Engine AMF

Service 5
Workshop Manual
FABIA 2000 ³
1.4/55 TDI Engine, Mechanics
Edition 07.03
Engine code AMF
Service Department. Technical Information Printed in Czech Republic

S00.5325.00.20
5 Service
The Workshop Manual is intended only for use within the Organisation Škoda. Printed in Czech Republic
It is not permitted to pass it on to other persons. S00.5325.00.20
© ŠKODA AUTO a. s.
FABIA 2000 ³ 1.4/55 TDI Engine, Mechanics
List of Supplements to Workshop Manual

FABIA 2000 ³
1.4/55 TDI Engine, Mechanics
Edition 07.03
Supple-
Edition Subject Article Number
ment
07.03 Basic Edition S00.5325.00.20
Edition 07.03 List of Supplements

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List of Supplements Edition 07.03

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Table of Contents
00 – Technical Data
Technical Data .......................................................................................... 00-1 page 1
- Engine number ......................................................................................... 00-1 page 1
- Engine characteristics ................................................................................ 00-1 page 1
10 – Removing and Installing Engine

Removing and Installing Engine .................................................................... 10-1 page 1
- Removing engine ...................................................................................... 10-1 page 1
- Securing the engine to the assembly stand ....................................................... 10-1 page 5
- Installing the engine ................................................................................... 10-1 page 7
- Tightening torques .................................................................................... 10-1 page 9
- Assembly bracket ...................................................................................... 10-1 page 9
13 – Crankgear
Removing and installing V-ribbed belt ............................................................ 13-1 page 1
- Removing and installing V-ribbed belt .............................................................. 13-1 page 1
- Routing of the V-ribbed belt .......................................................................... 13-1 page 2
Removing and installing, tightening the timing belt ........................................... 13-2 page 1
- Timing belt - Summary of components ............................................................. 13-2 page 1
- Removing and installing, tightening the timing belt .............................................. 13-2 page 2
Disassembling and assembling engine ........................................................... 13-3 page 1
- Cylinder block - Summary of components ......................................................... 13-3 page 1
Removing and installing sealing flange and flywheel ......................................... 13-4 page 1
- Replacing gasket ring for crankshaft - on the belt pulley side .................................. 13-4 page 2
- Removing and installing the front sealing flange ................................................. 13-4 page 3
Crankshaft, Piston and Conrod ..................................................................... 13-5 page 1
- Removing and installing crankshaft ................................................................ 13-5 page 1
- Disassembling and assembling piston and conrod .............................................. 13-5 page 3
- Checking piston projection in TDC .................................................................. 13-5 page 5
Removing and installing balancing shaft and retaining frame .............................. 13-6 page 1
- removing and installing balancing shaft ............................................................ 13-6 page 2
15 – Cylinder Head, Valve Gear

Removing and installing cylinder head ........................................................... 15-1 page 1
- Removing and installing cylinder head ............................................................. 15-1 page 3
- Testing the compression ............................................................................. 15-1 page 6
Repairing Valve Gear .................................................................................. 15-2 page 1
- Summary of components ............................................................................. 15-2 page 1
Camshaft ................................................................................................. 15-3 page 1
- Removing and installing camshaft .................................................................. 15-3 page 1
- Removing and installing gasket ring for camshaft ................................................ 15-3 page 3
.................................................... Valve seats, valves guides, valve stem seals 15-4 page 1
- Grinding in valve seats ............................................................................... 15-4 page 1
- Inspect valve guides .................................................................................. 15-4 page 2
- Replacing valve stem seals .......................................................................... 15-4 page 2
Edition 07.03 Table of Contents I

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17 – Lubrication
Removing and installing parts of the lubrication system ..................................... 17-1 page 1
- Lubrication system - Summary of components ................................................... 17-1 page 1
- Disassembling and assembling oil filter holder ................................................... 17-1 page 3
Removing and installing oil pan .................................................................... 17-2 page 1
- Removing and installing oil pan ..................................................................... 17-2 page 1
Testing oil pressure and oil pressure switch .................................................... 17-3 page 1
19 – Cooling
Parts of cooling system - Summary of components ........................................... 19-1 page 1
- Parts of the cooling system fitted to body ......................................................... 19-1 page 2
- Parts of cooling system engine side ................................................................ 19-1 page 3
- Connection diagram for coolant hoses ............................................................. 19-1 page 4
- Draining and filling up coolant ....................................................................... 19-1 page 4
- Checking the coolant system for tightness ........................................................ 19-1 page 6
Removing and installing radiator, coolant pump and coolant thermostat ............... 19-2 page 1
- Removing and installing radiator .................................................................... 19-2 page 1
- Removing and installing coolant pump ............................................................ 19-2 page 2
- Removing and installing coolant regulator ........................................................ 19-2 page 3
20 – Fuel Supply
Removing and installing parts of the fuel supply - Part 1 .................................... 20-1 page 1
- Fuel tank with component parts - Summary of components .................................... 20-1 page 1
- Repairing the fuel filter ................................................................................ 20-1 page 3
- Safety precautions when working on the fuel supply system ................................... 20-1 page 4
- Rules of cleanliness ................................................................................... 20-1 page 4
- Removing and installing the fuel delivery unit .................................................... 20-1 page 5
- removing and installing fuel gauge ................................................................ 20-1 page 6
- Check the fuel delivery unit .......................................................................... 20-1 page 6
Removing and installing parts of the fuel supply - Part 2 .................................... 20-2 page 1
- Removing and installing the fuel tank .............................................................. 20-2 page 1
- Removing and installing fuel cooler ................................................................ 20-2 page 2
- Inspecting a tandem pump ........................................................................... 20-2 page 2
- Removing and installing the tandem pump ........................................................ 20-2 page 4
Servicing accelerator pedal .......................................................................... 20-3 page 1
- Summary of components ............................................................................ 20-3 page 1
21 – Turbocharging
Charge air system with turbocharger ............................................................. 21-1 page 1
- Safety measures ...................................................................................... 21-1 page 1
- Rules of cleanliness ................................................................................... 21-1 page 1
- Removing and installing exhaust turbocharger with component parts ........................ 21-1 page 2
- Removing and installing parts of the charge air cooling ......................................... 21-1 page 4
- Removing and installing charge-air cooler ........................................................ 21-1 page 4
Charge-air system with exhaust turbocharger - Part 2 ........................................ 21-2 page 1
- Removing and installing turbocharger ............................................................. 21-2 page 1
- Checking charge pressure control .................................................................. 21-2 page 2
26 – Exhaust System
Table of Contents Edition 07.03

II S00.5325.00.20
Removing and installing parts of the exhaust system ........................................ 26-1 page 1
- Align exhaust system free of stress ................................................................ 26-1 page 2
- Replacing front or rear silencer ...................................................................... 26-1 page 2
Exhaust gas recirculation system .................................................................. 26-2 page 1
- Removing and installing parts of the exhaust gas recirculation system ...................... 26-2 page 1
- Testing mechanical exhaust gas recirculation valve ............................................. 26-2 page 2
Edition 07.03 Table of Contents III

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Table of Contents Edition 07.03

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FABIA 2000 ³ 1.4/55 TDI Engine, Mechanics 00
00 – Technical Data
00-1 Technical Data
Engine number
The engine number („engine code“ and „serial number“)
is located at the front at the joint separating engine/gear-
box.
In addition, a sticker with the „engine identification char-
acters“ and „serial number“ is affixed to the timing belt
guard.
The engine identification characters are also indicated on
the vehicle data sticker.
Engine characteristics
Engine identification characters AMF

Manufactured 06.03 ³
Exhaust limits conforming to EU-3
Displacement l 1,4
Power output kW at rpm 55/4000
Torque Nm at rpm 195/2200
Bore ∅ mm 79,5
Stroke mm 95,5
Compression 19,5 : 1
CN minimum 49
Firing order 1-2-3
Catalytic converter yes
Exhaust gas recirculation yes
Turbocharging yes
Charge air cooler yes
Edition 07.03 Technical Data 00-1 page 1

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00 FABIA 2000 ³ 1.4/55 TDI Engine, Mechanics
Technical Data Edition 07.03

00-1 page 2 S00.5325.00.20
10 – Removing and Installing Engine
10-1 Removing and Installing

Engine
Special tools, test and measuring equipment and
auxiliary items required
♦ Workshop crane (e.g. -V.A.G 1202 A -)
♦ Catch pan (e.g. - V.A.G 1306-)
♦ Torque wrench
♦ Engine/gearbox jack (e.g. -V.A.G 1383 A-)
♦ Engine mount -T10012-
♦ Bushing -T30010-
♦ Socket insert -MP 9-200/7-
♦ Engine mount -MP 1-202-
♦ Assembly stand -MP 9-101-
♦ Lifting device -MP 9-201-
♦ Pliers for spring strap clips
♦ Snap hook
♦ Grease -G 000 100-
♦ Hot bolt paste -G 052 112 A3-
♦ Wire
♦ Adhesive tape
Removing engine
Note
♦ The engine is removed towards the front together with
the gearbox.
♦ Jacking up points for raising the vehicle ⇒ Inspection
and Maintenance.
♦ Pay attention to the correct assignment of the connec-
tors, if necessary mark.
♦ If the battery is disconnected and reconnected, carry
out certain additional operations ⇒ Electrical System;
Rep. Gr. 27.
Procedure
– Disconnect the battery-earth strap with the ignition off.
– Remove the sound dampening system -arrows-
⇒ Body work; Rep. Gr. 50.
– Remove drive shaft to the right ⇒ Running gear;
Rep. Gr. 40.
– Unscrew the drive shaft to the left of the gearbox
flange.
– Raise drive shaft on the left and secure.
– Remove front exhaust pipe with catalyst ⇒ Chapter S10-0114
26-1.
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– Remove front bumper ⇒ Body work; Rep. Gr. 63.

– Release screw -3-.
– Remove charge-air pipe at bottom -1- with connecting
hose -2- -arrows-.
– Remove charge-air routing from charge-air cooler
⇒ Chapter 21-1.
– Unbolt the pendulum support -arrows-.

– Drain coolant ⇒ Chapter 19-1.
– Remove engine cover.
– Remove air filter with intake hose ⇒ 1.4/55 TDI En-
gine, Fuel Injection; Rep. Gr. 23.
– Remove battery and battery tray ⇒ Electrical System;
Rep. Gr. 27.
– Unscrew the generator cables from the battery cover
and remove the wiring loom from the holder.
– Remove the coolant hoses from the radiator.
For vehicles with air conditioning
Caution!
♦ Refrigerant circuit of the air conditioning sys-
tem must not be opened. Therefore, when re-
moving the lock carrier the hoses must be fitted
onto the air conditioning. They must neither be
folded nor exposed to stress.
♦ To avoid damaging the condenser, wiring and
air conditioning hoses make sure the lines and
hoses are not excessively expanded, buckled or
bent.
– Release the retaining clips of the AC system lines.

– Remove AC compressor ⇒ Heating, Air conditioning;
Rep. Gr. 87, the lines remain connected.
– Tie up AC compressor to lock carrier.
For all vehicles

– Removing lock carrier ⇒ Body Work; Rep. Gr. 50 and
lay aside.
S10-0128
Removing and Installing Engine Edition 07.03

10-1 page 2 S00.5325.00.20
– Disconnect the coolant hose -1- from the pipe.
– Disconnect the fuel-intake hose -3- and the fuel-return 1
hose -2- from the pipes.
S10-0148
– Remove charge-air pipe at the top -1- with connecting

hose -2- -arrows-.
– Pull off the coolant hose from the expansion bottle at
the bottom.
– Pull out vacuum hoses from the valve block
⇒ Chapter 21-1 .
– Remove the coolant feed hose -3- from the supports

-4-.
– Remove the coolant return hose -2- from the heat ex- 3
changer connection fittings -1-. 4
5
1 6
S10-0150

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– Unplug connector -1- from the engine control unit.

– Disconnect the plug connections -2- and -3- and re-
move from bracket.
– Unclip cable clip -4- -arrows-. 1
– Remove shift cables of shift mechanism from bracket 2 3
at gearbox and place down to the side ⇒ Manual
Gearbox 02R; Rep. Gr. 34.
– Disconnect lines for brake fluid from clutch slave cyl-
inder ⇒ Manual Gearbox 02R; Rep. Gr. 30. 4
– Unplug connector from reversing light switch -F4-.
– Unscrew the earth line from the body.
– Disconnect connector and cables from the starter.
S10-0117
– Disconnect the plug connections -2- and -3- under the

starter and remove from bracket.
2
3
S10-0151
– Suspend lifting device -MP 9-201- as follows and

carefully raise engine with gearbox with workshop
crane -V.A.G 1202 A-.
Warning!
Use securing pins on the hooks and rig pins to
prevent release.

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– Unscrew bolts for engine mounting -arrows-.
Note
If the engine/gearbox unit drops when the screws are re-
leased raise it up again. m
ax
in
m
S10-0149
– Unscrew bolts for gearbox mount -arrows-.

The note on unscrewing the engine mounting also ap-
plies for the gearbox mount.
– Carefully raise the engine with gearbox and pull out

towards the front.
Note
Carefully guide the engine and gearbox during withdraw-
al. Ensure adequate clearance to other neighbouring
components.
Securing the engine to the assembly

stand S10-0120
To perform the assembly work the engine must be se-

cured to the assembly stand -MP 9-101-.
Note
When measuring the cylinder bore (⇒ Chapter 13-4) the
engine must not be fixed to the assembly stand.
Modify engine mount -T10012-

– Make additional hole -a- according to the given dimen-
sions at the height of the already existing holes, if
these do not yet exist.

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Procedure
– Screw centering pin -1- and centering pin -2- accord-
ing to the illustration onto the engine mount -arrows-.
– Fix engine mount -T10012- with fixing nut -3- and fix-
ing bolt at cylinder block.
– Unscrew the bottom fixing screws for the engine/gear-
box.
– Raise the engine and gearbox with the engine/gear-
box jack.
– Dismantle the lifting device -MP 9-201-.
– Position engine/gearbox with engine/gearbox jack

onto a work bench.
– Lower the engine/gearbox unit in such a way that the
gearbox is positioned on the support.
T 10012 V.A.G 1383/A

N10-0148
– Remove cover plate -A- for flywheel behind the right

flange shaft -arrows-.
– Unplug the connector from the speedometer sender
-G22-.
– Remove engine/gearbox connecting screws. A
– Press gearbox from engine.
V34 - 3005

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– Suspend lifting device -MP 9-201- and lift engine out
of engine/gearbox jack using the workshop crane.
On the belt pulley side: 4. Hole of the perforated bar in po-
sition 1
On the flywheel side: 2. Hole of the perforated bar in po-
sition 8
Warning!
Use -arrows- securing pins on the hooks and rig
pins to prevent release.
Note
♦ The rig positions on the supporting bracket marked
1…4 point towards the belt pulley.
♦ The holes in the perforated bars are counted from the
hook.
– Unscrew Engine mount - T10012-.

– Attach engine to the assembly stand -MP 9-101 - with
the engine / gearbox mount -MP 1-202 - and sleeves MP 1-202
-T30010-. (The figure shows the 1.9l/47kW SDI en-
gine; the fixing system is identical).
Note
Engine can be fixed at the engine mount -MP 1-202 -
without sleeves -T30010-.
T30010
Installing the engine
Note
♦ Always replace the seals and gaskets during assem- S10-0123
bly work.
♦ Always replace self-locking nuts.
♦ Coat stud bolts of exhaust manifold with hot bolt paste
-G 052 112 A3- before installing.
♦ Tightening torques ⇒ 10-1 page 9.
♦ Assembly bracket ⇒ 10-1 page 9.
Procedure
Installation is performed in the reverse order. Pay atten-
tion to the following points:
– Check whether the dowel sleeves for centering the

engine/gearbox are present in the cylinder block; in-
sert if necessary.
– Check whether the intermediate plate has been insert-
ed on the sealing flange and rests on the dowel A10-0129
sleeves -arrows-.

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– If necessary check the centering of the clutch driver

disc.
– Inspect clutch release bearing for wear, replace if nec-
essary.
– Grease the drive shaft serration with grease
-G 000 100-.
– Assemble together the engine with gearbox
⇒ Manual gearbox 02R; Rep. Gr. 34.
– When installing the unit, ensure adequate clearance
to other components.
– Align unit free of stress and attach firmly.
When tightening the bolts for engine and gearbox
mounts, engine and gearbox support brackets must
be resting fully against mount.
Tightening torques ⇒ 10-1 page 9.
– Connect lines for brake fluid to clutch slave cylinder

⇒ Manual Gearbox 02R; Rep. Gr. 30.
– Install and adjust the shift cables of the shift mecha-
nism ⇒ Gearbox 02R; Rep. Gr. 34.
– Install the right drive shaft and screw the left drive
shaft onto the gearbox ⇒ Chassis; Rep. Gr. 40.
– Install the front exhaust pipe with catalytic converter
and the exhaust system so that they are not under
tension. ⇒ Chapter 26-1.
– Install the lock carrier with component parts ⇒ Body
Work; Rep. Gr. 50.
– Electrical connections and proper routing ⇒ Current
Flow Diagrams, Electrical Fault Finding and Fitting Lo-
cations.
– Install coolant hoses ⇒ Chapter 19-1.
Note
Only then re-use drained coolant if none of the following
components has been replaced: Engine block, cylinder
head, radiator, heat exchanger.
– Top up coolant ⇒ Chapter 19-1.

– Check oil level before starting the engine.
– Perform test drive, interrogate fault memory ⇒ 1.4/55
TDI Engine, Fuel Injection; Rep. Gr. 23.

10-1 page 8 S00.5325.00.20
Tightening torques
Component Nm
Screws/nuts M6 9
M8 23
M10 40
M12 60
In variation of this:
Front exhaust pipe to turbo- 25 Nm
charger
Assembly bracket
Engine assembly bracket

1 - 30 Nm + 90° (1/4 turn) - replace
2
2 - 40 Nm + 90° (1/4 turn)
3 - 45 Nm 1
Gearbox assembly bracket 1
1 - 50 Nm + 90° (1/4 turn) - replace
2 - 40 Nm + 90° (1/4 turn) - replace
1 S10-0125
Hinged bracket
Note
Position the screws -1- in the elongated holes of the pen-
dulum support in such a way that there is maximum dis-
tance between the gearbox and the assembly carrier.
1 - 30 Nm + 90° (1/4 turn) - replace

2 - 40 Nm + 90° (1/4 turn) - replace
2
S10-0126

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13 – Crankgear
13-1 Removing and installing

V-ribbed belt
Removing and installing V-ribbed belt

♦ Locking pin -T10060-
Note
♦ Mark the rotation direction before removing the V-
ribbed belt. Reversing the rotation direction of an al-
ready used belt may destroy it.
♦ Pay attention to the correct position of the V-ribbed
belt in the belt pulley when installing it.
Removing the V-ribbed belt

hose -2-.
– Mark the rotation direction of the V-ribbed belt.
– Loosen the V-ribbed belt by turning the tensioning pul-
ley in the -direction of the arrow-.
A13-0083
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– Lock tensioning pulley with rig pin -T10060-.

– Remove the V-ribbed belt.
Installing the V-ribbed belt

– Installation is carried out in the reverse order.
Note
♦ Inspect V-ribbed belt ⇒ Inspection and Maintenance.
♦ Before fitting the ribbed V-belt make sure that all as-
semblies (generator, AC compressor) are securely
mounted.
♦ Pay attention to the correct position and rotation direc-
tion of the V-ribbed belt in the belt pulley when install-
ing it.
♦ Finally position the V-ribbed belt on the generator.
After finishing the work always:
– Start engine and check belt run.
Routing of the V-ribbed belt
Belt run without AC compressor
Belt run with AC compressor
Removing and installing V-ribbed belt Edition 07.03

13-1 page 2 S00.5325.00.20
13-2 Removing and installing, tightening the timing belt

Timing belt - Summary of components
1 - Timing belt guard - top part
2 - Timing belt
T before removing mark run-
ning direction
T check for wear
T do not kink
T removing and installing, ten-
sioning ⇒ 13-2 page 2
3 - 20 Nm + torque a further 1/8
turn (45 °)
4 - Tensioning pulley
5 - 100 Nm
turn (45 °)
7 - Camshaft sprocket
8 - Hub
T with rotor
T to release and tighten use
the counterholder -T10051 -
T to remove use the extractor
-T10052-
T removing and installing
⇒ Chapter 15-3
9 - 10 Nm
10 - Timing belt guard rear
11 - Sealing sleeve
T replace if damaged
12 - Guide pulley
13 - Coolant pump
⇒ Chapter 19-2
14 - Timing belt gear - crankshaft
T contact surface between crankshaft timing belt sprocket and crankshaft must be clean and free of grease
T Fitting position: flats on timing belt sprocket and on crankshaft must be aligned
15 - 120 Nm + torque a further 1/4 turn (90°)
T replace
T to release and tighten use counterholder -MP 1-310- or -T30004-
T neither oil nor grease new screw
16 - 15 Nm
17 - 20 Nm
18 - Timing belt guard - bottom part
19 - Belt pulley with vibration damper
T Assembly only possible in one position - holes offset
20 - 10 Nm + torque a further 1/4 turn (90°)
21 - Timing belt guard - middle part
Edition 07.03 Removing and installing, tightening the timing belt 13-2 page 1
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Removing and installing, tightening the

timing belt
♦ Rig pin -MP 1-301- or -3359-
♦ Two-hole nut turner -T10020-
♦ Locking device -T10050-
♦ Torque wrench
♦ Supporting device -MP 9-200- with feet -MP 9-200/3-
Removing
Note
Adjusting work on the timing belt must only be performed
on a cold engine, as the position of the pointer at the ten-
sioning element is temperature dependent.

hose -2-.
– Remove the connecting pipe between the charge air
cooler and the intake ⇒ Chapt. 21-1.
– Install supporting device -MP 9-200- according to the
illustration and support engine in fitting position.
– Remove engine mount -1- and engine console -2-.

– Remove the V-ribbed belt ⇒ Chapter 13-1.
– Remove locating bolts -T10060- from tensioning ele-
ment.
– Remove timing belt guard - top part.
Removing and installing, tightening the timing belt Edition 07.03

13-2 page 2 S00.5325.00.20
– Remove the noise insulation.
S10-0114
– Release screw -3-.

– Remove charge-air pipe at bottom -1- with connecting
hose -2- -arrows-.
– Remove belt pulley ⇒ item 19 in 13-2 page 1.
– Remove middle part of timing belt guard ⇒ item 21 in
13-2 page 1.
– Remove bottom part of toothed belt guard ⇒ item 18
in 13-2 page 1.
– Position crankshaft on TDC cylinder 1.
Note
Turn crankshaft until the marking on the timing belt
sprocket and the marking on the timing belt guard stand
are opposite each other -arrows A- at the rear.
– Lock hub with locking pin -MP 1-301- or -3359-. Insert

locking pin through the free left slot into the hole at the
cylinder head.
– Secure crankshaft timing belt sprocket with locking
device-T10050-. Insert locking device from the front of
the timing belt sprocket into the teeth.
To facilitate this step, it is recommended to colour the
TDC marking at the crankshaft timing belt sprocket and
on the locking device-T10050- with white paint -arrows
B-.
Note
♦ The marking on the crankshaft timing belt sprocket
and the marking on the locking device must be posi-
tioned opposite -arrows B-. Pin of locking device must
engage in the hole of the sealing flange -arrow C-.
♦ Locking device - T10050- must not be used as a coun-
terholder when releasing or tightening the bolts for the
toothed belt gear - crankshaft.
– Mark the rotation direction of the timing belt.
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– Loosen the fixing nut on the tensioning roller.

– Slacken bolts of camshaft sprocket -1- sufficiently so
that the camshaft sprocket can be turned in the area
of the slots.
– Remove guide pulley ⇒ item 12 in 13-2 page 1.
– Turn two-hole nut turner -T10020- up to the stop and

first of all remove the timing belt from the coolant
pump and then from the other timing gears.
Install timing belt and tension
Note
Adjusting work on the timing belt must only be performed
on a cold engine, as the position of the pointer at the ten-
sioning element is temperature dependent.
– Turn camshaft sprocket in the slots anti-clockwise in

-direction of arrow- as far as the stop.
– Fit timing belt onto crankshaft timing belt sprocket,
tensioning pulley, camshaft sprocket and onto the
coolant pump.

13-2 page 4 S00.5325.00.20
Note
Pay attention to correct fitting of the tensioning pulley in
the rear timing belt guard -arrow-.
A13-0053
– Install guide pulley ⇒ item 12 in 13-2 page 1.
– Carefully turn tensioning pulley with two-hole nut turn-
er -T10020- in anti-clockwise direction until the pointer
is positioned in the middle of the recess in the base
plate.
– Hold tensioning pulley in this position and tighten fix-
ing nut of the tensioning pulley as follows:
20 Nm + torque a further 45° (1/8 turn)
– Tighten bolts of camshaft sprocket to 20 Nm + torque

a further 1/8 turn (45°).
– Remove locking pin -MP 1-301- and locking device
-T10050-.
– Turn crankshaft two turns further in the direction of ro-
tation of the engine and again position on TDC for cyl-
inder 1.
Note
♦ Pin for locking device must engage in the sealing
flange. (Locking device should be inserted just ahead
of TDC on toothed belt sprocket.)
♦ If the crankshaft is positioned after TDC of piston for
cylinder 1 and the pin of the locking device does not
engage in the sealing flange, rotate the crankshaft
back no more than 1/4 revolution and again set the
crankshaft to the TDC of the piston for cylinder 1 by
turning in direction of rotation of engine.
♦ It is not permittedto carry out the correction by turning
in the opposite direction of rotation of the engine in or-
der to insert the locking device.
– Check after inserting the locking device -T10050-, if

the hub can be interlocked with the rig pin -MP 1-301-
or -3359-.
If the hub cannot be arrested:
– Remove pin for locking device from the hole at the

sealing flange and rotate the crankshaft until the hub
can be arrested with the rig pin.
– Slacken bolts of camshaft sprocket -1-.
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– Rotate crankshaft in opposite direction of rotation of

engine long enough until the pin for the locking device
in the sealing flange is positioned close to the hole -ar-
row-.
– Now turn crankshaft in direction of rotation of engine
until the pin for the locking device clicks during this
motion into the sealing flange.
– Tighten bolts of camshaft sprocket to 20 Nm + torque
a further 1/8 turn (45°).
– Remove locking pin -MP 1-301- and locking device
-T10050-.
– Turn crankshaft two turns further in direction of rota-
tion of engine until the crankshaft is again in TDC for
cylinder 1.
Note
♦ Pin for locking device must engage in the sealing
flange. (Locking device should be inserted just ahead
of TDC on toothed belt sprocket.)
♦ If the crankshaft is positioned after TDC of piston for
cylinder 1 and the pin of the locking device does not
engage in the sealing flange, rotate the crankshaft
back no more than 1/4 revolution and again set the
crankshaft to the TDC of the piston for cylinder 1 by
turning in direction of rotation of engine.
♦ It is not permitted to carry out the correction by turning
in the opposite direction of rotation of the engine in or-
der to insert the locking device.
– Further installation occurs in a similar way in reverse

order to removal.
Tightening torques for engine mounts and pendulum sup-
port ⇒ Chapter 10-1.
Tightening torque of the engine mount on the vehicle
body: 45 Nm.

13-2 page 6 S00.5325.00.20
13-3 Disassembling and assembling engine

Cylinder block - Summary of components
1 - 45 Nm
2 - Engine mount
3 - Cylinder block
T removing and installing the
sealing flange and flywheel
⇒ Chapter 13-4
T disassembling and assem-
bling pistons and conrod
⇒ Chapter 13-5
4 - Connection fitting, 40 Nm
T for oil return line from turbo-
charger
T replace
5 - Distance sleeve
6 - Rubber bearing
7 - Bracket
T for plug connections from
hall sender -G40- for cam-
shaft position and for engine
speed sender -G28-
8 - 10 Nm
9 - Gasket
T replace
10 - Oil filter holder
bling ⇒ Chapter 17-1
turn (90°)
T replace
T first of all set up the bolt at
the top left and the bottom
right and then tighten all four
bolts cross-wise
12 - O-ring
T replace
13 - 20 Nm
14 - Engine speed sender -G28-
15 - Connection fittings
T for coolant regulator
16 - 15 Nm
17 - Coolant regulator
T removing and installing ⇒ Chapter 19-2
18 - 45 Nm
T Tightening sequence: from inside to outside
19 - Compact holder
T for generator, AC compressor and tensioning pulley for ribbed V-belt
T note the fitting bush between the compact holder and the cylinder block
T for the V-ribbed belt
21 - 25 Nm
Edition 07.03 Disassembling and assembling engine 13-3 page 1

S00.5325.00.20
22 - Oil pan
T clean sealing surface before installing
T fit with silicone sealant -D 176 404 A2- ⇒ Chapter 17-2
T The gearbox must be removed in order to remove the oil pan ⇒ Manual Gearbox 02R; Rep. Gr. 34
23 - 15 Nm
T The gearbox must be removed in order to remove the rear bolts to the gearbox ⇒ Manual Gearbox 02R;
Rep. Gr. 34
24 - Cover
T with sealing tape
T clean strainer if dirty
25 - Retaining frame
T before assembly, check whether the dowel sleeve is present in the cylinder block and the O-ring is seated in
the retaining frame
26 - 40 Nm
27 - Protective cap
T for drive shaft
Disassembling and assembling engine Edition 07.03

13-3 page 2 S00.5325.00.20

sealing flange and fly-
wheel
Note
♦ Repairs to clutch ⇒ Manual Gearbox 02R; Rep. Gr.
30.
♦ Secure the engine with engine mount - MP 1-202- and
distance sleeves - T30010- on the assembly stand be-
fore performing assembly work.
1 - Gasket ring
T do not additionally lubricate
or grease sealing lips of the
gasket ring
T before installing remove oil
residues on crankshaft jour-
nal with a clean cloth
T replace the gasket ring for
the crankshaft - on the belt
pulley side ⇒ 13-4 page 2
2 - Front sealing flange
T must be positioned on dowel
sleeves
⇒ 13-4 page 3
T install with silicone sealant
-D 176 404 A- ⇒ 13-4
page 4
3 - Cylinder block
crankshaft ⇒ Chapter 13-5
bling pistons and conrod
⇒ Chapter 13-5
4 - Flywheel
T for removing and installing
secure ⇒ Fig. 1 in 13-4
page 2 the flywheel using
-MP 1-504-
turn (90°)
T replace
6 - Intermediate plate
T must be positioned on dowel sleeves
T do not damage/bend during assembly work
T hang on the sealing flange ⇒ Fig. 2 in 13-4 page 2
7 - 15 Nm
8 - Sealing flange with sealing ring
T must be replaced completely
T do not additionally lubricate or grease sealing lips of the gasket ring
T before installing remove oil residues on crankshaft journal with a clean cloth
T use supporting sleeve supplied for installing
T supporting sleeve must not be removed until after pushing sealing flange onto the crankshaft journal
Edition 07.03 Removing and installing sealing flange and flywheel 13-4 page 1
S00.5325.00.20
Fig. 1: Lock the flywheel

MP 1-202
– Position the flywheel lock -MP 1-504- on the ring gear
and turn until it rests against the distance sleeve
-T30010-.
T30010
T30010
MP 1-504
S13-0191
Fig. 2: Installing intermediate plate
– Insert intermediate plate on sealing flange and push

onto the dowel sleeves -arrows-.
Replacing gasket ring for crankshaft - on

the belt pulley side
♦ Gasket ring extractor -MP1-226-
♦ Counterholder -T 30004-
♦ Assembly device -T10053 -
♦ Torque wrench A10-0129
Removing
– Remove the timing belt ⇒ Chapter 13-2.
– Remove crankshaft timing belt sprocket. To this end
lock the timing belt gear with counterholder -T 30004-.
– To guide the gasket ring extractor, screw central bolt
by hand fully into the crankshaft.
– Unscrew inner part of the gasket ring extractor
-MP1-226- two turns (approx. 3 mm) out of the outer
part and lock with knurled screw.
Removing and installing sealing flange and flywheel Edition 07.03

13-4 page 2 S00.5325.00.20
– Oil the thread head of the gasket ring extractor, posi-
tion and forcely screw into the gasket ring as far as
possible.
– Release knurled screw and turn the inner side against
the crankshaft until the gasket ring is pulled out.
Installing
Note
Sealing lip of the gasket ring must not be oiled or greased
additionally.
– Remove oil residue on the crankshaft stub with a

clean cloth.
– Install guide bushing -T10053/1- on the crankshaft
stub.
– Slide gasket ring over the guide bushing onto the
crankshaft stub.
– Press in gasket ring -T10053- with the pressure plate

up to the stop of the central screw.
Note
Replace central screw for toothed belt gear - crankshaft.
– Tighten new central screw for toothed belt gear -

crankshaft to 120 Nm and turn a further 90° (1/4 turn).
– Installing the timing belt, tightening ⇒ Chapter 13-2.
Removing and installing the front seal-

ing flange
♦ Counterholder -MP1-226-
♦ Assembly device -T10053 -
♦ Torque wrench
♦ Hand-held power drill with plastic brush insert
♦ Silicone sealant - D 176 404 A2-
♦ Flat scraper
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Removing
– Remove crankshaft timing belt sprocket. To this end
lock the timing belt gear with counterholder -T30004-.
– Removing oil pan ⇒ Chapter 17-2.
– Unscrew front sealing flange.
– Remove sealing flange, if necessary release by apply-
ing slight blows with a rubber-headed hammer.
– Use a flat scraper to remove sealant residues on the
cylinder block.
– Cover the gasket ring with a clean cloth.
– Use a rotating plastic brush to remove sealant resi-

dues on the sealing flange (wear protective goggles).
– Clean the sealing surfaces. They must be free of oil
and grease.
Installing
Note
♦ Pay attention to the 'use by date' on sealant.
♦ The sealing flange must be installed within 5 minutes
after applying the silicone sealant.
– Cut off nozzle tube of the silicone sealant at the front

marking (∅ of nozzle approx. 3 mm).
– Apply silicone sealant to the clean sealing surface of
the sealing flange, as shown in the illustration.
♦ Thickness of sealant bead -arrows-: 2...3 mm
Note
♦ The sealant bead must not be thicker, otherwise ex-
cess sealant may get into the oil pan, clogg the strain-
er in the retaining frame cover and can get onto the
sealing surface of the sealing ring for the crankshaft.
♦ Before applying the sealant bead cover over the gas-
ket ring with a clean cloth.
– Fit sealing flange immediately and lightly tighten all

bolts.

13-4 page 4 S00.5325.00.20
Note
When installing the sealing flange with the gasket ring fit-
ted use guide sleeve -T10053/1-.
– Tighten the fixing screws of the sealing flange cross-

wise. Tightening torque: 15 Nm
– Remove excess sealant.
– Installing oil pan ⇒ Chapter 17-2.
Note
After installing, allow the sealant to dry for about 30 min-
utes. Only then may engine oil be filled in.
– Installing the toothed belt and setting the timing T10053/1 S13-0194
⇒ Chapter 13-2.
S00.5325.00.20

13-4 page 6 S00.5325.00.20
13-5 Crankshaft, Piston and

Conrod
Removing and installing crankshaft
Note
♦ Before removing the crankshaft, ensure a suitable
place is available for placing it down so that the sensor
rotor (⇒ item 5) does not rest against anything or get
damaged.
♦ Before assembly moisten all bearing and work surfac-
es with oil.
1 - Bearing shells 1, 2 and 4

T for bearing cap without lubri-
cating groove
T for cylinder block with lubri-
cating groove
T do not mix up used bearing 4
3
shells (mark) 2
1
turn (90 °)
T replace
3 - Bearing caps
T Bearing cap 1: on the belt
pulley side
T retaining lugs of the bearing
shells of the cylinder block/
bearing cap must be on top
of one another
4 - Bearing shell 3
T for bearing cap without lubri-
cating groove
T for cylinder block with lubri-
cating groove
5 - Rotor
T for engine speed sender
-G28 -
⇒ Fig. 2 in 13-5 page 2
turn (90 °)
T replace
7 - Fit pin
T Checking projection from crankshaft ⇒ Fig. 1 in 13-5 page 2
8 - Crankshaft
θ ∅ Crankshaft bearing journal: 54.00 mm
θ ∅ Conrod bearing journal 47.80 mm
T Axial play when new: 0.07...0.17 mm
Wear limit: 0.37 mm
9 - Thrust washer
T for cylinder block, bearing 3
Edition 07.03 Crankshaft, Piston and Conrod 13-5 page 1

S00.5325.00.20
Fig. 1: Checking projection of fit pin from crank-

shaft

♦ Depth gauge
Test sequence
– Use depth gauge to inspect projection -a- of dowel pin
when rotor -1- is removed.
1 - Rotor
2 - Fixing screw
3 - Projection of the fit pin -3- from crankshaft a =
2.5...3.0 mm
Fig. 2: Removing and installing sensor rotor
– Always replace the sensor rotor -2- each time the 1 2

bolts -1- are slackened.
Tightening torque: 10 Nm + 90° (1/4 turn)
Note
After being attached a second time, the attachment point
of the recess head screws in the sensor rotor is sufficient-
ly misshapen that the bolt heads rest against crankshaft 3
-3- -arrows- and the sensor rotor is positioned loosely be-
low the screws.
A13-0150
Crankshaft, Piston and Conrod Edition 07.03

13-5 page 2 S00.5325.00.20
Disassembling and assembling piston and conrod
1 - Piston rings
T Offset joint 120 °
T use piston ring pliers for re-
moving and installing
T Marking „TOP“ faces up
T inspect gap clearance
⇒ Fig. 3 in 13-5 page 4
T inspect end clearance
⇒ Fig. 4 in 13-5 page 4
2 - Piston
T with combustion chamber
T mark installation position and
matching cylinder
T Installation position and as-
signment of piston/cylinder
⇒ Fig. 6 in 13-5 page 5
T arrow on piston crown faces
towards the belt pulley side
T use piston ring tensioning
strap for installing
T if cracks present on piston
stem - replace piston
T inspect piston projection at
TDC ⇒ 13-5 page 5
θ ∅ Pistons: 79.47 mm
3 - Piston pin
T if stiff, heat piston to 60°C
T removing and installing with
Drift -222A-
4 - Circlip
5 - Conrod
T replace as a set only
T mark matching cylinder -ar-
rows A-
T Fitting position: Markings -arrows B- point towards the belt pulley side
6 - Bearing shell
T Check fitting position
T Pay attention to version:
top bearing shell (towards the piston) must be in long wearing material
Distinguishing feature:
Black streak on working surface close to separation cut
T do not mix up used bearing shells
T insert bearing shells in the middle
T check for firm seating
T Axial clearance:
Wear limit: 0.37 mm
7 - Cylinder block
T inspect cylinder bore ⇒ Fig. 5 in 13-5 page 5
θ ∅ Cylinder: 79.51 mm
8 - Conrod cap
9 - Oil injection nozzle
T for cooling pistons
10 - Pressure relief valve, 25 Nm

S00.5325.00.20
T opens at an overpressure of 0.25 to 0.32 MPa (2.5 to 3.2 bar)

T replace without sealant
11 - Conrod bolt, 30 Nm + torque a further 1/4 turn (90°)
T replace
T oil thread and head contact surface
Fig. 3: Inspecting piston ring gap clearance

♦ Feeler gauge
– Insert ring at right angles from above down into lower

cylinder opening, about 15 mm away from edge of cyl-
inder.
Piston ring new Wear limit

dimensions in mm
1. Compression ring 0,25...0,40 1,0
Oil scraper ring 0,25...0,50 1,0
Fig. 4: Inspect piston ring end clearance

♦ Feeler gauge
Clean ring groove before inspecting.
Piston ring new Wear limit

dimensions in mm
Oil scraper ring 0,03...0,06 0,15
V13 - 0687

13-5 page 4 S00.5325.00.20
Fig. 5: Inspecting cylinder bore

♦ Internal precision measuring instrument 50...100 mm
Piston dimenston ⇒ item 2 in 13-5 page 3.

Cylinder dimenston ⇒ item 7 in 13-5 page 3.
Test sequence
– Measure at 3 points crosswise in a transverse direc-

tion -A- and lengthwise -B-.
Variations compared to nominal dimension max. 0.10
mm
Note
Do not measure the cylinder bore if the cylinder block is
fixed to the assembly stand with the engine mount
-MP 1-202-, as this may result in incorrect measure-
ments.
Fig. 6: Piston fitting position and assignment of

the piston/cylinder

♦ e.g. electric stylus
Procedure
– Mark installation position and assignment on inside of

piston (not on piston crown), with e.g. an electric sty-
lus.
Piston in cylinder -1- and -2-:
Large piston relief for inlet valve to flywheel side -arrows-
Piston in cylinder -3-:
Large piston relief for inlet valve to belt pulley side -arrow-
Note
♦ For new pistons the cylinder assignment is colour-
coded on the piston crown.
♦ Pistons in cylinders 1 and 2: Identification 1/2
♦ Piston in cylinder 3: Identification 3
Checking piston projection in TDC

♦ Measuring tool for piston projection -MP 1-107-

S00.5325.00.20
Procedure
When installing new pistons or a short engine, inspect the
piston projection at TDC. Depending on the piston projec-
tion fit the relevant cylinder head seal in accordance with
the table below:
Note
Turn the engine in a clockwise direction in order to meas-
ure the piston projection in TDC.
Piston projection over Marking of bore

cylinder block - top side
0.91 mm 1.00 mm 1
1.01 mm 1.10 mm 2
1.11 mm 1.20 mm 3
Identify cylinder head gasket

♦ Spare parts No. = -arrow 1-
♦ Control code = -arrow 2- (ignore)
♦ Bores = -arrow 3-
Note
If different values are measured during the piston projec-
tion measurement, the greatest dimension applies for the
seal assignment.

13-5 page 6 S00.5325.00.20

balancing shaft and re-
taining frame
Note
Before assembly moisten all bearing and work surfaces
with oil.
1 - Chain
T pay attention to correct in-
stallation position ⇒ 13-6
page 2
T before removing mark run-
ning direction
turn (90 °)
T replace
T tightening may occur in suc-
cessive stages
3 - Balancing weight
T can be installed only in one
position
4 - Sprocket
T for balancing shaft
position
5 - Fitting sleeve
turn (90 °)
T replace
7 - Sprocket
T for oil pump
position
8 - Cover
T Clean strainer if dirty
9 - 5 Nm
10 - O-ring
T replace
T check tightness
T lightly oil for assembly
11 - 20 Nm
12 - Oil pump
T with pressure relief valve 1.15 MPa (11.5 bar)
T Before installing, check whether both dowel sleeves are present
13 - Balancing shaft
T removing and installing ⇒ 13-6 page 2
T before assembly, check whether the dowel sleeve is present in the cylinder block and the O-ring is seated in
the retaining frame
15 - O-ring
T replace
T check for correct fitting in the retaining frame
Edition 07.03 Removing and installing balancing shaft and retaining frame 13-6 page 1
S00.5325.00.20
16 - Cylinder block
17 - Chain sprocket for guide pulley
18 - 20 Nm
19 - Chain tensioner with tensioning rail
T to remove lock with -T10060-
20 - 8 Nm + torque a further 1/4 turn (90 °)
T replace
removing and installing balancing shaft

♦ Locating bolts -T10060-
♦ Torque wrench
Removing
– Removing oil pan ⇒ Chapter 17-2.
– Remove the sealing flange on the belt pulley side
⇒ Chapter 13-3.
– Unscrew fixing screws for cover.
– Remove cover from retaining frame.
– Lock chain tensioner with locating bolts -T10060- -ar-
row-.
– Unscrew chain sprocket for guide pulley -1- from re-
taining frame.
– Unscrew fixing screws -2- from the chain tensioner
and remove chain tensioner.
– Remove chain from chain sprockets and place on a
clean surface.
– Lock balancing shaft with open-end wrench -1-.
Note
The open-end wrench must be positioned in the centre
for the safety weight of the balancing shaft and at right
angles to the balancing shaft.
– Loosen fixing bolt -2- for balancing weight.
Note
Only loosen fixing bolt -2- for balancing weight, do not un-
screw.
– Unscrew retaining frame -3- from cylinder block and

remove retaining frame with balancing shaft.
– Lay aside retaining frame on a clean surface.
– Unscrew fixing bolt from the balancing weight.
Removing and installing balancing shaft and retaining frame Edition 07.03
13-6 page 2 S00.5325.00.20
– Remove balancing weight and chain sprocket from
the balancing shaft.
– Turn balancing shaft in such a way that it can be taken
out of its bearing.
Installing
– Oil work surfaces of the bearing.
– Insert balancing shaft in the bearing.
– Slide chain sprocket and balancing weight onto the
balancing shaft.
Note
Assembly of chain sprocket and balancing weight is only
possible in one position.
– Tighten fixing bolt for balancing weight and chain

sprocket by hand.
– Screw retaining frame onto cylinder block clearance
free and by hand.
Note
♦ When installing the retaining frame ensure, that the
dowel sleeve is seated in the cylinder block and the O-
ring in the retaining frame.
♦ Align retaining frame in such a way, that it is aligned
on the belt pulley side with the cylinder block outer
side.
– Screw retaining frame with balancing shaft onto cylin-

der block.
Tightening torque: 20 Nm.
– Check if the retaining frame is aligned on the belt pul-

ley side with the cylinder block outer side.
– Lock balancing shaft with open-end wrench -1- ac-
cording to the illustration.
Note
The open-end wrench must be positioned in the centre
for the safety weight of the balancing shaft and at right
angles to the balancing shaft.
– Tighten fixing bolt -2- for balancing weight.

Tightening torque: 100 Nm + torque a further 1/4 turn (90°)
Note
Fixing bolt is an antifatigue bolt and must always be re-
placed.
– Install chain tensioner.

Tightening torque: 8 Nm + torque a further 1/4 turn (90°)
S00.5325.00.20
Note
Fixing bolts for chain tensioner are antifatigue bolts and
must always be replaced.
– Clean chain with a non-fluffy cloth.

– Check, if the marking -arrow- at the chain sprocket of
the crankshaft is located at the top.
– Fit chain onto chain sprocket of crankshaft, onto chain

sprocket of oil pump and onto chain sprocket of bal-
ancing shaft. While doing so the markings of the col-
our marked chain links -arrows- at chain sprocket of
crankshaft and at chain sprocket of balancing shaft
must be opposite each other, as shown.
Note
Colour marked chain links are additionally marked with a
notch.
– Insert chain sprocket for guide pulley into the chain

and screw chain sprocket for guide pulley onto retain-
ing frame.
– Remove locating bolts -T10060- from chain tensioner.

– Check if the markings of the colour marked chain links
-arrows- at chain sprocket of crankshaft and at chain
sprocket of balancing shaft are opposite each other.
Note
Colour marked chain links are additionally marked with a
notch.
– Install the sealing flange on the belt pulley side

⇒ Chapter 13-3.
– Install cover for balancing shaft.
Note
♦ Oil O-ring for oil pump and inner shank of cover before
installing the cover.
♦ Pay attention to correct fitting of the sealing tape in the
cover.
♦ When installing the cover ensure that it locks into the
retaining frame.
– Installing oil pan ⇒ Chapter 17-2.
13-6 page 4 S00.5325.00.20
– Install the timing belt ⇒ Chapter 13-2.
S00.5325.00.20
13-6 page 6 S00.5325.00.20
15 – Cylinder Head, Valve Gear

cylinder head
Removing and installing toothed belt ⇒ Chapter 13-2
Testing compression pressure ⇒ 15-1 page 6.
Note
♦ When installing an exchange cylinder head with the
camshaft installed, it is necessary to oil the contact
surfaces between bucket tappets and the cam track.
♦ Do not remove the plastic covers supplied as a protec-
tion for the open valves until just before fitting on the
cylinder head.
♦ If the cylinder head is replaced, also the entire coolant
must be replaced.
♦ It is not permissible to rework the cylinder head of die-
sel engines.
1 - Timing belt guard - top part

2 - Timing belt
T removing and installing, ten-
sioning ⇒ Chapter 13-2
3 - 10 Nm
turn (45 °)
5 - 100 Nm
6 - Camshaft sprocket
7 - Hub
T with rotor
T to release and tighten use
the counterholder -T10051 -
T to remove the extractor
-T10052- use
⇒ Chapter 15-3
8 - Timing belt guard rear
9 - Sealing sleeve
10 - Camshaft position sensor
-G40-
T for removing the sealing
grommet ⇒ item 9 from the
timing belt cover remove
from behind
11 - Cylinder head bolt
T replace
T pay attention to sequence for
loosening and tightening
⇒ 15-1 page 3
Edition 07.03 Removing and installing cylinder head 15-1 page 1

S00.5325.00.20
T if bearing caps of the camshaft are removed, insert special bases into the cylinder block before installing the
cylinder head bolts ⇒ Chap. 15-2
12 - Bolts, 10 Nm
T for the engine cover
13 - Cylinder head cover
T before fitting on, thoroughly clean sealing surface with a clean cloth
14 - to charge air pipe at the rear
15 - 10 Nm
T tighten all bolts first of all by hand
T Tighten crosswise from the inside outwards
16 - Pressure control valve
17 - Oil filler inlet
18 - Cap
19 - Sealing sleeve
20 - Bracket
T with fuel line
21 - Gasket for cylinder head cover
22 - 20 Nm
23 - Lifting eye
24 - The unit injector
T removing and installing ⇒ 1.4/55 TDI Engine, Fuel Injection; Rep. Gr. 23
25 - Central plug connection
T for pump-nozzle unit
26 - To the brake servo unit
27 - Tandem pump
T for fuel and vacuum supply
T inspect ⇒ Chapter 20-2
28 - Intake hose
T from the fuel filter ⇒ Chapter 20-1
T white marking
T secure with spring strap clamps
29 - Return-flow hose
T to fuel filter ⇒ Chap. 20-1
T blue marking
T secure with spring strap clamps
30 - Gasket
T replace
31 - Bracket
32 - Hexagon taper nut
33 - Cylinder head
T after replacing fill entire system with fresh coolant
T Inspecting the cylinder head for distortion ⇒ Fig. 1 in 15-1 page 3
34 - Cylinder head gasket
T replace
T Pay attention to the marking ⇒ Fig. 2 in 15-1 page 3
35 - Glow plug
T 15 Nm
Removing and installing cylinder head Edition 07.03

15-1 page 2 S00.5325.00.20
Fig. 1: Inspecting the cylinder head for distortion

♦ Feeler gauge
♦ Knife-edge straightedge
Max. permissible distortion: 0.1 mm
Note
It is not permissible to rework the cylinder heads of diesel
engines.
V15 - 0673
Fig. 2: Identify cylinder head gasket

♦ Spare parts No. = -arrow 1-
♦ Control code = -arrow 2- (ignore)
♦ Bores = -arrow 3-
Note
Cylinder head seals of different thicknesses are fitted de-
pending on the piston projection from the cylinder block.
If only the gasket is replaced, then it must be replaced
with a gasket with the same marking.
Removing and installing cylinder head

♦ Supporting device - MP 9-200-
♦ Bracket -T10014-
♦ Catch pan (e.g. -V.A.G 1306-)
♦ Torque wrench
♦ Hand vacuum pump, e.g. -V.A.G 1390 -
♦ Ventilation reservoir e.g. -V.A.G 1390/1-
Removing
– Remove intake hose between air filter and intake
manifold ⇒ 1.4/55 TDI Engine, Fuel Injection;
Rep. Gr. 23.
– Remove battery and battery tray ⇒ Electrical System;
Rep. Gr. 27.
– Removing charge air pipe at the rear with connecting
hose ⇒ Chap. 21-1.
– Unplug connector with glow plugs.

S00.5325.00.20
– Remove front exhaust pipe with catalytic converter

from exhaust manifold.
– Remove charge air connection hose between turbo-
charger and charge air pipe at bottom ⇒ Chapter 21-
1.
– Pull out vacuum hoses from the turbocharger
⇒ Chapter 21-1 . 1
– Remove oil feed and oil return line for the exhaust tur-
bocharger ⇒ Chapter 21-1.
5
2
– Unscrew inlet connection from intake manifold and 4
place to the side with the hoses connected ⇒ 1.4/55
– Slacken bolts of cylinder head cover. 3
– Use hand vacuum pump and bleeding bottle to extract
the fuel at the return-flow hose of the tandem pump
⇒ Chap. 20-2. S15-0165
– Remove fuel hoses -1- and -4-.
– Remove coolant hose -5-.
– Remove central plug connection -2- for pump-nozzle
unit.
– Disconnect plug -3- from the fuel temperature sender
-G81-. 1
– Unbolt oil feed line at the brackets for oil filter, turbo-
charger and from the mounts.
– Disconnect coolant hose -1- from T-piece and the
coolant hoses -2- and -3- from the connection fittings.
– Disconnect plug -4- from the coolant temperature 2 3
sender -G62-. 4
S15-0166
– Remove the coolant hose -3- from the supports -4-.

– Pull off vacuum hose -6- from tandem pump -5-.
3
4
5
1 6
S10-0150

15-1 page 4 S00.5325.00.20
– Screw bracket -T10014- into the threaded holes in the
area of the coolant pump in the cylinder block. Tight-
ening torque: 20 Nm.
– Follow the specified order for loosening cylinder head

bolts.
Installing
Note
♦ Always replace the cylinder head bolts.
♦ When conducting repairs sealant residues should
carefully be removed from the cylinder block and cyl-
inder head using a chemical cleaner.
♦ Remove the new cylinder head seal from its wrapping
immediately before fitting.
♦ Treat the new seal with the utmost care. Damage to
the silicone layer and in the area of the bead results in
leakages.
– Before fitting the cylinder head position the crankshaft

on the TDC marking.
– Turn crankshaft against the running direction of the
engine until all pistons are almost evenly at TDC.
– Fit on cylinder head gasket.
– Fit on cylinder head and screw on all 8 cylinder head
bolts by hand.
– Tighten cylinder head in four stages in the following
order:
1. Pre-tighten with torque wrench:
Stage I = 40 Nm
stage II = 60 Nm
2. Tighten further with a rigid wrench:
Stage III = 1/4 turn (90°)

Stage IV = 1/4 turn (90°)
Note
Tightening up the cylinder head bolts after doing repair
work is not necessary.

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– After securing the cylinder head turn the camshaft in

such a way that the cams for cylinder 1 point upwards
evenly. Before fitting on the timing belt set the crank-
shaft in the direction of rotation of the engine to the
TDC ⇒ Chapter 13-2.
– After installing the cylinder head, fill tandem pump and
cylinder head with fuel using a hand vacuum pump
and ventilation reservoir ⇒ Chapter. 20-2.
– Further installation occurs in reverse order to removal.
– Perform test drive, interrogate fault memory ⇒ 1.4/55
Testing the compression
Test condition
• Engine oil temperature at least 30 °C

♦ Flexible-head wrench for glow plugs
♦ Torque wrench
♦ Adapter (e.g. -V.A.G 1381/12-)
♦ Compression tester e. g. (-V.A.G 1763-)
Test sequence
– Separate central plug connection for unit injector.
– Remove all glow plugs using a flexible-head wrench.
– Screw in adapter -V.A.G 1381/12- instead of the glow
plugs.
– Check compression pressure with compression tester
-V.A.G 1763 -.
Note
Use of tester ⇒ Operating Instructions. Zyl bar
– Operate starter until the tester no longer indicates a Zylinder
pressure rise. PRINT
! C
Compression readings:
V.A.G 1783
New engine Wear limit Pressure differ-

ence between
individual cyl-
inders
2.5...3.1MPa 1.9 MPa max. 0.5 MPa
(25...31 bar) (19 bar) (5 bar)
– Screw in glow plugs with flexible-head wrench.

Tightening torque: 15 Nm
– Interrogate fault memory ⇒ 1.4/55 TDI Engine, Fuel

Injection System; Rep. Gr. 23.

15-1 page 6 S00.5325.00.20
Note
Faults are stored as a result of separating the central plug
connection for the unit injector. For this reason interro-
gate fault memory or erase ⇒ 1.4/55 TDI Engine, Fuel In-
jection; Rep. Gr. 01.

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15-1 page 8 S00.5325.00.20
15-2 Repairing Valve Gear

Summary of components
Note
Cylinder heads with cracks between the valve seats may
continue to be used without any reduction in the life time
provided the cracks are slight and max. 0.5 mm wide.

turn (90 °)
T replace
T Pay attention to tightening
and release sequence
⇒ Chapter 15-3
2 - Valve-lever shaft
T do not interchange
3 - Cylinder head bolt
T replace
T Pay attention to tightening
and release sequence
⇒ Chapter 15-1
T before installing, insert
washers ⇒ item 4 into the
cylinder head
4 - Washer
T for cylinder head screws
T before installing the bearing
cap, insert into the cylinder
head
5 - Bucket tappets
T do not interchange
T with hydraulic valve clear-
ance compensation
T lay aside with contact sur-
face facing down
T before installing check axial
play of the camshaft ⇒ Fig. 1
in 15-2 page 2
T oil contact surfaces
T before removing, take off
camshaft bearing shell
6 - Collets
7 - Valve spring retainer
8 - Valve spring outside
T removing and installing:
♦ Cylinder head removed: with - MP 1-206-, -MP 1-211-, -MP 1-213-
♦ Cylinder head installed ⇒ Chap. 15-4
9 - Valve spring inside
T removing and installing:
♦ Cylinder head removed: with - MP 1-206-, -MP 1-211-, -MP 1-213-
♦ Cylinder head installed ⇒ Chap. 15-4
10 - Valve stem seal
T replacing ⇒ Chapter 15-4
11 - Valve guide
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12 - The unit injector
T removing and installing ⇒ 1.4/55 TDI Engine, Fuel Injection; Rep. Gr. 23
13 - Cylinder head
T pay attention to note ⇒ 15-2 page 1
T reworking valve seats ⇒ Chapter 15-4
14 - Gasket ring
T Neither oil nor grease sealing lip of sealing ring
T before installing, remove oil residues on the camshaft studs with a clean cloth
T before fitting cover slot on the camshaft cone with adhesive tape (e.g. Scotch tape).
15 - Valves
T Valve dimensions ⇒ Fig. 3 in 15-2 page 3
16 - Bearing shell
T do not mix up used bearing shells (mark)
T ensure the retaining lugs are correctly located in the bearing caps and in the cylinder head
17 - Camshaft
T inspecting axial play ⇒ Fig. 1 in 15-2 page 2
T Slack: max. 0.01 mm
T Identification, timing ⇒ Fig. 4 in 15-2 page 3
18 - Bearing caps
T Fitting sequence ⇒ Chap. 15-3
T Bearing cap 4 is identified like bearing cap 5.
T for installing seal the separator surfaces of bearing caps 1 and 4 with sealant -AMV 174 004 01- ⇒ Fig. 2 in
15-2 page 3
T replace
Fig. 1: Inspecting axial play of camshaft
Special tools, test and measuring equipment and MP 3-447

♦ Universal dial gauge holder -MP 3-447-
♦ Dial gauge
Perform measurement with removed bucket tappets and

installed bearing caps.
Wear limit: max. 0.15 mm
S15-0168
Repairing Valve Gear Edition 07.03

15-2 page 2 S00.5325.00.20
Fig. 2: Seal contact surface of bearing caps 1 and 4
with sealant -AMV 174 004 01- 1
Apply a thin layer of sealant -AMV 17400401- evenly to
the sealing surfaces -1-.
Note
♦ Make sure no sealant penetrates into the slots -ar-
rows-.
♦ Bearing cap 4 is identified like bearing cap 5.
N15-0270
Fig. 3: Valve dimensions
Note
Valves must not be reworked. Only grinding in is permis-
sible.
Dimension Inlet valve Exhaust valve

∅a mm 35,95 31,45
∅b mm 6,980 6,956
c mm 89,95 89,95
α ∠ 45 45
Fig. 4: Camshaft identification, timing

♦ Base circle of cam: a = ∅ 52.8 mm
♦ Camshaft identified with digits and characters
stamped in on the end face of the cam for outlet valve
on 3rd cylinder.
3. Cylinder -arrow- 858 C
Edition 07.03 Repairing Valve Gear 15-2 page 3

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Repairing Valve Gear Edition 07.03

15-2 page 4 S00.5325.00.20
15-3 Camshaft
Removing and installing camshaft
♦ Counterholder - T10051-
♦ Extractor -T10052-
♦ Torque wrench
♦ Sealant -AMV 174 004 01-
Removing
– Unscrew fixing screws -1- for camshaft sprocket.
– Take camshaft sprocket off the hub.
– Loosen fixing screw -1- of the hub.
Use counterholder -T10051- for this purpose.
– Turn bolt attaching the hub out about 2 turns.

– Position extractor -T10052- align them with the hub
bores.
– Screw fixing screws -1- into the hub.
– Put the hub under tension by uniformly tightening the
central bolt -2- until the hub is released from the cam-
shaft cone.
Note
Hold the extractor firmly using an open-end wrench.
– Remove hub from cone of camshaft.

– Remove cylinder head cover.
– Remove valve-lever shaft.
Note
First release crosswise the two outer and then both inner
fixing screws.
– Remove tandem pump ⇒ Chap. 20-2.

– First remove bearing caps 2 and 3. Release bearing
caps 1 and 4 alternately and crosswise.
Edition 07.03 Camshaft 15-3 page 1

S00.5325.00.20
Note
Bearing cap 4 is identified like bearing cap 5.
Installing
Note
♦ When fitting the camshaft the cams of cylinder 1 must
point upwards.
♦ Do not mix up used bearing shells (mark).
♦ When installing the camshaft, ensure it is correctly lo-
cated in the retaining lugs of the bearing shells in the
bearing caps and in the cylinder head.
♦ Before installing the bearing caps make sure the
washers for the cylinder head screws have been in-
serted in the cylinder head.
– Oil the contact surfaces of the bearing shells.

– Tighten bearing caps 2 and 3 alternately crosswise
and tighten to 8 Nm + torque a further 1/4 turn (90 °)
(replace screws).
– Install bearing caps 1 and 4 and also tighten to 8 Nm
+ torque a further 1/4 turn (90 °) (replace screws).
Note
♦ Bearing cap 4 is identified like bearing cap 5.
♦ Seal the separator surface of bearing caps 1 and 4
with sealant -AMV 174 004 01- ⇒ Chap. 15-2
♦ Bearing cap 4 must be aligned with the outer edge of
the cylinder head, as this may otherwise cause leaks
on the tandem pump
– Install camshaft seal ⇒ 15-3 page 3.

– Install valve-lever shafts and tighten evenly and cross-
wise, clearance free to bearing, first the two inside and
then the outside fixing screws, once again tighten.
Tightening torque: 20 Nm + torque a further 1/4 turn

(90 °) (replace)
– Position hub onto camshaft.

– Tighten fixing screw -1- of the hub.
Use counterholder -T10051- for this purpose.
Camshaft Edition 07.03

15-3 page 2 S00.5325.00.20
– Push camshaft sprocket onto hub.
Note
The gear segment -arrow- of the camshaft timing gear
must be at the top.
– Align camshaft so that the longitudinal holes are in the

centre position.
– Fit the bolts -1- attaching the camshaft sprocket on by
hand so that no play exists.
– Lock hub with rig pin -3359-.
– Install tandem pump ⇒ Chap. 20-2.
Note
After installing new bucket tappets, the engine must not
be started for about 30 minutes. The hydraulic clearance
compensation elements must settle (otherwise valves
would strike the pistons).
Removing and installing gasket ring for

camshaft
♦ Insertion tool -MP 1-214-
♦ Gasket ring extractor -T30003-
♦ Torque wrench
♦ Screw -M12x65-
Removing
– Remove camshaft sprocket and hub ⇒ 15-3 page 1.
– Unscrew inner part of the gasket ring extractor
-T 30003- two turns (approx. 3 mm) out of the outer
part and lock with knurled screw.
– Oil the thread head of the gasket ring extractor, posi-
tion and forcely screw into the gasket ring as far as
possible.
– Slacken knurled screw and turn inner part of gasket
ring extractor against the camshaft until the gasket
ring is pulled out.
Installing
Note
Sealing lip of the gasket ring must not be oiled or greased
additionally.
– Remove oil residue on the camshaft stud with a clean

cloth.
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– Cover slot on the camshaft cone with commercially

available adhesive tape (e.g. with sellotape).
– Carefully fit seal onto the camshaft.
– Push on the sealing ring with the pressure plate of the
insertion tool -MP 1-214- and with screw -M12x65- up
to the stop.
Camshaft Edition 07.03

15-3 page 4 S00.5325.00.20
15-4 Valve seats, valves

guides, valve stem seals
Grinding in valve seats

♦ Depth gauge
Note
♦ Do not re-mill valve seats. Only grinding in of valves is
permissible.
♦ inspecting valve guides ⇒ 15-4 page 2. If the wear
limit is exceeded, repeat measurement with new
valves. If the wear limit is again exceeded, replace cyl-
inder head.
♦ Calculating max. permissible reworking dimension
⇒ 15-4 page 1. If the wear limit is exceeded, repeat
measurement with new valves. If the wear limit is
again exceeded, replace cylinder head.
Calculating max. permissible reworking dimen-

sion
– Insert valve and press firmly into the valve seat.
Note
If the valve is replaced when carrying out repair work, use
a new valve for the measurement.
– Measure distance -a- between the end of the valve

stem and the upper face of the cylinder head.
– Calculate max. permissible reworking dimension from
the distance -a- measured and from the minimum di-
mension.
a
Minimum dimension:
♦ Inlet valve 43.4 mm
♦ Outlet valve 43.2 mm
Measured distance less minimum dimension = max. per-

missible reworking dimension.
Example: N15-0253
Measured distance 44,1 mm

- minimum dimension 43,4 mm
= Max. permissible rework- 0,7 mm
ing dimension
Edition 07.03 Valve seats, valves guides, valve stem seals 15-4 page 1
S00.5325.00.20
Note
If the max. permissible reworking dimension is 0 mm, re-
peat measurement with a new valve. If the max. permis-
sible reworking dimension is again 0 mm, replace
cylinder head.
Inspect valve guides

♦ Universal dial gauge holder -MP 3-447-
♦ Dial gauge
Test sequence
– Insert a new valve into the guide. The end of valve
stem must be flush with guide.
Because of the different stem diameters only use inlet
valve in inlet guide or outlet valve in outlet guide.
Valve rock: max. 1.3 mm
Note
♦ If the wear limit is exceeded, repeat measurement
with new valves. If the wear limit is again exceeded,
replace cylinder head.
♦ If the valve is replaced when carrying out repair work,
use a new valve for the measurement.
Replacing valve stem seals

♦ Assembly device -MP 1-213 -
♦ Extractor -MP 1-206-
♦ Insertion tool -MP 1-212-
♦ Valve lever -MP 1-211-
Removing
(Cylinder head fitted) MP 1-213
– Removing camshaft ⇒ Chap. 15-3.
– Remove bucket tappets and lay aside with the contact
surface facing down. Make sure that you do not mix up
the tappets.
– Position piston of the relevant cylinder in dead centre.
– Insert the assembly device -MP 1-213- and adjust
bearing to the stay bolt height.
– Remove valve springs with valve lever -MP 1-211-.
MP 1-211 S15-0171
Valve seats, valves guides, valve stem seals Edition 07.03

15-4 page 2 S00.5325.00.20
Note
♦ The valves rest on the piston crown.
♦ Release collets that are tight by striking with light
blows of a hammer on the valve lever.
– Pull off valve stem seals with -MP 1-206-.
Installing
– Insert the supplied plastic bushings -A- on the relevant
valve stem. This will prevent any damage to the new
valve stem seals -B-.
– Insert the new valve stem seal in the insertion tool
-MP 1-212-.
– Oil the sealing lip of the valve stem seal and carefully
slide into the valve guide.
Note
♦ After carrying out work on the valve gear, carefully
crank engine at least 2 revolutions to ensure that no
valve touches the piston when the engine is started.
♦ After installing the camshaft, the engine must not be
started for about 30 minutes. The hydraulic clearance
compensation elements must settle (otherwise valves
would strike the pistons).
Edition 07.03 Valve seats, valves guides, valve stem seals 15-4 page 3
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15-4 page 4 S00.5325.00.20
17 – Lubrication

parts of the lubrication
system
Note
♦ If considerable quantities of metal swarf or abrasion is
found in the engine oil when carrying out engine re-
pairs, carefully clean the oil galleries in order to avoid
consequential damage and additionally replace the oil
cooler.
♦ Testing oil pressure and oil pressure switch
⇒ Chapter 17-3.
♦ The oil level must never exceed the „max“ marking -
risk of damage to catalytic converter!
Check oil specifications, capacity and oil level
⇒ Inspection and Maintenance; Chap. 02-3
Lubrication system - Summary of components

1 - 15 Nm
2 - Sealing flange
T with gasket
T must be positioned on dowel
sleeves
⇒ Chapter 13-4
T fit with silicone sealant
-D 176 404 A2- ⇒ Chapter
13-4
T Neither oil nor grease sealing
lip of sealing ring
T before installing remove oil
residues on crankshaft jour-
nal with a clean cloth
T replace sealing ring for
crankshaft at belt pulley side
⇒ Chapter 13-4
3 - Cylinder block
4 - Gasket
T replace
bling ⇒ 17-1 page 3
turn (90 °)
T replace
bolts cross-wise
7 - Dipstick
Edition 07.03 Removing and installing parts of the lubrication system 17-1 page 1
S00.5325.00.20
T oil level must not exceed max. marking

8- Filler funnel
T Remove for extracting oil
9- 5 Nm
10 - Guide tube
11 - 10 Nm
12 - O-ring
T replace
T check tightness
T lightly oil for assembly
13 - Cover
T with sealing tape
14 - 20 Nm
15 - Oil pump
T with pressure relief valve 11.5 MPa (1.15 bar)
T Before installing, check whether both dowel sleeves are present
16 - Fitting sleeve
17 - 25 Nm
T replace without sealant
T before installing, check whether the dowel sleeve is present in the cylinder block and the O-ring is seated in
the retaining frame
19 - Oil injection nozzle
T for cooling pistons
T check fitting position: Turn oil injection nozzle anti-clockwise up to the stop in the cylinder block and tighten
in this position
20 - O-ring
T replace
21 - Oil pan
T clean the sealing surfaces before installing
T fit with silicone sealant -D 176 404 A2- ⇒ Chapter 17-2
T The gearbox must be removed in order to remove the oil pan ⇒ Manual Gearbox 02R; Rep. Gr. 34
22 - Bracket
T for connection pipe of charge air cooler
23 - 15 Nm
T The gearbox must be removed in order to remove the rear bolts to the gearbox ⇒ Manual Gearbox 02R;
Rep. Gr. 34
24 - Gasket ring
T replace
25 - Oil drain plug, 30 Nm
T replace
26 - Sprocket
T for oil pump
T can be installed only in one position
T replace
28 - Chain
T Observe the correct fitting position ⇒ Chapter 13-6
29 - Sprocket
T for balancing shaft
Removing and installing parts of the lubrication system Edition 07.03

17-1 page 2 S00.5325.00.20
T replace
T tightening may occur in successive stages
T to release and tighten use the socket wrench -T10061-
31 - Wheel weight
32 - 20 Nm
33 - Chain sprocket for guide pulley
T replace
35 - Chain tensioner with tensioning rail
T to remove lock with -T10060 -
36 - O-ring
T replace
37 - Oil level/temperature sender -G266-
T check ⇒ Binder Current Flow Diagrams, Fault Finding with -VAS 5051C-
Disassembling and assembling oil filter holder

1 - Gasket
T replace
turn (90 °)
T replace
bolts cross-wise
4 - Gasket ring
T replace
T for oil feed line to turbocharg-
er
6 - Oil feed line
T to turbocharger
7 - Oil pressure switch 0.07 MPa
-F1-, 20 Nm
T Cut open gasket ring if leak-
ing and replace
8 - Cap, 25 Nm
9 - O-ring
T replace
10 - Oil filter element
T if replaced, fit new O-rings
⇒ item 9
11 - Screw plug, 10 Nm
12 - Gasket
T replace
Edition 07.03 Removing and installing parts of the lubrication system 17-1 page 3
S00.5325.00.20
T fit into the grooves on the oil cooler

13 - Oil cooler
14 - Gasket
T replace
15 - Screw plug, 25 Nm
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17-1 page 4 S00.5325.00.20

oil pan
Removing and installing oil pan

♦ Hand-held power drill with plastic brush insert
♦ Silicone sealant - D 176 404 A2-
♦ Flat scraper
Removing
– Remove noise insulation -arrows-.
– Drain engine oil.
– Removing the gearbox ⇒ Body Work; Rep. Gr. 50
– Removing the oil pan. S10-0114
– Release oil pan if necessary by applying slight blows
with a rubber-headed hammer.
– Use a flat scraper to remove sealant residues on the
cylinder block.
– Remove sealant residues on the oil pan with a rotating
brush, e.g. with a hand drill with plastic brush attach-
ment (wear protective goggles).
– Clean the sealing surfaces. They must be free of oil
and grease.
Installing
Note
♦ Pay attention to the 'use by date' on sealant.
N17-0012
♦ Oil pan must be installed within 5 minutes after apply-
ing the silicone sealant.
– Cut off nozzle tube at the front marking (∅ of nozzle

approx. 3 mm).
the oil pan, as shown in the illustration.
♦ Thickness of sealant bead: 2...3 mm
♦ The sealant bead must be run past on the inside in the
area of the bolt holes -arrows-.
Note
The sealant bead must not be thicker otherwise excess
sealant may get into the oil pan and clog the strainer in
the oil pump.
N17-0019
Edition 07.03 Removing and installing oil pan 17-2 page 1

S00.5325.00.20

the oil pan, as shown in the illustration. (The diagram
shows the sealant bead on the cylinderblock.)
– Fit oil pan immediately and lightly tighten all oil pan
screws.
– Tighten oil pan screws to 15 Nm.
– Installing the gearbox ⇒ Gearbox 02R; Rep. Gr. 34.
– Tighten the oil pan/gearbox screws to a torque of 45
Nm.
Note
♦ After installing the oil pan, allow the sealant to dry for
about 30 minutes. Only then may engine oil be filled
in.
♦ Oil pan must be aligned with cylinder block.
Further installation occurs in reverse order to removal.
Removing and installing oil pan Edition 07.03

17-2 page 2 S00.5325.00.20
17-3 Testing oil pressure and

oil pressure switch
♦ Oil pressure tester (e.g. -V.A.G 1342-)
♦ Diode test lamp (e.g. -V.A.G 1527 B-)
♦ Measuring tool set -V.A.G 1594 C-
♦ Current flow diagram
Function of dynamic oil pressure warning system if

oil pressure low
The oil pressure switch is opened when pressureless and
closed when the switching pressure is reached.
The oil pressure warning is activated for about 10 sec-
onds after the ignition is switched on („terminal 15 on“).
Activation delay of oil pressure warning system: max. 3
seconds. De-activation delay of the oil pressure warning
system: max. 5 seconds.
Test warning light
After the ignition is switched on and with the engine not
running, the oil pressure warning light in the dash panel
insert must come on for about 3 seconds and then go out.
The check is ended when the engine is started.
Warning criteria
The visual oil pressure warning is switched on (oil pres-
sure warning light flashes) and the buzzer sounds 3 times
as an audible warning if at least one of the following con-
ditions exists:
• „Ignition on“, engine not running, oil pressure switch

closed
• Engine speed above 1500 rpm, oil pressure switch
open
– At an engine speed above 5000 rpm, the oil pressure

warning is also not cancelled if the oil pressure switch
is closed. The oil pressure warning is cancelled once
engine speed is below 5000 rpm.
– If the oil pressure switch is opened for only 0.5 to 3 s
at an engine speed of above 500 rpm, this is stored in
the combination processor of the dash panel insert. If
this situation occurs 3 times when the engine is run-
ning, the oil pressure warning is immediately activated
and is also not cancelled once engine speed is below
1500 rpm. The oil pressure warning is cancelled once
the oil pressure switch is closed for more than 5 s at
an engine speed of above 1500 rpm, or if „ignition off“.
Test conditions
• Engine oil level o.k., testing ⇒ Chap. 17-1

• Oil pressure warning light (-K3-) must come on for
about 3 seconds when ignition is switched on.
• Engine oil temperature at least 80 °C (radiator fan
must have run once).
Edition 07.03 Testing oil pressure and oil pressure switch 17-3 page 1
S00.5325.00.20
Test sequence
– Unplug connector from oil pressure switch.

– Unscrew oil pressure switch and screw in oil pressure V.A.G 1342
tester ( e.g. - V.A.G 1342-)
– Screw oil pressure switch -2- into tester -V.A.G 1342-.
– Connect brown cable -1- of tester to earth (-).
– Connect diode test lamp (e. g. -V.A.G 1527 B-) to oil
pressure switch -2- and to battery positive (+).
The LED must not light up.
+ -
– If the LED lights up, replace the oil pressure switch.
1
– Start engine and slowly increase engine speed. 2
– The LED must come on at an overpressure of
0.055…0.085 MPa The oil pressure switch has be re- A17-0025
placed if it does not come on.
– Increase engine speed further. At 2000 rpm and an oil
temperature of 80 °C the oil pressure should be at
least 0.2 MPa.
At higher engine speeds the oil pressure must not be low-
er than 0.7 MPa, if necessary replace oil filter holder to-
gether with pressure relief valve.
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17-3 page 2 S00.5325.00.20
19 – Cooling
19-1 Parts of cooling system -

Note
♦ When the engine is warm the cooling system is under
pressure. If necessary reduce pressure before re-
pairs.
♦ The hose connections are secured with spring-type
clips. In the event of repairs only use spring-type clips.
♦ Use pliers for spring strap clips to remove and fit the
spring strap clips.
♦ Always replace seals and gasket rings.
♦ When installing fit the coolant hoses free of stress,
without them touching any other components (pay at-
tention to the marking on the coolant connection and
hose).
Coolant mixing ratios ⇒ 19-1 page 4.
Edition 07.03 Parts of cooling system - Summary of components 19-1 page 1

S00.5325.00.20
Parts of the cooling system fitted to body

1 - Radiator
⇒ Chapter 19-2
1 2 3
T after replacing fill entire sys-
tem with fresh coolant
4 5 6
2 - O-ring
T replace
7 8
3 - Top coolant hose
T attached to radiator by re- 19
taining clips
G12
T connection diagram for cool-
ant hoses ⇒ 19-1 page 4
4 - Cap 18 17
T Pressure test ⇒ 19-1 9
page 6
5 - Connector 10
6 - Double screw, 2 Nm
7 - Air duct scoop 16 5 13
8 - 5 Nm 8
9 - Expansion reservoir
T check the coolant system for 11
tightness ⇒ 19-1 page 6 14
T connection diagram for cool- 5 12
ant hoses ⇒ 19-1 page 4 11
10 - Auxiliary fan
T on vehicles with air condi- 8
tioning 2 15
11 - Fan holder
12 - Retaining clip
T for ventilator cable 5 8 12 S19-0088
T check correct fitting
13 - Fan for radiator
14 - Bracket
T for fan connector
15 - Bottom coolant hose
T attached to radiator by retaining clips
T connection diagram for coolant hoses ⇒ 19-1 page 4
16 - Thermoswitch for radiator fan -F18-, 35 Nm
T for radiator fan
T switching temperatures:
1. Stage
♦ on: 91…97 °C
♦ off: 84…91 °C
2. Stage
♦ on: 99…105 °C
♦ off: 91…98 °C
17 - Bottom radiator bearing
18 - 5 Nm
19 - Top radiator bearing
Parts of cooling system - Summary of components Edition 07.03

19-1 page 2 S00.5325.00.20
Parts of cooling system engine side
1 - Coolant hose
T to heat exchanger
3 - 10 Nm
4 - Coolant hose
T from heat exchanger
5 - 25 Nm
6 - Coolant hose
T to the expansion reservoir
7 - Holding claw
8 - Coolant pipe
9 - O-ring
T replace
10 - Coolant hose
T to the expansion reservoir
11 - Coolant hose
T towards top radiator
12 - Coolant hose
T from bottom of radiator
T for coolant regulator
14 - 15 Nm
15 - Coolant regulator
T Observe the fitting position ⇒ Chapter 19-2
T test: heat up regulator in a water bath
T Start of opening approx. 85°C
T finish with approx.105°C
T opening stroke at least 7 mm
16 - Coolant pump
T check smooth operation
17 - O-ring
T check tightness
T replace
18 - Retaining clip
T check tightness
19 - Sender for coolant temperature -G62-
T with coolant temperature gauge sensor -G2-

S00.5325.00.20
Connection diagram for coolant hoses

1- Intake manifold
2- Expansion reservoir
3- Heat exchanger for heating
4- Coolant pipe
5- Oil cooler
6- Top coolant hose
7- Radiator
8- Bottom coolant hose
9- Coolant pump/coolant regula-
tor
10 - Cylinder block/cylinder head
Draining and filling up coolant

♦ antifreeze tester
Draining
Caution!
Hot steam may escape when the compensation
bottle is opened. Cover the cap with a cloth and
open carefully.
– Open the cap of the compensation bottle.

19-1 page 4 S00.5325.00.20
– Place a catch pan under the engine.
S10-0114
– Turn the drain plug -arrow- on the radiator to the left

and to the rear; fit auxiliary hose onto connection if
necessary.
A10-0118
– Also pull off the coolant hoses on the oil cooler -ar-
rows- in order to drain coolant out of the engine.
Note
Observe the disposal instructions for coolant.
Filling up
Select the appropriate coolant additive from the original
spare parts catalogue ŠKODA or from the list of allowed
coolant additives ⇒ Inspection and Maintenance;
Rep. Gr. 02.
Recommended mixture ratios:
Antifreeze protec- Antifreeze Water 2)

tion down to concentra-
tion1)
-25 °C 40% (2.0 ltr.) 60% (3.0 litres)
-35 °C 50% (2.5 litres) 50% (2.5 litres)
1) The proportion of coolant additive must not go below 30% due to
corrosion protection considerations but must also not exceed 60%
otherwise the frost protection effect will be reduced and the cooling
effect worsened.

S00.5325.00.20
2) The coolant amount may differ according to the version of the vehi-
cle.
– Insert and tighten the coolant drain plug.

– Fit coolant hose onto oil cooler.
– Fill up coolant up to „max“ marking on the expansion
reservoir.
– Seal expansion reservoir.
– Run engine until fan starts.
Caution!
Hot steam may escape when the compensation max
open carefully.
min
– Check the level of coolant and top up if necessary.
When engine is at operating temperature the coolant
V19-0579
level must be at the „max“ marking, when engine is
cold between the „min“ and „max“ markings.
Checking the coolant system for tight-

ness
♦ Coolant system tester (e. g. -V.A.G 1274-)
♦ Adapter (e.g. -V.A.G 1274/9 -)
♦ Adapter (e.g. -V.A.G 1274/9 -)
Test condition
• Engine must be warm
Test sequence
Caution!
Hot steam may escape when the compensation
open carefully.
– Open the cap of the coolant expansion reservoir. V.A.G 1274

– Position coolant system tester (e.g. -V.A.G 1274-)
with adapter (e.g. -V.A.G 1274/8-) on the compensa-
tion bottle.
– Using the hand pump of the testing device generate
an overpressure of approx. 0.1 MPa (1 bar).
– If the pressure drops determine position of the leak V.A.G 1274/8
and repair.
G12
S19-0082

19-1 page 6 S00.5325.00.20
Testing the pressure relief valve in the cap
– Screw cap onto tester with adapter (e.g. -V.A.G 1274/
9 -).
– Using the hand pump of the testing device generate
an overpressure of approx. 0.15 MPa (1.5 bar).
– The pressure relief valve should open at a pressure of
0.12…0.15 MPa (1.2...1.5 bar).

S00.5325.00.20

19-1 page 8 S00.5325.00.20

radiator, coolant pump
and coolant thermostat
1
Removing and installing radiator
auxiliary items required 2
♦ Catch pan (e.g. - V.A.G 1306 -)
♦ Torque wrench
♦ Pliers for spring strap clips 3
Removing
– Remove connector -1- from thermo-switch for the S19-0078
coolant fan -F18- and disconnect plug connection -2-
at the fan shroud.
To do so press the latch clips.
There are 2 plug connections on vehicles fitted with air
conditioning.
– Separate the coolant hose from the radiator at the top

and bottom of the connection fittings.
To do so pull the retaining clip -3- up to the stop and
remove the quick coupling towards the rear.
Vehicles without air conditioning

1
– Unbolt cable clip -1- from the starter -arrow-.
Lay cable with cable clip towards the rear. S19-0079

– Unscrew bolts for radiator bearing -arrows-.
– Pull radiator with fan backwards and remove down-

wards.
Vehicles with air conditioning
Caution!
Do not open the refrigerant circuit of the air condi-
tioning system.
S19-0080
Edition 07.03 Removing and installing radiator, coolant pump and coolant 19-2 page 1
S00.5325.00.20 thermostat
– Unscrew bolts for radiator bearing -arrows-.

– Remove the lock carrier with component parts

⇒ Body work; Rep. Gr. 50.
Attach the condenser with the radiator to the engine or
support.
Note
♦ Do not suspend the condenser to the wires.
♦ Do not fold the condenser wires.
S19-0083
– Unscrew fixing bolts for condenser -arrows- and take

out radiator with fan.
Installing
Installation is carried out in the reverse order. Pay atten-
tion to the following:

– Re-adjust headlights on vehicles fitted with air condi-
tioning.
Removing and installing coolant pump S19-0081

♦ Catch pan (e.g. - V.A.G 1306 -)
♦ Torque wrench
Removing
Note
♦ Always replace seals and gasket rings.
♦ Cover the toothed belt with a cloth before removing
the coolant pump in oder to protect it from the coolant.

S10-0114
Removing and installing radiator, coolant pump and coolant Edition 07.03
19-2 page 2 thermostat S00.5325.00.20
– Unscrew the fixing screws -1- of the coolant pump -2-
and carefully remove the coolant pump.
Installing
Installation is performed in the reverse order. Pay atten- 1 2 3
N19-0234
– Clean sealing surface for O-ring.
– Moisten new O-ring -3- with coolant and fit onto cool-
ant pump.
– Position the coolant pump -2- in the cylinder block and
tighten the fixing screws -1-.
Tightening torque: 15 Nm 1 2 3
Note
Plugs of coolant pump point downwards.
– Install toothed belt and tension ⇒ Chapter 13-2.

Removing and installing coolant regula- N19-0234

tor
♦ Torque wrench
Removing
Note
Always replace seals and gasket rings.

– Remove alternator ⇒ Electrical System; Rep. Gr. 27.
– Detach coolant hoses from connection fitting.
– Unscrew the fixing bolts -1- of the connection fittings
-2- and remove connection fitting -2- with coolant reg-
ulator -4-.
– Turn coolant thermostat -4- 1/4 turn (90 °) to the left
and remove from connection fittings -2-.
Edition 07.03 Removing and installing radiator, coolant pump and coolant 19-2 page 3
S00.5325.00.20 thermostat
Installing
Installation is performed in the reverse order. Pay atten-
– Moisten new O-ring -3- with coolant.

– Fit coolant regulator -4- in the connection fitting -2-
and turn 1/4 turn. (90 °) to the right.
Note
Coolant thermostat arms must be practically vertical.
– Insert connection fitting -2- together with coolant ther-

mostat -4- into the engine block.
Removing and installing radiator, coolant pump and coolant Edition 07.03
19-2 page 4 thermostat S00.5325.00.20
20 – Fuel Supply

parts of the fuel supply -
Part 1
Fuel tank with component parts - Sum-

mary of components
Note
♦ Fuel lines are secured with quick-release fittings.
♦ Fuel hoses at engine and fuel filter must only be se-
cured with spring strap clamps. The use of clamp-type
or screw-type clips is not allowed.
♦ Observe safety measures ⇒ 20-1 page 4.
♦ Observe rules for cleanliness ⇒ 20-1 page 4.
Repairing the accelerator control ⇒ Chap. 20-3
1 - Fuel filler cap

2 - 1.5 Nm 1 2
3 - Fuel tank lid unit 3 4 5
T Removing and installing 16
⇒ Body Work; Rep. Gr. 50
4 - Gravity valve 15
T to remove, unclip valve at top
and lift out of filler neck.
T inspect valve for blockage:
♦ valve vertical: Valve open
14
♦ valve tilted 45°: Valve closed
6
5 - Earth connection 13
T check for firm seating 17
6 - 10 Nm 12
7 - Vent line 7
T clipped in place at top of fuel 11
tank
8 - 25 Nm
9 - Fuel tank
T support with engine/gearbox 8
jack -V.A.G 1383 A- when
removing
T removing and installing 9
⇒ Chapter 20-2
10
10 - Tensioning strap
11 - Fuel delivery unit
T Pay attention to the correct 8
fitting position of the flange at
fuel tank ⇒ Fig. 1 in 20-1
page 2 S20-0091
⇒ 20-1 page 5
Edition 07.03 Removing and installing parts of the fuel supply - Part 1 20-1 page 1
S00.5325.00.20
T Check the fuel delivery unit ⇒ 20-1 page 6.

T removing and installing fuel gauge ⇒ 20-1 page 6
12 - Gasket ring
T moisten with fuel before installing
13 - Union nut
T use wrench -MP 1-227- for removing and installing
14 - Feed line
T to fuel filter ⇒ item 7 in 20-1 page 3
T clipped in place on fuel tank
T black
T to remove from flange press release button on the connecting part
15 - Return-flow line
T from fuel cooler ⇒ Chapter 26-2
T blue or blue marking
T clipped in place on fuel tank
T to remove from flange press release button on the connecting part
16 - Vent valve
T Check ⇒ Fig. 2 in 20-1 page 3
T when removing, unclip valve at side and take out of filler neck.
T before installing, unscrew fuel filler cap
17 - O-ring
Fig. 1: Installation position of flange of fuel deliv-

ery unit
Marking on the flange must be aligned with marking on
the fuel tank -arrows-. 2
Blue or blue marked return-flow line -1- to connection
marked -R-.
Black feed line -2- to connection marked -V-.
V
Note
R
After installing the flange of the fuel delivery unit, check

whether the feed, return-flow and vent lines are still 1
clipped in place on the fuel tank.
A20-0096
Removing and installing parts of the fuel supply - Part 1 Edition 07.03
20-1 page 2 S00.5325.00.20
Fig. 2: Inspect vent valve
Lever in off position: closed
Lever pushed in -direction of arrow-: open
Note
Before installing the vent valve, unscrew fuel filler cap.
V20-1040
Repairing the fuel filter

The fuel flow direction is indicated with arrows on the hoses, on the glow valve and on the fuel filter.
T from the tandem pump 4 5
T blue marking
2 - Intake hose
T to the tandem pump
T white marking 3
12
3 - Retaining clip
T replace if damaged 1 2
4 - Preheating valve
T Fitting position: Arrow points
to fuel tank
T if the filter is replaced remove 6
retaining clip and preheating
valve with the fuel lines con- 11
nected
T Temperature less than +
15°C: access to filter open
T Temperature above + 31°C: 7
access to filter closed
T to fuel filter ⇒ Chap. 20-2 8
T blue marking
6 - Intake hose 10 9
T from fuel tank
T white marking
7 - Fuel filter 10
T fill with diesel fuel before fit-
ting
T do not interchange connec- 10
tions
T replace if damaged S20-0096
⇒ Fig. 3 in 20-1 page 4
8 - Gasket
S00.5325.00.20
9 - Drain plug
T to ventilate remove the retaining clip of the preheating valve and remove preheating valve with the fuel lines
connected
T release and drain approx. 0.1 litre fluid (catch)
10 - 25 Nm
11 - Bracket
12 - Plastic insert
T with holder ⇒ item 11 a spare part
Fig. 3: Removing and installing fuel filter
– Remove the preheating valve with the fuel hoses fitted

(pull out retaining clip).
– Remove fuel feed line.
– Push the retaining lugs -arrows- of the plastic insert
outwards.
– Remove fuel filter from the top.
Note
Fuel filter can be removed in one position only.
S20-0097
Safety precautions when working on the
fuel supply system
Pay attention to the following points when removing and
installing the fuel delivery unit/the fuel gauge sender on a
fuel tank that is filled or partially filled:
♦ The extraction hose of an exhaust extraction system
which is switched on, must be positioned close to the
assembly opening of the fuel tank in order to extract
the released fuel gases, even before the work is com-
menced. If no exhaust extraction system is available,
a radial fan (motor not in air flow of fan) with a delivery
volume above 15 m3/h must be used.
♦ Avoid skin contact with fuel! Wear fuel-resistant
gloves!
Rules of cleanliness
Carefully observe the following 6 rules for cleanliness
when working on the fuel supply or injection system.
♦ Thoroughly clean the connection points and their sur-
roundings before releasing.
♦ Place removed parts on a clean surface and cover. Do
not use fuzzy cloths!
♦ Carefully cover or close opened components if the re-
pair is not completed immediately.
♦ Only install clean parts. Remove spare parts from
their wrapping immediately before fitting. Do not use
any parts which have been stored unwrapped (e.g. in
tool boxes).
20-1 page 4 S00.5325.00.20
♦ When the system is open: Avoid using compressed
air. Avoid moving the vehicle.
♦ Also make sure no diesel fuel runs onto the coolant
hoses. If this is the case clean the hoses immediately.
Immediately replace contaminated hoses.
Removing and installing the fuel delivery

unit
♦ Wrench for union nut -MP 1-227 -
♦ Torque wrench
Removing
Observe safety measures ⇒ 20-1 page 4.
Observe rules for cleanliness ⇒ 20-1 page 4.
– Fold rear seat forwards.

– Removing fuel delivery unit guard.
– Pull out 4-pole plug connector and feed and return
flow line from flange.
Note
Press buttons on the hose connections.
– Unscrew union nut with wrench -MP 1-227-.

– Pull the fuel delivery unit and the gasket ring out of the
opening of the fuel tank.
Note
You must empty the old delivery unit before disposing of
it if you wish to replace it.
Installing
– Installation of the fuel delivery unilt occurs in reverse
order.
Note
♦ Do not bend the fuel gauge sender when installing it.
♦ Insert dry gasket ring of the flange or the fuel delivery
unit into the opening of the fuel tank. 2
♦ Moisten gasket ring with fuel only when installing the
flange or the fuel delivery unit.
♦ Make sure the fuel hoses fit tightly.
♦ After installing the fuel delivery unit, check whether V
the feed, return-flow and vent lines are still clipped in

place on the fuel tank. R
♦ Pay attention to installed position of flange of fuel de-

livery unit: Marking on the flange must be aligned with
1
marking on the fuel tank -arrows-. A20-0096
S00.5325.00.20
removing and installing fuel gauge
Removing
– Removing fuel delivery unit ⇒ 20-1 page 5.
– Unlatch and disconnect the line contact studs -3- and
-4-.
– Raise catches -1- and -2- with a screwdriver and re-
move the fuel gauge towards the bottom -arrow-.
Installing
– Insert the fuel gauge sender in the fuel delivery unit
guides and press upwards until they latch into posi-
tion.
Check the fuel delivery unit

♦ Multimeter, e.g. -V.A.G 1715-
♦ Remote control, e.g. -V.A.G 1348/3A-
♦ Measuring tool set, e.g. -V.A.G 1594 C-
♦ Wrench for union nut -MP 1-227-
♦ Pressure gauge appliance, e.g. -V.A.G 1318-
♦ Adapter, e.g. -V.A.G 1318/1-
♦ Adapter, e.g. -V.A.G 1318/11-
♦ Adapter, e.g. -V.A.G 1318/17-
♦ Adapter, e.g. -V.A.G 1318/23-
♦ Measuring vessel
Test conditions
• Battery voltage at least 11.5 volts
• Fuses o.k.
Inspecting proper operation and power supply

– Removing fuel delivery unit guard.
– Switch on ignition. The fuel delivery unit must be
heard to start running. 11 17 23 31
1 6 12
– Switch off ignition. 2 7 13
18
19
24
25
32
33
3 8 14 20 26 34
If the fuel delivery unit does not run: 4 9 15 21 27 35
5 10 16 22 28 36
– Remove cover from the fuse holder. 39 49 59
29
30
37
38
40 50 60
– Remove fuse No. 61 from the fuse holder. 41 51 61
42 52
– Connect remote control -V.A.G 1348/3A- with the 43 53
62
63
adapter cable combination from the adapter cable set 44 54 64
in fuse holder 61 and to positive terminal of battery (+). 45 55 65
46 56 66
– Activate remote control. 47 57 67
48 58 68
If the fuel delivery unit runs: S01-0094
20-1 page 6 S00.5325.00.20
– Test fuel pump relay ⇒ Current Flow Diagrams, Elec-
trical Fault Finding and Fitting Locations.
If the fuel delivery unit does not run:
V
– Disconnect 4-pin plug from flange at the fuel delivery
unit.
– Connect multimeter for voltage measurement to con-
tacts 1 and 4.
– Activate remote control.
V
Specified value: approx. battery voltage.
If the specified voltage value is not reached: R
– Determine and remove open circuit in the wiring ac-

cording to the current flow diagram ⇒ Current Flow
A20-0099
Diagrams, Electrical Fault Finding and Fitting Loca-
tions
If the specified voltage value is reached:
– Unscrew union nut with wrench -MP 1-227-.

– Remove fuel delivery unit and check whether the elec-
tric wiring between the flange and fuel delivery unit is
connected.
If no open circuit was detected:
– Replace the fuel delivery unit.
Inspecting fuel flow rate
Test conditions
• Supply voltage is o.k.
• Battery voltage at least 11.5 V.
• Fuel temperature 15...30 °C.
• Fuel tank at least 1/4 full.
Test sequence
– Unscrew the fuel tank cap from the filler neck. 1
1
– Remove cover of fuel delivery unit/fuel gauge sender 4
unit under rear seat. V
4
– Unplug the 4-pin plug from the fuel delivery unit.
R
– Connect remote control -V.A.G 1348/3A- with con-

nection lines from measuring tool set to contact -1- of
the fuel delivery unit and to battery +.
– Use connection lines from the measuring tool set to
connect the contacts -4- to the plug and to the fuel de-
livery unit. V.A.G 1348/3A
M20-0076
S00.5325.00.20
– Pull off the fuel feed line -arrow- and gather residual
fuel in a cloth.
Caution!
The fuel feed line is pressurized! Place a clean
cleaning cloth around the connection point before
detaching hose connections. Reduce pressure by
carefully releasing the connection point.
S20-0136
– Connect pressure gauge -V.A.G 1318- with adapter

-V.A.G 1318/23 - and -V.A.G 1318/17- to the fuel feed V.A.G 1318
line. V.A.G 1318/11
– Connect hose -V.A.G 1318/1- to adapter V.A.G 1318/23
-V.A.G 1318/11- of the pressure gauge and hold in the
measuring vessel.
– Open shut-off cock of the pressure measuring device.
The lever points in the direction of flow -A-.
– Activate remote control -V.A.G 1348/3A-. Slowly
close the shut-off cock until the manometer displays 3
bar overpressure (0.3 MPa). Now do not change the
position of the shut-off cock. A
– Emty measuring vessel.
– Activate remote control for 30 seconds. B
V.A.G 1318/1
V.A.G 1318/17
N20-0132
– Compare the amount of the fuel pumped to the spec-

ified value (the amount of the fuel pumped is depend-
ent on the voltage of the fuel delivery unit).
If the minimum flow rate is not reached:
– Check the fuel lines for possible diameter restrictions

(kinks) or blocking.
– Remove the fuel delivery unit and check whether the
pump strainer is not clogged up.
If no fault was detected until now:
– Replace the fuel delivery unit.
20-1 page 8 S00.5325.00.20

parts of the fuel supply -
Part 2
Removing and installing the fuel tank

Observe the safety precautions ⇒ Chapter 20-1.
Observe the rules for cleanliness ⇒ Chapter 20-1.

♦ Torque wrench
♦ Engine/gearbox jack (e.g. -V.A.G 1383 A-)
♦ Fuel extraction device
Removing
Note
If the battery is disconnected and reconnected, carry out
certain additional operations ⇒ Electrical System;
Rep. Gr. 27.
– Disconnect the earth strap from the battery with the ig-
nition off.
– Fold rear seat forwards.
– Remove the fuel delivery unit guard and disconnect
the plug connection at the fuel delivery unit flange.
– Drain fuel tank using the fuel extraction device. Fuel
tank cap remains removed.
– Removing rear axle ⇒ Running Gear; Rep. Gr. 42.
– Removing front and rear silencer ⇒ Chap. 26-1.
– Remove left heat shield next to the fuel tank.
– Remove rear right wheelhouse liner. S20-0093
– Unscrew bolts at tank filler neck -arrows-.
– Detach feed line (black) -1- and return-flow line (blue)
-2- from the fuel tank (press release buttons).
– Position the engine/gearbox jack under the fuel tank
for support.
1 2
S20-0094
S00.5325.00.20
– Release the securing bolts of the fuel tank -arrows-.

– Draw the filler neck from the rubber bowl of the tank lid
unit and lower fuel tank.
Installing
Installation occurs in reverse order. Pay attention to the
following:
– Do not mix-up the fuel feed and fuel return line.

– Interrogate fault memory and erase ⇒ 1.4/55 TDI En-
gine, Fuel Injection; Rep. Gr. 01.
Removing and installing fuel cooler S20-0095

♦ Torque wrench
Removing
Observe the rules for cleanliness ⇒ Chapter 20-1.
Note
Fuel cooler is located at the return-flow line to the fuel
tank. It is attached to the underfloor of the vehicle body.
– Removing cover -A-.

– Separate fuel line at fuel cooler.
– Unscrew fixing nuts -arrows-. A
Installing
Installation is carried out in the reverse order. Pay atten-
tion to the following:
♦ Tighten nuts of the fuel cooler to 15 Nm.
Inspecting a tandem pump

N20-0294
♦ Vehicle system tester -V.A.G 1552-
♦ Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C-
♦ Torque wrench
♦ Pressure gauge appliance (e.g. -VAS 5187 - )
Test conditions
• Coolant temperature must be at least 85 °C.
• Unit injector must be O.K.
• Fuel filter and fuel line must not be blocked.
20-2 page 2 S00.5325.00.20
• The non-return valve in the fuel-intake hose must be
O.K.
• Fuel gauge sender must be O.K.
Procedure
– Unscrew screw plug -arrow-.
N20-0288
– Connect pressure gauge appliance (e.g. -VAS 5187-),

as shown in the figure. VAS 5187
– Connect vehicle system tester -V.A.G 1552- and se-
lect address word 01 „Engine electronics“. The engine
must be running in idle ⇒ 1.4/55 TDI Engine, Fuel In-
jection; Rep. Gr. 01.
– Select function 0 8 „Read measured value block“
and display group 002.
N20-0292
– Read off idle speed value in display block 1. Reading measured value block 2 ->
– Engine speed must increase to more than 1500 rpm. 1 2 3 4
– Observe pressure displayed on pressure gauge.

Specified value: at least 3.5 bar (0.35 MPa)
If the specified value is not reached:
– Replace tandem pump ⇒ 20-2 page 4.
Note
After removing the pressure gauge appliance tighten the
plug to 25 Nm. Always replace the gasket ring.
S00.5325.00.20
Removing and installing the tandem

pump
♦ Torque wrench
♦ Hand vacuum pump (e.g. -V.A.G 1390 -) V.A.G 1390
♦ Water drain reservoir, (e.g. -V.A.G 1390/1-)
Removing
– Separate feed hose -1- (marked in white) and return-
flow hose -2- (marked in blue) from the fuel filter.
V.A.G 1390/1
– Connect hand vacuum pump -V.A.G 1390- with water 1
drain reservoir -V.A.G 1390/1- at return-flow hose. 2
– Operate hand vacuum pump until no more fuel comes
out of the return-flow hose.
S20-0109
Ensure that no fuel is drawn into the hand vacuum
pump.
– Disconnect vacuum hose -1- for brake servo unit from

1
tandem pump -4-. 2
– Remove feed hose -2- (marked in white) at the tan-
dem pump -4-.
– Unscrew securing bolts -arrows-.
– Remove tandem pump -4- from cylinder head.
– Pull tandem pump -4- upwards, separate return-flow
hose -3- (marked in blue) and remove tandem pump
-4-.
4
Installing 3
Installation is performed in the reverse order. Pay atten- N15-0254
Note
♦ Ensure the tandem pump coupling is correctly insert-
ed into the camshaft.
♦ Always replace the tandem pump seals.
– Connect return-flow hose -3- (marked in blue) to the

1
return-flow coupling of the tandem pump. 2
– Install tandem pump and tighten the top fixing screws
to 20 Nm.
– Tighten the bottom fixing screws to 10 Nm.
– Connect the feed hose -2- (marked in white) to the
feed connection and the vacuum hose -1- of the brake
servo unit to the tandem pump -4-.
4
3
N15-0254
20-2 page 4 S00.5325.00.20
– Connect feed hose -1- (marked in white) to fuel filter.
– Connect hand vacuum pump (e.g. -V.A.G 1390-) to-
gether with water drain reservoir (e.g. -V.A.G 1390/1-) V.A.G 1390
at return-flow hose -2- (marked in blue) of fuel filter.
– Operate hand vacuum pump until fuel flows out of the
return-flow hose.
Ensure that no fuel is drawn into the hand vacuum
pump. V.A.G 1390/1
– Connect return-flow hose -2- (marked in blue) to fuel 1
filter.
2
S20-0109
S00.5325.00.20
20-2 page 6 S00.5325.00.20
20-3 Servicing accelerator pedal

1 - Bracket
⇒ Chassis; Rep. Gr. 46
1 2
2 - Connector
T 6-pin, black
3 - Accelerator pedal position
sender -G79-
T not adjustable
T The sender transmits the
driver's instructions (by de- 3
pressing the brake pedal as
shown) to the engine control
unit.
T remove the footwell cover
before removing the sender
(driver side) 4
T inspecting ⇒ 1.4/55 TDI En-
gine, Fuel Injection;
Rep. Gr. 28
4 - 10 Nm
S20-0110
Edition 07.03 Servicing accelerator pedal 20-3 page 1

S00.5325.00.20
Servicing accelerator pedal Edition 07.03

20-3 page 2 S00.5325.00.20
21 – Turbocharging
21-1 Charge air system with

turbocharger
Safety measures
Caution!
When undertaking all assembly work, particularly
in the engine compartment due to its cramped con-
struction, please observe the following:
♦ Lay lines of all kinds (e.g. for fuel, hydraulic flu-
id, the active charcoal container-unit, cooling
fluid and refrigerent, brake fluid, vacuum) and
electrical lines in such a way that the original
line guide is re-established.
♦ Ensure that there is adequate free access to all
moving or hot components.
If test and measuring devices are required during test

drives observe the following:
♦ Always secure the test and measuring devices on the
rear seat and have a second person operate them
there.
If the test and measuring devices are operated from the
passenger seat the passenger could be injured by the re-
lease of the passenger airbag in the event of an accident.
Rules of cleanliness
Carefully observe the following rules for cleanliness when
working on the exhaust turbocharger:
♦ Thoroughly clean the connection points and their sur-
roundings before releasing.
♦ Place removed parts on a clean surface and cover. Do
not use fuzzy cloths!
♦ Carefully cover or close opened components if the re-
pair is not completed immediately.
♦ Only install clean parts: Remove spare parts from
their wrapping immediately before fitting. Do not use
any parts which have been (stored unwrapped, e.g.
on a shelf or in a tool box).
♦ Transportation and protection packaging as well as fit-
tings should only be removed immediately before fit-
ting.
♦ During repairs clean supports and hose ends from oil.
♦ When the system is open: Avoid using compressed
air. Avoid moving the vehicle.
Edition 07.03 Charge air system with turbocharger 21-1 page 1

S00.5325.00.20
Removing and installing exhaust turbocharger with component parts
Note
♦ The charge-air system must be tight.
♦ Before connecting the oil feed line, fill the exhaust turbocharger on the connection fitting with engine oil.
♦ After installing the exhaust turbocharger, run engine at idling speed for about 1 minute and do not increase the
speed immediately. This secures the lubrication of the turbocharger.
1 - Exhaust manifold
2 - 30 Nm
T replace
T Coat thread and head con-
tact surfaces with paste
-G 052 112 A3-
3 - Intake manifold
4 - from charge-air cooler
5 - Gasket
T replace
6 - 25 Nm
7 - Gasket
8 - Bracket
T for the shield plate ⇒ item 10
9 - Washer
10 - Shield
T secure in the bracket
⇒ item 8
11 - 10 Nm
12 - Circlip
13 - Vacuum unit
T for the charge pressure con-
trol valve
T Component part of the ex-
haust turbocharger cannot
be replaced separately
14 - of valve block
T Connection diagram for vac-
uum hoses ⇒ 21-1 page 3
15 - Release rod
16 - 10 Nm
T coat with -D 000 600 A2-
17 - Bracket
18 - Connecting hose
T from rear charge air pipe ⇒ 21-1 page 4
19 - Hollow screw, 15 Nm
20 - Gasket ring
T replace
21 - of valve block
T Connection diagram for vacuum hoses ⇒ 21-1 page 3
T replace
T Coat thread and head contact surfaces with paste -G 052 112 A3-
Charge air system with turbocharger Edition 07.03

21-1 page 2 S00.5325.00.20
23 - Oil return line, 30 Nm
T To cylinder block
24 - 15 Nm
25 - Gasket
T replace
26 - Front exhaust pipe
27 - 25 Nm
T replace
28 - Exhaust turbocharger
T replace
T Coat thread and head contact surfaces with paste -G 052 112 A3-
T before connecting the oil feed line fill connection fitting with engine oil.
30 - Oil feed line, 22 Nm
T from oil filter holder ⇒ Chapter 17-1
T Check oil feed line for continuity before installing.
Connection diagram for vacuum hoses

Connect vacuum hoses at valve block
1- Connection air filter/exhaust turbocharger
2- to vacuum reservoir at exhaust turbocharger
3- To turbocharger
4- To intake manifold flap
5- To air filter
6- from non-return valve for brake servo unit
7- to mechanical exhaust gas recirculation valve

S00.5325.00.20
Removing and installing parts of the charge air cooling
Note
♦ The hose connections are secured with clamps.
♦ The charge-air system must be tight.
♦ Remove oil and grease from the charge pressure hoses and charge pressure pipes and from their connections
before installing.
1 - Air deflector
2 - Charge air cooler
⇒ 21-1 page 4
3 - 8 Nm
4 - O-ring
5 - Intake manifold pressure
sender -G71- with intake man-
ifold temperature sender
-G72-
6 - Bracket
7 - 5 Nm
8 - Connecting hose
9 - Top charge-air pipe
10 - To induction pipe
11 - From air filter
12 - From cylinder head cover
T Crankcase ventilation
13 - Rear charge-air pipe
14 - Exhaust turbocharger
15 - Bottom charge air pipe
16 - Bracket
T screwed onto the V-ribbed
belt holder ⇒ Chapter 13-1
Removing and installing charge-air cool-

er
♦ Torque wrench

21-1 page 4 S00.5325.00.20
Removing
– Removing right headlights ⇒ Electrical System;
Rep. Gr. 94.
– Remove plug -1- from the intake manifold pressure
sender -G71- with intake manifold temperature sender
- G72- (-2-).
– Remove the connecting hose -3- from the supports.
– Remove the front right wheelhouse liner ⇒ Body
work; Rep. Gr. 66.
– Unclip front charge-air routing.
– Remove the connecting hose -1- from the charge-air

cooler -3-.
– Release screws -2- and remove charge-air cooler -3-.
Installing
Installation is carried out in the reverse order.
S21-0027

S00.5325.00.20

21-1 page 6 S00.5325.00.20
21-2 Charge-air system with

exhaust turbocharger -
Part 2
Removing and installing turbocharger

♦ Torque wrench
Removing
hose -2- -arrows-.
– Removing connecting hose intake manifold/air filter
⇒ 1.4/55 TDI Engine, Fuel Injection; Rep. Gr. 23.
– Removing connecting tube inlet connection/exhaust
manifold ⇒ Chap. 26-2.
– Remove connecting tube for rear charge-air pipe with
connecting hose to turbocharger ⇒ Chap. 21-1.
– Unscrew the oil feed line for the exhaust turbocharger
⇒ Chapter 21-1.
– Unscrew fixing screws of exhaust manifold at turbo-
charger ⇒ Chapter 21-1.
– Remove drive shaft to the right ⇒ Running gear;
Rep. Gr. 40.
– Unscrew the propeller-shaft guard from the cylinder
block.
– Removing bottom charge air pipe with connecting
hose to turbocharger ⇒ Chap. 21-1.
– Pull out vacuum hoses from the turbocharger
⇒ Chapter 21-1 .
– Unscrew the oil return-flow line from the cylinder block
⇒ Chap. 21-1.
– Remove front exhaust pipe with catalyst ⇒ Chapter S10-0114
26-1.
– Remove fixing nut of turbocharger at exhaust manifold
⇒ Chapter 21-1.
– Remove turbocharger downwards.
Installing
Installation occurs in reverse order. Pay attention to the
following:
Edition 07.03 Charge-air system with exhaust turbocharger - Part 2 21-2 page 1
S00.5325.00.20
Note
♦ Tightening torques ⇒ Chapter 21-1
♦ After installing the exhaust turbocharger, run engine
at idling speed for about 1 minute to ensure that oil is
supplied to the exhaust turbocharger.
Checking charge pressure control

♦ Hand vacuum pump (e.g. -V.A.G 1390-)
♦ Hand multimeter (e.g. -V.A.G 1715-)
♦ Vehicle system tester -V.A.G 1552-
♦ Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C-
♦ Adapter cable set (e.g. -V.A.G 1594 C-)
♦ Test box -V.A.G 1598/31-
Test conditions
• No fault stored in fault memory ⇒ 1.4/55 TDI Engine,
Fuel Injection; Rep. Gr. 01
• No leaks on the intake and exhaust side
• No fault on the engine/fuel injection system
• Engine oil temperature at least 80 °C
Test sequence
If test and measuring devices are required during test
drives observe the following:
♦ Always secure the test and measuring devices on the
rear seat and have a second person operate them
there.
♦ If the test and measuring equipment is operated from
the front passenger seat, this can result in injuries to
the persons sitting on that seat in the event of an ac-
cident which involves the front passenger airbag be-
ing deployed.
– The charge pressure is measured with vehicle system

tester -V.A.G 1552- when the engine is idling and dur-
ing a road test.
– Connect vehicle system tester -V.A.G 1552- and se-
lect address word 01 „Engine electronics“. (the engine
must be idling at the time) ⇒ 1.9/74 TDI Engine, Fuel
Injection; Rep. Gr. 01.
– Select function 0 4 for „Basic setting“ and display
group 0 1 1 .
Basic setting 11 ->
Readout on display:
1400 rpm OFF 200 mbar 99 %
Charge-air system with exhaust turbocharger - Part 2 Edition 07.03

21-2 page 2 S00.5325.00.20
Note
After selecting display group 011, the idling speed is in-
creased by the engine control unit in display block 1 to
1380…1420 rpm.
The display in display field 2 must switch between „off“
and „on“ every 10 seconds.
The following readouts must fluctuate in display fields 3
and 4:
Display field 2: off.
♦ Specification in display field 3: Atmospheric pressure
in mbar
♦ Specification in display field 4: 98…100 %
Display field 2: on.

♦ Specification in display field 3: Atmospheric pressure
in mbar +80…250 mbar
♦ Specification in display field 4: 0…2 %
Continue the test as follows:
Press → .
– Select function 0 8 for „Read measured value

block“ and display group 0 1 1 .
– Accelerate vehicle in 3rd gear at full throttle from
about 1500 rpm.
Reading measured value block 11 ->
– At about 3000 rpm read off the value indicated in dis- 3090 rpm 1866 mbar 1917 mbar 62 %
play block.
Specification in display field 3: 1850…2250 mbar
If the specified value is not reached:
– Activate charge pressure control solenoid valve with

final control diagnosis ⇒ 1.4/55 TDI Engine, Mechan-
ics; Rep. Gr. 01.
Charge pressure control solenoid valve must operate for
this test. While doing so the linkage of the charge pres-
sure control vacuum unit at the bottom of the turbocharg-
er must move back and forward. This linkage must move
at least 3…4 times as long as a vacuum is present in the
vacuum system.
If the linkage moves and the nominal charge pressure is
not reached:
– Check charge air pressure system for leaks.

– Replace exhaust turbocharger ⇒ 21-2 page 1.
If the linkage does not move because the charge pres-
sure control solenoid valve is not operating:
– Inspect charge pressure control solenoid valve -N75-

⇒ 1.4/55 TDI Engine, Mechanics; Rep. Gr. 23.
– Inspect vacuum hoses ⇒ Chapter 21-1 .
If the linkage does not move although the charge pres-
sure control solenoid valve is operating:
Edition 07.03 Charge-air system with exhaust turbocharger - Part 2 21-2 page 3
S00.5325.00.20
– Connect hand vacuum pump to charge pressure con-

trol valve and inspect linkage for unobstructed move-
ment.
If the linkage only moves with difficulty or does not move
at all:
– Replace exhaust turbocharger ⇒ 21-2 page 1.
Charge-air system with exhaust turbocharger - Part 2 Edition 07.03

21-2 page 4 S00.5325.00.20
26 – Exhaust System

parts of the exhaust sys-
tem
Note
♦ After performing installation work on the exhaust sys-
tem, make sure the exhaust system is not mounted
under tension and has adequate clearance from the
vehicle body. If necessary slacken double clamp and
collar clamp and align silencer and exhaust pipe so
that ithere is adequate clearance between these com-
ponents and the body and that the weight is evenly
distributed over the hangers.
♦ Gaskets and self-locking nuts must be replaced.
1 - Gasket
T replace
2 - 25 Nm
T replace
3 - Spring loop
4 - Front exhaust pipe with cata-
lytic converter
5 - Identification
6 - Dimension -a- = approx. 12
mm.
7 - Double clamp
8 - 40 Nm
9 - Hanger
T with spring loop
10 - 25 Nm
11 - Rear silencer
Edition 07.03 Removing and installing parts of the exhaust system 26-1 page 1
S00.5325.00.20
Align exhaust system free of stress

♦ Torque wrench
Procedure
• The exhaust system is aligned when cold.
– Slacken bolted connections of double clamp between
catalytic converter and front silencer and replace nuts.
– Position double clamp at the distance -a- = 5 mm from
the marking on the pipe of the catalytic converter a
(bolts at bottom and horizontal) and tighten front bolt- S26-0064
ed connection slightly.
– Push front silencer -1- sufficiently far forward into the
double clamp until the dimension -b- of 3…7 mm is
achieved between hanger of body and hanger of front 1
silencer.
-Arrow- points in direction of travel.
– Tighten bolted connections on the double clamp in

this position.
Note
After tightening the double clamp, inspect dimension -b- b
and adjust if necessary.
S26-0065
Replacing front or rear silencer

♦ Torque wrench
♦ Body saw (e.g. -V.A.G 1523-)
A separation point is provided for repair purposes for re-

placing the front silencer or rear silencer.
– Separate exhaust pipe with body saw at right angles

at the separation point -arrow 1-. 4
– When installing double clamp -4- position on the side
markings -arrows 2 and 3-.
– Align exhaust system free of stress ⇒ 26-1 page 2.
– Align rear silencer horizontally.
– Tighten bolted connections of the double clamp even- 3
ly to 40 Nm. 2
Installation position of double clamp: Bolts positioned
vertically at front of exhaust pipe.
1
S26-0063
Removing and installing parts of the exhaust system Edition 07.03

26-1 page 2 S00.5325.00.20
26-2 Exhaust gas recirculation

system
Note
♦ The exhaust gas recirculation system is operated by
the diesel direct injection system control unit -J248-
via the EGR valve -N18- to the mechanical exhaust
gas recirculation valve.
♦ The mechanical exhaust gas recirculation valve with
cone-shaped valve plunger makes it possible to
achieve different opening cross-sections at different
valve strokes.
♦ Any desired valve position is possible as a result of the
pulsed operation
Removing and installing parts of the exhaust gas recirculation system

1 - Intake manifold
2 - O-ring
T replace
3 - Inlet connection
T with mechanical exhaust gas
recirculation valve and intake
manifold flap
4 - Mechanical exhaust gas recir-
culation valve
T part of inlet connection
T Must be replaced together
with the inlet connection
5 - 10 Nm
6 - from charge-air cooler
7 - Gasket
T replace
8 - 25 Nm
9 - Exhaust manifold
10 - Connecting tube
Edition 07.03 Exhaust gas recirculation system 26-2 page 1

S00.5325.00.20
Testing mechanical exhaust gas recircu-

lation valve
♦ Hand vacuum pump (e.g. -V.A.G 1390 -)
Test sequence
– Disconnect vacuum hose on mechanical exhaust-gas
recirculation valve.
– Connect hand vacuum pump to valve. V.A.G 1390
– Operate pump and observe.
The diaphragm must move in the -direction of the ar-
row-.
– Detach hose of hand vacuum pump from mechanical

exhaust gas recirculation valve.
The diaphragm must move back to its original position
against the -direction of the arrow-.
S13-0161
Exhaust gas recirculation system Edition 07.03

26-2 page 2 S00.5325.00.20

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Service 5

Service Department. Technical Information Printed in Czech Republic

List of Supplements to Workshop Manual

Edition 07.03 List of Supplements

List of Supplements Edition 07.03

10 – Removing and Installing Engine

15 – Cylinder Head, Valve Gear

Edition 07.03 Table of Contents I

Table of Contents Edition 07.03

Edition 07.03 Table of Contents III

Table of Contents Edition 07.03

00-1 Technical Data

Engine identification characters AMF

Edition 07.03 Technical Data 00-1 page 1

Technical Data Edition 07.03

10 – Removing and Installing Engine

10-1 Removing and Installing

Edition 07.03 Removing and Installing Engine 10-1 page 1

– Remove front bumper ⇒ Body work; Rep. Gr. 63.

– Unbolt the pendulum support -arrows-.

For vehicles with air conditioning

– Release the retaining clips of the AC system lines.

For all vehicles

Removing and Installing Engine Edition 07.03

– Remove charge-air pipe at the top -1- with connecting

– Remove the coolant feed hose -3- from the supports

Edition 07.03 Removing and Installing Engine 10-1 page 3

– Unplug connector -1- from the engine control unit.

– Disconnect the plug connections -2- and -3- under the

– Suspend lifting device -MP 9-201- as follows and

Removing and Installing Engine Edition 07.03

– Unscrew bolts for gearbox mount -arrows-.

– Carefully raise the engine with gearbox and pull out

Securing the engine to the assembly

To perform the assembly work the engine must be se-

Modify engine mount -T10012-

Edition 07.03 Removing and Installing Engine 10-1 page 5

– Position engine/gearbox with engine/gearbox jack

T 10012 V.A.G 1383/A

– Remove cover plate -A- for flywheel behind the right

Removing and Installing Engine Edition 07.03

– Unscrew Engine mount - T10012-.

– Check whether the dowel sleeves for centering the

Edition 07.03 Removing and Installing Engine 10-1 page 7

– If necessary check the centering of the clutch driver

– Connect lines for brake fluid to clutch slave cylinder

– Top up coolant ⇒ Chapter 19-1.

Removing and Installing Engine Edition 07.03

Engine assembly bracket

1 - 30 Nm + 90° (1/4 turn) - replace

Edition 07.03 Removing and Installing Engine 10-1 page 9

Removing and Installing Engine Edition 07.03

13-1 Removing and installing

Removing and installing V-ribbed belt

Removing the V-ribbed belt

Edition 07.03 Removing and installing V-ribbed belt 13-1 page 1

– Lock tensioning pulley with rig pin -T10060-.

Installing the V-ribbed belt

After finishing the work always:

– Start engine and check belt run.

Routing of the V-ribbed belt

Belt run without AC compressor

Belt run with AC compressor

Removing and installing V-ribbed belt Edition 07.03