantling and assembling piston and conrod
=> Page 13-50
LT 1997 ➤
AG. Volkswagen AG d
agen oes
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aut ra
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nl
pt
du
an
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ab
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
14 Cylinder head gasket

om
ion
c
◆ Renew
in t
or
◆ Clean sealing surfaces before mounting

his
ate
◆ After renewing, renew entire coolant

do
priv
cum
or
15 Cylinder head
f
en
ng
t.
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Co
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=> Page 15-1 t. C rig
gh ht
◆ Check tooth flank clearance of intermediate shaft after mounting and adjust if necessary => Page 13-28
pyri by
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◆ Renew entire coolant after renewing
lksw
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Prote
◆ Removing and installing injectors:
AG.
=> Repair group 23; Servicing Diesel Direct Injection System; Removing and installing injectors Servicing Diesel
Direct Injection System Removing and installing injectors

LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
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ara
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ris nte
ho eo
aut ra
ss c
ce
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nl
pt
du
an
itte
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, is n
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
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at
om
ion
c
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or
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ate
do
priv
cum
for
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Cop py
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rig ht
py by
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Part IV
AG.
1 Cylinder block
◆ Removing and installing drive gears and dual-mass flywheel
=> Page 29
◆ Removing and installing crankshaft
=> Page 49
◆ Stripping down and assembling piston and connecting rod
=> Page 52
2 Drive-gear housing
◆ Clean sealing surfaces before installing
◆ Observe correct location when assembling
◆ Apply AMV 188 001 to sealing surfaces
3 Injection pump
=> Repair group 23; overhauling diesel direct injection system; removing and installing injection pump over‐
hauling diesel direct injection system removing and installing injection pump
LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
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ce
e
nl
pt
du
an
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
4 Baffle plates
nf
ercia
5 30 Nm
orm
6 Sealing ring
m
atio
m
o
n in
or c
7 Oil pickup line

thi
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sd
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◆ Clean strainer if contaminated

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8 Gasket for oil sump

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t.
◆ Renew
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9 Oil sump
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◆ Clean sealing surface before assembly
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10 30 Nm Prote AG.
11 Oil drain plug, 50 Nm

12 Sealing ring
◆ Renew

LT 1997 ➤
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es, in part or in w
t to the co
rrectness of i
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nf
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orm
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or c
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Cop py
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Prote AG.
13 Pulley
◆ For vacuum pump
14 100 Nm
◆ Counter-lock vibration damper bolts with wrench 3447 when installing or removing
16 Sealing ring
◆ Renew if leaking or damaged
=> Page 44
LT 1997 ➤
AG. Volkswagen AG d
agen oes
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d by ara
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ility
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17 Coil spring
h re
hole
spec
18 Lock screw
es, in part or in w
19 10 Nm
t to the co
20 Dustcap
21 30 Nm
rrectness of i
22 30 Nm
23 TDC position marker
l purpos
◆ Take care not to bend during removal/assembly

nform
mercia
a
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Prote AG.

lkswage es n
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LT 1997 ➤ ir se
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4-cyl. diesel engine, mechanicsau - Edition 11.1998
th or
ac
ss
1.3 - Removing and installing ribbed V-belt
ce
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ility
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spec
t to the co
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mer
- Mark the direction of travel of the ribbed V-belt.
atio
-
om
n
- -> Turn the tensioning roller at the retaining screw in the direction of the arrow with the aid of a wrench.
c
i
or
n
- Remove or fit the ribbed V-belt as appropriate.
thi
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sd
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Note:
um
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t.
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◆ When fitting the ribbed V-belt, ensure that it is correctly located in the pulleys.
Co
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◆ Before fitting the ribbed V-belt, ensure that all assemblies (alternator, air conditioning compressor) are se‐
t. rig
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p by
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Ribbed belt run
-> Belt drive without air conditioner compressor

1- Vibration damper/pulley
2- Viscous fan pulley
3- Tensioner
4- Alternator pulley
AG. Volkswagen AG d
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eo
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➤
a
4-cyl.
ss diesel engine, mechanics - Edition 11.1998 c
ce
le
un
pt
-> Belt drive with air conditioner compressor
an
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ility
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3- Tensioner
h re
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4- Idler pulley
spec
5- Alternator pulley
6- Air conditioner compressor pulley
t to the co
rrectness o
cial p
f inform
mer
atio
om
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Cop py
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-> Belt drive with second alternator
py by
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Prote AG.
3- Tensioner
4- Alternator 1 pulley
5- Alternator 2 pulley
1.4 - Removing and installing tensioning device for ribbed V-belt
Special tools, testing and measuring equipment and auxiliary media required
◆ Torque wrench V.A.G 1331 (5...50 Nm)
Removing
- Remove ribbed V-belt => Page 26 .
1.3 - Removing and installing ribbed V-belt 27

lkswage es n
o ot g
byV ua
LT 1997 ➤ ir se
d ran
tee
o
4-cyl. diesel engine,
auth mechanics - Edition 11.1998 or
ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
- -> Remove retaining screws -arrows-.

- Stripping down and assembling the tensioning device => Page 14 .
nform
mercia
a
Installing
com
tion in
r
te o
The tensioning device for the ribbed V-belt is installed according to the reverse of the procedure for removal.
thi
s
iva
do
r
rp
c
Tightening torque
um
fo
en
ng
t.
yi Co
op
Screw connection Tightening torque
C py
t. rig
gh ht
yri
Tensioning device to holder M8 30 Nm
p by
co Vo
by lksw
cted agen
Prote AG.
Test procedure
- -> Swing the tensioner at the bracket approx. 5-10 mm in the direction of the arrow using a wrench (WAF
27). For this a clear, continually applied resistance must be detected and the tensioner moved relatively
slowly
- Repeat (pump) several times if resistance is uneven. If the resistance does not become even, replace re‐
taining ring.
LT 1997 ➤
2 - Removing and installing drive gears and dual-mass flywheel

2.1 - Removing and installing drive gears and dual-mass flywheel
lkswage es n
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du
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erm
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ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note:
Overhauling work on the clutch:
=> 5-Speed Manual Gearbox 000.1 and 000.2; Repair group 30
I => Page 30
II => Page 32
2.1 - Removing and installing drive gears and dual-mass flywheel 29

LT 1997 ➤
AG. Volkswagen AG d
agen oes
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byV gu
ara
ed
ris nte
ho eo
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ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Part I
1 60 Nm
2 Flywheel housing
3 Spring-type pin
4 Crankshaft
=> Page 49
LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
6 Spring pin s aut ra
c
s
7 Drive gear
ce
e
nl
pt
du
◆ Renewing => Page 40

an
itte
◆ Arrangement of drive gears

y li
erm
ab
=> Page 36
ility
ot p
8 O-Ring
wit
, is n
h re
◆ Replace
hole
spec
9 Bush
es, in part or in w
t to the co
10 Threaded insert
11 Dual-mass flywheel
◆ When removing and installing, counter-lock vibration damper with wrench 3447
rrectness of i
◆ With gear ring

l purpos
12 125 Nm
13 50 Nm
nform
ercia
14 Sealing ring
m
◆ Renewing => Page 44

at
om
io
15 Spacer ring
n
c
in t
or
16 Spring pin
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
31
Prote AG.
2.1 - Removing and installing drive gears and dual-mass flywheel
LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Part II
2 Coolant connection
3 Packing washer
◆ Renew
4 Stopper
5 Intermediate gear
◆ For camshaft drive
=> Page 36
◆ Adjusting axial play => Page 36
LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
c
6 Bearing
um
for
en
g
◆ For intermediate gear

n
t.
yi Co
op
7 Bearing bush
C py
t. rig
gh ht
yri
◆ For intermediate gear p by
co Vo
◆ Removing => Fig. 1
by lksw
cted agen
Prote AG.
8 Intermediate gear
◆ For coolant pump drive
=> Page 36
◆ Adjusting axial play => Page 36
9 Shim
◆ Available in various thicknesses
◆ for adjusting axial play
10 Thrust washer
◆ for gear wheel bearing
11 60 Nm
12 Thrust washer
◆ for gear wheel bearing

LT 1997 ➤
lkswage es n
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a ac
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un
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an
d
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pe
ility
ot
wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
13 Circlip
te o
thi
s
iva
14 Spacerfork
do
r
rp
cum
15 Intermediate gear
fo
en
ng
t.
◆ For driving the vane pump for power steering op
yi Co
C py
t. rig
gh
=> Page 36
ht
pyri by
Vo
o
◆ Adjusting axial play =>Page 36
c by lksw
cted agen
Prote
16 60 Nm
AG.
17 Cap
LT 1997 ➤
-> Fig.1 Remove gear wheel bearing bush

Press out on hydraulic press using special tool VW 454 and VW 412 and base plate VW 402.
The installation also takes place in the reverse order on the hydraulic press.
swage es n
2.2 - Check drive gear wheels and adjust d byV
olk
if necessary ot g
ua
ran
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d
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spec
es, in part or in w
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rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

LT 1997 ➤
◆ VW 387 dial gauge holderolkswage es n
ot g
◆ 3445 camshaft locking d b device
yV ua
ran
◆ 3447 wrench rise tee
◆ V.A.G 1331 torque tho wrench (5...50 Nm) or
au ac
◆ V.A.G 1332 torque
ss
wrench (40...200 Nm)
ce
e
◆ Dial gauge
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
-> Arrangement of drive gears
p by
co Vo
by lksw
cted agen
Prote AG.
1- Crankshaft gear wheel
2- Vane pump gear wheel for power assisted steering
3- Intermediate gear wheel
6- Coolant pump gear wheel
7- Injection pump gear wheel
10 - Camshaft gear wheel
Check axial play of gear wheels 3, 4, 5, 8 and 9.
Checking axial play of camshaft at gear wheel (10) => Page 76
LT 1997 ➤
olksw
- Edition 11.1998
.V agen AG
gen AG does
swa
- -> Check axial play of drive gear wheels (3, 4, 5 and y V8)
olk not
gu
db ara
rise nte
Axial play: 0.06... 0.12 mm tho eo
s au ra
c
s
ce
e
nl
pt
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an
itte
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erm
ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
- -> Check axial play at intermediate gear wheel of camshaft (9)
nf
ercia
or
Axial play: 0.06... 0.12 mm
m
m
atio
om
n in
Please use shims for adjusting, % Page 33 , item. 9 , which are available in 3 different thicknesses. They
or c
are fitted between the thrust washer and gear wheel.
thi
te
sd
iva
o
r
rp
cu
Shim Thickness
o
m
f
en
ng
t.
yi
Shim 1 2.45 - 2.49 mm
Co
Cop py
t. rig
Shim 2 2.50 - 2.54 mm opyri
gh by
Vo
ht
Shim 3 2.56 - 2.60 mm by c lksw

cted agen
Prote AG.
Check gear backlash of intermediate shaft (9) and camshaft (10); adjust if necessary
Location of drive gear wheels => Page 36
Notes:
◆ The gear backlash of the drive gear wheels 1...8 is not adjustable.
◆ Check the gear backlash at the intermediate shaft first, then at the camshaft.
- Remove maintenance hatch cover:
=> General Body Repairs; Repair group 50; Removing cover of service opening Removing cover of service
opening
- Remove the cylinder head cover.
- Removing rocker arm => Page 78 .
2.2 - Check drive gear wheels and adjust if necessary 37

LT 1997 ➤
- -> Before removing the camshaft gear wheel, turn the crankshaft to the TDC marking using the wrench 3447
-arrow- .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
-
ce
le
- -> Position wrench 3447 on the vibration damper's bolts to counter-lock the engine.
un
pt
an
d
- Remove the camshaft gear wheel.

itte
y li
erm
- Attach the dial gauge to the cylinder head with the Universal dial gauge holder VW 387.
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
- -> Determine the gear backlash at the intermediate shaft.
i
or
n thi
te
sd
va
Gear backlash: 0.06... 0.17 mm

i
o
pr
cum
r
fo
en
ng
t.
- Mount the camshaft gear wheel and screw in the camshaft bolt hand-tight.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- -> Now determine the gear backlash by holding the intermediate shaft securely and turning the camshaft at
the same time -arrow-.
Gear backlash: 0.06... 0.17 mm
If the specified values are not reached, adjust the gear backlash as follows:
- Unscrew the intermediate shaft cap.
LT 1997 ➤
- -> Loosen the screw of the adjusting bearing -arrow A- (do not unscrew).
- The gear backlash can be adjusted by moving the bearing sideways -arrow-.
- After adjusting, tighten the adjusting bearing screw to 65Nm.
- Re-tighten the intermediate shaft cap with a new oil seal.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
le
un
pt
an
d
itte
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ab
pe
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
- -> Lock the camshaft at no. 4 cylinder using the camshaft locking device 3445.
- Remove the camshaft locking device 3445.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
-
cted agen
Prote AG.
- Tighten the bolt of the camshaft gear wheel to 180 Nm.
- Remove wrench 3447.
- Tighten the dust cap of the vibration damper to 10 Nm.
- Install the rocker arm => Page 78 .
2.2 - Check drive gear wheels and adjust if necessary 39

LT 1997 ➤
2.3 - Replace crankshaft gear wheel
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
◆ 3447 wrench
◆ 30-11 pressure plate
◆ Two-arm puller (commercially available)
LT 1997 ➤
Procedure
- Remove gearbox:
- Remove the vibration damper's dust cap.

- Remove pressure plate and driver disc:
=> 5-Speed Manual Gearbox 000.1 and 000.2; repair group 30; Servicing clutch Servicing clutch
- Remove the dual-mass flywheel.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
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le
un
pt
an
d
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ab
ility
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wit
is n
h re
ole,
spec
t to the co
- -> Place the pressure plate 30-11 in the central bore of the crankshaft and pull off the gear wheel and
crankshaft bush using a commercially available puller.
rrectne
- Heat up the new gear wheel to approx. 605C and push it onto the crankshaft, paying attention to the fixing
of the gear wheel.
s
- Mount the crankshaft bush on the crankshaft and drive the bush on flush with the crankshaft using a synthetic
s o
cial p
head hammer.
inform
mer
- Mount the dual-mass flywheel on the crankshaft and tighten the securing bolts.
atio
m
Tightening torque: 125 Nm

o
n
c
- Install pressure plate and driver disc:

i
or
n thi
te
sd
iva
=> 5-Speed Manual Gearbox 000.1 and 000.2; Repair group 30; Servicing clutch Servicing clutch
o
pr
cum
r
fo
en
ng
t.
yi
Co
op py
- Tightly screw on the vibration damper's dust cap.
. C rig
ht ht
rig by
opy Vo
- Install gearbox:
by c lksw
cted agen
Prote AG.
2.3 - Replace crankshaft gear wheel 41

LT 1997 ➤
2.4 - Replacing needle bearing of dual-mass flywheel
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
◆ 3447 wrench
◆ 3434 centring alignment tool
rrectne
ss o
cial p
Procedure
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
LT 1997 ➤
- Removing gearbox:
=> 5-speed manual gearboxes 0001 and 0002 and final drive; Repair group34; Removing and installing gearbox
- Remove the dust cap of the vibration damper.

- -> Mount the wrench 3447 on the bolts of the vibration damper to steady the engine.
- Remove pressure plate and drive plate:
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
=> 5-speed manual gearboxes 0001 and 0002 and final drive; Repair group30; Servicing clutch
y li
erm
ab
ility
ot p
wit
is n
- -> Drive out the needle bearing of the dual-mass flywheel using a commercially available impact drift.
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
r
- -> Drive the new needle bearing into the dual-mass flywheel using centring alignment tool 3434.
p
cum
r
fo
- Mount the dual-mass flywheel on the dual-mass flywheel on the crankshaft and tighten the securing bolts
en
ng
t.
yi
Co
op py
- Installing pressure plate and drive plate: t. C rig
gh ht
pyri by
Vo
o
by c
=> 5-speed manual gearboxes 0001 and 0002 and final drive; Repair group30; Servicing clutch
lksw
cted agen
Prote AG.
- Remove the wrench 3447.

- Tighten the dust cap of the vibration damper.
- Install gearbox:
2.4 - Replacing needle bearing of dual-mass flywheel 43

LT 1997 ➤
2.5 - Renewing sealing ring for crankshaft (pulley

gen AG
. Vend)
olkswagen AG
wa does
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
◆ 10-221 extractor hook

◆ 3447 wrench
◆ 3384 assembly alignment tool
Removing
- Remove the ribbed V-belt => Page 26 , removing and installing ribbed V-belt
LT 1997 ➤
-
- Unscrew the vibration damper.
- Lever the old sealing ring out of the oil pump with extractor hook 10-221.
Installing
- Lightly oil the sealing lip of the sealing ring.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
-
y li
erm
ab
- -> Push the new sealing ring on the mandrel 3384 and drive in the sealing ring as far as it will go.
ility
ot p
- Fit the vibration damper on the crankshaft.

wit
is n
- Screw in the vibration damper's bolts until flush.

h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
-
pr
cum
r
fo
- -> Position wrench 3447 on the vibration damper's bolts and tighten these.
en
ng
t.
Tightening torque: 100 Nm op
yi Co
C py
t. rig
gh
ht
pyri by
Vo
o
- Fit the ribbed V-belt => Page 26 , removing and installing ribbed
c by lksw
cted agen
V-belt. Prote AG.
2.5 - Renewing sealing ring for crankshaft (pulley end) 45

LT 1997 ➤
2.6 - Renewing sealing ring for crankshaft (flywheel end)
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
◆ VW 681 release lever

◆ 3447 wrench
◆ 3446 assembly device
Removing
- Remove gearbox:
LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
- Remove pressure plate and driver disc
rrectness of i
=> 5-Speed Manual Gearbox 000.1 and 000.2; Repair group 30; Servicing clutch Servicing clutch
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
-
- -> Carefully pull bushing -1- off the crankshaft with the aid of multigrip pliers.
-
- -> Lever the old sealing ring out of the flywheel housing with forcing-off lever VW 681.
2.6 - Renewing sealing ring for crankshaft (flywheel end) 47

LT 1997 ➤
Installing
-
- -> Screw guide sleeve 3446/1 of fitting device 3446 onto the crankshaft.
- Lightly oil the sealing lip of the new sealing ring.
AG. Volkswagen AG d
agen oes
olksw not
- d by
V gu
ara
- -> Push the new sealing oris ring onto the pressure piece 3446/2 and
e ntdrive
ee the sealing ring into the flywheel
housing until flush. auth or
ac
- Remove fitting device
ss 3446.
ce
e
- Position the crankshaft bushing on the crankshaft and drive it onto the crankshaft with the aid of a plastic
nl
pt
du
mallet until it is flush.

an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
-
om
ion
c
in t
or
- Position the dual-mass flywheel on the crankshaft and tighten the retaining screws.
his
ate

do
priv
- Install pressure plate and driver disc:

um
for
en
ng
t.
yi Co
=> 5-Speed Manual Gearbox 000.1 and 000.2; Repair group 30; Servicing clutch Servicing clutch t. Cop py
rig
gh
ht
pyri by
Vo
o
by c lksw
cted agen
Tightening torque: 10 Nm Prote AG.
LT 1997 ➤
- Install gearbox:
wage
3 - Removing and installing crankshaft byV
olks es n
ot g
ua
d ran
ir se tee
3.1 - Removing and installing crankshaft
tho
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ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
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by
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Prote AG.
1 Bearing shells 1, 2, 4 and 5

◆ For bearing caps without lubricating groove
◆ For cylinder block with lubricating groove
◆ Do not switch bearing shells that are already run in (mark appropriately)
2 25 Nm + 1/3 turn (120 °) further
3 Bearing caps
◆ Bearing cap 5: pulley end
◆ Bearing cap 3: with recesses for thrust washers
◆ Retaining lugs for bearing shells between cylinder block and bearing cap must be located above each
other
2.6 - Renewing sealing ring for crankshaft (flywheel end) 49

LT 1997 ➤
◆ In the bearing caps are two bores of different depth to support the centring sleeves => Fig. 1
AG. Volkswagen AG d
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es, in part or in w
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ion
c
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for
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Prote AG.
4 Thrust washer
◆ For bearing cap 3
◆ Observe correct location
5 Bearing shell 3
◆ For bearing cap without lubricating groove
◆ For cylinder block with lubricating groove
6 Crankshaft
◆ Axial play: 0.080...0.251 mm
◆ Measure radial play with Plastigage: 0.044...0.098 mm
◆ Do not turn crankshaft while measuring radial play
◆ Crankshaft dimensions => Page 51
7 Thrust washer
◆ For cylinder block, bearing 3
AG. Volkswagen AG d
agen oes
olksw not LT 1997 ➤
byV gu
ara
rised
4-cyl. diesel nte engine, mechanics - Edition 11.1998
ho eo
aut ra
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nl
pt
du
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ility
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-> Fig.1 Centring sleeves in crankshaft bearing caps
nf
ercia
orm
m
atio
The bearing caps have two bores of different depth to locate the centring sleeves. Accordingly in the cylinder
om
n in
block there are also two bores of different depth on each crankshaft bearing.
or c
thi
te
sd
a
When installing the bearing caps the side of the bearing cap with the shorter bore (centring sleeve projects
iv
o
r
rp
cu
further -arrow-) must be installed so that it is on the cylinder block side to which the oil filter/oil cooler is also
o
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f
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fitted.
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3.2 - Crankshaft dimensions cted agen
Prote AG.
(Dimensions in mm)
Grinding dimension Crankshaft Connecting-rod

journal ø journal ø
Basic dimension 69.981 54.981
to to
70.000 55.000
Stage I 69.731 54.731
to to
69.750 54.750
Stage II 69.481 54.481
to to
69.500 54.500
Stage III 69.231 54.231
to to
69.250 54.250
3.1 - Removing and installing crankshaft 51

LT 1997 ➤
4 - Dismantling and assembling piston and connecting rod

4.1 - Dismantling and assembling piston and connecting rod
AG. Volkswagen AG d
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es, in part or in w
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c
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do
priv
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1 Piston rings
Prote AG.
◆ Offset joint by 120 5

◆ Remove and install with piston ring pliers
◆ "TOP" marking towards piston crown
◆ Checking ring gap => Fig. 1
◆ Checking side clearance => Fig. 2
2 Circlip
3 Piston
◆ with combustion chamber
◆ Arrow on piston crown points towards gearbox side
◆ Install with piston ring clamp
◆ If cracks have formed on the piston skirt, replace the piston
◆ with recess for oil spray nozzles
LT 1997 ➤
AG. Volkswagen AG d
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nl
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or c
4 Piston pin bushing

thi
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◆ Check for damage, cracks and wear and replace if necessary

iv
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5 Connecting rod
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t.
◆ Check for damage, cracks and wear
yi Co
op py
◆ Only replace in sets . C rig
ht ht
◆ Mark relationship to cylinder
rig by
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◆ Observing fitting location of connecting rod=> Fig. 5 by c lksw
cted agen
◆ Observing appropriateness for bearing cap => Fig. 4
Prote AG.
6 Oil spray nozzle

◆ for piston cooling
◆ Do not mix up
◆ Observing fitting location of oil spray nozzles=> Fig. 6
7 Banjo bolt
◆ Tightening torque 10 Nm
8 Sealing washer
4.1 - Dismantling and assembling piston and connecting rod 53

LT 1997 ➤
AG. Volkswagen AG d
agen oes
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byV gu
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ris nte
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aut ra
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un
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an
d
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erm
ab
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ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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fo
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
9 Connecting rod bolt'20 Nm

+ continue turning 1/4 turns (90 °)
◆ Replace
◆ Lubricate thread and bearing surface
◆ Use old bolts for radial clearance measurement
10 Spring pin
11 Bearing shell
◆ Observe installed position
◆ Do not mix up used bearing shells
◆ Pay attention to firm seating in the retaining lugs
◆ Axial clearance
wear limit:0.251 mm
◆ Measure radial clearance with Plastigage:
Wear limit: 0.098 mm
Do not turn crankshaft when measuring radial clearance
LT 1997 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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un
pt
an
d
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ab
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spec
t to the co
rrectness o
cial p
f inform
mer
12 Cylinder block
atio
m
◆ Checking cylinder bore

o
n
c
i
or
=> Fig. 3
thi
e
◆ Cylinder dimensions => Page 57

t
sd
iva
o
r
13 Piston pin
p
cum
r
fo
en
ng
◆ Heat up piston to 60 °C if difficult to move

t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by
cted agen
Prote AG.

LT 1997 ➤
-> Fig. 1 Check piston ring gap
◆ Feeler gauge lkswage es n
o ot g
byV ua
d ran
ir se
Test procedure tho tee
or
au ac
ss
- Push in ring square from above down into the lower cylinder opening, approx. 15 mm from the edge of the
ce
e
nl
pt
cylinder
du
an
itte
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erm
ab
Piston ring New Wear limit
ility
ot p
Dimensions in mm
wit
, is n
h re
1st compression ring 0.30...0.55 1.0 hole
spec
2nd compression ring 0.30...0.55 1.0
es, in part or in w
t to the co
Oil scraper ring 0.30...0.50 1.0
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
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f
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t.
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Cop py
t. rig
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pyri by
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by
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Prote AG.
-> Fig. 2 Checking piston ring side clearance
◆ Feeler gauge
Test procedure
Clean ring groove before checking.
Piston ring
Dimensions in mm
1st compression ring 0.085...0.090
2nd compression ring 0.070...0.105
LT 1997 ➤
Piston ring
Dimensions in mm
Oil scraper ring 0.030...0.065
4.2 - Cylinder dimension
AG. Volkswagen AG d
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nf
ercia
-> Fig. 3 Checking cylinder bore orm

m
atio
om
Notes:
n in
or c
thi
e
◆ The cylinder dimension relates to the internal dimension of the liner when installed.
t
sd
iva
◆ The cylinder bore must not be measured when the cylinder block is attached to the assembly stand with
o
r
rp
cu
engine bracket 3444 as incorrect measurements are possible.

o
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t.
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op
C py
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◆ Internal precision measuring instrument 50...100 mm p by
o Vo
by c lksw
cted agen
Prote AG.
Test procedure
- Measure at 3 positions diagonally in the transverse direction -A- and longitudinal directions -B-. Deviations
from nominal dimension:
Dimension mm Cylinder borej

Basic dimension 93.000... 93.022
Wear limit 93.082

LT 1997 ➤
-> Fig.4 Marking of connecting rod bearing cap
lkswage es n
o ot g
byV ua
Before installing the bearing caps observe the marking of ir sethe connecting rod relative to the respective
d ran
tee bearing
cap -arrow-. utho
or
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un
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itte
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es, in part or in w
t to the co
rrectness of i
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nform
-> Fig.5 Marking the connecting rod for the correct fitting location
mercia
a
com
tion in
The connecting rod has a round lug on one side -arrow-. The connecting rod must be installed to that this lug
r
te o
thi
points towards the flywheel side.
s
iva
do
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cum
fo
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t.
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Cop py
t. rig
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pyri by
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co lksw
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Prote AG.
-> Fig.6 Installed position of oil spray nozzles
Two oil spray nozzles are fitted for each cylinder. There is a centring pin on each oil spray nozzle.
The oil spray nozzles of a cylinder differ by different positioning of the centring pins -arrows-, preventing incorrect
fitment.
LT 1997 ➤
15 - Cylinder head, Valve gear
1 - Removing and installingwcylinder

agen
AG. Volkshead
wagen AG
doe
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Vol t gu
by
1.1 - Removing and installing
ris
ed cylinder head ara
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es, in part or in w
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Prote AG.

◆ 3447 wrench
◆ 3445 camshaft locking device
◆ Abrasive paper
1.1 - Removing and installing cylinder head 59

LT 1997 ➤
AG. Volkswagen AG d
agen oes
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V gu
d by ara
ise nte
or eo
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aut ra
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ce
le
un
pt
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d
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erm
ab
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is n
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spec
t to the co
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cial p
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mer
atio
om
n
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Prote
Check compression pressure
AG.
=> Page 15-11
Notes:
◆ When installing a replacement cylinder head with a mounted camshaft, the contact surfaces between the
rocker finger and the cam surface must be oiled after the head is installed.
◆ The plastic washers provided to protect the open valves may not be removed until directly prior to fitting the
cylinder head.
◆ When renewing the cylinder head, the entire coolant must be renewed.
◆ After mounting the cylinder head, check the tooth flank clearance of the intermediate shaft and adjust if
necessary =>Page 13-28
60 15 - Cylinder head, Valve gear

LT 1997 ➤
lkswage es n
o ot g
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d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
1 Cylinder head cover

2 Cap
3 Seal
4 15 Nm
5 Bush
6 Cover gasket
7 Cylinder head bolt
◆ Observe order when loosening and tightening

LT 1997 ➤
4-cyl. diesel engine,wamechanics
gen AG - eEdition
. Volkswag n AG d
oes 11.1998
lks o n ot g
yV ua
edb ran
ris tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
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t.
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Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote AG.
8 Injection lines
◆ Tighten with 30 Nm on injectors
◆ Tighten with 27 Nm on injection pump
◆ Do not change shape of bends
◆ Always remove entire set of lines
9 10 Nm
10 Bracket
◆ Always use bracket (Item 10) with M8 x 30 bolt (Item 11) (renew if necessary) when renewing injection
lines
11 20 Nm
12 Dowel sleeve
13 Cylinder block
◆ Removing and installing drive gears and two-part flywheel => Page 13-18
◆ Removing and installing crankshaft => Page 13-46
◆ Dismantling and assembling piston and conrod
=> Page 13-50

LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
14 Cylinder head risegasket nte
tho eo
◆ Renewss au ra
c
◆ Clean sealing surfaces before mounting
ce
le
un
◆ After renewing, renew entire coolant

pt
an
d
itte
15 Cylinder head
y li
erm
ab
◆ Check for warping => Fig. 1

ility
ot p
◆ Renew entire coolant after renewing

wit
is n
◆ Check tooth flank clearance of intermediate shaft after mounting and adjust if necessary => Page 13-28
h re
ole,
16 Washer
spec
◆ ä 12.97
t to the co
17 40 Nm
18 Clamping strap
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
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t.
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Cop py
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63
c by lksw
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Prote AG. 1.1 - Removing and installing cylinder head
LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
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Cop py
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rig ht
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by lksw
cted agen
Prote AG.
19 Heat shield seal

◆ Renew
◆ Thickness:
Engine code
AGK = 1 mm
ATA = 3 mm
20 Injector
◆ Removing and installing injectors
=> Rep. Gr. 23; Servicing Diesel Direct Injection System; Removing and installing injectors
21 Rubber bush
◆ Ensure proper installation position

LT 1997 ➤
Removing
Notes:
lkswage es n
o ot g
byV ua
ed ran
◆ To prevent
thor damaging the open valves, please remove
is tee the rocker arms before detaching the cylinder head.
Removing
s au and installing rocker arms => Page 78 . or
ac
◆ Only install the rocker arms again after fitting the cylinder head.
s
ce
e
nl
pt
du
an
- -> Follow sequence when loosening the cylinder head bolts.
itte
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
-> Fig. 1 Checking cylinder head for distortion

or
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ate
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priv
cum
or
f
en
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t.
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Cop py
◆ Straight edge
t. rig
gh ht
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◆ Feeler gauge p by
co Vo
by lksw
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Prote AG.
Max. permissible distortion: 0.1 mm
Note:
Diesel cylinder heads may not be remachined.
Installing
Notes:
◆ Always renew cylinder head bolts.

◆ When carrying out repairs, always carefully remove any gasket residue from the cylinder head and cylinder
block. Take care not to cause any long score marks or scratches in the process. If sandpaper is used, the
grade must not be lower than 100.
◆ Carefully remove any sanding or grinding residue.
◆ Always leave new cylinder gaskets in their wrapping until immediately before fitting.

LT 1997 ➤
◆ Handle the gasket with extreme care. Any damage to the silicone coating and to the bead could result in
leaks.
- -> Before fitting the cylinder head, set crankshaft to TDC mark -arrow- with wrench 3447.
- -> Turn the camshaft to TDC for cylinder 1.
Note:
Cylinder 1 is at the flywheel end.agThe

en AGcylinders
. Volkswageare
n AGnumbered
do from the power-discharging end (flywheel).
w es n
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- -> Lock the camshaft with the camshaft locator 3445.

rrectness of i
- Place cylinder head gasket in position.

l purpos
- Fit cylinder head, insert the 10 cylinder head bolts and tighten by hand.
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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rig ht
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by lksw
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Prote AG.
agen
AG. Volkswagen AG d
oes LT 1997 ➤
ksw
by
Vol 4-cyl. diesel
not
gu engine, mechanics - Edition 11.1998
d ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
- -> Tighten the cylinder head in five stages in the sequence indicated:
l purpos
- 1. Pre-tighten with torque wrench:

Stage I = 30 Nm
Stage II = 60 Nm
nform
ercia
Stage III = 100 Nm

- 2. Tighten further with rigid wrench:
m
a
com
ti
Stage IV = 1/4 turn (90 °)
on in
Stufe V = 1/4 turn (90 °)
r
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thi
s
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Note:
r
rp
cum
fo
en
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t.
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◆ It is not necessary to tighten the cylinder head bolts after conducting repairs.
Co
Cop py
t. rig
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pyri by
Vo
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Prote AG.

LT 1997 ➤
. Volkswagen AG
4-cyl. diesel engine, mechanics - Edition
ksw
a11.1998
gen AG does
n ol ot g
yV ua
db
1.2 - Checking compression pressure oris e ran
tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
◆ V.A.G 1381 or V.A.G 1763 compression pressure tester

◆ T 50001 plug-in insert
◆ V.A.G 1381/12 adapter
Checking requirement
• Engine oil temperature at least 30 °C.

LT 1997 ➤
Checking procedure
AG. Volkswagen AG d
agen oes
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du
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spec
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- Pull off plug for fuel cutoff valve on injection pump.
- Disconnect connections for all glow plugs.
- Remove all glow plugs with socket insert T 50001.
rrectness of i
- -> Screw in adapter V.A.G 1763/12 in the place of the glow plugs.
- Check compression pressure with tester V.A.G 1763 or V.A.G 1381.
l purpos
Note:
nf
ercia
orm
Operation of the tester => see operating instructions.
m
atio
om
n in
c
- Operate the starter motor until no further increase in pressure is registered by the tester.
or
thi
te
sd
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Compression pressure values:

rp
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f
en
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t.
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New: approx. 28 bar
Co
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Limit of wear: 23 bar
t. C rig
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by
Permissible pressure difference between all cylinders: 3 bar Prote
cted AG.
agen
- Insert glow plugs with socket insert T 50001

Tightening torque: 15 Nm.
1.2 - Checking compression pressure 69

LT 1997 ➤
4-cyl. diesel engine, mechanics -waEdition
gen AG 11.1998
. Volkswagen AG
doe
ks s no
Vol t gu
by
2 - Overhauling valve train ris
ed ara
nte
utho eo
ra
a c
2.1 - Overhauling valve train ss
ce
e
nl
pt
du
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itte
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erm
ab
ility
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1 Thrust washer
2 Camshaft
◆ Checking gear backlash=>Page 36
◆ Check axial play => Fig. 1
=> Page 83
◆ Measure radial play with Plastigage: 0.12... 0.16 mm
◆ Runout: max. 0.04 mm
◆ Marking, timing => Fig. 3
3 Spring-type pin
4 30 Nm
5 Bearing cap, top
◆ Mark when removing
◆ Do not switch
◆ Lubricate contact surface

LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
6 Bearing
l purpos
7 Adjusting bearing
8 Camshaft gear
nf
ercia
or
9 180 Nm
m
m
atio
m
10 Bearing bush
o
n in
or c

thi
te
sd
a
11 Intermediate gear wheel

iv
o
r
rp
cu
◆ Checking gear backlash=>Page 36

o
m
f
en
ng
◆ Checking axial play=>Page 37

t.
yi Co
◆ To remove, remove camshaft Cop py
t. rig
=>Page 83 pyri
gh by
ht
12 80 Nm
o Vo
by c lksw
cted agen
Prote
13 Cap
AG.
2.1 - Overhauling valve train 71

LT 1997 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
14 Oil seal
do
priv
15 65 Nm
um
for
en
ng
16 Washer
t.
yi Co
op py
17 Female thread sleeve t. C rig
gh ht
yri
18 Circlip
p by
co Vo
by lksw
cted
19 Thrust washer
agen
Prote AG.
◆ Available in various gauges
◆ for adjusting axial play
20 Cylinder head
◆ Observe note => Page 70
21 Banjo bolt, 10 Nm
22 Oil spraying nozzle

LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
23 Sealing ring
spec
24 Exhaust valve
t to the co
◆ Valve dimensions => Fig. 2

25 Intake valves
rrectne
◆ Valve dimensions => Fig. 2

26 Threaded insert
ss
27 Retaining spring
o
cial p
28 Adjusting screw
inform
mer
◆ Adjusting valve clearance

atio
=> Page 85
om
n
c
29 Finger for intake valve

i
or
n thi
e

t
sd
va
=>Page 78
i
o
pr
cum
r
◆ Do not switch
fo
en
ng

t.
yi Co
op
◆ Adjusting valve clearance C py
ht. rig
=> Page 85 rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
30 Finger for inlet valve

or c
thi
e

t
sd
iva
=>Page 78
o
r
rp
cu
◆ Do not switch
o
m
f
en
ng

t.
yi Co
op
◆ Adjusting valve clearance C py
ht. rig
=> Page 85 rig ht
py by
o Vo
31 Finger for exhaust valve by c lksw
cted agen
Prote
AG.
=>Page 78
◆ Do not switch
◆ Adjusting valve clearance
=> Page 85
32 Spring-type pin
33 Bearing cap, lower
◆ Do not switch
◆ Installation sequence => Page 83 , removing and installing camshaft
34 Valve cotters

LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
35 Valve spring pocket, top

36 Valve spring
◆ Removing and installing:
Cylinder head removed: with fitting device 2036 => Page 80 , renewing valve stem seals
37 Valve stem seal
◆ Renewing=>Page 80
38 Valve spring pocket, bottom
39 Spacing ring
◆ only at the valves under the camshaft
40 Valve guide
◆ Checking => Page 77

LT 1997 ➤
-> Fig. 1 Camshaft, check axial play
◆ Universal measuring gauge holder VW 387 AG. Volkswagen AG d
◆ Measuring gauge agen oes
olksw not
V gu
d by ara
ise nte
Limit of wear: 0.16 mm hor eo
aut ra
Perform the measurement with the first and last bearing cap fitted. ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f in
-> Abb. 2 Valve dimensions
form
mer
atio
m
Note:
o
n
c
i
or
n
Valves may not be remachined. Only grinding-in is permitted.
thi
te
sd
iva
o
r
Dimension Intake valve Exhaust valve

p
cum
r
fo
en
ng
øa mm 31,9...32,1 39,9...40,1
t.
yi Co
op py
øb mm 6,952...6,970 6,952...6,970 t. C rig
gh ht
yri by
α <° 30 45 op Vo
by c lksw
cted agen
Prote AG.

LT 1997 ➤
-> Fig. 3 Camshaft markings, timing
Markings
◆ Base diameter of cams: a = ø 35 mm

◆ Marked by punched-in digits and letters on the camshaft:
Engine code letter AGK

Cylinder 1 -arrow A- 4010
Cylinder 2 -arrow B- MWM
Cylinder 3 -arrow C- 980
142
Timing at 1 mm valve stroke

AG. Volkswagen AG d
agen oes
Engine code letter yV
olks
w
AGK not
gu
b ara
Intake 1 opens after TDC orised 5.3 ° nte
th eo
Intake 1 closes after BDC au 32.0 ° ra
c
ss
Intake 2 opens after TDC 37 °
ce
le
un
pt
Intake 2 closes after BDC 31.7 °
an
d
itte
y li
erm
Exhaust opens before BDC 55.6 °
ab
ility
ot p
Exhaust closes after TDC 5.0 °
wit
is n
h re
ole,
spec
2.2 - Checking valve guides
t to the co
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
◆ Universal measuring gauge holder VW 387
◆ Measuring gauge
Checking procedure
- -> Insert new valve in guide. Valve stem end must be flush with the guide.
Tilt play: max. 1.3 mm

LT 1997 ➤
2.3 - Removing and installing rocker arms
◆ 3447 wrench
◆ V.A.G 1331 torque wrench (5 50 Nm)
Removing
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
- Remove the cylinder head cover.

rrectness of i

- -> Turn the crankshaft in the direction of rotation of the engine using the wrench 3447 until the cams of the
l purpos
particular cylinder are on top.
Note:
nform
mercia
The pistons must not be at TDC.

com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
- -> Press valve springs downwards using a wooden or plastic wedge -arrow- and remove rocker arms. (do
du
an
itte
not mix up rocker arms).
y li
erm
ab
ility
ot p
Installing
wit
, is n
h re
The installation takes place in the reverse order.
hole
spec
es, in part or in w
t to the co
- Install the cylinder head cover .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.3 - Removing and installing rocker arms 79

LT 1997 ➤
2.4 - Renewing valve stem seals
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
(with cylinder head removed)
◆ 3047A puller
◆ 2036 assembly device
◆ VW 541/1A valve lever
◆ 10-204 pressing-on tool
Removing
- Remove camshaft => Page 83 .

LT 1997 ➤
- Remove finger (do not switch).
Removing valve springs in intake valves
- -> Insert fitting device 2036.

- Remove valve springs with valve lever VW 541/1A and pressure piece.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
Removing valve springs for exhaust valves
t to the co
- -> Insert fitting device 2036.
- Remove valve springs with valve lever VW 541/1A and pressure piece.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
- -> Pull off valve stem seals with pulling device 3047A.
Prote AG.
2.4 - Renewing valve stem seals 81

LT 1997 ➤
Installing
- -> To avoid damaging the new valve stem seals, fit plastic sleeve -A- on the valve stem.
- Lubricate valve stem seal -B-, insert in the pressing-in device 10-204 and carefully push onto the valve guide.
wage es n
2.5 - Removing and installing camshaft olks ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

LT 1997 ➤
◆ Camshaft locator 3445
◆ Wrench 3447
◆ Torque wrench V.A.G 1331 (5...50 Nm)
Removing
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
Note: s aut
h
ra
c
s
-> Cylinder 1 is at the flywheel end. The cylinders are numbered from the power-discharging end (flywheel)
ce
e
nl
pt
du
an
◆ The camshaft bearing caps are interchangeable. Please mark the bearing caps before removal.
itte
y li
erm
ab
ility
ot p
- Remove the cylinder headcover.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e

at
do
riv
- -> Using the wrench 3447, turn the crankshaft until the TDC marking on the flywheel -1- aligns with the notch
p
cum
or
on the intermediate flange -arrow-.

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
- Remove the bolt on the camshaft toothed wheel and take off the camshaft toothed wheel.
- Release the bolts on the camshaft bearing caps, working from the centre outwards in a crosswise manner.
2.5 - Removing and installing camshaft 83

LT 1997 ➤
- Lift out the camshaft.
Installing
G. Volkswage
- Lubricate the camshaft's contact
lksw
agen
A
surfaces.n AG does n
o ot g
yV ua
db
Notes: se ran
ri tee
ho
aut or
ac
s
◆ Cylinder 1 sis at the flywheel
end. The cylinders are numbered from the power-discharging end (flywheel)
ce
e
◆ When installing the camshaft, the cams for cylinder 1 must point upwards.
nl
pt
du
an
itte
y li
- Release the bolts on the camshaft bearing caps, working from the centre outwards in a crosswise manner.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
- Position camshaft to TDC for cylinder 1. (The cams for the intake valves and the exhaust valve point up‐
te
sd
iva
wards.)
o
r
rp
cu
- -> Lock the camshaft at no. 4 cylinder using the camshaft locking device 3445.
o
m
f
en
ng
- Fit the camshaft toothed wheel and screw the camshaft bolt by hand into the camshaft.
t.
yi Co
- Remove the camshaft locator 3445. Cop py
t. rig
- Remove the dust cap of the vibration damper. gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- Tighten the bolt on the camshaft toothed wheel.
- Remove the wrench 3447.
- Tighten the vibration damper's dust cap.
- Install the rocker cover.

LT 1997 ➤
2.6 - Checking and adjusting valve clearance
◆ 3447 wrench
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n

h re
◆ Feeler gauge
hole
spec
es, in part or in w
Procedure
t to the co
Notes:
rrectness of i
◆ Check the valve clearance when the engine is cold and adjust.
◆ The vehicle must not be in gear.
l purpos
◆ The valve adjusting screws have a locking device which locks in position audibly when the valve adjusting
screw is rotated every 1805. The valve clearance may only be adjusted by an entire detent. If you position
nf
ercia
the valve adjusting screw between two detents, the locking clip releases when the vehicle is operated sub‐
or
sequently and the valve clearance will then automatically adjust itself. Engine damage will result.
m
m
atio
om
n in
c
- Remove the rocker cover.

or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.6 - Checking and adjusting valve clearance 85

LT 1997 ➤
- -> Turn the crankshaft with wrench 3447 in the direction of engine rotation until the cams of the cylinder to
be checked are pointing upwards.
G. Volkswagen
- -> Check the valve clearance on thelkcylinder
wage
n A in question.AThe
G do feeler gauge must shift under slight resistance;
es n
o s
if necessary, adjust valve clearance
d by V by turning the adjusting screw.
ot g
ua
Valve clearance: oris
e ran
tee
Clearance of intake valves
auth 0.2 mm or
ac
Clearance of exhaust
ss valves 0.3 mm
- Install the rocker cover.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

LT 1997 ➤
AG. Volkswagen AG d
agen
17 - Lubrication
oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
1 - Removing and installing lubricating system components

itte
y li
rm
ab
pe
ility
ot
1.1 - Removing and installing lubricating system components
wit
, is n
h re
hole
spec
Note:
es, in part or in w
If significant levels of swarf or abraded metal (caused by seizing up e.g. of the crankshaft and connecting rod
t to the co
bearings) are detected in the engine oil when repairs are being carried out, the oil cooler should be renewed
to prevent follow-on damage and the oil ducts thoroughly cleaned.
rrectness of i
Check oil pressure => Page 94 .
Oil filling capacities1):
l purpos
With oil filter 8.5 l

1) Current values:
nform
ercia
=> File on testing exhaust emissions

m
a
Engine oil specification:
com
tion in
Use only engine oil acc. to VW standard 50500.
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.1 - Removing and installing lubricating system components 87

LT 1997 ➤
gen AG
. Volkswagen AG
d wa oes
olks not
I => Page 88 byV gu
ara
ed nte
ris
tho eo
II => Page 93 au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Part I
1 Cylinder block
◆ Removing and installing drive gears and dual-mass flywheel
=> Page 29
◆ Removing and installing crankshaft
=> Page 49
◆ Stripping down and assembling piston and connecting rod
=> Page 52
2 Sealing ring
3 Baffle plates
4 30 Nm
5 Sealing ring
6 Oil pickup line
88 17 - Lubrication
LT 1997 ➤
◆ Clean strainer if contaminated
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
7 Gasket for oil sump
ole,
spec
◆ Renew
t to the co
8 Oil sump
◆ Clean sealing surface before assembly
9 30 Nm
rrectne
10 50 Nm
11 Packing washer
ss o
◆ Renew
cial p
f inform
12 Sealing ring
mer
13 Threaded connection
atio
om
14 Oil line
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
15 Dipstick tube
en
ng
t.
yi Co
op
◆ For oil dipstick C py
ht. rig
16 Pulley
rig ht
py by
co Vo
◆ For vacuum pump
by lksw
cted agen
Prote AG.
17 100 Nm
◆ When removing and installing, counter-lock the vibration damper's bolts with wrench 3447
19 Sealing ring
◆ Renew if leaking or damaged
20 Oil dipstick
◆ Oil level must not exceed the maximum mark
90 17 - Lubrication
LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
21 Coil spring
o
n in
c
22 Lock screw
or
thi
te
23 10 Nm
sd
iva
o
r
rp
cu
24 Dust cover
o
m
f
en
ng
25 30 Nm
t.
yi Co
op
26 30 Nm
C py
ht. rig
rig ht
27 TDC position marker py by
co Vo
by lksw
◆ Take care not to bend during dismantling/assembly
cted agen
Prote AG.
28 Oil pump
◆ Renew only as a complete assembly
◆ Smearing sealing surfaces with D 176 404 A2 => Fig. 1

LT 1997 ➤
-> Fig.1 Clean sealing surface of oil pump
Clean the sealing surfaces. They must be free from oil and grease.
Apply sealing agent to the clean sealing surface of the oil pump as shown.
Before fitting the sump gasket, please also seal thenparting
AG. Volksline
wagebetween
n AG d the oil pump and cylinder block with
sealing agent (arrows). olks
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t to the co
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om
n
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t.
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Cop py
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rig ht
py by
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by lksw
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Prote AG.
92 17 - Lubrication
LT 1997 ➤
Part II
1 Threaded connection
2 Oil filter
◆ Remove e.g. with Hazet 2195 or 3380/18
3 Oil pressure switch (F22)
◆ Check => Page 94
◆ Pinch open sealing ring if leaking and renew
◆ Tightening torque 25 Nm
4 Stopper
5 Non-return valve
6 30 Nm olkswage es n
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ility
ot p
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spec
t to the co
rrectness o
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f inform
mer
atio
om
n
c
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t.
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Cop py
t. rig
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pyri by
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by
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Prote AG.
7 Oil cooler cover

8 Gasket
◆ Renew
9 Oil cooler
10 Gasket
◆ Renew
11 Spring-type pin
12 Cap
13 Pressure relief valve

LT 1997 ➤
1.2 - Checking oil pressure and oil pressure switch
lkswage es n
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a ac
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nl
pt
du
an
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ab
ility
ot p
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, is n
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spec
es, in part or in w
◆ V.A.G 1342 oil pressure tester

t to the co
◆ V.A.G 1342/6 and 1342/7 adapter

◆ V.A.G 1527 B diode test lamp
◆ V.A.G 1594 A measuring accessory set
rrectness of i
l purpos
Note:
Operational testing and repair of the optical oil pressure gauge:

nform
mercia
=> Current flow diagrams, electrical fault finding and fitting locations
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
94 17 - Lubrication
LT 1997 ➤
4-cyl. diesel
olksw
engine, mechanics - Edition 11.1998
AG. V agen AG
agen does
olksw not
yV gu
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un
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is n
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spec
t to the co
rrectne
Checking procedure
ss
- -> Remove the oil pressure switch (white insulation) and screw the oil pressure switch with adapter 1342/7
o
cial p
f i
into the tester.
nform
- Screw the oil pressure tester V.A.G 1342 into the engine block with adapter 1342/6 instead of the oil pressure
mer
switch.
atio
om
- Apply the brown lead -3- of the tester to earth (-).
n
c
i
or
n
- Connect the diode test lamp V.A.G 1527 to the battery positive connection (+) and to the oil pressure switch
thi
te
(F22) -B- using the auxiliary leads from V.A.G 1594. The LED must light up.
sd
iva
o
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- Allow the engine to idle. Once it has reached its normal operating temperature, the oil pressure must be at
en
ng
t.
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least 1.0 bar.
Co
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- Switch off the engine.
t. C rig
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- Start the engine and slowly raise the engine speed. p by
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At
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1.0 bar pressure
AG.
the LED must go out; if it does not,

renew the oil pressure switch.
- Raise the engine speed further.
At 3800 rpm and 90 °C oil temperature the oil pressure must be at least 4.0 bar.
1.2 - Checking oil pressure and oil pressure switch 95

LT 1997 ➤
19 - Cooling system
. Volkswagen AG
gen AG
1 - Removing and installing coolingbysystem componentsoes not gu
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1.1 - Removing and installing cooling
au system
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an
Notes:
itte
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ab
ility
◆ When the engine is warm, the cooling system is pressurised.
ot p
wit
Always depressurise before performing any repairs.
, is n
h re
◆ When fitting the water pump, please note that the securing bolts => Page 103 ; Item 22 on the wheel drive
hole
spec
housing are tightened first. Risk of fracture.
es, in part or in w
◆ Hose connections are protected by spring band clips. After repairing, use only spring band clips.
t to the co
◆ Pliers V.A.G 1921 are recommended for fitting spring band clips.
Check the cooling system for leaks with cooling system tester V.A.G 1274.
rrectness of i
Cooling system components, radiator end =>Page 97 .
l purpos
Cooling system components, engine end =>Page 101 .
nform
ercia
Draining off and adding coolant=>Page 104 .

m
at
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Coolant mixing ratios => Page 104 , draining off and adding coolant.
o
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for
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Cop py
t. rig
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Prote AG.
96 19 - Cooling system
LT 1997 ➤
1.2 - Cooling system components, radiator end
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1 Air guide
◆ Front left
rrectness of i
2 Hex bolt
3 Air guide
l purpos
◆ Top
4 Charge-air cooler
nform
ercia
◆ => Page 126 , No. 12

m
at
5 Air guide scoop

om
ion
c
◆ Front right
in t
or
◆ For air intake hose

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ate
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6 Hex bolt
p
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7 Air guide
f
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ng
t.
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◆ Base Cop py
◆ Mounted on radiator
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.2 - Cooling system components, radiator end 97

LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
le
un
pt
an
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ility
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spec
t to the co
rrectness o
cial p
8 To heat exchanger for heating system (outlet)
f inform
9 To heat exchanger for heating system (inlet)
mer
10 Coolant hose atio

om
◆ For heat exchanger for heating system (inlet line)

c
i
or
n thi
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11 Coolant hose
t
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◆ For heat exchanger for heating system (outlet line)

pr
cum
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12 Coolant hose
en
ng
t.
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13 Junction Cop py
t. rig
gh
14 Coolant hose
ht
pyri by
Vo
co
15 To coolant pump
by lksw
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Prote AG.
◆ Page 103 , No. 21
LT 1997 ➤
AG. Volkswagen AG d
agen oes
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y V gu
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ility
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t to the co
rrectness o
cial p
f inform
mer
atio
16 Air guide
om
n
c
◆ Mounted to radiator with 4 bolts

i
or
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17 Hex bolt
t
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18 Coolant hose, top

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19 To coolant regulator
t.
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op
◆ Page 102 , No. 12
C py
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20 Coolant hose, base
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21 To coolant connection Prote
cted AG.
agen
◆ Page 102 , No. 8

22 Coolant hose
23 Equalising tank
24 10 Nm
1.2 - Cooling system components, radiator end 99

LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
tho eo
au ra
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ce
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nl
pt
du
an
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ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
25 Equalising tank cap

◆ Check with cooling system tester V.A.G 12-74
rrectness of i
◆ Gauge pressure 1.2...1.5 bar

26 Coolant pipe
l purpos
27 Coolant hose
28 Hex bolt
nf
ercia
29 Retaining clip
rm
m
atio
30 Rubber retaining element

om
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c
31 Radiator
or
thi
e

t
sd
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=>Page 106
o
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◆ Renew the entire coolant content after exchanging

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32 Drain plug
Co
Cop py
33 To coolant connection
t. rig
gh ht
yri by
◆ Page 102 , No. 8
cop Vo
by lksw
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Prote AG.

LT 1997 ➤
1.3 - Cooling system components, engine end
AG. Volkswagen AG d
agen oes
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ility
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spec
t to the co
rrectne
1 Coolant hose
ss o
cial p
◆ For heat exchanger for heating system (outlet)

f inform
2 Coolant hose
mer
◆ For heat exchanger for heating system (inlet)

atio
om
3 Pipe connection
c
i
or
n thi
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4 Sealing ring
t
sd
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◆ Renew
pr
cum
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fo
5 Coolant temperature sensor (G62)

en
ng
t.
yi Co
◆ With sensor for temperature display (G2) Cop py
t. rig
6 Coolant hose, top
gh ht
pyri by
Vo
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7 30 Nm
lksw
cted agen
Prote AG.
1.3 - Cooling system components, engine end 101

LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
8 Coolant connection
es, in part or in w
t to the co
9 O-ring
◆ Renew
rrectness of i
10 Viscous fan
l purpos
=> Page 107

11 40 Nm
nf
ercia
12 Coolant regulator
rm
m
atio
◆ Check: heat regulator in a water bath

om
◆ Initial opening temperature approx. 79 °C

n in
or c
◆ Final opening temperature approx. 94 °C

thi
te
◆ Opening distance at least 8 mm

sd
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13 Coolant regulator housing

o
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en
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14 Coolant hose, base
yi Co
Cop py
15 30 Nm
t. rig
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pyri by
Vo
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Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
rise nLT
tee 1997 ➤
ho
4-cyl.
aut diesel engine, mechanics - Editionor11.1998 ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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cted agen
Prote AG.
16 Gasket
◆ Renew
17 Oil cooler
=>Page 93 , No. 9
18 30 Nm
19 Flange
20 30 Nm
◆ To prevent cracks in the water pump housing, follow the sequence when fitting the water pump, Item
22 Always tighten first
21 Coolant pump
◆ Check for ease of running
◆ In the event of damage or leaks, renew only as a complete assembly
22 30 Nm
1.3 - Cooling system components, engine end 103

LT 1997 ➤
1.4 - Draining off and adding coolant
◆ V.A.G 1921 pliers for spring band clamps
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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nl
pt
du
an
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
◆ Anti-freeze tester
Not shown:
rrectness of i
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◆ VAS 6096 Cooling system filler
Draining off
nf
ercia
orm
m
atio
om
n in
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Cop py
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rig ht
py by
co Vo
by lksw
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Prote AG.
- Open the cap of the coolant equalising tank.

-
- -> Drain off coolant:
- Either via drain plug -1-,
- Or via lower coolant hose on radiator

AG. Volkswagen AG d
agen oes
olksw not
V
d by gu
ara LT 1997 ➤
ise nte
thor 4-cyl. diesel engine, mechanics eo - Edition 11.1998
au ra
s c
Note: s
ce
le
un
pt
an
d
Please observe the disposal regulations for coolant
itte
y li
rm
ab
pe
ility
Filling
ot
wit
, is n
h re
Notes: hole
spec
es, in part or in w
◆ Only G 12 according to TL VW 774 F may be used as a coolant additive.
t to the co
Distinguishing characteristic: Purple colour
◆ G 12 purple (as per TL VW 774 F) may be mixed with the coolant additives G 11 and G 12 red used up until
now!
rrectness of i
◆ G 12 and coolant additives with the reference "as per TL VW 774 F" prevent frost and corrosion damage,
scale deposits and increase the boiling temperature. For these reasons the cooling system must always be
l purpos
filled with radiator antifreeze and anti-corrosion agent throughout the year.
◆ Particularly in countries with a tropical climate, such additives assure reliable operation of the engine by
nform
ercia
raising the coolant's boiling point when the engine is working hard.
◆ The coolant must protect the engine at temperatures down to approx. -25 °C (in countries with an arctic
m
a
com
t
climate, down to approx. -35 °C).
ion in
◆ The coolant concentration should not be diluted in the summer or in warmer climates by the addition of
r
te o
thi
water. The coolant additive concentration must be at least 40 %.
s
iva
◆ If protection against even lower temperatures is required, the concentration of G 12 can be increased, but
do
r
rp
c
to no more than 60 % (for protection against temperatures of down to approx. -40 °C); the antifreeze is less
um
fo
en
g
effective at higher concentrations than this, and the fluid's cooling performance deteriorates.
n
t.
yi Co
◆ If the radiator, heat exchanger, cylinder head or cylinder head gasket have been renewed, never refill with
Cop py
t. rig
coolant that has already been in use. opyri
gh by
Vo
ht
c by lksw
cted
Recommended concentrations:
agen
Prote AG.
Low-temper‐ Antifreeze Coolant addi‐ Water2)

ature protec‐ concentra‐ tive1)
tion down to tion1)
-25 °C 40 % 4.6 l 6.9 l
-35 °C 50 % 5.75 l 5.75 l
1) Antifreeze concentration must not exceed 60 %, as low-temperature protection and cooling effect
deteriorate at higher concentrations.
2) Coolant capacity may vary, depending on vehicle's equipment specification.
With VAS 6096 cooling system filler:
- Fill the coolant circuit with the VAS 6096 cooling system filler.
=> Operating instructions for VAS 6096 cooling system filler
Without VAS 6096 filler:
- Press down upper hose on radiator.
1.4 - Draining off and adding coolant 105

LT 1997 ➤
- -> Slowly add coolant until the maximum mark on the equalising tank is reached.
Note:
The marks are at the rear of the equalising tank.
- Start the engine.

- Allow the engine to run for max. 2 minutes at approx. 1500 rpm and gradually top up with coolant until it
reaches the overflow aperture on n Athe equalising
G. Volkswagen AGtank.
- Fit the equalising tank cap l wage
ksagain.
does
not
o
- Run the engine untiledwarm.by V gu
ara
- Check the coolant horilevel
s and top up if necessary. When the engine
nte
eo is at its normal operating temperature,
the coolant level
s aut
must be at the max. mark; when the engine is rcold,
ac the coolant level should be between
the max. andsmin. marks.
ce
e
nl
pt
du
an
itte
y li
erm
ab
1.5 - Removing and installing radiator
ility
ot p
wit
, is n
h re
hole
spec
Removing
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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- Drain off coolant=> Page 104 . op
yi Co
- Pull coolant hoses off radiator using pliers for spring band clips V.A.G 1921.
C py
t. rig
gh
- Disconnect the hoses from the charge-air cooler.
ht
pyri by
Vo
- -> Remove the retaining screw for the air intake hose -arrow- and pull off the air intake hose -1-.
co lksw
by
cted agen
- Remove the coolant hose -2- from the air guide for the radiator. Prote AG.
- Remove the retaining clips -3- on right and left.
- -> Remove the torx screws -arrows- for the coolant equalising tanks and set down the equalising tank
together with spacer -1- to one side.
- Remove steps on right and left:
=> General Body Repairs; Repair group 63; Front bumper Front bumper
- Remove catch plate with add-on components:

LT 1997 ➤
=> General Body Repairs; Repair group 50; Lock carrier plate wiht attached parts - removing and installing
Lock carrier plate wiht attached parts - removing and installing
- Lift out the radiator together with air guide and charge-air cooler to the front.
- Remove the add-on components and charge-air cooler from the radiator => Page 96 , removing and in‐
stalling cooling system components.
Installing
- Install catch plate with add-on components:
=> General Body Repairs; Repair group 50; Lock carrier plate wiht attached parts - removing and installing
Lock carrier plate wiht attached parts - removing and installing
- Install steps on right and left:
=> General Body Repairs; Repair group 63; Front bumper Front bumper
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
- -> Install the coolant equalising tank with coolant hoses.
wit
, is n
h re
hole
Note:
spec
es, in part or in w
t to the co
When installing the coolant equalising tank, ensure that spacer -1- is in place.
- Add coolant => Page 104 .
rrectness of i
- Check headlight settings and adjust if necessary:
l purpos
=> Manual of correct repair procedures nform

mercia
1.6 - Removing and installing viscous fan

com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.5 - Removing and installing radiator 107

LT 1997 ➤

AG. Volkswagen AG d
agen
Procedure Volksw
oes
not
by gu
d ara
ise nte
- Drain off the coolant =>thPage
or 104 . eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
- Remove the radiator => Page 106 .

- -> Remove the central bolt on the viscous fan and take off the viscous fan together with fan impeller.
nf
ercia
orm
Install the viscous fan in the reverse order of dismantling.
m
atio
om
n in
or c
- Tightening torque for viscous fan: 40 Nm
thi
te
sd
iva
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

LT 1997 ➤
4-cyl. diesel
en AGengine,
. Volkswagemechanics
n AG - Edition 11.1998
ag does
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Vol
20 - Fuel supply system by gu
ara
ed nte
oris eo
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
1 - Removing and installing fuel system components
erm
ab
ility
ot p
wit
, is n
1.1 - Removing and installing fuel system components
h re
hole
spec
es, in part or in w
t to the co
Overhauling the fuel filter:
=> Repair group 23; Servicing diesel direct injection system; Servicing fuel filter Servicing diesel direct injection
rrectness of i
system Servicing fuel filter
l purpos
Observe safety dimensions =>Page 112 .
nf
ercia
Observe cleanliness rules => Page 113 .
orm
m
atio
m
Notes:
o
n in
or c
thi
e
◆ Hose connections are protected by jubilee clips or collar clamps.

t
sd
iva
o
◆ Always replace collar clamps with spring band or jubilee clips.
r
rp
cu
o
m
◆ Only spring band clips may be used on fuel lines on the engine. The use of collar clamps or jubilee clips is
f
en
ng
t.
not permitted.
yi Co
op
◆ The use of pliers V.A.G 1921 is recommended for fitting spring band clips.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.1 - Removing and installing fuel system components 109

LT 1997 ➤
1.2 - Removing and installing fuel tank and add-on components
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1 Collar nut
rrectness of i
◆ Remove and install with wrench 3217

l purpos
2 Fuel level sensor (G)

◆ Note installed position
nform
ercia
=> Page 117

m
at
3 Sealing ring
om
ion
c
in t
or
◆ Moisten with fuel when fitting

his
ate
do
riv
◆ Note installed position

p
cum
or
4 Damping pads
f
en
ng
t.
yi
5 Anchoring rods
Co
Cop py
◆ For tightening straps
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
110 20 - Fuel supply system

LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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te
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Cop py
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by
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Prote AG.
6 Tightening strap
7 10 Nm
◆ Renew
8 Tank cap
◆ Renew seal if damaged
9 Filler pipe
10 Foam rings
11 Screw clamp
1.2 - Removing and installing fuel tank and add-on components 111
LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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ris nte
ho eo
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ce
le
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pt
an
d
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ab
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ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
12 Hose
m
a
com
13 Tank vent line

ion in
r
te o
14 Fuel tank
thi
s
iva
◆ When removing, support using engine/gearbox hoist V.A.G 1383 A

do
r
rp

um
fo
en
g
=> Page 114

n
t.
yi Co
op
15 Breather/bleed valve C py
ht. rig
ht
16 Feed line
rig by
copy Vo
by lksw
◆ Black Prote
cted AG.
agen
17 Return line
◆ Blue
1.3 - Safety measures when working on the fuel system
When removing and installing the fuel level sensor with the tank full or partly full, the following should be noted:
◆ The intake tube of an exhaust gas extraction system must be positioned near the fuel tank aperture and
switched on before work is commenced, to remove any fuel vapours that arise.
If no such apparatus is available, a radial fan (with the motor positioned away from the airflow) with a cir‐
culation rate of more than 15 m3/h can be used.

LT 1997 ➤
◆ Protect skin against contact with fuel - wear fuel-resistant gloves!
n AG. Volkswagen A age G do
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ua
b
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1.4 - Cleanliness rules au
th or
ac
ss
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nl
pt
du
an
Whenever performing work on the fuel system/fuel injectors, the following "6 rules" on cleanliness should be
itte
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closely followed:
ab
ility
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, is n
◆ Thoroughly clean all connections and their surrounding area before disconnecting.
h re
◆ Set down parts on a clean surface after removal and keep covered over. Do not use linting cloths!
hole
spec
◆ Carefully cover over any open components, or reseal the packages if the repair is not to be carried out
es, in part or in w
immediately.
t to the co
◆ Fit only clean parts:
Leave spare parts in their packaging until just before fitting.
Do not use any parts that have been stored unwrapped (e.g. in toolboxes etc.).
rrectness of i
◆ When the fuel system is open:
Avoid using compressed air if at all possible.
l purpos
Avoid moving the vehicle.

◆ It is also important to ensure that no diesel fuel is allowed to seep onto the coolant hoses. If necessary,
nform
ercia
clean the hoses again immediately. Renew any hoses that have been attacked by fuel.
m
at
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ion
c
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or
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ate
do
priv
cum
for
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Prote AG.
1.3 - Safety measures when working on the fuel system 113

AG. Volkswagen AG d
agen oes
olksw not
y V gu
LT 1997 ➤ rise
d b ara
nte
4-cyl. diesel engine,
autho
mechanics - Edition 11.1998 eo
ra
ss c
1.5 - Removing and installing the fuel tank
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
◆ Engine/gearbox hoist V.A.G 1383 A

◆ Fuel extraction device V.A.G 1433 A
◆ Wrench for collar nut 3217
Removing
Observe safety measures=>Page 112 .
Note:
Before disconnecting the battery, if the vehicle is equipped with a radio protected by anti-theft code, request
details of this code from the owner.

LT 1997 ➤
- -> Clean the area surrounding
agen
AG. Vthe fuel
olkswagenfiller
AG dopipe and empty the fuel tank through the tank opening using the
fuel extraction device
VolkswV.A.G 1433 A. es n
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y ua
db ran
rise tee
tho or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
- -> Loosen the retaining nuts on the two anchoring rods as far as the end of the thread.
l purpos
nform
mercia
at
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ion
c
in t
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ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- -> Remove the plug from the socket -3-.
Note:
Mark the fuel lines to avoid confusion.
- Remove the fuel feed line -1- and the fuel return line -2- at the flange.
- Stop up the fuel feed and return lines.
1.5 - Removing and installing the fuel tank 115

LT 1997 ➤
- -> Pull the tank vent line -1- off the fuel tank. agen AG. Volkswagen AG do
- Release the jubilee clip -2-. olks
w es n
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yV
- Pull the fuel filler pipe -3- off the fuel stank.
ed
b ua
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ho
aut or
ac
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ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
- -> Disengage the two anchoring rods.

- Support the fuel tank with engine/gearbox hoist V.A.G 1383 A.
nform
ercia
Installing
m
at
om
ion
c
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or
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ate
do
priv
cum
for
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
- -> Check that all the damping pads are present and correctly positioned -arrows-.
◆ Position the vent lines in such a way that they are not kinked.
◆ Secure fuel lines with jubilee clips.
◆ Do not confuse the feed and return lines (return line is blue).

LT 1997 ➤
1.6 - Removing and installing fuel level gauge
◆ Wrench for collar nut 3217
Removing
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
- Remove the fuel tank => Page 114 .
erm
ab
ility
- -> Unscrew the collar nut using wrench 3217.
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
- -> Take out the fuel level sensor together with its seal -1-.
te
sd
iva
o
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rp
cu
Installing
o
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Install the fuel level sensor in the reverse order of removal.
C py
ht. rig
rig ht
py by
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Notes: by c lksw
cted agen
Prote AG.
◆ When installing the fuel level sensor, take care not to bend the fuel level display sensor.
1.6 - Removing and installing fuel level gauge 117

. Volkswage
LT 1997 ➤ wage
n AG n AG d
oes
olks no
4-cyl. dieseld engine,
by
V mechanics - Edition t 11.1998
gu
ar
ise an
or tee
◆ Moisten the flange's
au
th sealing ring with fuel when fitting. or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
- -> Note installed position:
nform
ercia
The mark on the sensor -1- must be aligned with the mark on the fuel tank -2-.
m
at
om
ion
c
- Press the fuel level sensor down, overcoming the resistance of the spring, and screw on the collar nut to
in t
or
secure it.
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

LT 1997 ➤
1.7 - Servicing throttle controls
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1 Locking clip
2 Knurled wheel
◆ must contact the throttle cable end fitting
rrectness of i
3 Clip
l purpos
◆ The edge of the clip must finish flush with the edge of the accelerator pedal
4 Lock washer
nf
ercia
5 Accelerator pedal
orm
6 Fulcrum pin
m
atio
om
n in
or c
thi
te
sd
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.7 - Servicing throttle controls 119

LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
7 Console
f inform
8 Tension spring
mer
atio
9 Throttle cable
om
10 Locking device
c
i
or
n thi
e
◆ When the accelerator pedal is in the full throttle position, adjust the throttle cable by repositioning the
t
sd
va
locking device so that the injection pump lever contacts the stop without any stress.
i
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

LT 1997 ➤
21 - Charging
1 - Charge-air system with exhaust gas turbocharger

1.1 - Charge-air system with exhaust gas turbocharger
Notes:
◆ All hose connections are protected by clips.

◆ Charge-air system must be airtight.
◆ Renew all self-locking nuts.
◆ Pliers V.A.G 1921 are recommended for fitting spring band clips.
Removing and installing turbocharger and add-on components

=> Page 122 .
Removing and installing charge-air cooler components

=> Page 125 .
. Volkswagen AG
gen AG does
swa
Observe cleanliness
by
Vol rules => Page 126 .
k not
gu
ara
ed nte
oris eo
th
au ra
c
ss
ce
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.1 - Charge-air system with exhaust gas turbocharger 121

LT 1997 ➤
1.2 - Removing and installing turbocharger and add-on components
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
1 60 Nm
wit
, is n
h re
2 Spacer sleeve
hole
spec
3 60 Nm
es, in part or in w
t to the co
◆ Renew
◆ Grease thread and contact surface of head with G 000 500
4 30 Nm
rrectness of i
5 Oil seal
l purpos
◆ Renew
6 Exhaust manifold
nform
ercia
7 5 Nm
m
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
122 21 - Charging
LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
8 Heat shield
wit
, is n
h re
9 Holder
hole
spec
10 Stud bolt
es, in part or in w
t to the co
11 15 Nm
12 Stud bolt
13 Stud bolt
rrectness of i
14 Pipe connection
l purpos
15 30 Nm
16 Sealing ring
nf
ercia
◆ Renew
orm
m
17 Oil feed line

atio
om
◆ Before installing, fill turbocharger with engine oil at the pipe connection on the oil feed line
n in
or c
thi
18 Pipe connection
te
sd
iva
o
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cu
o
m
f
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.2 - Removing and installing turbocharger and add-on components 123

LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
19 Sealing ring
◆ Renew
20 Oil seal
◆ Renew
21 Pipe connection
22 Oil return line
23 Pipe connection
24 Sealing ring
◆ Renew
25 Turbocharger
=> Page 127
◆ Checking charge pressure
=> Page 129 , checking turbocharger
26 15 Nm
27 5 Nm
124 21 - Charging
LT 1997 ➤
1.3 - Removing and installing charge-air cooler components
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
1 Screw clamp
n in
or c
2 Pressure hose
thi
te
sd
iva
3 Charge air tube

o
r
rp
cu
o
m
f
4 Pressure hose
en
ng
t.
yi Co
5 To turbocharger Cop py
t. rig
◆ => Page 124 , No. 25
gh ht
pyri by
Vo
o
6 Intake manifold
c by lksw
cted agen
Prote AG.
1.3 - Removing and installing charge-air cooler components 125

LT 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
7 Gasket
nf
ercia
◆ Renew
rm
m
atio
8 Pipe connection
om
n in
c
9 30 Nm
or
thi
e
10 Pressure hose
t
sd
iva
o
r
11 O-ring
rp
cu
o
m
f
12 Charge-air cooler
en
ng
t.
yi Co
op
◆ Secured to radiator C py
ht. rig
=> Page 97 , cooling system components, radiator end rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.4 - Cleanliness rules

Whenever performing work on the turbocharger, the following "5 rules" on cleanliness should be closely fol‐
lowed:
◆ Thoroughly clean all connections and their surrounding area before disconnecting.
◆ Set down parts on a clean surface after removal and keep covered over. Do not use linting cloths!
◆ Carefully cover over any open components, or reseal the packages if the repair is not to be carried out
immediately.
◆ Fit only clean parts:
Leave spare parts in their packaging until just before fitting.
Do not use any parts that have been stored unwrapped (e.g. in toolboxes etc.).
126 21 - Charging
LT 1997 ➤
◆ When the fuel system is open:
Avoid using compressed air if at all possible.
Avoid moving the vehicle.
1.5 - Removing and installing turbocharger
lkswage es n
o ot g
byV ua
ed ran
Special tools,
horis factory equipment, test and measuring teinstruments
eo and accessories required
ut ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia

orm
◆ Grease G 000 500

m
atio
om
n in
c
Removing
or
thi
te
sd
iva
Note:
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.4 - Cleanliness rules 127

LT 1997 ➤
Before disconnecting the battery, if the vehicle is equipped with a radio protected by anti-theft code, request
details of this code from the owner.
- -> Remove retaining screws -arrows- and take off the heat shield -1-.
- -> Release the jubilee clips -1-, pull the hose -arrow- off the oil separator and remove the complete hoses.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
- -> Pull the charge-air hose -arrow- off the turbocharger.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
- -> Unscrew the oil feed line -1- and oil return line -2- from the turbocharger.
co Vo
by lksw
cted
- Remove the exhaust pipe at the front => Page 131 , removing and installing exhaust system components.
agen
Prote AG.
- Unscrew the retaining nuts between the exhaust manifold and turbocharger.
- Take out the turbocharger.
Installing
- Grease the thread and the contact surface of the retaining nuts between the exhaust manifold and the
turbocharger with G 000 500 and tighten to
60 Nm.
- Fit oil return line with new seal and tighten to
10 Nm.
- Fill the turbocharger at the pipe connection of the oil feed line with engine oil.
128 21 - Charging
LT 1997 ➤
- Fit oil feed line with new sealing rings and tighten banjo bolt to
25 Nm.
- Flange on front exhaust pipe with new seal and tighten to
25 Nm.
Note:
When installing, slacken off all screw connections again slightly (components must just be able to move in
relation to one another), then retighten without generating stresses.
- Allow the engine to idle for about 1 minute after installing the turbocharger; do not rev up the engine imme‐
diately, to ensure that oil can reach all parts of the turbocharger first.
1.6 - Checking turbocharger
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
◆ Turbocharger tester V.A.G 1397 A
es, in part or in w
t to the co
◆ Connecting hose V.A.G 1397 A/1 with T-piece
Checking requirements
rrectness of i
The turbocharger and boost-pressure control valve constitute a single unit. If a fault develops in the turbo‐
charger, it must always be renewed as repairing is not feasible with the facilities available in the workshop.
l purpos
For the turbocharger to function efficiently and the specified boost pressure to be achieved, the following con‐
ditions must be satisfied:
nform
ercia
• No leaks on either the intake or exhaust end.

• The control line (black) between the valve for boost pressure limiting and the compressor's outlet must not
m
at
om
be blocked, loose or leaking.

ion
c
• There must be no engine/fuel injection system malfunctions, such as incorrect timing, defective injectors,
in t
or
his
compression pressure.
ate
do
riv
• Engine oil temperature at least 80 °C.

p
cum
for
en
g
Checking procedure
n
t.
yi Co
op
- The boost pressure is measured at full load, either on the road or on the dynamometer. Testing duration
C py
t. rig
gh
per measurement: max. 10 seconds.
ht
pyri by
Vo
o
- Pull off control line (black) between valve for boost pressure limiting and the compressor's air outlet.
c by lksw
cted agen
Prote AG.
1.5 - Removing and installing turbocharger 129

LT 1997 ➤ agen
AG. Volkswagen AG d
oes
ksw
4-cyl. diesel engine, mechanics b-y VEdition 11.1998
ol not
gu
ara
ed nte
ris
- -> Fit auxiliary hose on the compressor t connection
and connect up to the control lineorwith the aid of a T-
ho e
piece. au ac
ss
- Fit connecting hose V.A.G 1397 A/1 to turbocharger tester V.A.G 1397 A (measuring connection II) with T-
ce
le
un
pt
piece.
an
d
itte
- Switch on measuring range II.
y li
rm
ab
pe
ility
Notes:
ot
wit
, is n
h re
hole
◆ Operation of the turbocharger tester => operating instructions.
spec
◆ The connections of all hoses and lines must be absolutely free from leaks.
es, in part or in w
◆ If the boost pressure is measured in a road test, in the interests of safety a second person should accompany
t to the co
the driver to operate the turbocharger tester.
◆ Ensure that the connecting hoseV.A.G 1397 A/1 does not become trapped between the front lid and the
body.
rrectness of i
l purpos
- Measuring boost pressure at full throttle:

On the dynamometer:
In 3rd gear (manual) or 2nd (automatic) at 3500 rpm.
nform
ercia
Road test:
In 2nd gear (manual) or 1st (automatic), simultaneously decelerating to approx. 40 km/h by braking
m
a
com
ti
- At 2000...3500 rpm, press store button "M" am turbocharger tester and read off the value.
on in
Target value: (relative pressure)
r
te o
thi
0.90 ... 1.00 bar
s
iva
do
r
rp
cum
fo
If the target value is not achieved:
en
ng
t.
yi Co
op py
- Renew turbocharger => Page 127 , removing and installing turbocharger. t. C rig
gh ht
- If the boost pressure is too high and the control line to the boost pressure limiting valve is not blocked, loose
pyri by
Vo
o
by c
or leaking, again renew the turbocharger, as the boost pressure limiting valve is leaking.
lksw
cted agen
Prote AG.
130 21 - Charging
LT 1997 ➤
AG. Volkswage- Edition
nA 11.1998
n G do
wage es n
olks
26 - Exhaust system
V ot g
by ua
ed ran
oris tee
th or
au ac
ss
ce
le
un
pt
an
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1.1 - Removing and installing exhaust system components 131

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8 Dimension -d- = at least 23 mm
9 Dimension -c- = 55 ± 10 mm
10 Dimension -b- = 45 - 52 mm
11 Tailpipe
12 Dimension -a- = mind. 20 mm
13 Collar clamp
◆ Tightening torque: 40 Nm
14 Centre silencer
15 25 Nm
132 26 - Exhaust system

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1.1 - Removing and installing exhaust system components 133

2.8 Tdi VW Agk-Ata

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Service

4-cyl. diesel engine, mechanics

Engine ID AGK ATA

Service Department. Technical Information

20 - Fuel supply system

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Copyright © 2010 Volkswagen AG, Wolfsburg K0050006220

1.3 Securing engine to mounting trestle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

1 Dismantling and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

1.2 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

1.3 Removing and installing ribbed V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

2.2 Check drive gear wheels and adjust if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

1.1 Removing and installing cooling system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

1 Charge-air system with exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121

1.1 Charge-air system with exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121

1.3 Removing and installing charge-air cooler components . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

1.6 Checking turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129

1.3 - Engine data

Code letter AGK ATA

1.1 - Technical data 1

Code letter AGK ATA

10 - Removing and installing engine

1 - Removing and installing the engine

◆ V.A.G 1202 A workshop crane

1.1 - Removing and installing the engine 3

◆ V.A.G 1306 collecting tray

◆ V.A.G 1921 Pliers for spring band clamps

◆ V.A.G 1331 torque wrench (5...50 Nm)

◆ V.A.G 1332 torque wrench (40...200 Nm)

◆ The vehicle is secured by means of 4 lashing straps.

4 10 - Removing and installing engine

- The engine is removed to the front, together with the gearbox.

refitted at the same point when the engine is installed again.

- Drain off coolant => Page 104 .

- Remove front bumper:

1.2 - Notes on removing 5

- Remove the radiator => Page 106 .

6 10 - Removing and installing engine

Removing engine with gearbox

- -> Remove the sensor -1- for the speedometer (G22).

- Remove clutch slave cylinder and lead on gearbox:

1.2 - Notes on removing 7

- Unscrew propeller shaft on gearbox flange:

- -> Support the gearbox with retaining device VW 785/1B.

- Remove the bolts holding the engine and gearbox together.

- Raise the assembly and pullenitAG

- Disconnect the gearbox.

Install in the reverse order of removal, observing the following points:

- Check declutching bearing for wear and renew if necessary.

- Shake the engine and gearbox mounting to release any stresses.

- Tighten retaining screws for engine mounts on right and left.

1.2 - Notes on removing 9

- Fit propeller shaft on gearbox flange:

- Remove exhaust pipe to the front => Page 131 .

- Install gearbox shift lever:

- Install inspection window cover:

- Install vane pump for power steering.

- Install steps on right and left:

- Install front bumper: