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Passat 1997 ➤
Passat Variant 1997 ➤
4-cylinder diesel engine with unit injector
Engine ID AJM ATJ AVB AVF AWX
Edition 07.2011
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Passat 1997 ➤ , Passat Variant 1997 ➤
4-cylinder diesel engine with unit injector - Edition 07.2011
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2 Sealing flange and flywheel or drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Renewing crankshaft oil seal - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4 Removing and installing sealing flange - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2 Pulling needle roller bearing out of and driving into crankshaft . . . . . . . . . . . . . . . . . . . . . . 28
3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2 Separating new conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3 Pistons and cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.4 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.5 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.2 Assembly overview - parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.3 Assembly overview - oil filter bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Contents i
Passat 1997 ➤ , Passat Variant 1997 ➤
4-cylinder diesel engine with unit injector - Edition 07.2011
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1 Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.1 Assembly overview - parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.2 Assembly overview - parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . 82
1.3 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.4 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.6 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.7 Removing and installing viscous fan coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.8 Check fuel cooling pump V166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.9 Check radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1.1 Assembly overview - turbocharger with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1.2 Removing and installing parts of charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.3 Vacuum hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.4 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
ii Contents
Passat 1997 ➤ , Passat Variant 1997 ➤
4-cylinder diesel engine with unit injector - Edition 07.2011
Contents iii
Passat 1997 ➤ , Passat Variant 1997 ➤
4-cylinder diesel engine with unit injector - Edition 07.2011
iv Contents
Passat 1997 ➤ , Passat Variant 1997 ➤
4-cylinder diesel engine with unit injector - Edition 07.2011
00 – Technical data
1 Technical data
Engine number and engine code ⇒ page 1 .
Engine data ⇒ page 1 .
1. Technical data 1
Passat 1997 ➤ , Passat Variant 1997 ➤
4-cylinder diesel engine with unit injector - Edition 07.2011
Note
– All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
– Remove engine cover.
– Remove connecting pipe between charge air cooler and intake
connection.
– Detach fuel supply hose (with white marking) and return hose
(with blue marking) from fuel lines (clipped to bulkhead) and
use a cloth to absorb any fuel which escapes.
– Remove intake connection with intake manifold flap and ex‐
haust gas recirculation valve (mechanical).
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .
– Remove front bumper ⇒ General body repairs, exterior; Rep.
gr. 63 ; Assembly overview - front bumper
– Drain coolant ⇒ page 87 .
Note
Note
WARNING
Note
Note
WARNING
1 - Cross tube
❑ With torque support
2 - Stop buffer
3 - Stop
❑ Allow to move onto stop
buffer under its own
weight and tighten se‐
curing bolts.
4 - 30 Nm
WARNING
Note
13 – Crankshaft group
1 Dismantling and assembling engine
Note
I ⇒ page 13
II ⇒ page 14
III ⇒ page 15
IV ⇒ page 17
1.1.1 Part I
1 - 25 Nm
2 - Alternator
3 - 25 Nm
4 - Relay lever
5 - Spacer
❑ Note installation posi‐
tion.
6 - Belt pulley
❑ For poly V-belt.
7 - Tensioning element
❑ For poly V-belt.
❑ Removing and installing
poly V-belt
⇒ page 18 .
8 - Bracket for ancillaries
❑ For alternator, poly V-
belt tensioning element,
radiator fan viscous
coupling and power-as‐
sisted steering vane
pump
9 - 45 Nm
❑ Observe tightening se‐
quence ⇒ page 18 .
10 - 45 Nm
11 - Vane pump
❑ For power-assisted
steering
❑ Removal and installing:
⇒ Running gear, axles,
steering; Front and four-
wheel drive; Rep. gr. 48 ; Vane pump, reservoir, hydraulic lines for vehicles with 4 or 5-cylinder engines
12 - Banjo bolt, 30 Nm
13 - Seal
❑ Renew.
14 - Pressure line
15 - Belt pulley
❑ For vane pump
16 - Bracket
❑ For tensioning element
17 - Belt pulley
❑ For viscous fan coupling.
1.1.2 Part II
17 - 15 Nm
18 - 20 Nm
19 - Toothed belt guard lower part
20 - Belt pulley and vibration damper
❑ Can only be installed in one position, holes are offset.
21 - 10 Nm + 1/4 turn (90°) further
22 - Cover
23 - Toothed belt guard centre part
1.1.4 Part IV
1 - 45 Nm
2 - Screen
3 - Bracket
❑ For vacuum reservoir
and charge pressure
control solenoid valve -
N75-
4 - Cylinder block
❑ Removing and installing
sealing flanges and fly‐
wheel/drive plate
⇒ page 19 .
❑ Removing and installing
crankshaft
⇒ page 26 .
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 30
5 - Bracket
❑ For fuel filter.
6 - Bolt
7 - 10 Nm
8 - Gasket
❑ Renew.
9 - Oil filter bracket
❑ Dismantling and assem‐
bling ⇒ page 69 .
10 - 15 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew.
❑ First fit upper left and
lower right bolts and then tighten all four bolts diagonally.
11 - Engine speed sender
12 - Connection
❑ For thermostat.
13 - 15 Nm
14 - O-ring
❑ Renew.
15 - Thermostat
❑ Removing and installing ⇒ page 94
16 - 45 Nm
❑ Observe tightening sequence ⇒ page 18 .
17 - Bracket for ancillaries
❑ For alternator, radiator fan viscous coupling, poly V-belt tensioning element and power-assisted steering
vane pump
18 - Oil sump
❑ Clean sealing surface before fitting.
Note
Note
1 - Seal
❑ Do not additionally oil or
grease the oil seal seal‐
ing lip.
❑ Before installing, re‐
move oil residue from
crankshaft journal using
a clean cloth.
❑ Renewing crankshaft oil
seal - belt pulley end
⇒ page 20 .
2 - Sealing flange
❑ Must seat on dowel
sleeves.
❑ Removing and installing
⇒ page 23
❑ Install with silicone seal‐
ant -D 176 404 A2-
⇒ page 23 .
3 - Cylinder block
❑ Removing and installing
crankshaft
⇒ page 26 .
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 30
4 - Flywheel/drive plate
❑ When removing and in‐
stalling flywheel, lock
with counterhold
-3067- .
❑ Removing and installing
drive plate
⇒ page 21 .
5 - 60 Nm + 1/4 turn (90°) further
❑ Renew.
6 - Intermediate plate
❑ Must seat on dowel sleeves.
❑ Do not damage or bend when assembling.
7 - 15 Nm
8 - Sealing flange with oil seal
❑ Renew complete only.
❑ Do not additionally oil or grease the oil seal sealing lip.
2.2.1 Removing
– Remove poly V-belt ⇒ page 18 .
– Remove toothed belt ⇒ page 37 .
Note
2.2.2 Installing
– Remove oil residue from crankshaft journal using clean cloth.
– Fit guide sleeve -T10053/1- onto crankshaft journal.
– Slide oil seal over guide sleeve onto crankshaft journal.
– Remove drive plate again and fit shim -2-. Tighten bolts to 30
Nm again.
– Tighten bolts to 60 Nm and turn 90° (1/4 turn) further (turning
further can be done in several stages).
Not illustrated:
2.4.1 Removing
– Remove poly V-belt ⇒ page 18 .
– Remove toothed belt ⇒ page 37 .
– Remove crankshaft toothed belt pulley. To do this, lock tooth‐
ed belt pulley using counterhold -3099- .
Note
2.4.2 Installing
Note
Note
Note
When fitting sealing flange with oil seal installed use guide sleeve
-T10053/1- .
Note
3 Crankshaft
10 - Crankshaft
❑ Axial clearance new: 0.07 … 0.17 mm wear limit: 0.37 mm
❑ Check radial clearance with Plastigage, new: 0.03 … 0.08 mm, wear limit: 0.17 mm
❑ Do not rotate crankshaft when checking radial clearance.
❑ Crankshaft dimensions ⇒ page 29 .
❑ Different design for manual and automatic gearboxes; note part number
11 - Thrust washer
❑ For cylinder block, bearing 3.
12 - Bearing shell 3
❑ For cylinder block with oil groove.
Note
3. Crankshaft 27
Passat 1997 ➤ , Passat Variant 1997 ➤
4-cylinder diesel engine with unit injector - Edition 07.2011
3.2 Pulling needle roller bearing out of and driving into crankshaft
Note
Removing
– Extract with puller -A-, e.g. Kukko -21/2- and Kukko -22/1- or
puller -10-202- .
Installing
3. Crankshaft 29
Passat 1997 ➤ , Passat Variant 1997 ➤
4-cylinder diesel engine with unit injector - Edition 07.2011
1 - Piston rings
❑ Offset gaps by 120°.
❑ Use piston ring pliers to
remove and install.
❑ „TOP“ faces towards
piston crown.
❑ Checking ring gap
⇒ page 32 .
❑ Checking ring-to-groove
clearance ⇒ page 32 .
2 - Piston
❑ With combustion cham‐
ber.
❑ Mark installation posi‐
tion and cylinder num‐
ber.
❑ Installation position and
allocation of piston to
cylinder ⇒ page 33 .
❑ Arrow on piston crown
points to belt pulley end.
❑ Install using piston ring
clamp.
❑ If piston skirt is cracked,
renew piston.
❑ Checking piston projec‐
tion at TDC
⇒ page 33 .
3 - Piston pin
❑ If difficult to remove,
heat piston to 60 °C.
❑ Remove and install us‐
ing drift -VW 222A- .
4 - Circlip
5 - Conrod
❑ Renew as set only.
❑ Mark with cylinder number -A-.
❑ Installation position: Marking -B- faces towards pulley end.
6 - Bearing shell
❑ Note installation position.
❑ Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identifi‐
cation: Black line on bearing surface in area of joint.
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally.
❑ Check for secure seating.
❑ Axial clearance, wear limit: 0.37 mm
❑ Measure radial clearance with Plastigage: Wear limit: 0.08 mm, do not rotate crankshaft when measuring
radial clearance.
7 - Cylinder block
❑ Checking cylinder bores ⇒ page 32 .
❑ Piston and cylinder dimensions ⇒ page 34 .
8 - Conrod bearing cap
❑ Note installation position.
9 - Oil spray jet
❑ For piston cooling.
10 - 25 Nm
❑ Insert without sealant.
11 - Conrod bolt, 30 Nm + 1/4 turn (90°) further
❑ Renew.
❑ Oil threads and contact surface.
❑ Use old bolt for measuring radial clearance.
Note
Note
Note
Test procedure
Piston projection at TDC must be measured when installing new
pistons or a short engine. Install the appropriate cylinder head
gasket depending upon piston projection, according to following
table:
Note
Note
Note
1. Cylinder head 35
Passat 1997 ➤ , Passat Variant 1997 ➤
4-cylinder diesel engine with unit injector - Edition 07.2011
30 - Cylinder head
❑ Removing and installing ⇒ page 48
❑ If renewed, change entire coolant in system
31 - Cylinder head gasket
❑ Renew.
❑ Note marking ⇒ page 37 .
❑ If renewed, change entire coolant in system
32 - Glow plug
❑ 15 Nm
❑ Checking ⇒ page 165 .
33 - 15 Nm
34 - Tensioning roller
35 - 20 Nm + 1/8 turn (45°) further
Note
♦ Cracks between the unit injector holes and the valve seats are
not critical and do not justify exchanging the cylinder head.
♦ Reworking diesel cylinder heads is not permissible.
Note
Note
1. Cylinder head 37
Passat 1997 ➤ , Passat Variant 1997 ➤
4-cylinder diesel engine with unit injector - Edition 07.2011
Removing
– Turn crankshaft to TDC No. 1 cylinder.
1. Cylinder head 39
Passat 1997 ➤ , Passat Variant 1997 ➤
4-cylinder diesel engine with unit injector - Edition 07.2011
Note
Turn the crankshaft until the mark on the crankshaft toothed belt
pulley is on the top and the arrow on the rear toothed belt guard
aligns with the lug on the hub sender wheel -arrows-.
Note
– Insert a hexagon key into the hexagon hole onto limit stop and
push the tensioning roller anti–clockwise -direction of arrow-
until the toothed belt tensioner can be fixed with the locking
plate -T10008- .
Note
Note
Note
1. Cylinder head 41
Passat 1997 ➤ , Passat Variant 1997 ➤
4-cylinder diesel engine with unit injector - Edition 07.2011
Note
♦ When doing this, the pin of the crankshaft stop -T10050- must
engage in the sealing flange from the rotational movement.
♦ If the crankshaft is turned past TDC No. 1 cylinder and the
crankshaft stop was unable to engage in the sealing flange,
turn the crankshaft back 1/4 turn to set it to TDC No. 1 cylinder
by again turning in the direction of engine rotation. Corrections
to the position by turning against the direction of engine rota‐
tion in order to insert the crankshaft stop are not permissible.
Note
♦ When doing this, the pin of the crankshaft stop -T10050- must
engage in the sealing flange from the rotational movement.
♦ If the crankshaft is turned past TDC No. 1 cylinder and the
crankshaft stop was unable to engage in the sealing flange,
turn the crankshaft back 1/4 turn to set it to TDC No. 1 cylinder
by again turning in the direction of engine rotation. Corrections
to the position by turning against the direction of engine rota‐
tion in order to insert the crankshaft stop are not permissible.
– Repeat check.
– Install lower toothed belt guard and pulley vibration damper.
– Install centre toothed belt guard.
– Bolt relay lever for poly V-belt to ancillary bracket.
– Bolt fuel cooler coolant lines in place and and fit upper belt
guard.
– Install poly V-belt ⇒ page 18 .
– Install viscous fan coupling fan wheel.
– Install lock carrier ⇒ General body repairs, exterior; Rep. gr.
50 ; Body - front .
– Check headlight adjustment and correct if necessary ⇒ Main‐
tenance ; Booklet 36 .
WARNING
1. Cylinder head 43
Passat 1997 ➤ , Passat Variant 1997 ➤
4-cylinder diesel engine with unit injector - Edition 07.2011
Removing
– Turn crankshaft to TDC No. 1 cylinder.
Note
Turn the crankshaft until the mark on the crankshaft toothed belt
pulley is on the top and the arrow on the rear toothed belt guard
aligns with the lug on the hub sender wheel -arrows-.
Note
1. Cylinder head 45
Passat 1997 ➤ , Passat Variant 1997 ➤
4-cylinder diesel engine with unit injector - Edition 07.2011
Note
Note
Note
♦ When doing this, the pin of the crankshaft stop -T10050- must
engage in the sealing flange from the rotational movement.
♦ If the crankshaft is turned past TDC No. 1 cylinder and the
crankshaft stop was unable to engage in the sealing flange,
turn the crankshaft back 1/4 turn to set it to TDC No. 1 cylinder
by again turning in the direction of engine rotation. Corrections
to the position by turning against the direction of engine rota‐
tion in order to insert the crankshaft stop are not permissible.
1. Cylinder head 47
Passat 1997 ➤ , Passat Variant 1997 ➤
4-cylinder diesel engine with unit injector - Edition 07.2011
Note
♦ When doing this, the pin of the crankshaft stop -T10050- must
engage in the sealing flange from the rotational movement.
♦ If the crankshaft is turned past TDC No. 1 cylinder and the
crankshaft stop was unable to engage in the sealing flange,
turn the crankshaft back 1/4 turn to set it to TDC No. 1 cylinder
by again turning in the direction of engine rotation. Corrections
to the position by turning against the direction of engine rota‐
tion in order to insert the crankshaft stop are not permissible.
– Repeat check.
– Install lower toothed belt guard and pulley vibration damper.
– Install centre toothed belt guard.
– Bolt relay lever for poly V-belt to ancillary bracket.
– Bolt fuel cooler coolant lines in place and and fit upper belt
guard.
– Install poly V-belt ⇒ page 18 .
– Install viscous fan coupling fan wheel.
– Install lock carrier ⇒ General body repairs, exterior; Rep. gr.
50 ; Body - front .
– Check headlight adjustment and correct if necessary ⇒ Main‐
tenance ; Booklet 36 .
WARNING
1.3.1 Removing
Note
1. Cylinder head 49
Passat 1997 ➤ , Passat Variant 1997 ➤
4-cylinder diesel engine with unit injector - Edition 07.2011
1.3.2 Installing
Note
Note
1. Cylinder head 51
Passat 1997 ➤ , Passat Variant 1997 ➤
4-cylinder diesel engine with unit injector - Edition 07.2011
Test prerequisite
• Engine oil temperature min. 30 °C.
Test procedure
– Pull off central connector for unit injectors.
– Remove all glow plugs using hinged socket -3220- .
Note
Note
1. Cylinder head 53
Passat 1997 ➤ , Passat Variant 1997 ➤
4-cylinder diesel engine with unit injector - Edition 07.2011
Note
Cylinder heads with cracks between the valve seats may be used
without reducing engine life, provided the cracks are small and
not more than 0.5 mm wide.
♦ Dial gauge
Check with bucket tappets removed and with first, third and last
bearing caps fitted.
Wear limit: max. 0.15 mm
Seal parting surfaces of bearing caps 1 and 5 with sealant -AMV
174 004 01-
– Apply sealant -AMV 174 004 01- thinly and evenly on the sur‐
faces -1-.
Note
Valve dimensions
Note
Note
Note
Note
The 30° lower valve seat chamfer is necessary to ensure that the
inlet channel flow characteristics are maintained.
♦ Dial gauge
Test procedure
– Insert new valve into guide. The end of the valve stem must
be flush with the guide. On account of differing stem diame‐
ters, only use inlet valve in inlet guide and exhaust valve in
exhaust guide.
– Rock: max. 1.3 mm
– Cylinder head must be renewed if rock exceeds wear limit.
2.4.1 Removing
(With cylinder head installed)
– Remove camshaft ⇒ page 60 .
– Remove bucket tappets and place them with the contact sur‐
face downwards. When doing this, ensure that the tappets are
not interchanged.
– Set piston of respective cylinder to top dead centre (TDC).
– Fit assembly tool -2036- and adjust mountings to height of
studs.
– Remove valve springs using valve lever -VW 541/1A- and
press tool -VW 541/5- .
Note
2.4.2 Installing
– Place the plastic sleeve -A- supplied on the respective valve
stem. This will prevent the new valve stem seal -B- being
damaged.
– Place new valve stem seal in fitting tool -3129- .
– Oil valve stem seal sealing lip and press carefully onto the
valve guide.
2.5.1 Removing
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front .
– Remove poly V-belt ⇒ page 18 .
– Remove toothed belt ⇒ page 37 .
– Remove securing bolts for camshaft toothed belt pulley -1-.
– Pull camshaft toothed belt pulley off hub.
Note
Note
♦ First loosen both outer and then inner securing bolts respec‐
tively.
♦ Mark rocker arm shafts to prevent interchanging. This will pre‐
vent having to perform basic settings of unit injectors.
2.5.2 Installing
Note
Note
Note
Note
When new bucket tappets have been installed the engine must
not be started for about 30 minutes. The hydraulic compensation
elements must settle (otherwise valves will strike pistons).
2.6.1 Removing
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front .
– Remove poly V-belt ⇒ page 18 .
– Remove toothed belt ⇒ page 37 .
– Remove camshaft toothed belt pulley and hub ⇒ page 60 ,
Removing and installing camshaft.
– Screw inner part of oil seal extractor -3240- two turns (approx.
3 mm) out of outer part and lock using knurled screw.
2.6.2 Installing
– Remove oil residue from camshaft journal using a clean cloth.
– Tape over groove in camshaft taper (e.g. with adhesive tape).
– Fit oil seal carefully on camshaft.
– Press in oil seal with press piece of fitting tool -10-203- and
bolt M12×65 onto stop.
– Install and tension toothed belt ⇒ page 37 .
– Install poly V-belt ⇒ page 18 .
– Install lock carrier ⇒ General body repairs, exterior; Rep. gr.
50 ; Body - front .
– Check headlight adjustment and correct if necessary ⇒ Main‐
tenance ; Booklet 36 .
17 – Lubrication
1 Parts of lubrication system
Note
1 - 15 Nm
2 - Sealing flange
❑ With seal.
❑ Must seat on dowel
sleeves.
❑ Removing and installing
⇒ page 23
❑ Install with silicone seal‐
ant -D 176 404 A2-
⇒ page 23 .
❑ Do not additionally oil or
grease the oil seal seal‐
ing lip.
❑ Before installing, re‐
move oil residue from
crankshaft journal using
a clean cloth.
❑ Renewing crankshaft oil
seal on belt pulley end
⇒ page 20
3 - Chain tensioner with ten‐
sioning rail, 15 Nm
❑ When installing, preten‐
sion spring and fit.
4 - 25 Nm
❑ Insert without sealant.
5 - Oil spray jet
❑ For piston cooling.
6 - Oil dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 66 .
7 - Piston fitting tool
Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ Pull out to extract oil.
8 - Guide tube
9 - Dowel sleeves
10 - Seal
❑ Renew.
11 - Suction line
❑ Clean strainer if soiled.
12 - Baffle plate
13 - 40 Nm
14 - 15 Nm
15 - Oil sump
❑ Removing and installing ⇒ page 70
❑ Clean sealing surface before fitting.
❑ Remove and install both rear bolts to gearbox using socket -T10058-
❑ For vehicles from 09.02 with acoustic cover ⇒ page 67
16 - Seal
❑ Renew.
17 - Oil drain plug, 30 Nm
❑ If seal is leaking, nip open and renew.
18 - 10 Nm
19 - Protective cap
20 - Oil level/oil temperature sender -G266-
❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
21 - Chain sprocket for oil pump
22 - Oil pump
❑ With 12 bar pressure relief valve.
❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
❑ Renew if running surfaces and gears are scored.
23 - 25 Nm
❑ Engine code AVF: 20 Nm + 1/4 turn (90°) further
24 - Chain
17 - Plug
❑ For pressure relief valve
❑ Do not loosen.
Not illustrated:
♦ Cable ties
♦ Hand drill with plastic brush attachment
♦ Silicone sealant -D 176 404 A2-
♦ Eye protection
1.4.1 Removing
Engine codes ATJ, AVF, AWX:
To remove the sump you need to remove the engine: ⇒ page 3 .
Note
– First remove front bolts -2- and -3- on left and right-hand sides
of subframe Then remove bolts -4-.
Vehicles with manual gearbox.
– Loosen rear left gearbox mounting rear bolt -2- several turns,
remove left gearbox mounting front bolt -1-.
Continuation for all vehicles
– Loosen rear right gearbox mounting rear bolt -2- several turns,
remove right gearbox mounting front bolt -1-.
Note
Use socket -T10058- to loosen and tighten two rear oil sump bolts.
– Remove sump.
– Remove sump, it may be necessary to release sump by tap‐
ping lightly with a rubber head hammer.
– Remove sealant residue from cylinder block with a flat scraper.
1.4.2 Installing
Note
♦ When fitting the oil sump to the removed engine, make sure
that the oil sump is aligned flush with the intermediate plate on
the flywheel side, i.e. the sump must protrude 0.8 mm beyond
the cylinder block.
♦ When the engine is installed, the oil sump must be flush with
the gearbox flange.
♦ Observe expiry date of sealing compound.
♦ The sump must be installed within 5 minutes of applying sili‐
cone sealing compound.
Note
Note
Note
Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
Test procedure
– Remove oil pressure switch -F1- and screw into tester.
– Screw tester into oil filter bracket in place of oil pressure
switch.
– Connect brown wire of tester to earth (-).
– Connect voltage tester -V.A.G 1527B- using test cables from
-V.A.G 1594 A- or -V.A.G 1594C- to battery positive (+) and
oil pressure switch. LED must not light up.
– Start engine and increase speed slowly.
Oil pressure switch, brown:
– At 0.55 ... 0.85 bar, the LED must light up; otherwise renew oil
pressure switch.
– Increase engine speed further. At 2000 rpm and an oil tem‐
perature of 80 °C the oil pressure should be at least 2.0 bar.
At higher engine speed, oil pressure must not exceed 7.0 bar. If
necessary renew oil filter bracket.
Oil pressure switch, grey:
– At 0.75 ... 1.05 bar, the LED must light up; otherwise renew oil
pressure switch.
– Increase engine speed further. At 2000 rpm and an oil tem‐
perature of 80 °C the oil pressure should be at least 2.0 bar.
At higher engine speed, oil pressure must not exceed 7.0 bar. If
necessary renew oil filter bracket.
19 – Cooling
1 Parts of cooling system
Note
1 - Coolant hose
❑ From fuel cooler unit
⇒ Item 29 (page 84)
2 - Connection piece
3 - Connecting hose
4 - Coolant hose
❑ To fuel cooler unit
⇒ Item 30 (page 84)
5 - Fuel cooling pump -V166-
❑ Switched on at a tem‐
perature of approx. 70°
C
❑ Checking ⇒ page 97 .
6 - Secondary cooler for cool‐
ant
❑ For fuel
❑ Installation location: in
front of right wheel
housing
❑ To remove, clamp off
coolant hoses
⇒ Item 1 (page 79) and
⇒ Item 4 (page 79) with
hose clip -3094- .
7 - 10 Nm
8 - Rubber grommet
9 - Retaining frame
❑ For secondary cooler for
coolant
10 - Retaining clip
11 - Rubber mounting
12 - Bracket
13 - Radiator fan -V7-
❑ Vehicles with optional equipment only.
❑ Checking ⇒ page 98 .
14 - Locking bolt
15 - Fan ring
❑ Clipped into air ducting and secured with locking bolt ⇒ Item 14 (page 79) .
16 - 2-pin connector
17 - Cap
❑ Check using cooling system tester -V.A.G 1274- and adapter -V.A.G 1274/9- .
❑ Test pressure 1.4 ... 1.6 bar.
18 - O-ring
❑ Renew if damaged.
19 - 3 Nm
20 - Coolant expansion tank
❑ Test cooling system for leaks using cooling system tester -V.A.G 1274- and adapter for expansion tank
-V.A.G 1274/8- .
21 - Coolant hose
❑ From upper coolant pipe ⇒ Item 26 (page 80) .
22 - O-ring
❑ Check for secure seating.
❑ Renew.
23 - Lower coolant hose
❑ To connection for thermostat ⇒ Item 22 (page 84)
❑ Secured to radiator and thermostat connection with a retaining clip.
❑ Check for secure seating.
24 - Junction
25 - Rubber washer
26 - Coolant hose
❑ To shut-off valve ⇒ Item 17 (page 83) .
27 - Connector
❑ Black, 3-pin.
❑ For radiator fan thermal switch
28 - Radiator fan thermal switch -F18- , 35 Nm
❑ For radiator fan.
❑ Vehicles with optional equipment only.
❑ Switching temperatures: speed 1 on: 92 ... 97°C, off: 84 ... 91°C, speed 2 on: 99 ... 105°C, off: 91 ... 98°
C
29 - Seal
❑ Renew.
30 - Drain plug
❑ Draining and filling with coolant ⇒ page 87 .
31 - Upper coolant hose
❑ From upper coolant pipe ⇒ Item 1 (page 83) .
❑ Secured to radiator with retaining clip.
❑ Check for secure seating.
32 - Radiator/cooler
❑ Removing and installing ⇒ page 90
❑ After renewing, renew entire coolant.
❑ With AFT cooler on vehicles with automatic gearbox: ⇒ Automatic gearbox 01V; Rep. gr. 37 ; Dismantling
and assembling gearbox
❑ Cleaning ATF cooler: ⇒ Automatic gearbox 01V; Rep. gr. 37 ; Dismantling and assembling gearbox
33 - Connector
❑ For fuel cooling pump
1 - Radiator/cooler
❑ Removing and installing
⇒ page 90
❑ After renewing, renew
entire coolant.
❑ With AFT cooler on ve‐
hicles with automatic
gearbox: ⇒ Automatic
gearbox 01V; Rep. gr.
37 ; Dismantling and as‐
sembling gearbox
❑ Cleaning ATF cooler: ⇒
Automatic gearbox 01V;
Rep. gr. 37 ; Disman‐
tling and assembling
gearbox
2 - Retaining clip
3 - Rubber mounting
4 - Rubber washer
5 - Radiator fan -V7-
❑ Vehicles with optional
equipment only.
❑ Checking: ⇒ page 98 .
6 - Locking bolt
7 - Fan ring
❑ Clipped into air ducting
and secured with lock‐
ing bolt
⇒ Item 14 (page 79) .
8 - 10 Nm
9 - 2-pin connector
10 - Cap
❑ Check using cooling system tester -V.A.G 1274- and adapter for cap -V.A.G 1274/9- .
❑ Test pressure 1.4 ... 1.6 bar.
11 - O-ring
❑ Renew if damaged.
12 - 3 Nm
13 - Coolant expansion tank
❑ Test cooling system for leaks using cooling system tester -V.A.G 1274- and adapter for cap -V.A.G
1274/9- .
14 - Coolant hose
❑ From upper coolant pipe ⇒ Item 26 (page 80) .
15 - O-ring
❑ Check for secure seating.
❑ Renew.
16 - Lower coolant hose
❑ To connection for thermostat ⇒ Item 22 (page 84)
❑ Secured to radiator and thermostat connection with a retaining clip.
❑ Check for secure seating.
17 - Connector
❑ Black, 3-pin.
1 - To top of radiator
❑ ⇒ Item 31 (page 80)
2 - Upper coolant pipe
3 - Coolant hose
❑ To top of expansion tank
⇒ Item 21 (page 80)
4 - O-ring
❑ Check for secure seat‐
ing.
❑ Renew.
5 - Coolant hose
6 - Coolant temperature send‐
er -G62-
❑ With coolant tempera‐
ture display sender -
G2- .
7 - Retaining clip
❑ Check for secure seat‐
ing.
8 - O-ring
❑ Renew.
9 - 10 Nm
10 - Connection
❑ Vehicles with optional
equipment only.
❑ With glow plugs for cool‐
ant
11 - Coolant hose
❑ To heat exchanger
❑ Secured to connection
with retaining clip Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ Check for secure seating.
12 - Connection
13 - Cooler unit
❑ For fuel
❑ Do not interchange connections.
❑ Fuel and coolant hose schematic diagram ⇒ page 109
14 - Fuel filter
❑ Observe change intervals.
❑ Fill with diesel before installing.
❑ Renew if damaged.
❑ Tighten by hand.
15 - Vacuum hose
❑ To non-return valve of brake servo ⇒ page 138 , schematic diagram for vacuum hoses
16 - Vacuum unit
17 - Shut-off valve
❑ For fuel cooling system coolant pump
18 - Coolant hose
❑ From junction ⇒ Item 24 (page 80)
19 - Coolant hose
❑ From heat exchanger
❑ Secured to coolant pipe with retaining clip
❑ Check for secure seating.
20 - Lower coolant pipe
21 - 15 Nm
22 - Coolant hose
❑ From bottom of radiator ⇒ Item 23 (page 80)
❑ Secured to radiator and thermostat connection with a retaining clip.
❑ Check for secure seating.
23 - Connection
❑ For thermostat.
24 - Thermostat
❑ Removing and installing ⇒ page 94
❑ Observe installation position ⇒ page 94 , removing and installing thermostat.
❑ Checking: heat thermostat in water.
❑ Opening begins at approx. 85 °C.
❑ Ends at approx. 105 °C.
❑ Opening lift at least 7 mm.
25 - 40 Nm
26 - Engine oil cooler
❑ Removing and installing ⇒ page 69 , and ⇒ Item 14 (page 69)
27 - Fan wheel
28 - Coolant pump
❑ Check for ease of movement.
❑ Note installation position.
❑ Removing and installing ⇒ page 92
29 - Coolant hose
❑ To secondary cooler for coolant and pump for fuel cooler -V166- ⇒ Item 1 (page 79)
30 - Coolant hose
❑ From secondary cooler for coolant and pump for fuel cooler -V166- ⇒ Item 4 (page 79)
31 - Coolant lines
32 - 25 Nm
1 - To top of radiator
❑ ⇒ Item 31 (page 80)
2 - Upper coolant pipe
3 - Coolant hose
❑ To top of expansion tank
⇒ Item 21 (page 80)
4 - O-ring
❑ Check for secure seat‐
ing.
❑ Renew.
5 - Coolant hose
6 - Coolant temperature send‐
er -G62-
❑ With coolant tempera‐
ture display sender -
G2- .
7 - Retaining clip
❑ Check for secure seat‐
ing.
8 - O-ring
❑ Renew.
9 - 10 Nm
10 - Connection
❑ Vehicles with optional
equipment only.
❑ With glow plugs for cool‐
ant
11 - Coolant hose
❑ To heat exchanger
❑ Secured to connection
with retaining clip
❑ Check for secure seating.
12 - Connection
13 - Coolant hose
❑ From heat exchanger
❑ Secured to coolant pipe with retaining clip
❑ Check for secure seating.
14 - Lower coolant pipe
15 - 15 Nm
16 - Coolant hose
❑ From bottom of radiator ⇒ Item 23 (page 80)
❑ Secured to radiator and thermostat connection with a retaining clip.
❑ Check for secure seating.
17 - Connection
❑ For thermostat.
18 - Thermostat
❑ Removing and installing ⇒ page 94
❑ Observe installation position ⇒ page 94 , removing and installing thermostat.
❑ Checking: heat thermostat in water.
1 - Radiator/cooler
❑ With AFT cooler on ve‐
hicles with automatic
gearbox
2 - Coolant pump and thermo‐
stat
3 - Cylinder head/cylinder
block
4 - Intake manifold
5 - Exhaust gas recirculation
cooler
❑ Only on vehicles with
automatic gearbox
6 - Heat exchanger for heater
unit
7 - Engine oil cooler
8 - Cap
9 - Expansion tank
Not illustrated:
1.3.1 Draining
– Detach vacuum hose from vacuum unit of shut-off valve (only
in vehicles up to 01.02).
– Open filler cap on coolant expansion tank.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .
– Pull off lower coolant hose retaining clip -arrow- and remove
coolant hose from radiator.
Note
1.3.2 Filling
Note
1.4.1 Removing
– Drain coolant ⇒ page 87 .
– Remove front bumper ⇒ General body repairs, exterior; Rep.
gr. 63 ; Front bumper .
– Pull coolant hoses off radiator.
– Pull connectors off thermal switch and radiator fan.
– Remove upper radiator securing clips and take out radiator
forwards.
Vehicles with air conditioning system:
– Observe additional information and installation work
⇒ page 92 .
1.4.2 Installing
Installation is carried out in the reverse order. When installing,
note the following:
– Replenish coolant ⇒ page 87 .
– Install front bumper: ⇒ General body repairs, exterior; Rep.
gr. 63 ; Front bumper .
WARNING
Note
1.5.1 Removing
Note
1.5.2 Installing
Installing
Note
♦ If the new coolant pump contacts the rear toothed belt guard,
the toothed belt guard must be adapted using workshop equip‐
ment.
♦ Remove marked surface -arrow-.
♦ For the sake of clarity, the rear toothed belt guard and the
coolant pump are shown removed.
Note
1.6.1 Removing
Note
1.6.2 Installing
Installation is carried out in the reverse order. When installing,
note the following:
– Moisten new O-ring -3- with coolant.
– Insert thermostat -4- in union -2- and turn 1/4 turn (90°) to right.
Note
1.7.1 Removing
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front .
– Remove poly V-belt ⇒ page 18 .
– Remove viscous fan coupling fan wheel.
– Counterhold belt pulley for visco fan coupling using 2-hole pin
wrench -3212- and unscrew using 8 mm Allen key from brack‐
et for ancillaries.
1.7.2 Installing
Installation is carried out in the reverse order. When installing,
note the following:
– Bolt viscous fan coupling to bracket for ancillaries, tightening
to 45 Nm.
– Bolt fan wheel to viscous fan coupling, tightening to 30 Nm.
– Install poly V-belt ⇒ page 18 .
– Bypass contact -1- and contact -2- of plug connector using test
cables from auxiliary test set -V.A.G 1594A- or -V.A.G
1594C- . Radiator fan -V7- must start up at speed 1.
– Bypass contact -1- and contact -3- of plug connector using test
cables from auxiliary test set -V.A.G 1594A- or -V.A.G
1594C- . Radiator fan -V7- must start up at speed 2.
If fan speeds 1 or 2 do not run:
– Locate and eliminate open circuit referring to current flow di‐
agram: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
If no open circuit is found:
– Renew radiator fan -V7- .
Note
WARNING
When removing and installing the fuel gauge sender from a full or
partly full fuel tank the following must be observed:
♦ Even before work commences, the extraction hose of an ac‐
tivated fume extraction system has to be placed in the vicinity
of the assembly opening of the fuel tank to extract any escap‐
ing fumes. If no exhaust gas extraction system is available, a
radial fan with a displacement greater than 15 m3/h can be
used providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ When system is open: do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
1 - Cap
2 - Seal
❑ Renew if damaged.
3 - Securing bolt
4 - Tank flap unit
❑ With rubber cup.
5 - O-ring
❑ Renew if damaged.
6 - Breather valve
❑ To remove valve unclip
sideways out of support.
❑ Remove cap before in‐
stalling
⇒ Item 1 (page 102) .
❑ Checking ⇒ page 104 .
7 - Connecting hose
8 - Gravity valve
❑ To remove valve unclip
upwards out of support.
❑ Check valve for
through-flow, valve ver‐
tical: open, valve tilted
45°: closed
9 - 25 Nm
10 - Fuel tank filler neck
11 - Non-return valve
❑ Note installation posi‐
tion.
12 - Connecting hose
13 - Heat shield
❑ For fuel filler neck
14 - 10 Nm
15 - Union nut, 60 Nm
❑ Remove and install using union nut tool -3218- .
16 - Connector
❑ Black, 2-pin.
❑ For fuel gauge sender
17 - Flange
❑ Note installation position on fuel tank ⇒ page 106 .
18 - Seal
❑ Renew if damaged.
❑ Moisten with fuel when installing
19 - Breather line
❑ Black
❑ Check for secure seating.
❑ Secure with spring-type clips.
20 - Fuel gauge sender 3 -G237-
❑ Checking ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
21 - Heat shield
❑ For fuel tank.
22 - Retaining clip
❑ Check for secure seating.
23 - Securing strap
❑ Note installation position.
24 - Fuel gauge sender 2 -G169-
❑ Checking ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
❑ Removing and installing suction jet pump ⇒ page 115
25 - Locking ring, 145 Nm
❑ Check for secure seating.
❑ Remove and install using fuel tank sender unit tool -3087- .
26 - Fuel tank
❑ When removing, support using engine and gearbox jack -V.A.G 1383 A- .
❑ Removing and installing ⇒ page 111
27 - Flange
❑ Note installation position on fuel tank ⇒ page 106 .
❑ Can only be renewed complete with fuel pump
28 - Return line
❑ From fuel filter ⇒ page 106 .
❑ Clipped onto fuel tank.
❑ Check for secure seating.
❑ Blue or with blue marking.
29 - Connector
❑ Black, 4-pin.
30 - Supply line
❑ Black
❑ To fuel filter ⇒ Item 2 (page 108) .
❑ Clipped onto fuel tank.
Note
After installing fuel pump flange, check that supply, return and
breather lines are still clipped onto fuel tank.
Note
1 - Cap
2 - Seal
❑ Renew if damaged.
3 - Securing bolt
4 - Gravity/overflow valve
❑ To remove valve unclip
upwards out of support.
❑ Check valve for
through-flow valve verti‐
cal: open, valve tilted
45°: closed
5 - Elbow
6 - O-ring
❑ Renew if damaged.
7 - Breather valve
❑ To remove valve unclip
sideways out of support.
❑ Remove cap before in‐
stalling
⇒ Item 1 (page 102) .
❑ Checking ⇒ page 106 .
8 - Earth connection
9 - Supply line
❑ To fuel filter
⇒ Item 2 (page 108) .
❑ Clipped onto fuel tank.
❑ Check for secure seat‐
ing.
❑ Black
10 - Return line
❑ From fuel filter ⇒ page 106 . Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ Clipped onto fuel tank.
❑ Check for secure seating.
❑ Blue or with blue marking.
11 - Fuel gauge sender -G-
❑ Clipped on reservoir housing in fuel tank.
❑ Removing and installing ⇒ page 122
12 - Seal
❑ When installing, fit dry in fuel tank opening.
❑ Renew if damaged.
❑ Moisten with fuel only when installing flange.
13 - Union nut, 80 Nm
❑ Remove and install using union nut tool -3217- .
14 - Connector
❑ Black, 4-pin.
15 - Flange
❑ Note installation position on fuel tank ⇒ page 106 .
Note
After installing fuel gauge sender, check whether supply and re‐
turn lines are still clipped onto fuel tank.
Note
1 - 8 Nm
2 - O-ring
❑ Renew.
3 - Cooler unit
❑ Do not interchange con‐
nections.
❑ Fuel and coolant hose
schematic diagram
⇒ page 109
4 - Fuel filter flange
❑ Direction of flow is
marked with arrows.
❑ Do not interchange con‐
nections.
❑ Fuel and coolant hose
schematic diagram
⇒ page 109
5 - Seal
❑ Renew.
6 - Breather bolt, 10 Nm
❑ Loosen to drain water
❑ Loosen to breathe in
event of filter change
7 - Gasket
❑ Renew.
8 - Fuel filter
❑ Observe change inter‐
vals.
❑ Fill with diesel before in‐
stalling.
❑ Renew if damaged.
❑ Tighten by hand.
9 - Water drain screw
❑ Loosen and allow approx. 100 cm3 fluid to drain
❑ Loosen breather bolt ⇒ Item 6 (page 107) to drain water
1 - Return line
❑ To fuel cooler
⇒ page 110
❑ Blue or with blue mark‐
ing.
❑ Check for secure seat‐
ing.
2 - Supply line
❑ From fuel tank
⇒ Item 9 (page 105) .
❑ White or with white
marking.
❑ Check for secure seat‐
ing.
3 - Retaining clip
4 - Regulating valve
❑ Installation position: ar‐
row points towards fuel
tank
❑ When changing filter,
remove retaining clip
and take control valve
off complete with fuel
lines
❑ Below + 15 °C: passa‐
geway to filter open
❑ Over + 31 °C: passage‐
way to filter closed
5 - O-ring
❑ Renew.
6 - Return line
❑ From tandem pump
⇒ Item 13 (page 15)
❑ Check for secure seating.
❑ Blue or with blue marking.
7 - Fuel line
8 - Fuel temperature sender -G81-
9 - Non-return valve
❑ Installation position: arrow points towards tandem pump
10 - Supply line
❑ To tandem pump ⇒ Item 13 (page 15) .
❑ Check for secure seating.
❑ White or with white marking.
11 - Fuel filter
❑ Fill with diesel before installing.
❑ Direction of flow is marked with arrows.
❑ Do not interchange connections.
❑ Renew if damaged.
12 - Gasket
❑ Renew if damaged.
1 - Return line
❑ To fuel tank.
❑ Clipped into bulkhead
❑ Blue or with blue mark‐
ing.
❑ Check for secure seat‐
ing.
2 - Supply line
❑ From fuel tank.
❑ Clipped into bulkhead
❑ White or with white
marking.
❑ Check for secure seat‐
ing.
3 - Charge air pipe
4 - Return line
❑ From tandem pump
⇒ Item 13 (page 15)
❑ Check for secure seat‐
ing.
❑ Blue or with blue mark‐
ing.
❑ Clipped onto bottom
coolant pipe
5 - Supply line
❑ To tandem pump
⇒ Item 13 (page 15) .
❑ Check for secure seat‐
ing.
❑ White or with white
marking.
❑ Clipped onto bottom
coolant pipe
6 - Non-return valve
❑ Installation position: arrow points towards tandem pump
7 - Lower coolant pipe
8 - Fuel filter
❑ Observe change intervals.
❑ Fill with diesel before installing.
❑ Renew if damaged.
❑ Tighten by hand.
1.6.1 Removing
Observe rules for cleanliness ⇒ page 101 .
Note
The fuel cooler is located in the return line to fuel tank. It is located
on the vehicle underbody.
– Remove retaining clips -C- and securing bolt -B- and remove
cover -A-.
– Separate fuel lines at fuel cooler.
1.6.2 Installing
Install in reverse order. In the process, note the following:
♦ Tighten fuel cooler securing nuts to 15 Nm.
1.7.1 Removing
Note
1.7.2 Installing
Install in reverse order. In the process, note the following:
♦ Route breather hoses without kinking.
♦ Route fuel hoses without kinking.
♦ Secure fuel hoses with clamp-type clips.
♦ Do not interchange supply line and return line (return line blue
or with blue marking, supply line black).
♦ Clip supply and return lines onto fuel tank.
1.8.1 Removing
Note
♦ Drain the fuel tank, if necessary, via the aperture for fuel gauge
sender 3 using the fuel extractor -V.A.G 1433 A-
⇒ Item 20 (page 103) .
♦ Note safety precautions before beginning work ⇒ page 101 .
– Unscrew locking ring with fuel tank sender unit tool -3087- .
– Pull flange and seal out of opening in fuel tank.
– Turn fuel pump approx. 15° anti-clockwise onto stop using fuel
pump tool -3307- and remove.
Note
If the fuel pump is to be renewed, drain the old fuel pump before
disposal.
1.8.2 Installing
– Installing the fuel pump is carried out in reverse order of re‐
moval.
Note
Note
1.9.2 Removing
Note
♦ Drain the fuel tank, if necessary, via the aperture for fuel gauge
sender 3 using the fuel extractor -V.A.G 1433 A-
⇒ Item 20 (page 103) .
♦ Note safety precautions before beginning work ⇒ page 101 .
1.9.3 Installing
– Check suction-jet pump for possible soiling.
– Install suction-jet pump and fuel gauge sender 2 -G169- again
in reverse order.
Note
♦ Please note that the seal has to be placed dry in the fuel tank
opening before installing the fuel tank or fuel gauge sender 2
-G169- .
♦ Always renew seals.
1.11.1 Removing
Note
– Pull 4-pin connector and supply and return lines -arrows- off
flange.
WARNING
– Detach fuel return line -2- and plug for fuel gauge sender from
underside of flange -1-.
Note
1.11.2 Installing
– Insert fuel delivery unit into reservoir housing in fuel tank so
that the notch -1- on fuel delivery unit aligns with mark -2- on
reservoir housing.
Note
The reservoir housing is shown without the fuel tank for a clearer
illustration.
– Turn fuel delivery unit approx. 15° clockwise onto stop with fuel
pump tool -3307- . Notch -1- is then aligned with marking -3-
(quick-release coupling).
Note
Ensure that the fuel hose from the reservoir housing to the Y-
junction coupling is held in the bracket on the outside of the
reservoir housing.
Note
♦ Insert seal for fuel delivery unit dry into opening of fuel tank.
♦ Moisten seal with fuel only when installing fuel delivery unit.
– Mark on flange -1- must align with mark on fuel tank -2-.
– Tighten union nut. Specified torque: 80 Nm
Further assembly is basically the reverse of the dismantling se‐
quence.
Note
1.12.1 Removing
Note
1.12.2 Installing
– Insert fuel gauge sender -G- in guide in reservoir housing and
press down until it engages.
– Install flange and carry out further assembly ⇒ page 117 , Re‐
moving and installing fuel delivery unit.
1 - 6-pin connector
❑ For accelerator pedal
position sender
2 - 10 Nm
3 - Accelerator position sender
-G79-
❑ Adjusting ⇒ page 124 .
❑ When removing and in‐
stalling accelerator po‐
sition sender, mounting
bracket
⇒ Item 9 (page 123)
must be removed
❑ To remove, remove
dash panel cover and
pedal cluster cover.
4 - Cable cam
5 - 10 Nm
6 - Operating rod
❑ With adjuster screw
7 - Accelerator pedal stop
❑ On vehicles with manual
gearbox „AG“ is visible
❑ On vehicles with auto‐
matic gearbox „AG“ is
visible
8 - Accelerator
9 - Bearing bracket
❑ Removing and instal‐
ling: ⇒ Brake systems;
Rep. gr. 46 ; Assembly
overview - brake pedal
(LHD) .
1 - Bearing bracket
❑ Removing and instal‐
ling: ⇒ Brake systems;
Rep. gr. 46 ; Assembly
overview - brake pedal
(LHD) .
2 - Connector
❑ Black, 6-pin.
3 - 10 Nm
4 - Accelerator pedal position
sender -G79- and accelerator
pedal position sender 2 -G185-
❑ To remove, remove
dash panel cover and
pedal cluster cover.
❑ If renewed, adapt con‐
trol unit for automatic
gearbox: ⇒ Self-diagno‐
sis for automatic gear‐
box 01NV; Rep. gr. 01 ;
Perform self-diagnosis
5 - Bracket
❑ For footwell cover
❑ Clipped to accelerator
position sender
Procedure
Adjust cable cam:
– In rest position cable cam must be set such that extension of
wrench surface intersects with centre of bore -arrow-.
– Bolt accelerator pedal position sender with pre-fitted cable
cam to mounting bracket.
– Install mounting bracket ⇒ Brake system; Rep. gr. 46 ; As‐
sembly overview - brake pedal (left-hand drive)
– Reconnect 6-pin connector for sender
Fine adjustment with sender installed:
– Turn accelerator pedal stop to position „HS“ for manual gear‐
box (also for vehicles with automatic gearbox)
⇒ Item 7 (page 123) , „HS“ is visible.
– Press accelerator pedal down by hand until accelerator pedal
is in contact with accelerator pedal stop.
Note
DANGER!
1.15.1 Removing
– Pull supply hose -1- (white marking) and return hose -2- (blue
marking) off fuel filter.
– Connect hand vacuum pump with accessories -V.A.G 1390-
and water drainage container -V.A.G 1390/1- to return hose.
– Operate hand vacuum pump until no more fuel comes out of
return hose. Be careful that no fuel is sucked into hand vacuum
pump.
– Unscrew charge air pipe and lay to side.
– Pull vacuum line -1- from brake servo off tandem pump -4-.
– Pull off central connector for unit injectors.
– Pull supply hose -2- (white marking) off tandem pump -4-.
– Remove securing bolts -arrows-.
– Remove tandem pump -4- from cylinder head.
– Pull tandem pump -4- slightly upwards, pull off return hose
-3- (blue marking) and remove tandem pump -4-.
1.15.2 Installing
Installation is carried out in the reverse order. When installing,
note the following:
Note
Note
Procedure
– Unscrew charge air pipe and lay to side.
– Remove screw plug -arrow-.
Note
Note
Procedure
– Pull fuel supply hose (white marking) and fuel return hose
(blue marking) off tandem pump.
– Seal fuel return union on tandem pump with a plug. Secure
sealing plug with a spring-type clip.
Prepare test unit -V.A.G 1687- as follows:
– Unscrew pressure regulating valve -2- and close valves -3-
and -4-.
– Connect test connection -5- to fuel supply union of tandem
pump using a commercially available compressed air connec‐
tion and a section of fuel hose. Use a spring-type clip to secure.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.
Note
If there is water in the sight glass, drain at water drain screw -6-.
Caution
The maximum test pressure is 1.3 bar and this must not be
exceeded.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary readjust pressure to 1.0 bar.
– Close valve -3- to retain pressure and observe the pressure
drop over a period of 1 minute.
If the pressure does not drop the tandem pump can be reused, if
the pressure drops the tandem pump must be renewed.
21 – Turbocharging/supercharging
1 Charge air system with turbocharger
Note
1 - Exhaust manifold
2 - 25 Nm
❑ Renew.
❑ Coat thread of studs
with grease -G 000
500- .
3 - Intake manifold
4 - From charge air cooler
5 - Gasket
❑ Renew.
❑ Coating (beading) to‐
wards intake pipe
6 - 25 Nm
7 - Gasket
❑ Note installation posi‐
tion.
8 - Bracket
❑ For heat shield
⇒ Item 10 (page 133)
9 - Washer
10 - Heat shield
❑ Engage in bracket
⇒ Item 8 (page 133)
11 - Vacuum unit
❑ For charge pressure
control.
❑ Integral part of turbo‐
charger and cannot be
replaced.
12 - Turbocharger
13 - From crankcase breather Volkswagen Technical Site: http://vwts.ru http://vwts.info
14 - From air filter.
15 - Oil return line
❑ To cylinder block.
16 - Gasket
❑ Renew.
17 - Seal
❑ Renew.
18 - Banjo bolt, 40 Nm
19 - Union, 40 Nm
20 - 15 Nm
21 - Oil return line, 25 Nm
❑ To cylinder block.
22 - Bracket
❑ Engine codes AJM, ATJ, AVB
Note
Note
WARNING
WARNING
Secure fault reader to rear seat and operate from this position.
1.6.1 Removing
– Lever old O-rings very carefully out of unit injector.
– Pay particular attention to ensure that seat of O-ring is not
damaged by burrs.
1.6.2 Installing
Note
Note
1.7.1 Removing
– Remove the upper toothed belt guard and the cylinder head
cover.
– Turn crankshaft until the cam pair point evenly upwards for the
unit injector which is to be removed.
1.7.2 Installing
Note
– Heat shield seal and O-rings must be renewed if old unit in‐
jector is reused ⇒ page 144
– Check that the three O-rings and the heat shield seal along
with securing clip are seated correctly before installing unit in‐
jector.
Note
– Oil the seals and fit the unit injector into the seat in cylinder
head with great care.
– Push the unit injector evenly into the cylinder head onto its limit
stop.
– Insert tensioning block in slot on side of unit injector.
Note
If the unit injector is not at right angles to the tensioning block the
securing bolt may loosen and this can damage the unit injector or
the cylinder head.
Note
Vehicles ► 09.00
– Pull cover off in direction of arrow.
– Connect connector of 3 m diagnostic cable with voltage supply
-VAS 5051/1- to diagnostic socket.
Vehicles 10.00 ►
2.3.1 Removing
– Switch off ignition.
26 – Exhaust system
1 Parts of the exhaust system
Note
1 - 25 Nm
2 - Mounting
❑ With retaining ring.
3 - 40 Nm
4 - Coach bolt
5 - Repair double clamp
6 - Separating point
❑ Centre and rear silenc‐
ers are installed as a
single component dur‐
ing production. In cases
of repair, the centre and
rear silencer are sup‐
plied separately, with a
double clamp for con‐
necting.
❑ Cut through separating
point on connecting pipe
at right angles using
body saw -V.A.G
1523A- for example
⇒ page 156 .
7 - Rear right silencer
8 - Mounting
9 - Bracket
10 - Rear left silencer
11 - Intermediate pipe
12 - Gasket
❑ Renew.
1 - Mounting
2 - 25 Nm
3 - Mounting
❑ With retaining ring.
4 - Rear silencer
❑ Centre and rear silenc‐
ers are installed as a
single component dur‐
ing production. In cases
of repair, the centre and
rear silencer are sup‐
plied separately, with a
double clamp for con‐
necting.
❑ Cut through separating
point on connecting pipe
at right angles using
body saw -V.A.G
1523A- for example
⇒ page 157 .
5 - Centre silencer
❑ Engine codes AJM,
ATJ, AVB
6 - Intermediate pipe
7 - Gasket
❑ Renew.
8 - Bolt
9 - Front exhaust pipe
❑ With catalytic converter.
❑ Engine codes AVB,
AVF, AWX: with one-
piece exhaust pipe
10 - Turbocharger
Volkswagen Technical Site: http://vwts.ru http://vwts.info
11 - Double clamp
12 - Centre silencer
❑ Engine codes AVF, AXW
Note
Test procedure
– Remove engine cover.
– Remove charge air pipe/intake connecting pipe connecting
hose
– Pull vacuum hose off exhaust gas recirculation valve (me‐
chanical).
– Connect hand vacuum pump with accessories -V.A.G 1390-
to valve.
– Operate pump and observe diaphragm rod.
The diaphragm rod must move in -direction of arrow-.
– Pull hand vacuum pump hose off exhaust gas recirculation
valve (mechanical).
The diaphragm rod must move back to its original position counter
to the -direction of the arrow-.
Test prerequisites
• Battery voltage at least 11.5 V
• Ignition switched off
• Diesel direct injection system control unit -J248- OK.
• Fuse for glow plugs S189 OK.
Test procedure
– Detach connector from coolant temperature sender
⇒ page 141 .
Note