3.2L Engine Part2

2004 Volkswagen Touareg
ENGINE 3.2L V6 4V Engine Mechanical, Fuel Injection Ignition, Engine Codes: BAA, BMX
ENGINE
3.2L V6 4V Engine Mechanical, Fuel Injection Ignition, Engine Codes: BAA, BMX
00 - GENERAL, TECHNICAL DATA

TECHNICAL DATA
Technical data
Engine specifications --> Engine data
Engine number
Fig. 1: Identifying Engine Number Located On Vibration Damper

Courtesy of VOLKSWAGEN UNITED STATES, INC.
The engine number "engine code" and "serial number" is located next to vibration damper on cylinder block
under the coolant pump.
The engine number consists of up to nine characters (alphanumeric). The first part (maximal 3 characters)
makes up the engine code, and the second part (6 characters), the serial number. If more than 999,999 engines
with the same engine code are produced, the first of the six characters is replaced with a letter.
In addition, a sticker with "engine code" and "serial number" is affixed to intake manifold.
The engine code is also included on vehicle data plate.
Engine data
Engine code BAA BMX

Manufactured 03.03 --> 04.04 -->
Cylinder arrangement VR * See note VR * See note
Cylinder angle 15.0° 15.0°
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Sunday, September 20, 2009 10:10:13
10:10:04 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
Displacement ltr. 3.2 3.2

Output kW at RPM 162/6000 177/6000
Torque Nm at RPM 300/4000 310/3200
Bore dia. mm 84.0 84.0
Stroke mm 95.9 95.9
Compression ratio 11.25 10.85
Valves per cylinder 4 4
RON min. 98 unleaded * See note 98 unleaded * See note
System designation Motronic ME7.1.1 Motronic ME7.1.1
Ignition sequence 1-5-3-6-2-4 1-5-3-6-2-4
Knock control 2 knock sensors 2 knock sensors
Oxygen sensor regulation 4 sensors 4 sensors
On Board Diagnostic (OBD) OBD II yes
Catalytic converter yes yes
Exhaust gas recirculation no no
Charging no no
Secondary air injection (AIR) system yes yes
Electronic Power Control (EPC) yes yes
Variable intake manifold yes yes
Variable valve timing Yes * See note Yes * See note
Leak diagnostic system yes yes
*VR = V-Arrangment in compact in-line design
*In exceptional circumstances min. 95 RON, however with reduced performance
*Two independently variable camshafts.
10 - ENGINE - ASSEMBLY
ENGINE, REMOVING AND INSTALLING
Engine, removing and installing
Engine, removing --> Engine, removing
Securing engine to engine stand --> Engine, securing to assembly stand
Installing engine --> Engine, installing
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Sunday, September 20, 2009 10:10:04 AM Page 2 © 2005 Mitchell Repair Information Company, LLC.
Fig. 2: Identifying Special Tools - Engine, Removing And Installing (1 Of 2)

Special tools, testers and auxiliary items required
 Lifting tackle 3033

 Tensioner Hooks (2) VW 552
 Engine and transmission holder VAS 6095
 Drip tray V.A.G 1306
 Torque wrench (5 to 50 Nm) V.A.G 1331

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Fig. 3: Identifying Special Tools - Engine, Removing And Installing (2 Of 2)

 Engine/transmission jack V.A.G 1383 A

 Spring-type clip pliers VAS 5024A
 Step ladder VAS 5085
 Diesel Extractor VAS 5226
 Shop crane VAS 6100

 Scissor lift table VAS 6131
 Not illustrated:
 Adapter V.A.G 1318/20
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 Adapter V.A.G 1318/20-1

 Container for removed components V.A.G 1698
 Left subframe mounting VAS 6131/6-1
 Right subframe mounting VAS 6131/6-2
 Left suspension support VAS 6131/6-3

 Right suspension support VAS 6131/6-4
 Supports VAS 6131/6-5 (Qty. 2)
 Supports VAS 6131/6-6 (Qty. 2)
 Transmission support VAS 6131/6-7

 V6 engine support VAS 6131/7
 Grease (Vehicles with manual transmission) G 000 1000
 Cable tie
Engine, removing
Work procedure
The engine with transmission is removed downward.
CAUTION: Fuel supply lines are under pressure! Wear protective goggles and
protective gloves to avoid damage and contact with skin. Before removing
from hose connection wrap a cloth around the connection. Then release
pressure by carefully pulling hose off connection.
NOTE:  To allow free rotation of the drive axle, move the selector lever in the "N"
position.
 Leave the key in the ignition lock to prevent the steering wheel lock from
engaging.
 It is advisable to remove the front wheels before removing the
engine/transmission assembly. The vehicle can be lowered on the hoist
until the cover plates of the brake discs are just above the floor. This
enables the most ergonomic work position possible regarding
accessibility of components in the engine compartment.
 To prevent damage to the removed components, use parts trolley V.A.G
1698 for storage.
 When the engine is installed in the engine compartment some components cannot be removed or can only
be removed with great difficulty. Therefore determine which components are faulty before removing
engine.
 Check DTC memories of all control modules, before removing engine:

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Disconnecting batteries
The procedure must be strictly followed!
 Switch off ignition and all electrical consumers.

 Disconnect battery under drivers seat. --> 27 - BATTERY, STARTER, GENERATOR, CRUISE
CONTROL
Work procedure
 Remove left and right wiper arms: --> 92 - WINDSHIELD WIPER AND WASHER SYSTEM
 Remove engine compartment cover seal off bulkhead.
Fig. 4: Identifying Covers In Engine Compartment And For Plenum Chamber

 Remove covers - A - , - B - and - C - in engine compartment and - D - for plenum chamber.
Fig. 5: Identifying V.A.G 1318/20-1 & V.A.G 1318/20

 Install adapter V.A.G 1318/20-1 on to adapter V.A.G 1318/20.

 Turn valve (on T-piece) counter-clockwise until completely open.
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CAUTION: Fuel supply lines are under pressure! Before opening fuel system, connect
Diesel Extractor VAS 5226 and release pressure.
 Remove breather valve.
Fig. 6: Connecting Adapter V.A.G 1318/20 With Adapter V.A.G 1318/20-1 And Diesel Extractor VAS
5226 To Bleed Valve
 Connect Adapter V.A.G 1318/20 with Adapter V.A.G 1318/20-1 and Diesel Extractor VAS 5226 to bleed
valve - 1 -.
 Turn valve (on T-piece) clockwise into bleed valve to stop.
 When fuel pressure has been released, fuel system may be opened.
Fig. 7: Identifying Fuel Supply Line

 In addition, wrap a cloth around connection to catch fuel which runs out.
 Disconnect fuel supply line - arrow -.
 All cable ties which are opened or cut open when removing engine, must be replaced in same position
when installing engine.
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Fig. 8: Identifying Breather Line To Solenoid Valve

 Disconnect breather line - arrow - to evaporative emission (EVAP) canister purge regulator valve N80 in
engine compartment.
Fig. 9: Identifying Small Connector, Engine Control Module (ECM) J623, And Wiring Harness Ground
Connection
 Disconnect small connector - A - off engine control module and disconnect Ground (GND) connection -
arrow - of wiring harness.
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Fig. 10: Identifying Connectors In Fuse Box

 Open fuse box cover on left in plenum chamber and separate connectors - A - , - B - and - C -.
 Remove wiring harness from plenum chamber and place it on engine.
Fig. 11: Identifying Starter Wire And Generator Wire

 Disconnect starter wire - A - and generator wire - B - and place them on engine.
Fig. 12: Identifying Vacuum Hoses Of Intake Manifold

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 Pull vacuum hoses - 1 - from intake manifold.
Vehicles with engine code BAA
 Pull vacuum hose - 4 - from intake manifold.
Continuation for all vehicles
Fig. 13: Identifying Pressure Hose And Secondary Air Injection Pump
 Pull pressure hose off secondary air injection pump - arrow -.
Fig. 14: Identifying Connectors For Oxygen Sensors

 Disconnect connectors - 1 to 4 - for oxygen sensors and place connectors on engine.
 Cylinders 1 to 3 = black
 Cylinders 4 to 6 = brown
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Fig. 15: Identifying Connecting Wire To Air Suspension Compressor

 Separate connecting line to air suspension compressor at air filter - arrow - as follows:
 Carefully pry off green circlip - 1 - using a screwdriver. Then press clamping ring - 2 - in direction of -
arrow -.
Fig. 16: Identifying Sealing Ring, Line Flange, Securing Sleeve, And Air Filter Connection
 Pull only loosened line - B - from connection - A - at air filter.

 Remove top part of air filter upward and out --> Air filter, assembly overview.
 Unclip transmission breather line from air filter housing.
 Extract refrigerant from air conditioning system: --> 87 AIR CONDITIONING
 Remove sound insulation tray: --> 50 - BODY - FRONT
CAUTION: Hot steam may escape when opening expansion tank. Wear protective
goggles and protective clothing to prevent damage to eyes and scalding.
Cover cap with a rag and open carefully.
 Drain coolant --> Cooling system, draining and filling.

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 Pull upper coolant hose off radiator, and lower coolant hose off coolant pipe.
NOTE:  Observe disposal regulations!
Fig. 17: Identifying Line From Transmission Oil Cooler

 Disconnect lines - arrow - from transmission oil cooler at lower right. Catch fluid which runs out.
 Disconnect line from power steering fluid cooler below on left. Catch fluid which runs out.
 Loosen double clamp between catalytic converter and center muffler and push clamp forward.
 Support rear muffler using Engine/transmission jack V.A.G 1383 A , remove rear mountings and lower
exhaust system.
 Remove heat shield on steering mechanism and loosen universal joint: --> 48 - STEERING
Fig. 18: Identifying Connectors At Transmission And Transfer Case

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 Separate connectors - A - on transmission as well as transfer case - B - and loosen selector lever cable: -->
37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING
 Remove driveshaft: --> 39 FINAL DRIVE, DRIVESHAFTS
 Remove front wheels.
 Remove front wheel housing liners: --> 66 - EXTERIOR EQUIPMENT
 Disconnect brake lines in wheel housing at brake hose and catch fluid which runs out. --> 46 - BRAKES
- MECHANICAL COMPONENTS
 In wheel housings, separate all connectors between body and front axle.
 Remove connection lines for air suspension at strut.
Fig. 19: Identifying Transmission Transverse Support

 Remove transmission transverse support - A -.
Fig. 20: Securing Suspension Struts Using Spring Compressor VW 552

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 Secure suspension struts using Tensioner Hooks (2) VW 552 as shown.

 Remove upper bolts from suspension strut on each side of vehicle. --> 40 - FRONT SUSPENSION
Preparing Scissor lift table VAS 6131 for the continued work procedure:
Fig. 21: Preparing Scissor Lift Table VAS 6131

 Attach pulley-end engine supports VAS 6131/6-1 left and VAS 6131/6-2 right - arrows show direction
of travel - on scissor lift table VAS 6131 and secure bolts at following positions:
 Left support - 1 - : A5, B4 and B5

 Right support - 2 - : G4, H4 and H5
 Bolt both axle supports VAS 6131/6-3 and VAS 6131/6-4 - 3 - to scissor lift table at following positions:
 Left axle support - 3 - : A6 and C6

 Right axle support - 3 - : F6 and H6
 Rotate turntables of axle supports downward.

 Place axle supports VAS 6131/6-5 - 4 - for subframe and - 5 - VAS 6131/6-6 for transmission mount in
appropriate positions on scissor lift table.
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Fig. 22: Identifying Supports And Mounts

 Position horizontally adjusted scissor lift table under engine/transmission assembly. The supports - 1 -
must be guided into corresponding mount - arrow - at right and left.
Fig. 23: Right And Left Supports For Transmission Console Guided Into Corresponding Holes
 Simultaneously, guide right and left supports for transmission mounts into corresponding holes - arrow -.
When all four supports are in appropriate receptacle holes without pressure:
 Using light pressure beneath control arm, install both turntables of axle supports until securing device can
be removed using Tensioner Hooks (2) VW 552.
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Fig. 24: Identifying Supports And Mounts

 Guide supports - 2 - into their respective receptacles in subframe, correcting support height as necessary
with knurled nuts.
Fig. 25: Identifying Subframe Bolts And Transmission Transverse Support

 Loosen subframe bolts - 1 - , - 2 - and - 3 - , as well as transmission transverse support - 4 -.
NOTE:  After loosening the subframe, it will be necessary to perform a wheel

alignment on the vehicle.
 Slowly lower engine/transmission assembly, constantly observing clearance.
Engine, securing to assembly stand

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Fig. 26: Special Tool - Engine And Transmission Holder VAS 6095
 Engine and transmission holder VAS 6095
Engine is to be secured to engine and transmission holder VAS 6095 for performing assembly work.
Work procedure
 Remove transmission.
NOTE:  To separate engine and transmission: Operating instructions for scissor-

type assembly platform 6131
Vehicles with automatic transmission
 After separating engine from transmission, secure torque converter to prevent it from "falling out".
Continuation for all vehicles
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Fig. 27: Identifying Lifting Tackle 3033 & VAS 6100

 Attach lifting device 3033 as follows and lift engine from Engine and Transmission Holder VAS 6100
using workshop hoist 6131.
 Vibration damper side: Position 3.

 Flywheel side: Position 11
NOTE:  The positions of lifting tackle 3033 inscribed with 1 to 12 point toward
flywheel side.
 Threaded spindles are set in length according to necessity.
Fig. 28: Securing Engine To Engine And Transmission Holder VAS 6095
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 Fasten engine to engine and transmission holder VAS 6095.
Engine, installing
CAUTION: When doing any repair work, especially in the engine compartment, pay
attention to the following due to clearance issues:
 Route all the various lines (e.g. for fuel, hydraulics, EVAP system,
coolant, refrigerant, brake fluid and vacuum lines and hoses) and
electrical wiring so that the original positions are restored.
 Ensure sufficient clearance to all moving or hot components.
NOTE:  When installing powertrain in body, it is absolutely necessary to rest

engine carrier against body using scissor lift table VAS 6131. Pulling up
engine carrier with mounting bolts damages thread inserts!
Work procedure
Installation is in reverse order of removal. When doing this note the following:
 Check whether dowel sleeves for centering engine/transmission are in cylinder block, install if necessary.
If subframe with suspension assembly has been removed from assembly platform :
Fig. 29: Preparing Scissor Lift Table VAS 6131

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 Position axle assembly with subframe again on prepared scissor lift table.
 Set engine on assembly carrier.
If transmission is not yet bolted on:
 Support engine with support VAS 6131/7.

 Before installing assembly, install exhaust manifolds with catalytic converters onto engine --> Exhaust
manifolds (with primary catalytic converters and attachments), assembly overview.
 When installing the engine, use scissor lift table to lift so far that the selector cable can be attached.
 Reconnect all lines, hoses and connections that were disconnected for the removal sequence.
 Connect air conditioning lines: --> 87 AIR CONDITIONING

 Fill up oil for power steering: --> 48 - STEERING
 Top off engine oil: --> 01 - MAINTENANCE
 Electrical connections and routing: --> Electrical Wiring Diagrams, Troubleshooting and Component
Locations
 Fill with coolant --> Cooling system, draining and filling.

 Top-off ATF level: --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING
NOTE:  After installation of aggregate, perform axle alignment --> 44 - WHEELS,

TIRES, WHEEL ALIGNMENT
 Perform vehicle system test "Guided Fault Finding".

 End vehicle system test in such a way that possibly existing DTC entries are automatically erased.
 Perform road test.
 Generate readiness code in conjunction with a road test.
NOTE:  Observe safety precautions that apply to road tests --> Safety precautions.
 After that perform vehicle system test again and repair any occurring malfunctions.
Torque specifications
Bolted connections Torque specifications

Bolts, nuts M6 10 Nm
M7 15 Nm
M8 25 Nm
M10 40 Nm
M12 60 Nm
Deviation from
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Engine bracket to engine mount (nut) * See note M10 75 Nm

Engine mount to engine carrier (bolt) * See note M10 60 Nm
Engine carrier to chassis (bolt) M12 100 Nm + 1 /2 turn (180°)
Drive axles to transmission --> 40 - FRONT SUSPENSION
* Engine bracket and engine mount, removing and installing
13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK

ENGINE, DISASSEMBLING AND ASSEMBLING
Engine, disassembling and assembling
NOTE:  Engine is to be secured to engine and transmission holder VAS 6095 for
performing assembly work.
 If large quantities of metal particles or abraded material are detected
during engine repairs, it may be an indication for a damaged crankshaft or
rod bearings. To prevent further damage, perform the following steps after
the repair:
 Thoroughly clean oil passages
 Replace oil non-return valve
 Replace oil spray jets

 Replace oil cooler
 Replace oil filter.
Chain drive, assembly overview --> Chain drive, assembly overview
Cylinder block, assembly overview --> Cylinder block, assembly overview
Engine bracket and left/right engine mounts, removing and installing
Removing and installing ribbed belt --> Ribbed belt, removing and installing
Removing and installing sealing flange and dual-mass flywheel --> Sealing flange and dual-mass flywheel,
removing and installing
Removing and installing crankshaft --> Crankshaft, removing and installing
Piston and connecting rod, disassembling and assembling, assembly overview --> Piston and connecting rod,
disassembling and assembling
Chain drive, assembly overview
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Fig. 30: Chain Drive, Assembly Overview

1 - Control housing
 Lightly oil contact surfaces of camshaft and control housing seals before installing
 Removing and installing --> Camshafts, removing and installing , camshafts, removing and installing
 Disassembling and assembling Disassembling and assembling control housing
 Check control housing strainer for soiling before installation Checking strainer of control housing for
soiling
2 - 8 Nm
 Replace
3 - Camshaft roller chain

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 Mark direction of rotation before removing (installation position) Marking roller chains
 Installing --> Valve timing, adjusting , adjusting timing
4 - Exhaust camshaft adjuster
 Identification: 32A
 Only rotate engine with camshaft adjuster installed
5 - Intermediate shaft
6 - Thrust washer
 Not installed on all engines
7 - 8 Nm
 Insert using locking fluid D 000 600 A2
8 - Tensioning rail
9 - Pivot pin, 18 Nm
10 - Chain tensioner, 40 Nm
 Only rotate engine with chain tensioner installed
11 - Seal
 Replace if damaged or leaking
12 - Chain sprocket
13 - Chain sprocket
14 - 60 Nm plus an additional 1 /4 turn (90°)
 Replace
 Use counter-holder tool T10069 to tighten and loosen To loosen and tighten securing bolt, lock vibration
damper using under Cylinder block, assembly overview
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15 - Chain tensioner with tensioning rail
 Before installation release locking device in chain tensioner with a small screwdriver and press tensioning
plate against chain tensioner
16 - Drive gear
 Integral part of crankshaft

 Ground down tooth aligned with main bearing joint = TDC cyl. 1 --> Valve timing, adjusting ,
Adjusting valve timing
17 - Roller chain
18 - Guide rail
 Remove and install together with roller chain --> Valve timing, adjusting , adjusting valve timing
19 - Locating pin without collar, 10 Nm
20 - 18 Nm
21 - 23 Nm
22 - Intake camshaft adjuster
 Identification: 24E
 Replace
 Contact surface of wheel sensor must be dry around bolt head when assembling
 To remove and install, counter-hold at camshaft using an open-end spanner (32 mm) --> Camshafts,
removing and installing , removing and installing camshaft
24 - Guide rail
25 - Camshaft Adjustment Valve 1 (exhaust) N318
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 For exhaust camshaft

 Before disconnecting, mark allocation of connector to component
26 - Camshaft Adjustment Valve 1 N205
 For intake camshaft

27 - Guide rail
 Clipped in at control housing
Marking roller chains
Fig. 31: Identifying Markings On Roller Chains

 Mark roller chains before removing (e.g. with paint, arrow pointing in direction of rotation).
NOTE:  Do not mark chain using a center punch or similar means!
Cylinder block, assembly overview
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Fig. 32: Cylinder Block, Assembly Overview

1 - 8 Nm
 Fastened to intake manifold
2 - Guide tube
 For dipstick
 Secured by a bolt to intake manifold
3 - Dipstick
 Oil level must not be above the max. mark!

 Marks
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4 - Oil check valve
 Note installation position

 Removing and installing
 Clean or replace if badly soiled
 See note --> Engine, disassembling and assembling
5 - Knock sensor 1 G61
 Component location: Between cyl. 1 and cyl. 3
6 - 20 Nm
 Torque setting influences function of knock sensor
7 - 10 Nm
8 - Oil pump drive cover
9 - O-ring
 Replace
 Oil before assembling
10 - Oil pump drive
11 - Cylinder block
 Removing and installing sealing flange and dual-mass flywheel --> Sealing flange and dual-mass
flywheel, removing and installing
 Removing and installing crankshaft --> Crankshaft, removing and installing
 Piston and connecting rod, disassembling and assembling --> Piston and connecting rod, disassembling
and assembling
13 - Thrust washer
 Not installed on all engines
14 - 10 Nm
15 - Input shaft
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 For oil pump drive
16 - Engine speed (RPM) sensor G28
17 - Oil pump
 Disassembling and assembling --> Oil pump, disassembling and assembling
18 - 23 Nm
19 - 8 Nm
20 - Oil drain plug, 30 Nm
 Replace
21 - Oil pan
 Removing and installing --> Oil pan, removing and installing
22 - Oil Level Thermal Sensor G266
 Only for vehicles with engine code "AZZ"
23 - Seal
 Replace
24 - 20 Nm
25 - Seal
 Replace
26 - Oil filter housing/left engine bracket
 Disassembling and assembling --> Oil filter housing, disassembling and assembling
 Coolant hose connection diagram --> Coolant hose connection diagram
 Engine bracket and left/right engine mounts, removing
27 - 23 Nm
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28 - To thermostat housing
29 - 25 Nm
30 - Fitting bolt, 25 Nm
31 - Compact bracket
 For generator, air conditioning compressor, and power steering pump
32 - Coolant line
 Removing and installing --> Cooling system components (on engine), assembly overview , components
of cooling system - engine side
33 - Knock sensor 2 G66
34 - Vibration damper
 Removing and installing ribbed belt --> Ribbed belt, removing and installing
 Replace
 Use counter-holder tool T10069 for loosening and tightening To loosen and tighten securing bolt, lock
vibration damper using under Cylinder block, assembly overview
 Tighten using torque wrench V.A.G 1601
Fig. 33: Loosening/Tightening Securing Bolt, Using Counter-Holder T10069 To Hold Vibration Damper
To loosen and tighten securing bolt, lock vibration damper using counter-holder tool T10069
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NOTE:  Vibration damper securing bolt must be replaced.

 Tighten securing bolt using torque wrench V.A.G 1601.
 Engine support bridge 10 - 222 A

 Shackle 10 - 222 A/12
 Adapter 10 - 222 A/16
Fig. 34: Identifying Support Assembly 10-222A

 Adapter 10 - 222 A/19
Removing
 Completely remove air filter with mass air flow (MAF) sensor.
Fig. 35: Identifying Nuts on Engine Mount At Left And Right Engine Supports
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 Remove nuts - 2 - on right and left engine bracket.

 Position adapter 10 - 222 A/16 on Engine and Transmission Holder 10 - 222 A with high side of threaded
spindle guide facing upward as shown in illustration.
 Now place adapter 10 - 222 A/19 on left and right of Engine and Transmission Holder 10 - 222 A. Place
Engine and Transmission Holder 10 - 222 A on long members.
Fig. 36: Engaging Engine With Two Shackles 10 - 222 A/12 At Adapter 10 - 222 A/16 And Pretensioning
Engine Slightly
 Engage engine with two Shackles 10 - 222 A/12 at Adapter 10 - 222 A/16 and pretension engine slightly.
 Remove bolts - 1 - from left and right engine mount/subframe.

 Be aware of available clearance between cylinder head and bulkhead.
 Now carefully lift engine with adapter 10 - 222 A/16.
 To remove engine mount, engine bracket must also be removed from cylinder block, because engine can
not be lifted high enough.
Installing
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Installation is in reverse order of removal.
 When installing, make sure alignment pin of engine mount is correctly positioned in engine bracket.
 First install all bolts by hand, and then tighten them all to the specified torque.
Torque specification for bolt - 1 - : 60 Nm.
Torque specification for nut - 2 - : 75 Nm.
Torque specification for oil filter housing/engine bracket bolts to cylinder block at left: 23 Nm.
Torque specification for engine bracket bolts to cylinder block at right: 40 Nm.
Ribbed belt, removing and installing
 Hex head bolt M8 x 50
Ribbed belt, removing
 Mark direction of rotation of ribbed belt.

 Press tensioning arm in direction of - arrow - using a suitable wrench.
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Fig. 39: Identifying M8x50 Bolt In Threaded Hole

 Install an M8x50 bolt into threaded hole - A - , thereby securing ribbed belt tensioner.
NOTE:  Only install bolt in so far until ribbed belt can be removed, otherwise the
housing of the tensioning roller can be damaged.
 Remove ribbed belt.
Ribbed belt, installing
NOTE:  Ensure, before installing ribbed belt, that all ancillaries (generator, air
conditioner compressor, power steering pump) are secured tightly.
 Check that idler roller turns easily.
 Note previously marked direction of belt rotation and be sure that it is
seated correctly on pulley.
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Fig. 40: Identifying Ribbed Belt Routing

 Route ribbed belt and remove M8 bolt from tensioning roller.
After completing repairs always:
 Start engine and check belt running.
SEALING FLANGE AND DUAL-MASS FLYWHEEL, REMOVING AND INSTALLING
Sealing flange and dual-mass flywheel, removing and installing
Sealing flange, assembly overview --> Sealing flange, assembly overview
Drive plate, removing and installing --> Drive plate, removing and installing
Oil seal (flywheel side), removing and installing --> Oil seal (flywheel side), removing and installing
Sealing ring for crankshaft, vibration damper side, replacing --> Crankshaft seal (vibration damper side),
replacing
Sealing flange, assembly overview
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Fig. 41: Sealing Flange, Assembly Overview

 Replace
 Use counter-holder tool T10069 for loosening and tightening To loosen and tighten securing bolt, lock
vibration damper using under Cylinder block, assembly overview
 Tighten using torque wrench V.A.G 1601
2 - Vibration damper
3 - 10 Nm
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4 - Seal
 Replacing --> Crankshaft seal (vibration damper side), replacing.
5 - Sealing flange
 Coat sealing surfaces with sealant AMV 176 501
6 - Cylinder block

and assembling
7 - Sealing flange
 Coat sealing surfaces with sealant AMV 176 501
8 - Seal
 Remove using pulling hook T20143/2

 PTFE version of oil seal
 Identification: No inner coil spring
 Do not additionally oil or grease sealing lip of sealing ring
 Before installing, remove oil remains from crankshaft journal with a clean cloth
 Replacing --> Oil seal (flywheel side), removing and installing.
9 - Dual mass flywheel
 Replace
 To loosen or tighten, use counter-hold T10044 (with 5 mm spacers), or counter-hold T10069.
11 - 25 Nm
Drive plate, removing and installing
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Fig. 42: Counter-Holder Tool T10069

 Counter-holder tool T10069
Fig. 43: Torque Wrench V.A.G. 1332


 Depth gauge
Removing
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 Remove drive plate. To do so, lock vibration damper using counter-holder tool T10069.
 Loosen drive plate securing bolts diagonally and remove.
 Remove drive plate.
Installing
 Tighten drive plate on crankshaft with at least 3 old securing bolts to 30 Nm.
Fig. 45: Measuring Dimension Using Depth Gauge

 Measure dimension - a - using depth gauge : Specified value: 21.0 to 23.0 mm
If specified value is not reached:
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Fig. 46: Identifying Appropriate Shim

 Remove drive plate again and use appropriate shim - 1 -.
NOTE:  Only one shim of the appropriate thickness may be used.
If specified value is obtained:
 Insert new securing bolts and tighten by hand.

 Tighten bolt to 60 Nm plus an additional 1 /4 turn (90°) (turning further may be performed in several
steps).
Oil seal (flywheel side), removing and installing
Fig. 47: Pulling Fixture T10122

 Pulling fixture T10122
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Fig. 48: Identifying Extractor Hook T20143

 Extractor hook T20143
Oil seal (flywheel side), removing
 Place pulling hook T20143/2 behind sealing lip of sealing ring as shown in the illustration.
Fig. 49: Supporting Pulling Hook T20143/2 On Sealing Flange And Prying Out Sealing Ring
 Support pulling hook T20143/2 on sealing flange and pry out sealing ring in direction of - arrow -.
Oil seal (flywheel side), installing
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Fig. 50: Identifying Seal, Sleeve T10122/1 And Assembly Tool T10122/2
 Pull seal - A - with outer side over sleeve T10122/1 onto assembly tool T10122/2.
 Separate both assembly sleeves.
 Then place assembly tool T10122/2 with dry sealing ring on to crankshaft pin.
Fig. 51: Driving Seal Into Sealing Flange Until Stop Using Thrust Piece T10122/3
 Now knock it into sealing flange until it stops using assembly tool T10122/3.
Crankshaft seal (vibration damper side), replacing
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Fig. 52: Identifying Special Tools -- Crankshaft Seal (Vibration Damper Side), Replacing
 Extractor hook T20143/1

 Assembly tool T10215
 Torque wrench V.A.G 1601
NOTE:  If a plastic sealing flange is installed, sealing ring cannot be replaced

separately and sealing flange must be replaced --> Sealing flange for
crankshaft (harmonic balancer side), replacing.
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Removing
 Bring lock carrier into service position --> 50 - BODY - FRONT .

 Remove ribbed belt --> Ribbed belt, removing and installing.
 Remove vibration damper. To do so, lock vibration damper using counter-holder tool T10069.
 Place pulling hook T20143/1 behind sealing lip of sealing ring as shown in the illustration.
Fig. 54: Supporting Pulling Hook T20143/1 On Sealing Flange And Prying Out Sealing Ring
 Support pulling hook T20143/1 on sealing flange and pry out sealing ring in direction of - arrow -.
Installing
 Before installing, remove oil remains from end of crankshaft with a clean cloth.
 Install guide sleeve T10215/1 - 1 - onto front of crankshaft journal.
 Carefully slide oil seal - 2 - onto guide sleeve as far as possible.
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Fig. 55: Identifying Guide Sleeve T10215/1, Oil Seal, Thrust Sleeve T10215/2 And Old Vibration Damper
Securing Bolt
 Press in oil seal until stop using thrust sleeve T10215/2 - 3 -. To do this use an old vibration damper
securing bolt - 4 -.

 Install vibration damper and secure using counter-holder tool T10069.

 Tighten new mounting bolt to 100 Nm plus an additional 1 /2 turn (180°).
 Install ribbed belt --> Ribbed belt, removing and installing.
Sealing flange for crankshaft (harmonic balancer side), replacing
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Fig. 57: Identifying Special Tools - Sealing Flange For Crankshaft (Harmonic Balancer Side), Replacing

Removing
 Bring lock carrier into service position --> 50 - BODY - FRONT .

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 Remove vibration damper. To do so, lock vibration damper using counter-holder tool T10069.
 Remove oil pan --> Oil pan, removing and installing.
 Remove sealing flange.
 Remove sealant residue on sealing surfaces.
Installing
 Before installing, remove oil remains from end of crankshaft with a clean cloth.
Fig. 59: Cutting Off Tube Nozzle At Front Marking & Applying Silicone Sealing Compound To Clean
Sealing Surface Of Sealing Flange
 Cut off nozzle on/tube of sealant at/front mark (dia. of nozzle approx. 3 mm).
 Apply a sealant bead of approx. 2 to 3 mm as shown - arrows - on to clean sealing surface of sealing
flange.
NOTE:  Cover sealing ring with a clean cloth before applying sealing bead.
 Sealant bead must not be thicker than 2 to 3 mm, otherwise excess sealant
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could get into oil pan and clog oil intake pipe strainer.
 Note the expiration date of the sealing compound.
 The sealing flange must be installed within 5 minutes after application of
silicon sealant.
 Insert guide sleeve T10215/1 - 1 - at front on to crankshaft pin - 3 -.

 Now slide sealing flange with sealing ring - 2 - carefully over guide sleeve.
Fig. 60: Identifying Guide Sleeve T10215/1, Crankshaft Pin & Sealing Ring
 Tightly bolt sealing flange on cylinder crankshaft housing.

 Install oil pan --> Oil pan, removing and installing.

 Install vibration damper and secure using counter-holder tool T10069.

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 Tighten new mounting bolt to 100 Nm plus an additional 1 /2 turn (180°).

CRANKSHAFT, REMOVING AND INSTALLING
Crankshaft, removing and installing
Install sensor wheel on crankshaft Installing sensor wheel to crankshaft
 Engine is to be secured to engine and transmission holder VAS 6095 for performing assembly work.
 When changing bearing shells ensure that bearing shells with the same color code are used.
Fig. 62: Crankshaft, Assembly Overview

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1 - Bearing cap
 Bearing cap 1: Vibration damper side

 Bearing cap 5 with notches for thrust washers
 Retaining tabs of bearing shells and cylinder block/bearing caps must lie above one another
 Replace
 Two 90° turns are permitted
3 - Bearing shell 1 to 7
 For bearing cap without oil groove

 For cylinder block with oil groove
 Do not interchange used bearing shells (mark)
4 - Thrust washer
 For bearing cap 5

 Observe locating point
5 - Crankshaft
 Before removing, observe note --> Crankshaft, removing and installing

 Axial play new: 0.07 to 0.23 mm, Wear limit: 0.30 mm
 Check radial clearance with Plastigage 0.02 to 00.06 mm, Wear limit: 0.10 mm
 Do not turn crankshaft when measuring radial play
 Crankshaft dimensions: Main bearing: 59.958 to 59.978 mm, Connecting rod bearing: 53.958 to 53.978
mm reworking is not permitted
6 - Sensor wheel
 For Engine Speed (RPM) Sensor G28

 Replace
 Installing Installing sensor wheel to crankshaft
 Replace
8 - Oil spray jet

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 For crankshaft bearing 2 to 7

 For piston cooling
 Opening pressure 2.0 bar pressure
 See note --> Engine, disassembling and assembling
Installing sensor wheel to crankshaft
Fig. 63: Identifying VR6 And Bolts


 Locking fluid D 000 600 A2
Work procedure
Make sure crankshaft/sensor wheel contact surfaces are free of oil and grease.
 Apply a thin coat of locking compound D 000 600 A2 to contact surfaces of crankshaft and sensor wheel
for additional security.
 Check that when installing "VR6" - arrow - is marked at individual threaded holes.
 Tighten all new securing bolts lightly by hand.
 Tighten securing bolt - 1 - to 10 Nm plus and additional 1 /4 turn (90°).
 Tighten securing bolts - 2 - to 10 Nm plus and additional 1 /4 turn (90°).
PISTON AND CONNECTING ROD, DISASSEMBLING AND ASSEMBLING
Piston and connecting rod, disassembling and assembling
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Pistons and connecting rods, assembly overview --> Piston and connecting rod, assembly overview
Checking pistons, piston rings and cylinder bore --> Pistons, piston rings and cylinder bore, checking
Piston and connecting rod, assembly overview
Checking piston ring end gap Checking piston ring gap
Checking piston ring side clearance Checking ring to groove clearance
Checking pistons Checking piston
Installing piston with Piston insertion Funnel T10147 Installing piston with under Installing piston with Piston
insertion Funnel T10147
Fig. 64: Piston And Connecting Rod, Assembly Overview
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1 - Piston rings
 Offset gaps by 120°

 Use piston ring pliers for removal and installation
 "TOP" faces toward piston crown
 Checking ring gap --> Pistons, piston rings and cylinder bore, checking
 Check piston ring groove clearance --> Pistons, piston rings and cylinder bore, checking
2 - Piston
 Checking --> Pistons, piston rings and cylinder bore, checking

 Mark installed location to connecting rod and affiliation to cylinder
 Flatter side of piston crown faces toward center of cylinder block
 Install using Piston insertion Funnel T10147 Installing piston with under Installing piston with Piston
insertion Funnel T10147
3 - Circlip
4 - Connecting rod
 Only replace as set

 Affiliation to cylinder mark - B -
 Installed location: Markings - A - must align
5 - Bearing shell

 Do not interchange used bearing shells
 Bearing shell retaining tabs must be firmly seated in notches
 Axial play new: 0.05 to 00.31 mm, Wear limit: 0.40 mm
 Measure radial clearance with Plastigage: New: 0.02 to 00.07 mm, Wear limit: 0.10 mm. Do not turn
crankshaft when checking radial clearance
6 - Connecting rod bearing cap
 Affiliation to cylinder mark - B -

 Installed location: Markings - A - must align
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 Replace
 Lubricate threads and contact surface
 Tighten to 30 Nm to measure radial play, do not turn further
8 - Cylinder block
 Cylinder bore, checking --> Pistons, piston rings and cylinder bore, checking
 Piston and cylinder dimensions --> Pistons, piston rings and cylinder bore, checking
9 - Piston pin
 If difficult to move, heat piston to 6°C

 Removing and installing using a Pilot Drift VW 222 A
Pistons, piston rings and cylinder bore, checking
Checking piston ring gap
Fig. 65: Checking Piston Ring Gap

 Feeler gauge
Test sequence
 Push ring squarely from above down to approx. 15 mm from bottom end of cylinder. To do this use a
piston without rings.
Piston ring Gap

New Wear limit
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Compression ring mm 0.20 to 0.40 1.0

Tapered ring mm 0.20 to 0.40 1.0
Oil scraping ring mm 0.25 to 0.50 1.0
Checking ring to groove clearance
Fig. 66: Checking Ring To Groove Clearance

 Feeler gauge
 Clean ring groove before checking.
Piston ring Ring to groove clearance

New Wear limit
Compression ring mm 0.04 to 0.09 0.15
Tapered ring mm 0.03 to 0.06 0.15
Oil scraping ring mm 0.02 to 0.06 0.15
Checking piston
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Fig. 67: Checking Piston

 External micrometer 75 to 100 mm
Take measurement approx. 6 mm from lower edge of piston skirt and offset 90° to piston axis.
Deviation from nominal dimension: max. 0.04 mm
Fig. 68: Checking Cylinder Bores

Checking cylinder bores
 Internal dial gauge 50 to 100 mm
Test sequence
Measure diagonally at 3 positions transversely - A - and longitudinally - B -.
Deviation from nominal size: max. 0.08 mm.
NOTE:  Cylinder bore measurement may not be performed when the cylinder block
is mounted on Engine and Transmission Holder VAS 6095 , false
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measurements are possible.
Piston and cylinder dimensions
Honing dimension Piston diameter Cylinder bore diameter

Basic dimension mm 83.965 84.010
Installing piston with Piston insertion Funnel T10147
Fig. 69: Identifying Funnel T10147

 Piston insertion Funnel T10147
Work procedure
NOTE:  If a new Piston insertion Funnel T10147 is used to install the pistons, first
pass piston with oiled piston rings through the funnel twice and remove
the resulting metal shavings if necessary. Only then install piston with
piston rings.
 Push piston by hand into oiled Piston insertion Funnel T10147. Flat side of piston crown must face
toward tab on Piston insertion Funnel T10147 - arrow -.
 Hold Piston insertion Funnel T10147 (with piston inserted) on upper edge and press piston in with both
thumbs.
 Push piston in until it protrudes approx. 15 mm from lower edge of Piston insertion Funnel T10147.
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Fig. 70: Identifying Piston Installation Tool T10147

 Insert piston into appropriate cylinder bore. Tab on Piston insertion Funnel T10147 - arrow - must face
center of cylinder block.
 Press Piston insertion Funnel T10147 tightly against cylinder block and push piston in.
15 - ENGINE - CYLINDER HEAD, VALVETRAIN

CYLINDER HEAD
Cylinder head
NOTE:  To remove the cylinder head the engine must first be removed --> Engine,
removing and installing.
 If a replacement cylinder head is installed, all contact surfaces between
support elements, roller cam followers and cam lubricating surfaces of
camshafts must be oiled before installing the cylinder head cover.
 The plastic protectors installed to protect the open valves must only be
removed immediately before fitting the cylinder head.
 When replacing the cylinder head or cylinder gasket, the complete amount
of coolant must be replaced.
Cylinder head, assembly overview --> Cylinder head, assembly overview
Cylinder head, removing and installing --> Cylinder head, removing and installing
Checking valve timing --> Valve timing, checking
Adjusting valve timing --> Valve timing, adjusting
Removing and installing cylinder head cover --> Cylinder head cover, removing and installing
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Cover, removing and installing --> Cover, removing and installing, assembly overview
Compression, checking --> Compression pressures, checking.
Valvetrain, servicing --> Valvetrain
Cylinder head, assembly overview
Fig. 71: Cylinder Head, Assembly Overview

1 - 10 Nm
2 - Bracket
 For wiring harness
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3 - 10 Nm
 With spacer sleeve and seal

 Replace seal if damaged
4 - Sealing cap
 Replace gaskets if damaged
5 - Seal
6 - Cylinder head cover
 Removing and installing --> Cylinder head cover, removing and installing
 Replace if damaged
7 - Lifting eye
8 - 23 Nm
10 - Combi-valve
 Removing and installing --> Secondary Air Injection (AIR) Pump Motor V101 system components,
assembly overview
 Checking --> Combi-valve, checking
11 - O-ring
 For oil channel seal

 Replace
12 - Camshaft position (CMP) sensor 2 G163


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14 - Seal

 Removing and installing --> Camshaft adjustment valves, removing and installing

 Removing and installing --> Camshaft adjustment valves, removing and installing
17 - 8 Nm
18 - Seal

 Installing
19 - Coolant thermostat housing
 Disassembling and assembling --> Coolant thermostat housing, assembly overview

20 - Seal
 Replace
21 - Camshaft Position (CMP) sensor G40

22 - Cover
 If only the cover has been removed, prepare cylinder head gasket for installation Preparing cylinder
head gasket for installation
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 Replace
 To remove and install, counter-hold with 32 mm open end wrench on camshaft --> Camshafts, removing
and installing , Removing and installing camshafts
25 - Guide rail
 Clipped in at control housing
27 - Lifting eye
28 - Cylinder head gasket
 Metal gasket
 Replace
 Prepare cylinder head gasket for installation Preparing cylinder head gasket for installation
 After replacing replace entire amount of coolant
29 - Cylinder head
 Check for distortion Checking cylinder head for distortion

 Removing and installing --> Cylinder head, removing and installing
30 - Tensioning element
 For ribbed belt

31 - Cylinder head bolt
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 Replace
 Observe installation instructions and sequence for loosening and tightening --> Cylinder head, removing
and installing , Cylinder head, removing and installing
32 - Gasket for cylinder head cover

Cylinder head, removing and installing
Fig. 72: Identifying Special Tools - Cylinder Head, Removing And Installing
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 Lifting tackle 3033

 Polydrive Key 3452
 Camshaft bar T10068 A

Fig. 73: Spring-Type Clip Pliers VAS 5024A

Fig. 74: Identifying Shop Crane VAS 6100

 Shop crane VAS 6100

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Not illustrated:
 Sealant AMV 174 004 01

 Sealant AMV 176 501
 Cable tie
Requirements
 Engine must be removed.

 The engine must be no more than warm to touch.
Removing
 All cable ties which are opened or cut open when removing, must be replaced in the same position when
installing.
Fig. 75: Identifying Crankshaft At Vibration Damper Securing Bolt In Engine At TDC Cyl. 1
 Set crankshaft to TDC No. 1 Cyl. marks by turning crankshaft on vibration damper securing bolt in
engine direction of rotation: 1 - arrow -.
 Remove ribbed belt --> Ribbed belt, removing and installing
 Remove intake manifold and cylinder head cover --> Cylinder head cover, removing and installing ,
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Cylinder head cover, removing and installing.
Fig. 76: Identifying Connecting Line And Knock Sensor

 Remove connecting line - 1 - at bracket for intake manifold support and pull connector for knock sensor
(KS) 1 G61 - 2 - out of its bracket.
 Unclip wire from retainer on cylinder head.
Fig. 77: Identifying Combination Valve And Coolant Hose

 Remove connecting line from combination valve - 1 - and pull off coolant hose - 2 - below combination
valve on cylinder head.
 Remove exhaust manifold from cylinder head.
 Disconnect connectors from Camshaft Adjustment Valve 1 N205 and camshaft adjustment valve 1,
exhaust N318.
NOTE:  Before disconnecting harness connectors, mark allocation to component.
 Remove securing clamps for wiring harness at bracket.

 Remove only thermostat housing --> Cooling system components (on engine), assembly overview ,
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Cooling system components, engine side
Fig. 78: Locating Camshaft Roller Chain Tensioner

 Remove camshaft roller chain tensioner - arrow -.

 Remove cover --> Cover, removing and installing, assembly overview.
NOTE:  The cover has a "hidden bolt". It can be removed only after the thermostat
housing has been removed.
 When all securing bolts have been removed, cover can be carefully pried off.
 Remove bolts for camshaft adjuster.
Fig. 79: Locating Counter-Hold Area On Camshaft

NOTE:  When loosening or tightening the camshaft adjuster, counter-hold only

with 32 mm open end wrench on camshaft - arrow -. Camshaft bar T10068
A must not be installed during this process.
 Remove camshaft adjuster together with camshaft roller chain from intake camshaft.
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 Remove exhaust camshaft adjuster.
Fig. 80: Locating Guide Rail & Bolts

 Remove guide rail securing bolts - arrow - and remove guide rail - 1 -.
 Place camshaft roller chain aside.
Fig. 81: Cylinder Head Bolts Tightening/Removal Sequence

 Loosen and remove cylinder head bolts in specified sequence starting from outside working toward
inside.
NOTE:  Use Polydrive Key 3452 for Polydrive cylinder head bolts.
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Fig. 82: Identifying Lifting Tackle 3033 & VAS 6100

 Engage lifting tackle 3033 as shown and carefully lift off cylinder head using workshop crane VAS 6100
or V.A.G 1202 A :
Vibration damper side: Position 3
Flywheel side: Position 11
NOTE:  The positions of lifting tackle 3033 inscribed with 1 to 12 point toward
flywheel side.
 Threaded spindles are set in length according to necessity.
 Carefully lift cylinder head off.

 Stuff clean cloths into cylinder so that no dirt or abrasive powder can get between cylinder wall and
piston.
 Also prevent dirt and emery cloth particles from getting into coolant.
 Carefully clean cylinder head and cylinder block sealing surfaces. Avoid introducing scratches or scoring
(do not use sandpaper with grit below "100").
 Clean all threaded bores for cylinder head bolts.
Installing
 Carefully remove metal particles, emery remains and cloths.
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If piston for cylinder 1 is not at TDC:
engine direction of rotation: 1 - arrow -. When doing this, guide camshaft roller chain by hand with aid
of a 2nd technician.
NOTE:  Only remove the new cylinder head gasket from its packing immediately
before installing.
 Handle the new gasket with extreme care. Damaging will lead to leaks.
 Install new cylinder head gasket. Install new cylinder head gasket. Inscription (Part No.) must be legible.
Fig. 84: Cylinder Head Tightening/Loosening Sequence

 Ensure that alignment bushings are inserted into cylinder block holes 12 and 20 and that cylinder head
gasket is seated.
 Position camshafts in cylinder head to TDC No. 1 cylinder 1.
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Fig. 85: Inserting Camshaft Bar T10068 A Into Both Shaft Grooves
 It must be possible to insert camshaft bar T10068 A into both shaft grooves.
 Install cylinder head, insert new cylinder head bolts and hand tighten.
Fig. 86: Cylinder Head Tightening/Loosening Sequence

 Tighten cylinder head bolts in tightening sequence as follows from inside to outside.
NOTE:  The longer cylinder head bolts must be inserted in the middle holes of
cylinder head.
 Pre-tighten all bolts to 30 Nm.

 Then tighten all bolts to 50 Nm.
 Tighten all bolts (1 /4 turn) (90°) further using a rigid wrench.
 Afterwards, tighten all bolts again 1 /4 turn (90°) further
The rest of assembly is basically a reverse of disassembling sequence.

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How to adjust valve timing --> Valve timing, adjusting.
NOTE:  Make sure that the O-ring for sealing the oil gallery and the seal in the
cover are installed.
 Install cylinder head cover and intake manifold --> Cylinder head cover, removing and installing ,
Removing and installing cylinder head cover.
Fill with new coolant --> Cooling system, draining and filling.
NOTE:  There is no requirement to re-tighten the cylinder head bolts after repairs.
Checking cylinder head for distortion
Fig. 87: Checking Cylinder Head For Distortion

 Straight edge
 Feeler gauge
Max. permissible distortion: 0.05 mm
Valve timing, checking
NOTE:  Valve timing can be checked when the engine is installed.
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Fig. 88: Identifying Camshaft Bar T10068 A

Test sequence
 Remove cylinder head cover and intake manifold --> Cylinder head cover, removing and installing ,
 Remove front noise insulation. --> 50 - BODY - FRONT
engine direction of rotation: 1 - arrow -.
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If camshaft bar cannot be engaged:
 Turn crankshaft over in direction of rotation one time.
NOTE:  If the camshaft bar T10068 A cannot be installed, turn the crankshaft in
engine direction of rotation up to 5 mm past the TDC setting for No. 1
cylinder (dependent on drive chain tolerances).
Verify installation markings of camshaft adjuster with markings on control housing:
Fig. 91: Identifying Marks And Camshaft Adjusters Aligned With Notches On Control Housing
 Marks - A - and - B - on camshaft adjusters must align with notches - arrows - on control housing - C -.
 Distance between tooth - 1 - and tooth - 2 - of camshaft adjuster must be exactly 16 rollers of camshaft
roller chain.
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NOTE:  Illustration shows a cover which has been removed.
If markings to not match:
 Adjust valve timing --> Valve timing, adjusting.
If markings match:
Valve timing, adjusting
(Install roller chain, work procedure possibly only with engine removed)
Fig. 92: Identifying Special Tools -- Valve Timing, Adjusting

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Work procedure
NOTE:  The timing chain can only be removed with the engine removed. The
following work sequence description begins with the engine
disassembled. The adjustments required depend on how far the engine
has been disassembled.
Install roller chain and chain tensioner with tensioning plate for intermediate shaft drive:
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Fig. 93: Identifying Guide Rail, Roller Chain, Both Chain Sprockets, And Marking On Roller Chain
Sprocket Aligned With Notch On Thrust Washer Of Intermediate Shaft
 Adjust position of crankshaft relative to intermediate shaft. To position: Align ground-down tooth of
drive chain sprocket - B - with bearing joint "TDC cyl. 1".
 Install both bolts without collar for guide rail - 2 - and tighten to 10 Nm.
NOTE:  Note direction of rotation of used chains Marking roller chains
 Install guide rail - 2 - with roller chain - 1 - and both chain sprockets - 3 - and - 4 -. Marking on roller
chain sprocket - 4 - must align with notch - C - or - D - on thrust washer of intermediate shaft.
During installation make sure that the roller chain runs completely straight in the guide rail from the crankshaft
to intermediate shaft.
 Tighten chain sprockets - 3 - and - 4 - on intermediate shaft by hand.
NOTE:  Be aware that all chain sprocket securing bolts must be replaced.
 Install chain tensioner on opposite side.

 Release locking splines of chain tensioner - A - with a small screwdriver and tensioning rail pressed
against chain tensioner.
 Install chain tensioner in this position and tighten to 8 Nm.
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 Lock vibration damper using counter-holder tool T10069.
Fig. 95: Identifying Guide Rail, Roller Chain, Both Chain Sprockets, And Marking On Roller Chain
Sprocket Aligned With Notch On Thrust Washer Of Intermediate Shaft
 Tighten new securing bolts for intermediate shaft sprockets - 3 - and - 4 - 60 Nm plus an additional 1 /4
(90°).
 Remove counter-holder T10069.
 Check position of crankshaft - B - to intermediate shaft - C - or - D - once again.
 Set engine to No. 1 cylinder TDC again.
Install roller chain for camshaft drive:

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 Position camshafts in cylinder head to TDC No. 1 cylinder.

NOTE:  If necessary use 32 mm open end wrench to turn camshafts - arrow - to

correct position. Camshaft bar T10068 A must not be inserted during this
process.
 The camshaft bar T10068 A must engage in both shaft grooves.
NOTE:  If the cylinder head is removed:

 Install cylinder head --> Cylinder head, removing and installing , Cylinder
head, removing and installing
 Place camshaft roller chain on intermediate shaft chain sprocket.

 Route chain between tensioning rail and guide rail toward control housing.
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Fig. 98: Identifying Camshaft Timing Adjusters Positioned On Camshaft Mountings

 Position both camshaft adjusters (identification: 24E on intake side and 32A on exhaust side) on ends of
camshafts as shown - arrows -.
 Install intake camshaft adjuster first.
Fig. 99: Turning Sensor Wheel On Intake Camshaft Adjuster Clockwise

 Turn wheel sensor - 1 - in camshaft adjuster to right - arrow - onto stop and bolt it on in this position.
Marking -24E- must align with notch in control housing.
 Place camshaft roller chain over sprocket in this position.
NOTE:  If the camshaft adjuster is to be fastened to the camshaft, the adjuster with
corresponding chain sprocket must be turned to the left. In any case, the
marking "24E" or "32A" must be aligned to the notch in the control
housing.
 Count exactly 16 rollers of timing chain to right from marking -24E- of camshaft adjuster.
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Fig. 100: Turning Sensor Wheel Of Exhaust Camshaft Adjuster To Right

 Insert tooth of exhaust camshaft adjuster with marking -32A- at that point. There must now be exactly 16
rollers between those two teeth. Turn wheel sensor - 1 - in camshaft adjuster to right - arrow - onto stop
and bolt it to exhaust camshaft in this position.
NOTE:  If the camshaft adjuster is to be fastened to the camshaft, the adjuster with
corresponding chain sprocket must be turned to the left. In any case, the
marking "24E" or "32A" must be aligned to the notch in the control
housing.
Fig. 101: Identifying Marks And Camshaft Adjusters Aligned With Notches On Control Housing
 Marks - A - and - B - on camshaft adjusters must align with notches - arrows - on control housing - C -.
 Remove camshaft bar T10068 A.
 Tighten new securing bolts for camshaft adjusters by hand.
 Check this adjustment.
 Press tensioner plate of tensioning element against camshaft roller chain.

 Turn over crankshaft twice in direction of engine rotation and check valve timing --> Valve timing,
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checking.
NOTE:  When turning the crankshaft, the tensioning plate must be pressed against
the camshaft roller chain by hand at the chain tensioner, so that the
camshaft roller chain does not jump over a tooth.
If markings do not match:
 Repeat valve timing adjustment.
If markings match:

 Hold respective fastening camshaft tightly with an open-end wrench 32 mm - arrow -.
NOTE:  Camshaft bar T10068 A must not be inserted during this process.
Fig. 103: Identifying Intake And Exhaust Camshaft Adjusters And Securing Bolt
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 Tighten new bolts - 3 - for intake and exhaust camshaft adjusters - 4 - and - 2 - to 60 Nm plus an
additional 1 /4 turn (90°) (additional turn may be performed in several steps.)
 Now sealing flange can be assembled as follows:
 Coat sealing surface of sealing flange with sealant AMV 176 501 and install.
 To do this, insert assembly tool T10122/2 into oil seal --> Oil seal (flywheel side), removing and
installing.
 Push seal over assembly tool T10122/2 onto crankshaft stub, and sealing flange further onto cylinder
block.
NOTE:  Consider the dowel pins in the cylinder block.
 Tighten bolts to 8 Nm.

 Remove assembly tool T10122/2 from crankshaft stub.
 Lubricate O-ring for oil channel seal and install with oil seal into cover.
 Install cover, insert all securing bolts with corresponding brackets and tighten lightly.
 First fasten bolts M8 to 23 Nm, then fasten bolts M6 to 8 Nm.
 Install chain tensioner for camshaft roller chain and tighten to 40 Nm.
 Turn over crankshaft twice in direction of engine rotation and check valve timing again.
 Bolt on thermostat housing.

Cylinder head cover, removing and installing
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Fig. 104: Identifying Special Tools -- Cylinder Head Cover, Removing And Installing
 Spring-type clip pliers VAS 5024 A

 Puller For Ignition Coil T10095 A
Removing
 All cable ties which are opened or cut open when removing, must be replaced in same position when
installing.
 Remove engine covers.
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 Remove ignition coils with power output stage --> Ignition coils with power output stage, removing
and installing.
 Remove intake hose between mass air flow sensor G70 and throttle valve control module J338.
 Disconnect 6-pin connector from throttle valve control module J338 , as well as 2-pin connector from
evaporative emission (EVAP) canister purge regulator valve N80 and crankcase breather valve.
Fig. 105: Identifying Vacuum Hoses And Securing Bolt


 Remove securing bolt - 5 - for intake manifold support.
 Remove intake manifold supports from right and left of intake manifold.
 Disconnect crankcase breather hose at cylinder head cover.
Fig. 106: Identifying Securing Bolts For Intake Manifold

 Now remove securing bolts - 1 - and - 2 - from intake manifold.

 Pull off vacuum hose from intake manifold change-over vacuum actuator.
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 Remove coolant pipe on front of cylinder head.

 Remove intake manifold and place it on a suitable surface so that vacuum actuator is not damaged.
NOTE:  Seal the intake ports in the intake manifold and in cylinder head with clean
cloths.
 At front of cylinder head cover, unbolt bracket for wiring to knock sensor (KS) 1 G61 and oil level
thermal sensor G266.
 Remove cylinder head cover.
Installing
Installation is in reverse order of removal, note the following:
NOTE:  First bolt intake manifold to cylinder head. Then, fasten bolts for shield
and intake manifold support.
 Ensure fuel hoses are seated securely.
Torque specifications
Bolted connections Torque specifications

Cylinder head cover to cylinder head 10 Nm
Intake manifold to cylinder head 13 Nm
Intake manifold to support 20 Nm
Shield to exhaust manifold 23 Nm
Oil dip stick guide tube to intake manifold 8 Nm
Cover, removing and installing, assembly overview
Installing sealing rings of cover piece
NOTE:  The cover can only be removed or installed with engine removed.
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Fig. 107: Cover, Assembly Overview

1 - Wiring router
 For wiring harness
2 - 8 Nm
3 - 8 Nm

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6 - Seal
7 - 8 Nm
8 - Seal

 Installing
9 - Bracket
 For after-run coolant pump V51

 For evaporative emission (EVAP) canister purge regulator valve N80
11 - 23 Nm
12 - Seal
13 - Cover

15 - O-ring
 For oil channel seal

 Replace
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Preparing cylinder head gasket for installation
Fig. 108: Locating 3 mm Holes In Cylinder Head Gasket


Work procedure
 Clean old sealing compound from 3 mm holes in cylinder head gasket - arrows -.
 Fill 3 mm holes in cylinder head gasket with sealant AMV 174 004 01 and coat sealing surface on cover
and sealing flange with sealant AMV 176 501 . Install cover immediately!
NOTE:  With the cylinder head installed only half of the holes in the cylinder head
gasket are visible.
Installing sealing rings of cover piece
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Fig. 109: Identifying Fitting Sleeve 3378

 Fitting sleeve 3378
Fig. 110: Identifying Fitting Sleeve 3253/6 From Wheel Bearing Assembly Set 3253
 Fitting sleeve 3253/6 from wheel bearing assembly set 3253
Installing
 Do not lubricate seal.
Fig. 111: Identifying Fitting Sleeve 3378, Fitting Sleeve 3253/6 And Cover
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 Install sealing ring using seal installer 3378 into cover piece - 1 - and pull in flush using seal installer
3253/6 from assembly tool 3253.
Compression pressures, checking
Fig. 112: Identifying Special Tools -- Compression Pressures, Checking

 Puller For Ignition Coil T10095A

 Compression tester V.A.G 1763
 Spark plug removal tool 3122 B
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Test conditions
 Engine oil temperature must be at least 30°C.

 Battery voltage must be at least 11.5 V.
 All electrical consumers such as, for example, lights and rear window defroster must be switched off.
 If vehicle is equipped with an air conditioning system, this must be switched off.
 For vehicles with automatic transmission, selector lever must be in position "P" or "N".
Fig. 113: Identifying Fuses

 Fuses - 13 - and - 14 - - arrows - must be removed from their sockets.
Test sequence
 Remove engine cover.

 Remove ignition coils with power output stage --> Ignition coils with power output stage, removing
and installing.
 Remove spark plugs using spark plug removal tool 3122 B.
 Check compression pressure using compression tester V.A.G 1763.
NOTE:  Using the compression tester Operating instructions.
 Have a second technician fully depress accelerator pedal and crank engine.
 Operate starter until tester shows no further pressure increase.
Compression pressure:
New: 10 to 13 bar pressure
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Wear limit: 7.5 bar pressure
Permissible difference between all cylinders: 3 bar
 Install spark plugs using spark plug removal tool 3122B and tighten to 20 Nm.
After completing installation:
 Connect Vehicle Diagnosis Serv. System VAS 5052.

 Perform vehicle system test "Guided Fault Finding".
 End vehicle system test in such a way that possibly existing DTC entries are automatically erased.
 Perform road test.
 Generate readiness code in conjunction with road test.
Observe safety precautions that apply to road tests.
 After that perform vehicle system test again and repair any occurring malfunctions.
VALVETRAIN
Valvetrain
Assembly overview --> Valvetrain, assembly overview
Camshaft, removing and installing --> Camshafts, removing and installing
Replacing valve stem oil seals --> Valve stem seals, replacing
Check valve guides --> Valve guides, checking
Rework valve seats --> Valve seats, reworking
Valve dimensions
Valvetrain, assembly overview
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Fig. 114: Valvetrain, Assembly Overview

2 - Exhaust camshaft bearing cap
 Installed location Installed position of camshaft bearing caps

 Lightly coat contact surfaces of bearing cap 8 with grease G 052 723 A2 before installing Lightly coat
contact surfaces of bearing caps 7 and 8 with under Installed position of camshaft bearing caps
 Installation sequence --> Camshafts, removing and installing , camshaft, removing and installing
3 - Seal
 If seal is leaking, replace completely
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 Lightly oil contact surface of sealing rings when installing control housing
 Do not spread sealing rings excessively when inserting
4 - Exhaust camshaft
 Checking radial clearance using Plastigage, Wear limit: 0.1 mm

 Run-out: max. 0.01 mm
 Checking axial play
 Identification
 Removing and installing --> Camshafts, removing and installing
5 - Control housing
 Lightly lubricate contact surfaces of oil seals before installing

 Disassembling and assembling Disassembling and assembling control housing
 Check control housing strainer for soiling before installation Checking strainer of control housing for
soiling
 Replace
 To remove and install, counter-hold with 32 mm open end wrench on camshaft --> Camshafts, removing
and installing , Removing and installing camshafts
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10 - Cylinder head height
 Minimum height: a = 139.9 mm
11 - Valves
 Do not rework, only lapping is permitted

 Valve dimensions
12 - Cylinder head
 Check for distortion Checking cylinder head for distortion

 Removing and installing --> Cylinder head, removing and installing
 Rework valve seats --> Valve seats, reworking
13 - Support element
 Before installing, check axial play in camshafts

 Do not interchange
 With hydraulic valve clearance compensation
14 - Valve stem seal
 Replacing --> Valve stem seals, replacing.
15 - Securing clip
 Check for secure seat
16 - Roller rocker lever
 Before installing, check axial play in camshafts

 Do not interchange
 Check roller for easy movement
 Lubricate contact surface
 Use securing clip to clip onto support element when installing
17 - Valve spring

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 Removing and installing --> Valve stem seals, replacing , replacing valve stem oil seal
18 - Valve spring plate
19 - Valve keepers
20 - Intake camshaft bearing cap
 Installed location Installed position of camshaft bearing caps

 Lightly coat contact surfaces of bearing cap 7 with grease G 052 723 A2 before installing Lightly coat
contact surfaces of bearing caps 7 and 8 with under Installed position of camshaft bearing caps
 Installation sequence --> Camshafts, removing and installing , camshaft, removing and installing
21 - Intake camshaft
 Checking radial clearance using Plastigage, Wear limit: 0.1 mm

 Run-out: max. 0.01 mm
 Checking axial play
 Identification
 Removing and installing --> Camshafts, removing and installing
Installed position of camshaft bearing caps
Fig. 115: Points Of Intake And Exhaust Camshaft Bearing Cap

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Points of bearing caps - arrow A - of intake and exhaust camshaft point outward.
Fig. 116: Identifying Contact Surfaces Of Bearing Caps 7 And 8

Lightly coat contact surfaces of bearing caps 7 and 8 with grease G 052 723 A2 before installing
Camshafts, removing and installing
Remove camshafts.
Install camshafts.
Camshafts, checking axial clearance
Camshaft identification
Replacing valve stem oil seals --> Valve stem seals, replacing
Check valve guides --> Valve guides, checking
Rework valve seats --> Valve seats, reworking
Valve dimensions
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Fig. 117: Identifying Special Tools -- Camshafts, Removing And Installing


Camshafts, removing
NOTE:  The camshafts can only be removed with the engine or cylinder head
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removed.
Work procedure
engine direction of rotation - arrow -.
 Remove intake manifold and cylinder head cover --> Cylinder head cover, removing and installing ,
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 Remove chain tensioner for camshaft roller chain - arrow -.

 Remove camshaft cover.
NOTE:  The cover has a "hidden bolt". It can be removed only after the thermostat
Fig. 120: Identifying Markings On Roller Chains

 Mark roller chains before removing (e.g. with paint, arrow pointing in direction of rotation).
NOTE:  Do not mark chain using a center punch or similar means!
 First, remove exhaust camshaft adjuster.
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NOTE:  Counter-hold only with 32 mm open end wrench on camshaft - arrow -.

Camshaft bar T10068 A must not be inserted when tightening or loosening
camshaft adjuster.
 Remove camshaft adjuster together with camshaft roller chain from intake camshaft.
 Place camshaft roller chain aside.
Fig. 122: Locating Control Housing-To-Cylinder Head Bolts

 Remove control housing from cylinder head - arrows -.

 Pull control housing carefully off camshaft seals.
NOTE:  If disassembling the control housing or cleaning strainer is necessary

Disassembling and assembling control housing and Checking strainer of
control housing for soiling
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Fig. 123: Identifying Intake Camshaft And Exhaust Camshaft

- A - Intake camshaft
 First remove bearing caps 1 and 13.

 Remove bearing caps 3 and 11.
 Remove bearing cap 7.
 Loosen and remove bearing caps 5 and 9 in alternating and in diagonal sequence.

- B - Exhaust camshaft
 First remove bearing caps 2 and 14.

 Remove bearing caps 4 and 12.
 Remove bearing cap 8.
 Loosen bearing caps 6 and 10 in alternating and in diagonal sequence.
Continuation for both camshafts
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 Carefully remove camshafts and place on a clean surface.

 Remove roller rocker lever together with support elements and place on a clean surface.
 Ensure roller rocker levers and support elements are not interchanged.
Camshafts, installing
Conditions
 When installing camshafts, cam lobes for cylinder 1 must point upward.
Work procedure
 Coat contact surface of bearing caps 7 and 8 lightly with grease G 052 723 A2 before installing.
Fig. 125: Identifying Contact Surfaces Of Bearing Caps 7 And 8

Bearing cap
 Insert support element in cylinder head and install roller rocker lever onto respective valve stem end and
support element.
Fig. 126: Identifying Roller Cam Followers And Support Elements

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 Make sure that all roller cam followers - 1 - properly contact valve shaft tips and are clipped into
respective support elements - 2 -.
 Oil running surfaces of both camshafts.
 Place respective camshaft carefully in camshaft bearings of cylinder head. While doing so, observe
identification of camshafts.
NOTE:  Observe installed position of bearing caps:
Fig. 127: Points Of Intake And Exhaust Camshaft Bearing Cap

 Points of bearing caps - arrow A - of intake and exhaust camshaft point outward.
 Markings on bearing caps are legible when viewed from intake side.
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- A - Intake camshaft
 Tighten bearing caps 5 and 9 alternating and diagonally to 5 Nm and 1 /8 turn (45°) further.
 Install bearing caps 1 and 13 and tighten to 5 Nm and 1 /8 turn (45°) further.
 Install bearing cap 7 and tighten to 5 Nm and 1 /8 turn (45°) further.

- B - Exhaust camshaft
 Tighten bearing caps 6 and 10 alternating and diagonally to 5 Nm and 1 /8 turn (45°) further.
 Install bearing cap 8 and tighten to 5 Nm and 1 /8 turn (45°) further.
Continuation for both camshafts
 Position camshafts in cylinder head to TDC No. 1 cylinder. 1.
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 Before installing, check control housing strainer for soiling Checking strainer of control housing for
soiling
 Before installing control housing, lightly oil sealing ring contact surfaces of camshafts in control housing.
 Lightly oil sealing ring contact surfaces of camshafts and slowly slide control housing over camshaft
sealing rings.
Fig. 131: Locating Control Housing-To-Cylinder Head Bolts

 Install control housing - arrows - and fasten with 8 Nm.
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gasket are visible.
 Fill 3 mm drillings in cylinder head gasket with sealant AMV 174 004 01 and apply a raised drop of
sealant at each of these points.
NOTE:  The Sealant AMV 174 004 01 hardens quickly.
 Lubricate O-ring for oil channel seal and install with oil seal into cover.
 Coat sealing surface of cover piece with sealant AMV 176 501 and install immediately.
 First insert all fastening bolts and lightly tighten.
 Then tighten bolts M8 to 23 Nm, and tighten bolts M6 to 8 Nm.
 Install chain tensioner for camshaft roller chain and tighten to 40 Nm.
Disassembling and assembling control housing
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Fig. 133: Control Housing, Components

1 - Glide track: Clipped in at control housing
2 - Control housing
5 - 8 Nm
Camshaft adjustment valves, removing and installing --> Camshaft adjustment valves, removing and
installing.
Checking strainer of control housing for soiling
Fig. 134: Checking Strainer Of Control Housing For Soiling

 Unclip strainer - 2 - at rear side of control housing - 1 - and remove possible soiling.
Camshafts, checking axial clearance

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Fig. 135: Dial Gauge Holder VW 387

 Dial gauge holder VW 387

 Dial gauge
Test sequence
Perform measurements with support elements and roller rocker levers removed.
Center bearing cap of respective camshaft installed.
Fig. 136: Securing Universal Dial Gauge Bracket VW 387 With Dial Gauge To Cylinder Head
 Fasten dial gauge holder VW 387 with installed dial gauge to cylinder head as shown and measure axial
clearance
Wear limit: max. 0.10 mm
Camshaft identification
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Fig. 137: Camshaft Identification, Valve Timing

Identification between cam pair cyl. 4 and cyl. 5 of respective camshaft.
Camshaft Identification
A - Exhaust camshaft 022 101 Index
B - Intake camshaft 022 102 Index
Valve timing at 1 mm valve lift
Intake valve Exhaust valve

Opens before TDC --- 211.5°
Closes before TDC --- 6.5°
Opens after TDC 18.50° ---
Closes after TDC 223.5° ---
Camshaft adjustment valves, removing and installing
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Fig. 138: Identifying Special Tools -- Camshaft Adjuster Valves, Removing And Installing

 Torx bit assortment V.A.G 1766
 Ratchet 1/4" VAS 6234
 Socket Wrench T10072
Not illustrated:
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Removing:
Requirements
 Engine must be removed.
 Remove cylinder head cover --> Cylinder head cover, removing and installing.
NOTE:  Before disconnecting harness connectors, mark allocation to component.
 On the following components, remove covers for connectors:
 Camshaft Adjustment Valve 1 N205

 Camshaft Adjustment Valve 1 (exhaust) N318
 Camshaft Position (CMP) sensor G40
 Camshaft position (CMP) sensor 2 G163
 Free up wiring harness.

NOTE:  The cover has a "hidden bolt". It can be removed only after thermostat

 Remove camshaft roller chain tensioner - arrow -.
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Fig. 140: Identifying Mounting Bolts For Cover

 Remove mounting bolts - arrows - from cover.

 When all securing bolts have been removed, cover can be carefully pried off.
CAUTION:  Carefully cover lower chain compartment so no parts can fall in.
 Do not completely remove camshaft adjustment valve securing bolts
so that valve is not tilted when removed.
Fig. 141: Loosening Camshaft Adjustment Valve Securing Bolts

 Loosen camshaft adjustment valve securing bolts approx. 3 mm (5 turns) - arrows - using Socket Wrench
T10072.
 Pull Camshaft Adjustment Valve out of seal seat in control housing against loosened bolts.
 Completely remove securing bolts and remove Camshaft Adjustment Valve from control housing.
Installing:
CAUTION:  The valve seat in the control housing must not be scored or
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scratched.
 The camshaft adjustment valves and control housing must be free of
dust and contamination.
 The camshaft adjustment valves must not be subjected to knocks or
impacts.
 Only remove new camshaft adjustment valve from packaging right
before installation.
 Camshaft adjustment valves must not be pulled into valve seat by

securing bolts. Only press them in by hand.
 Coat sealing rings with clean engine oil.

 Carefully insert Camshaft Adjustment Valve into housing and press it perpendicular to valve axle in by
hand until it stops.
Fig. 142: Loosening Camshaft Adjustment Valve Securing Bolts

 Tighten mounting bolts - arrows - to 3.8 Nm.
- 1 - Camshaft Adjustment Valve 1 N205 connector color: black.
- 2 - Camshaft Adjustment Valve 1 (exhaust) N318 connector color: brown.
 Clean sealing surface on cover piece as well as on cylinder head.

 If sealing rings in cover piece are to be replaced.
 Lubricate oil channel seal O-ring and insert in cover.
 Insert sealing ring in cover.
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 Fill 3 mm holes in cylinder head gasket with sealant AMV 174 004 01 and coat sealing surface on cover
and sealing flange with sealant AMV 176 501 .
gasket are visible.
 Install cover as quickly as possible.
Fig. 144: Identifying Mounting Bolts For Cover

 First install all mounting bolts - arrows - and tighten lightly.

 Then tighten bolts M8 to 23 Nm, and tighten bolts M6 to 8 Nm.
 Install camshaft roller chain tensioner and fasten to 40 Nm.
 Install cylinder head cover --> Cylinder head cover, removing and installing and intake manifold.
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Valve stem seals, replacing
Fig. 145: Identifying Special Tools -- Valve Stem Seals, Replacing

 Valve lever VW 541/1 A with thrust piece VW 541/6

 Adjustable rod 2036 with adapter plates 2036/1
 Spark plug removal tool 3122 B
 Valve seal removal tool 3364
 Valve stem seal driver 3365

 Adapter T40012/1
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Fig. 146: Torque Wrench V.A.G 1331

Torque wrench (5 to 50 Nm) V.A.G 1331
Removing
 Camshafts, removing --> Camshafts, removing and installing.

 Remove roller rocker lever together with support elements and place on a clean surface.
 Ensure roller rocker levers and support elements are not interchanged.
 Remove spark plugs using spark plug removal tool 3122 B.
 Move piston for respective cylinder to "Bottom Dead Center (BDC) position".
Fig. 147: Identifying Adjustable Rod 2036, Adapter T40012 And Valve Lever VW 541/1 A
 Insert adjustable rod 2036 with adapter plates 2036/1 and adjust bearing.
 Install adapter T40012/1 into spark plug hole, connect compressed air line with a commercially available
adapter and apply a constant pressure. At least 6 bar.
 Remove valve springs with valve lever VW 541/1 A and pressure piece VW 541/6.
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NOTE:  Tight keepers can be loosened by tapping lightly on lever.
 Remove valve stem seals using Valve Seal Removal Tool 3364.
Installing
Fig. 148: Plastic Sleeve, Valve Stem Seal And Valve Stem Seal Driver 3365
 Place plastic sleeve - A - on valve stem to prevent damage to new valve stem oil seals.
 Oil sealing lip of valve stem oil seal - B - , insert into valve stem seal driver 3365 and carefully slide onto
valve guide.
 Install camshafts --> Camshafts, removing and installing.
Valve guides, checking
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Fig. 149: Dial Gauge Holder VW 387

 Dial gauge holder VW 387

 Dial gauge
Test sequence
Fig. 150: Checking Valve Guides

 Insert new valve into guide. The end of valve stem must be flush with guide. Due to slight difference in
stem diameters, ensure that only an intake valve is used in intake guide and an exhaust valve in exhaust
guide.
 Determine tilt clearance. Wear limit: 0.8 mm
If tilt clearance is exceeded:
 Replace cylinder head.
Valve seats, reworking
Valve dimensions
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 Depth gauge
 Valve seat refacing tool
Work procedure
NOTE:  When repairing engines with leaking valves, it is not sufficient to rework or
replace valve seats and valves. It is also necessary to check the valve
guides for wear. This is particularly important on high mileage engines -->
Valve guides, checking.
 The valve seats should only be reworked just enough to produce a perfect
seating pattern. The maximum permissible reworking dimension must be
calculated before work is carried out. If the reworking dimension is
exceeded, the function of the hydraulic lifters can no longer be guaranteed
and therefore the cylinder head should be replaced.
 Remove camshafts --> Camshafts, removing and installing.
Maximum permitted refacing dimension is calculated as follows:
 Insert valve and press firmly against seat.
NOTE:  If the valve is to be replaced as part of a repair, use a new valve for the
calculation.
Fig. 151: Identifying Distance Between End Of Valve Stem And Upper Edge Of Cylinder Head
 Measure distance - a - between end of valve stem and upper edge of cylinder head.
 Calculate max. permissible reworking dimension from measured distance - a - and minimum dimension.
Minimum dimensions:
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Short intake valve mm 31.8

Long intake valve mm 10.2
Short exhaust valve mm 31.8
Long exhaust valve mm 10.2
Measured distance - a - minus minimum dimension = max. permissible refaced dimension.
Example:
Measured distance 10.6 mm

Minimum dimension 10.2 mm
= Max. permissible reworking dimension * See note 0.4 mm
* The max. permissible reworking dimension is shown on illustrations for reworking valve seats as dimension -
b -.
Fig. 152: Reworking Intake And Exhaust Valve Seat

Reworking intake valve seat
a - = Dia. 32.8 mm
b - = Max. permissible reworking dimension*
c - = 0.9 to 1.5 mm
d - = max. dia. 38.0 mm
r2 - = Radius 2.0 mm
Z - = Cylinder head lower edge
a - 45° valve seat angle

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ß - 30° upper correction angle
gamma - 60° lower correction angle
Fig. 153: Reworking Intake And Exhaust Valve Seat

Reworking exhaust valve seat
a - = Dia. 29.8 mm
b - = Max. permissible reworking dimension*
c - = 1.2 to 1.7 mm
d - = Max. dia. 35.0 mm
r2 - = Radius 2.0 mm
Z - = Cylinder head lower edge
a - 45° valve seat angle
ß - 30° upper correction angle
gamma - 60° lower correction angle
Valve dimensions
NOTE:  Valves must not be reworked. Only lapping is permitted.
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Fig. 154: Valve Dimensions

Valve dimensions for intake valves
Dimension Short intake valve Long intake valve

- Dia. a - mm 33.20 33.20
- Dia. b - mm 5.98 5.98
-c- mm 102.46 136.36
-a- Angle° 44° 40' 44° 40'
Valve dimensions for exhaust valves
Dimension Short exhaust valve Long exhaust valve

- Dia. a - mm 30.20 30.20
- Dia. b - mm 5.97 5.97
-c- mm 102.20 136.20
-a- Angle° 44° 40' 44° 40'
17 - ENGINE - LUBRICATION
LUBRICATION SYSTEM COMPONENTS, REMOVING AND INSTALLING
Lubrication system components, removing and installing
 The oil level must not be above the max. mark - danger of damage to
catalytic converter!
 If large quantities of metal particles or abraded material are detected
during engine repairs, it may be an indication for a damaged crankshaft or
rod bearings. To prevent further damage, perform the following steps after
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the repair:
 Carefully clean oil passages
 Replace oil check valve

 Replace oil injection jets
 Replace oil cooler
 Replace oil filter
Assembly overview --> Assembly overview
Checking oil pressure and oil pressure switch --> Oil pressure and oil pressure switch, checking.
Replace oil non-return valve.
Oil filling quantities
With oil filter 6.3 ltr.
Engine oil specifications:
Use "long life engine oils" in compliance with VW standard 503 00 .
NOTE:  The engine is filled at the factory with engine oil complying to VW
standard 503 00.
 Engine oils complying to VW standards 502 00 may continue to be used.
These oils must be changed every 12 months or every 15,000 km.
 For changing, engine oil "ILSAC GF3 with viscosity rating SAE 5W-40" can
be used. The Service Reminder Indicator (SRI) must be programmed
accordingly. Procedure: --> 01 - MAINTENANCE
 For topping off, engine oil "ILSAC GF3 with viscosity rating SAE 5W-30"
can be used.
Assembly overview
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Fig. 155: Lubrication System Components, Assembly Overview

1 - 8 Nm
 Fastened to intake manifold
2 - Dipstick
 Oil level must not be above max. mark!

 Marks
3 - Guide tube
 For dipstick
 Secured by a bolt to intake manifold
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4 - Cylinder block
 Removing and installing sealing flange and dual-mass flywheel --> Sealing flange and dual-mass
flywheel, removing and installing
and assembling
5 - Oil check valve

 Replace if badly soiled
 See note --> Lubrication system components, removing and installing
6 - 8 Nm
7 - Oil pump drive cover
8 - O-ring
 Replace
9 - Oil pump drive
11 - Thrust washer
12 - 10 Nm
13 - Oil spray jet
 For piston cooling

 Built into crankshaft bearing 2 to 7
 Opening pressure 2.0 bar pressure
14 - Input shaft
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15 - Oil pump
 Disassembling and assembling --> Oil pump, disassembling and assembling
16 - 23 Nm
 Replace if leaking
18 - Oil pan
 Removing and installing --> Oil pan, removing and installing
19 - Oil Level Thermal Sensor G266
 Only for vehicles with engine codes AZZ and BKJ
20 - 12 Nm
21 - Baffle plate
22 - 8 Nm
23 - Seal
 Replace
 Disassembling and assembling --> Oil filter housing, disassembling and assembling
25 - 23 Nm
Oil spray jet, removing and installing
 Drift dia. 4 mm
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 Drift dia. 6 mm
NOTE:  Oil injector jets are installed in crankshaft bearings 2 to 7.
Removing
 Using a drift dia. 4 mm, press oil spray jet toward engine bearing and out.
Installing
Fig. 156: Identifying Oil Spray Jet Application Area

 To install, press oil spray jet in by hand using a drift dia. 6 mm - arrow -.
Removing and installing oil check valve
Removing
Fig. 157: Identifying Oil Check Valve

 Install approx. 4 threads of a commercially available bolt M8x1.5 into valve - arrow - and pull it from
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bore.
Installing
 Coat O-ring with oil before installing. Press valve into oil channel - arrow - by hand.
Markings on oil dipstick
Fig. 158: Identifying Dipstick Markings

1 - Max. mark
2 - Min. mark
a - Area above hatched field up to Max. mark: Do not replenish with engine oil!
b - Oil level within hatched field: Can be replenished with engine oil
c - Area from Min. mark up to hatched field: Replenish with max. 0.5 ltr. of engine oil!
Oil filter housing, disassembling and assembling
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Fig. 159: Oil Filter Housing, Assembly Overview

 To remove, left and right engine bracket must be loosened from engine mount
2 - Seal
 Replace
3 - Oil cooler gasket
 Replace
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4 - Oil cooler
 Ensure sufficient clearance to surrounding components

5 - Oil cooler cover, 25 Nm
6 - Oil pressure switch F1 , 20 Nm
 Black
 Switch point at 1.4 bar
 If sealing ring is leaking cut open and replace.
 Checking --> Oil pressure and oil pressure switch, checking
7 - Oil filter element
 Observe change intervals --> 01 - MAINTENANCE

8 - Oil filter lower part, 25 Nm
 Drain before removing

 With bypass valve opening pressure: 2.50 bar pressure
10 - 23 Nm
Oil pump, disassembling and assembling
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Fig. 160: Oil Pump, Assembly Overview

1 - Input shaft
2 - Oil pump housing
3 - 23 Nm
4 - Gears
 Checking backlash --> Checking oil pump backlash

 Checking axial play --> Checking oil pump axial clearance
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5 - Oil pump cover with pressure relief valve
 Opening pressure 5.3 to 5.7 bar pressure

 Clean strainer if soiled
6 - 8 Nm
 Replace
7 - Oil pressure line
 To remove and install oil pressure line, oil pump must be removed
 Fasten with new "micro-encapsulated" bolts.
8 - 8 Nm
9 - Seal
Checking oil pump backlash
Fig. 161: Checking Oil Pump Backlash

 Feeler gauge
Wear limit: 0.20 mm
Checking oil pump axial clearance
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Fig. 162: Checking Oil Pump Axial Clearance

 Straight edge
 Feeler gauge
Wear limit: 0.10 mm
Oil pan, removing and installing
 Engine support bridge 10 - 222 A

 Shackle 10 - 222 A/12
 Adapter 10 - 222 A/16
Fig. 163: Identifying Support Assembly 10-222A

 Adapter 10 - 222 A/19
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Not illustrated:
 Old oil collecting and extracting device V.A.G 1782

 Silicon sealant D 176 501
 Hand drill with plastic brush attachment
 Flat scraper
 Protective glasses
Removing
 Drain engine oil.
 Disconnect wire connection to air suspension compressor at air filter

 Completely remove air filter with mass air flow (MAF) sensor.
 Remove nuts - 2 - on right and left engine bracket.

 Position adapter 10 - 222 A/16 on Engine and Transmission Holder 10 - 222 A with high side of threaded
spindle guide facing upward as shown in illustration.
 Now place adapter 10 - 222 A/19 on left and right of Engine and Transmission Holder 10 - 222 A. Place
Engine and Transmission Holder 10 - 222 A on long members.
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Fig. 165: Engaging Engine With Two Shackles 10 - 222 A/12 At Adapter 10 - 222 A/16 And Pretensioning
Engine Slightly
 Engage engine with two Shackles 10 - 222 A/12 at Adapter 10 - 222 A/16 and pretension engine slightly.
 Remove subframe --> 40 - FRONT SUSPENSION .
 Remove engine carrier. Engine mounts can remain attached to engine carrier.
 Disconnect 3-pin connector from Oil Level Thermal Sensor G266.
 Remove oil pan.

 Loosen oil pan with light blows of a rubber headed hammer if necessary.
 Remove sealant residue from cylinder block with a flat scraper.
Fig. 166: Removing Sealant Residue From Oil Pan With A Rotating Brush
 Remove sealant residue from pan with a rotating brush, e.g. a hand drill with a plastic brush attachment
(wear eye protection).
 Clean sealing surfaces, they must be free of oil and grease.
Installing
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NOTE:  Note expiration date of the sealant .

 Oil pan must be installed within 5 minutes of applying silicone sealant .
Fig. 167: Cutting Off Tube Nozzle & Applying Silicone Sealing Compound To Oil Pan Sealing Surface
 Cut off nozzle on tube of sealant at front mark (dia. of nozzle approx. 3 mm).
 Apply silicone sealant D 176 404 A2 , as shown, to clean oil pan sealing surface. Sealing compound
bead must be:
 2 to 3 mm thick
 And run on inside of bolt holes - arrows -.
NOTE:  The sealing compound bead must not be thicker, otherwise excess sealant
will enter oil pan and may block oil suction pipe strainer.
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Fig. 168: Identifying Silicone Sealing Compound Application Area

 Apply silicone sealant D 176 404 A2 as illustrated to clean sealing surface of oil pan.
 Install oil pan immediately and tighten all oil pan bolts lightly.
 Tighten oil pan bolts to 12 Nm.
NOTE:  After installing the oil pan sealant must be allowed to dry for approx. 30
minutes. Only after then may the engine oil be replenished.
Engine mount torque specification
Oil pressure and oil pressure switch, checking
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Fig. 169: Identifying Special Tools -- Oil Pressure And Oil Pressure Switch, Checking

 Voltage tester V.A.G 1527B
 Oil pressure gauge V.A.G 1342
 Connector test set V.A.G 1594C
 Wiring diagram
NOTE:  Function test and servicing the optical and acoustic oil pressure indicator:
--> Electrical Wiring Diagrams, Troubleshooting and Component Locations
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Oil pressure switch, checking
Oil pressure, checking
Oil pressure switch, checking
Test conditions
 Engine oil level OK, checking.

 Engine oil temperature at least 80°C (radiator fan must have run once)
Work procedure
Fig. 170: Identifying V.A.G 1342 With Adapter V.A.G 1342/14

 Remove oil pressure switch F1 and install oil pressure gauge.

 Install oil pressure gauge V.A.G 1342 with adapter V.A.G 1342/14 into oil filter bracket in place of oil
pressure switch.
NOTE:  Observe installation position of adapter V.A.G 1342/14 : The conical

connection of the adapter is threaded in with the pressure hose of the oil
pressure gauge V.A.G 1342.
 Connect brown wire of oil pressure gauge V.A.G 1342 to Ground (GND).
 Connect voltage tester V.A.G 1527B using adapter cables from connector test set V.A.G 1594C to battery
B+ and oil pressure switch F1. LED must not light up.
If LED lights up:
 Replace oil pressure switch F1.

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If LED does not light up:
 Start engine and run at idle speed.
LED must light up at 1.2 to 1.6 bar positive pressure, otherwise replace oil pressure switch F1.
Test conditions
 Engine oil level OK, checking.

 Engine oil temperature at least 80°C (radiator fan must have run once)
Work procedure
 Check oil pressure at different speeds:
 1500 RPM: at least 1.7 bar

 2000 RPM: 3.0 to 5.5 bar pressure
 Above 2000 RPM: maximum 7.0 bar
If specified values are not reached:
 Examine filter intake for contamination.

 Examine pressure pipe between oil pump and cylinder block for tightness.
NOTE:  Check for mechanical damage, e.g. bearing failures that can cause low oil
pressure.
If a malfunction is found despite insufficient oil pressure:
 Replace oil pump --> Oil pump, disassembling and assembling
The oil pressure must not exceed 7.0 bar.
If 7.0 bar is exceeded:
 Check oil channels.
Possibly/oil pressure relief valve in oil pump is plugged.
 Replace oil pump.
19 - ENGINE - COOLING SYSTEM

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COOLING SYSTEM COMPONENTS, REMOVING AND INSTALLING
Cooling system components, removing and installing
NOTE:  Hoses are secured with spring-type clips. In cases of repair only use
spring-type clips.

 The spring-type clip pliers VAS 5024 A are recommended for installing spring-type clips.
 When installing coolant hoses route stress-free, so that they do not come into contact with other
components (observe markings on coolant connection and hose).
Perform leak test of cooling system using cooling system tester V.A.G 1274 and adapters V.A.G 1274/8 and
V.A.G 1274/9.
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Radiator, assembly overview --> Radiator, assembly overview.
Coolant fan, assembly overview --> Coolant fan, assembly overview.
Cooling system components (on body), assembly overview --> Cooling system components (on body),
assembly overview.
Cooling system components (on engine), assembly overview --> Cooling system components (on engine),
assembly overview.
Coolant hose connection diagram --> Coolant hose connection diagram.
Draining and filling with coolant --> Cooling system, draining and filling.
Coolant mixture ratios --> Cooling system, draining and filling , Coolant, draining and filling.
Coolant pump, removing and installing --> Coolant pump, removing and installing.
Cooling system, checking for leaks --> Cooling system, checking for leaks
Radiator, assembly overview
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Fig. 172: Radiator, Assembly Overview

1 - Upper coolant hose
 Secured to radiator with a retaining clip

 Ensure seated tightly
2 - Radiator
 Removing and installing --> Radiator, removing and installing

 If radiator was replaced, coolant must be replaced.
3 - Condenser
4 - Oil cooler
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 For transmission oil
5 - Oil cooler
 For power steering
6 - Lock carrier
7 - 10 Nm
8 - Low-temperature cooler
 For generator and fuel cooling

 Only with certain equipment options
9 - 10 Nm
10 - Rubber bushing
 For lock carrier
11 - Retaining clip
12 - Rubber bushing
 For bottom of radiator
13 - Lower coolant hose
 Secured to radiator with a retaining clip

14 - Coolant hose
 Secured to top of radiator

15 - To expansion tank
Coolant fan, assembly overview
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Fig. 173: Coolant Fan, Assembly Overview

1 - Coolant Fan V7
2 - Fan support
3 - 10 Nm
4 - 10 Nm
5 - Coolant Fan 2 V177
6 - Coolant Fan Control (FC) Control Module J293
7 - 10 Nm
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Cooling system components (on body), assembly overview
Fig. 174: Cooling System Components (On Body), Assembly Overview

1 - After-run coolant pump V51
 Location of pump under Location of after-run coolant pump V51
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2 - Coolant hose

 To after-run coolant pump V51
3 - Coolant hose

 From cylinder head
4 - From radiator
5 - Expansion tank
 Perform cooling system leakage test with cooling system tester V.A.G 1274 and adapter V.A.G 1274/8
 Depending on optional equipment, connection may be sealed with a blanking plug.
6 - Sealing cap
 Check using cooling system tester V.A.G 1274 and adapter V.A.G 1274/9
 Test pressure 1.4 to 1.6 bar
7 - Coolant hose

 From heat exchanger for heater unit
8 - Coolant hose

 From after-run coolant pump V51
9 - To heat exchanger for heater unit
10 - From heat exchanger for heater unit
11 - To thermostat housing
Location of after-run coolant pump V51
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Fig. 175: Locating After-Run Coolant Pump V51

The after-run coolant pump V51 - 2 - is secured with damper rings to a bracket behind cylinder head below
evaporative emissions (EVAP) canister purge regulator valve N80.
Coolant thermostat housing, assembly overview
NOTE:  Routing of coolant hoses to thermostat housing --> Cooling system

components (on engine), assembly overview
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Fig. 176: Coolant Thermostat Housing, Assembly Overview

1 - O-ring
 Replace
2 - Retaining clip
4 - 8 Nm
5 - Coolant thermostat
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 Check ; "Guided Fault Finding"
 Opening begins approx. 80°C
 Ends approx. 105°C
6 - Connection
7 - Seal
 Replace
8 - Engine Coolant Temperature (ECT) Sensor G62
 For engine control module

 With Engine Coolant Temperature (ECT) Gauge Sensor G2
 If necessary release pressure in cooling system before removing
9 - Plug
 If necessary release pressure in cooling system before removing
Cooling system components (on engine), assembly overview
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Fig. 177: Cooling System Components (On Engine), Assembly Overview

1 - Coolant line
 Between thermostat housing and lower coolant hose

 Secured on cylinder block
 To remove, exhaust manifold must first be removed --> Exhaust manifolds and exhaust pipes (with
primary catalytic converters), removing and installing
2 - To expansion tank
4 - To cylinder block
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5 - Connection for oil cooler
6 - Coolant line
 Between coolant pump and thermostat housing
 Secured to radiator with a quick coupling

8 - Sealing plug, 3 Nm
9 - O-ring
 Replace
10 - From coolant pump
11 - 20 Nm
 To loosen and tighten pulley counter-hold with punch through holes
12 - Pulley
 For coolant pump

 Removing and installing --> Coolant pump, removing and installing
13 - 8 Nm
14 - Coolant pump
 Check for ease of movement

 Removing and installing --> Coolant pump, removing and installing
15 - From lower radiator

17 - 8 Nm
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Coolant hose connection diagram
Fig. 178: Coolant Hose Connection Diagram

1 - Radiator
2 - Oil cooler
 For transmission oil
3 - Cylinder head
4 - Expansion tank
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6 - Heater unit heat exchanger
7 - After-run coolant pump V51
8 - Oil cooler
 For engine oil
10 - Coolant line
11 - Cylinder block
13 - Coolant pump
Cooling system, draining and filling
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Fig. 179: Identifying Special Tools - Cooling System, Draining And Filling
 Refractometer T10007
 Spring-type clip pliers VAS 5024 A

 Cooling system charge unit VAS 6096
Drain coolant
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 Open cap on coolant expansion tank.

 Remove noise insulation. --> 50 - BODY - FRONT
Fig. 180: Locating Coolant Hose Retaining Clip

 Pull coolant hose retaining clip - arrow - off downward and remove coolant hose from radiator.
NOTE:  Observe disposal regulations for coolant!
Fig. 181: Locating Coolant Hose At Oil Cooler

 In addition, to drain coolant from engine, disconnect coolant hose at oil cooler - arrow -.
Fill with coolant
NOTE:  Only use coolant additive G 12 plus according to "TL VW 774 F".
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Distinguishing feature: colored violet

 G 12 plus and coolant additives marked: "according to TL-VW 774 F"
prevent damage from frost and corrosion, scaling and also raise boiling
point. For this reason the system must be filled all year round with frost
and corrosion protection additives.
 Because of its high boiling point, the coolant improves engine reliability
under heavy loads, particularly in countries with tropical climates.
 Protection against frost must be assured to about -25°C (in arctic climatic
countries to about -35°C).
 The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer
countries. The coolant additive portion must be at least 40%.
 If for climatic reasons a greater frost protection is required, the amount of G 12 plus can be increased, but
only up to 60% (frost protection to about -40°C), as otherwise frost protection is reduced again and
cooling effectiveness is also reduced.
 If the radiator, heater core, coolant pump or cylinder head gasket was replaced, completely replace engine
coolant.
 Refractometer T10007 is recommended for determining freeze protection density.
Recommended mixture ratios:
Frost protection to Anti-freeze portion G 12 * See note Water * See note

-25°C 40% 4.0 l 5.0 l
-35°C 50% 4.5 l 4.5 l
* The quantity of coolant can vary depending upon vehicle equipment.
Work procedure
 Install coolant hoses and secure.
Fig. 182: Identifying Adapter V.A.G 1274/8 On Expansion Tank

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 Install adapter V.A.G 1274/8 onto expansion tank.

 Fill coolant circuit using cooling system charge unit VAS 6096 : Operating instructions for cooling
system charge unit VAS 6096.
Radiator, removing and installing
Fig. 183: Identifying Drip Tray V.A.G 1306

Fig. 184: Torque Wrench V.A.G 1331

Removing
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Fig. 185: Locating Coolant Hose Retaining Clip

 Pull retaining clips out of quick-release couplings for upper and lower coolant hoses and pull coolant
hoses off radiator.
 Remove front bumper: --> 63 - BUMPERS
 Bring lock carrier into service position: --> 50 - BODY - FRONT
 Remove coolant fan and fan support --> Coolant fan, assembly overview.
Fig. 186: Identifying Securing Clamps For A/C System Condenser And ATF Oil Cooler
 Loosen securing clips - arrow - for condenser and transmission oil cooler.
 Remove upper radiator securing bolts and remove radiator upward.
Installing

 Electrical connections and routing: --> Electrical Wiring Diagrams, Troubleshooting and Component
Locations
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 Install front bumper --> 63 - BUMPERS

 Check headlight adjustment and adjust if necessary: --> 01 - MAINTENANCE
Coolant pump, removing and installing
Fig. 187: Identifying Special Tools - Coolant Pump, Removing And Installing

 Water pump wrench V.A.G 1590
Removing
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NOTE:  To remove coolant pump, pulley need not be removed.
Fig. 188: Identifying Coolant Pump Bolt Holes In Belt Pulley

 Remove coolant pump bolts through holes in belt pulley - arrows - and remove coolant pump.
If coolant pump must be replaced:
Fig. 189: Holding Belt Pulley With Water Pump Wrench V.A.G 1590
 Remove belt pulley. Hold belt pulley with water pump wrench V.A.G 1590 when doing this.
Installing
 Moisten new O-Ring with coolant.
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 Install coolant pump.

 Tighten securing bolts. Torque specification: 8 Nm
Cooling system, checking for leaks
Fig. 190: Cooling System Tester VAG 1274

 Cooling system tester V.A.G 1274
Fig. 191: Adapter VAG 1274/8


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Fig. 192: Identifying Cooling System Tester VAG 1274 With Adapter VAG 1274/8 On Expansion Tank
 Install cooling system tester V.A.G 1274 with adapter V.A.G 1274/8 onto reservoir as shown.
 Operate pump and generate a positive pressure of 1.4 to 1.6 bar.
 Check cooling system for leaks.
 Also test cap:
Fig. 193: Identifying Adapter VAG 1274/9 Of Cooling System Tester VAG 1274 On Cap
 To do this, install adapter V.A.G 1274/9 onto cooling system tester V.A.G 1274.
 Operate pump and generate a positive pressure of 1.4 to 1.6 bar.
 The pressure relief valve must not open before 1.4 bar.
 If valve in cap opens prematurely, replace cap.
20 - FUEL SUPPLY
FUEL SUPPLY SYSTEM COMPONENTS
Fuel supply system components
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NOTE:  Hose connections are secured with either spring-type or clamp-type clips.
 Always replace clamp-type clips with spring-type clips.
 Fuel hoses at engine must only be secured with spring-type clips. The use
of clamp or screw type clips is not permissible.

 Spring-type clip pliers VAS 5024 A or hose clip pliers V.A.G 1921 are recommended for installing
spring-type clips.
 The fuel system must be bled if the fuel delivery unit is replaced --> Fuel system, bleeding.
Observe safety precautions --> Safety precautions when working on fuel supply system.
Observe rules for cleanliness --> Rules for cleanliness.
Fuel tank with attachments, assembly overview --> Fuel tank with attachments, assembly overview.
Fuel filter, assembly overview --> Fuel filter, assembly overview
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Connection diagram for fuel lines and fuel tank components --> Fuel lines and fuel tank components,
connection diagram
Fuel filter, replacing --> Fuel filter, replacing
Fuel system, bleeding --> Fuel system, bleeding
Empty fuel tank --> Fuel tank, emptying
Fuel delivery unit, fuel gauge sensor and suction jet pump, removing and installing --> Fuel delivery unit, fuel
gauge sensor and suction jet pump, removing and installing
Fuel tank with attachments, removing and installing --> Fuel tank with attachments, removing and installing
Check fuel pumps --> Fuel pumps, checking
EVAP canister system components:
 Vehicles with engine code BAA and BMX --> Evaporative emission (EVAP) canister purge solenoid
valve system
Fuel tank with attachments, assembly overview
CAUTION: During all repair procedures on the fuel tank, be aware of the following:
 Route all the various lines (e.g. for fuel, EVAP system, or vacuum)
and electrical wiring so that the original routing positions are
restored.
 Make sure that the Ground (GND) strap between fuel filler tube and
body is securely fastened, to prevent electrostatic charging.
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Fig. 195: Fuel Tank With Attachments, Assembly Overview

1 - Fuel filler tube
 With connection for Ground (GND) strap to body

2 - To EVAP canister
3 - Fuel tank
 Support using Engine/transmission jack V.A.G 1383 A when removing
4 - Fuel filter
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 Disassembling and assembling --> Fuel filter, assembly overview
5 - Locking ring, 110 Nm
 Use wrench T10202 for removal and installation

6 - Fuel delivery unit
 Left side
 Check fuel pump --> Fuel pumps, checking
7 - Fuel Level Sensor 3 G237
 Left side
 Flat, rectangular floater
 Clipped into bottom of tank
8 - Suction jet pump
 Left side
9 - Protective cover
 For bottom of fuel tank
10 - Securing strap

12 - Protective cover
 For top of fuel tank
 Right side

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 Right side
 Check fuel pump --> Fuel pumps, checking
15 - Fuel Level Sensor G
 Right side
 Round, spherical floater
16 - Flange
 Right side
 With fuel pressure regulator
 With gravity valve
 Individual components Individual components of flange, right side
 Note installation position on fuel tank Installed position of sensor flange on fuel tank
17 - Vent line
18 - Expansion tank
19 - Gravity valve
20 - To pressure retaining valve
Individual components of flange, right side
Fig. 196: Individual Components Of Flange, Right Side

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1 - Connections for Fuel Pump (FP) G23 and Fuel Level Sensor G
2 - Fuel pressure regulator (4 bar)
3 - Ground (GND) wire
4 - Pressure regulator inlet (from fuel filter)
5 - Connection to left and right-hand fuel pump units (no pressure)
6 - Gravity valve
Installed position of sensor flange on fuel tank
Fig. 197: Location Of Flange On Fuel Reservoir

 Insert sensor flange with marking - arrow - in direction of travel.
Fuel filter, assembly overview
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Fig. 198: Fuel Filter, Assembly Overview

1 - Connection
 For breather line
2 - Flange
 Left side
 With fuel filter housing
 Note installation position on fuel tank Installed position of sensor flange on fuel tank
3 - Filter element
4 - Seal
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 Replace
5 - Ground (GND) wire
6 - 10 Nm
7 - Supply line
 To fuel pressure regulator
8 - Connection
 Filter supply from left fuel pump unit
9 - Connection
 Filter supply from left fuel pump unit
10 - Ground (GND) connection
11 - Sealing cap
 For filter housing
12 - Locating pin
Fuel lines and fuel tank components, connection diagram
- A - Left side of tank
- Arrow - indicates direction of travel
- B - Right side of tank
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Fig. 199: Fuel Lines And Fuel Tank Components, Connection Diagram
1 - Gravity valve
 Left side
2 - Flange
 Left side
3 - Fuel filter
4 - Gravity valve
 Right side
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5 - Supply line
 To fuel rail
6 - Supply line for auxiliary heating
7 - Flange
 Right side
8 - Fuel pressure regulator
9 - Return line
 From fuel pressure regulator

 To fuel delivery units on left and right sides
10 - Supply line for suction jet pump
 Right side
 Right side
13 - Delivery line
 Black
 To Fuel Pump (FP) unit, left side
14 - Delivery line
 Black
 To Fuel Pump (FP) unit, right side
 Left side
 Left side
Safety precautions when working on fuel supply system

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restored.
 Make sure that the Ground (GND) strap between the fuel filler tube
and body is securely fastened, to prevent electrostatic charging.

 For safety reasons, fuses - 13 - and - 14 - - arrow - must be removed before opening fuel system because
fuel pump can be activated by door contact switch in drivers door.
 Fuses 13 and 14 are located in fuse holder of electric box in plenum chamber on left.
Always observe the following when removing and installing fuel gauge sensor or fuel pump (fuel delivery unit)
from full or partially filled fuel tanks:
 Already before starting work, switch on exhaust extraction system and place an extraction hose close to
the sensor installation opening of fuel tank to extract escaping fuel fumes. If no exhaust extraction system
is available, a radial fan (as long as motor is not in air flow) with a displacement greater than 15 m 3 /h
can be used.
 Prevent fuel from contacting skin! Wear fuel-resistant gloves!
Rules for cleanliness
When working on the fuel supply/injection system, pay careful attention to the following "5 rules" of
cleanliness:
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 Thoroughly clean all connections and surrounding area before disconnecting.

 Place parts that have been removed on a clean surface and cover them. Use lint-free cloths.
 Carefully cover over opened components or seal, if repairs are not performed immediately.
 Only install clean components: Only unpack replacement parts immediately prior to installation. Do not
use parts that have been stored loose (e.g. in tool boxes etc.).
 When system is open: Avoid working with compressed air if possible. Do not move vehicle unless
absolutely necessary.
Fuel filter, replacing
Fig. 201: Identifying Wrench T10202

 Wrench T10202
Requirements
 The fuel tank must be drained --> Fuel tank, emptying , emptying fuel tank.

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Work procedure
 Read safety precautions before beginning work --> Safety precautions when working on fuel supply
system.
Fig. 203: Identifying Carpet Cutting Area

 Cut open carpet on left side from point - A - to point - B - in pre-cut area - arrow -.
Fig. 204: Identifying Nuts, Cover, Backrest Support And Anchor Plate
 Remove nuts - 1 - from cover. If necessary, remove backrest support - 2 - or support mounting. --> 72 -
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SEAT - FRAMES
 Remove locking ring from left sensor flange using fuel tank sensor Wrench T10202.
 Remove flange from left side of tank.
 Empty fuel filter housing.
Fig. 205: Identifying Installation Position Of Filter Cover, Ground (GND) Wire, And Filter Cover
 Mark installation position of filter cover - 2 - using colored felt tip marker pen.
 Disconnect Ground (GND) wire - 1 - and remove filter cover - arrows - from housing.
If filter insert is to be replaced, ensure that Ground (GND) connection contacts are not bent and have sufficient
pretension.
Fuel system, bleeding
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Fig. 206: Identifying Special Tools - Fuel System, Bleeding

 Hose Clamps Up to 25 mm dia. 3094

 Remote control connection V.A.G 1348/3A

 Adapter cable V.A.G 1348/3-3
Requirements
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 Battery voltage must be at least 11.5 V.
Fig. 207: Identifying Fuel Pump Relays

 Fuel pump relays - 1 - and - 2 - for left and right fuel delivery units must be removed from their sockets.
Work procedure
system.
 Remove cover in front of fuse holder.
Fig. 208: Identifying Connection For Fuel Pump Relay For Right Fuel Delivery Unit
 Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-3 to connection - arrow - for
fuel pump relay for right fuel delivery unit.
 Connect positive clamp of remote control to positive terminal in engine compartment.
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 Turn valve on T-piece - arrow - counter-clockwise until completely open.
5226 To Bleed Valve
valve - 1 -.
 Check adapter and hose connection for leaks.
 Operate remote control V.A.G 1348/3A until fuel flows (free of air bubbles) from bleed valve.
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 Turn valve on T-piece - arrow - counter-clockwise until completely open again.

 Clamp off hose from suction pump VAS 5226 (e.g. with Hose Clamps Up to 25 mm dia. 3094) and pull
hose off from Adapter V.A.G 1318/20-1.
 Remove adapter V.A.G 1318/20 from bleeder valve.
 Install cover onto bleed valve.
Fuel tank, emptying
Fig. 212: Identifying Fuel Siphoning Unit VAS 5190

 Fuel siphoning unit VAS 5190
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 Wrench T10202
Work procedure
system.
 Open fuel tank flap.
Fig. 214: Fuel Siphoning Unit VAS 5190 Suction Hose In Fuel Filler Neck
 Push suction hose - arrow - of fuel extractor VAS 5190 about 170 to 180 cm into fuel filler neck and
extract fuel.
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NOTE:  When no more fuel can be extracted the tank is emptied only enough for
the sensor flange to be opened without danger. The tank may be removed
while containing the remaining fuel.
 If work must be performed on the fuel pumps or fuel tank sensors,
proceed as follows:
Fig. 215: Identifying Carpet Cutting Area

 Cut open carpet from point - A - to point - B - in pre-cut area - arrows -.
Fig. 216: Identifying Nuts, Cover, Backrest Support And Anchor Plate
 Remove nuts - 1 - from cover. If necessary, remove backrest support - 2 - or support mounting. --> 72 -
SEAT - FRAMES
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 Hold a cloth on connections for fuel supply line and auxiliary heater and pull off hose couplings.
NOTE:  Release connection by pressing button on hose coupling.
 Pull off connectors for fuel pump and fuel gauge sensor.
Fig. 217: Opening Locking Ring Using Wrench T10202

 Remove locking ring from sensor flange using wrench T10202.

 Carefully pry out sensor flange and raise it slightly.
 Insert suction hose of fuel siphoning unit VAS 5190 as deeply as possible in right and then left sides of
fuel tank and extract fuel.
 For work on left side of fuel tank, proceed as described above.
Fig. 218: Assembly Tool T10118

 When breather line is pulled off, hose coupling button often cannot be pressed in. In that case, use
assembly tool T10118 - arrow -.
For additional work on components inside of fuel tank, sensor flanges may remain removed.
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If fuel tank only needed to be emptied, install sensor flange again.
 First check that sensor flange seals are properly seated.
NOTE:  The sealing rings should be replaced.
Fig. 219: Location Of Flange On Fuel Reservoir

 Insert sensor flange with locating tab in direction of travel - arrow -.

 Tighten left and right locking rings using fuel gauge sensor Wrench T10202 to 110 Nm.
Fuel delivery unit, fuel gauge sensor and suction jet pump, removing and installing
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 Wrench T10202
Requirements


 Connectors and wires for left and right sensor flanges have been removed.
 Locking rings of sensor flanges, right and left, are removed.
Work procedure
system.
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Fig. 223: Identifying Connectors And Hose Coupling

 Disconnect connectors - 1 - and - 2 - , as well as hose couplings - 3 - and - 4 - under right sensor flange.
 Remove sensor flange with pressure regulator.
Fig. 224: Identifying Black Filler Hose

 Unclip black filler hose - arrow - from fuel delivery unit housing on left and right sides of fuel tank.
Fig. 225: Identifying Fuel Supply Line And Fuel Delivery Unit
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 Pull fuel supply line off fuel delivery unit - arrow - on left and right sides of fuel tank to suction jet
pumps.
 Remove fuel delivery unit in bottom of fuel tank by turning approx. 90° to left.
NOTE:  The fuel delivery unit housing is filled with fuel. Fuel may run out if
housing is tipped or tilted.
 Unclip fuel gauge sensors on each side of fuel tank and pull them out.
 Unclip suction jet pumps from bottom on each side and remove with a slight turn.
 Pull out hose ends through left and right sensor openings.
Fuel tank with attachments, removing and installing
restored.
 Make sure that the Ground (GND) strap between the fuel filler tube
and body is securely fastened, to prevent electrostatic charging.
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Fig. 226: Identifying Special Tools - Fuel Tank With Attachments, Removing And Installing
 Wrench T10202
 Engine/transmission jack V.A.G 1383 A
 Fuel siphoning unit VAS 5190

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Requirements

Removing
system.
First, relieve fuel pressure as follows:


 Turn valve on T-piece - arrow - counter-clockwise until completely open.
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Fig. 229: Installed Position Of Adapter V.A.G 1318/20 Hand-Tight On Bleeder Valve
 Install adapter V.A.G 1318/20 hand-tight on to bleeder valve.

 Connect hose from Diesel Extractor VAS 5226 as illustrated.
 Turn valve (at T-piece) clockwise into bleeder valve to stop.
When fuel pressure has been released:
 Remove adapter V.A.G 1318/20 from bleeder valve.

 Install cover onto bleed valve.
 Remove mufflers and mountings --> Muffler with mountings.
 Remove driveshaft: --> 39 FINAL DRIVE, DRIVESHAFTS
 Remove rear axle: --> 42 - REAR SUSPENSION

 Open fuel flap and remove fuel tank cap.
 Pull rubber gasket off filler neck.
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Fig. 230: Identifying Securing Bolts On Filler Neck And Ground (GND) Wire
 Remove securing bolts - 1 - on filler neck and remove Ground (GND) wire - 2 -.
 Remove wheel housing liner, right rear: --> 66 - EXTERIOR EQUIPMENT
Fig. 231: Identifying Bolts For Cover Plate

 Remove cover plate - arrow -.
Fig. 232: Unclipping Fuel Tank Breather Lines At Securing Clip Attached On Longitudinal Member
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 Unclip fuel tank breather lines at securing clip attached on longitudinal member.
Fig. 233: Identifying Securing Bolts For Filler Pipe And EVAP Canister In Wheel Housing
 Remove securing bolts for filler tube - 1 - and EVAP canister - 2 - in wheel housing.
Fig. 234: Bending Filler Neck Slightly Downward And Pulling Off Breather Line Connections To EVAP
Canister
 Bend filler neck slightly downward and pull off breather line connections to EVAP canister.
NOTE:  Release connection by pressing button on hose coupling.
 Disconnect 3-pin connector from fuel system Leak Detection Pump (LDP) V144 as well as 2-pin
connector from EVAP canister purge solenoid valve N115.
 Disconnect Ground (GND) wire clipped to EVAP canister and remove canister.
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Fig. 235: Identifying Fuel Pump Connectors

 Separate fuel pump connectors, on left next to fuel tank.

 Remove securing straps with covers on left and right below fuel tank.
 Support fuel tank using Engine/transmission jack V.A.G 1383 A and remove securing strap at center of
fuel tank.
 Carefully lower fuel tank about 30 cm.
 Reach between fuel tank and vehicle underbody and pull fuel supply and breather lines off sensor flange.
When pulling off fuel supply line, hold a cloth around fuel supply line.
NOTE:  This step eliminates having to cut open the carpeting in the vehicle interior
in the vicinity of sensor flange cover.
 Lower fuel tank.
Installing
 Connections for breather and fuel lines must engage audibly when joined.
 Make sure ventilation and fuel lines are not kinked when installed.
 Secure fuel hoses with spring-type clamps.
 Ensure fuel hoses are seated securely.
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Fig. 236: Identifying Securing Bolts On Filler Neck And Ground (GND) Wire
 The Ground (GND) strap at fuel filler tube - 2 - must be securely connected to body.
NOTE:  Before fastening the fuel tank, check that the supply and ventilation lines
are still clipped onto the fuel tank.
Fuel pumps, checking
Checking fuel delivery
Checking current draw of pumps
Checking check valves of Fuel Pumps (FP)
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Fig. 237: Identifying Special Tools - Fuel Pumps, Checking (1 Of 2)

 Wrench T10202
 Pressure gauge V.A.G 1318
 Hose V.A.G 1318/13

 Adapter For VAG1318 VAG1318/17
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Fig. 238: Identifying Special Tools - Fuel Pumps, Checking (2 Of 2)


 Multimeter V.A.G 1715
 Hose V.A.G 1318/24
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 Measuring container
 Wiring diagram
Checking delivery rate
Test conditions


 Battery voltage at least 11.5 V
Test sequence
 Remove fuel filler cap from fuel filler tube.
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 Connect remote control for VAG 1348 V.A.G 1348/3A with the adapter cable V.A.G 1348/3-3 to
connection - arrow - for fuel pump relay for right fuel delivery unit.
 Connect positive clamp of - 1 - of remote control to positive terminal in engine compartment.


 Turn valve (on T-piece) counter-clockwise until completely open.
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5226 To Bleed Valve
valve - 1 -.
 When fuel pressure has been released, the fuel system may be opened.
Check delivery quantity of right pump
Fig. 244: Identifying Fuel Supply Hose And Measuring Container

 Pull fuel supply hose - 1 - off fuel rail.

 Hold hose in measuring container - 2 - with capacity of at least 1000 cm 3 .
 Empty measuring container before making measurement.
 Operate remote control for 15 seconds: At least 3 fuel per 15 seconds must be delivered.
Check delivery quantity of left pump
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Fig. 245: Checking Delivery Quantity Of Left Pump

 Connect remote control for VAG 1348 V.A.G 1348/3A with adapter cable V.A.G 1348/3-3 to connection
- arrow - for fuel pump relay for left fuel delivery unit.
 Empty measuring container before making measurement.
 Operate remote control for 15 seconds again. At least 3 fuel per 15 seconds must be delivered.
 Also test both fuel delivery units as follows:
 Connect Adapter V.A.G 1348/3-3 to fuel pump relay connections for left and right fuel delivery units.
 Operate remote control for 10 seconds: At least 800 cm 3 fuel per 10 seconds must be delivered.
If minimum delivery rate is not attained:
 Check fuel lines for possible restrictions (kinks) or blockages.
If lines are OK:
 Replace fuel filter:
If delivery rate has been attained but nevertheless you suspect a fuel supply system malfunction (e.g.
intermittent failure of fuel supply system):
 Check current consumption of fuel pumps.
Current draw of pumps, checking
 Check current draw of each individual Fuel Pump (FP) as follows:

 Reconnect all disconnected fuel lines.
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Fig. 246: Connecting Current Clamp Of Multimeter To Wire Of 4-Pin Connector Contact From Wiring
Harness To Right Fuel Delivery Unit
 Connect current clamp of multimeter V.A.G 1715 to wire of 4-pin connector contact - 1 - - arrow - from
wiring harness to right fuel delivery unit.
 Measure current draw of fuel pump. Specified value: max. 11 amps.
If current draw is exceeded:
 Right fuel pump is faulty. Replace fuel delivery unit --> Fuel delivery unit, fuel gauge sensor and
suction jet pump, removing and installing.
 Repeat test on left fuel delivery unit.
If current draw is exceeded:
 Left Fuel Pump (FP) malfunctioning, replace fuel pump unit --> Fuel delivery unit, fuel gauge sensor
and suction jet pump, removing and installing.
NOTE:  If malfunction in fuel system is sporadic, test can also be performed

during a road test, but a second person is required.
Check valves of Fuel Pumps (FP), checking
Conditions
 Remote control for VAG 1348 V.A.G 1348/3A is still connected.
NOTE:  With this check, the fuel supply line connections from the fuel delivery
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units to the point at which pressure gauge V.A.G 1318 is connected will be
checked for leaks at the same time.
Test sequence
 Turn valve on T-piece of adapter V.A.G 1318/20 counter-clockwise until completely open.
Fig. 247: Connecting Pressure Tester V.A.G 1318 To Breather Valve Using Adapter V.A.G 1318/20 ,
V.A.G 1318/20-1 , V.A.G 1318/9 And Diesel Extractor VAS 5226
 Connect pressure tester V.A.G 1318 to breather valve - 1 - as shown using adapter V.A.G 1318/20 ,
V.A.G 1318/20-1 , V.A.G 1318/9 and Diesel Extractor VAS 5226.
 Install valve on T-piece of adapters V.A.G 1318/20 clockwise into bleed valve to stop.
 Open cut-off tap of pressure tester and operate remote control briefly to bleed air.
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Fig. 248: Locating V.A.G 1318 Shut-Off Tap

 Then, close pressure gauge shut-off tap - arrow - (lever perpendicular to direction of flow).
 Operate remote control at short intervals, until a pressure of approx. 4 bar has built up.
CAUTION: Danger of spray when opening the shut-off tap Diesel Extractor VAS 5226
must be connected.
 If pressure builds up too high, lower excess pressure by carefully opening shut-off tap.
 Watch pressure drop on gauge. After 10 minutes pressure must not drop below a 3.0 bar decrease.
If pressure drops:
 Check fuel lines and connections to fuel tank for leaks.
If no fault is detected in the wiring:
 Remove pressure gauge V.A.G 1318 with adapters.
Check right pump check valve
Test conditions
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Test sequence
 Disconnect 4 pin connector from left flange

 Remove locking ring from left sensor flange (fuel filter) using fuel tank sensor Wrench T10202.
 Carefully pry up sensor flange and raise it slightly.
 Disconnect connector next to fuel filter for attaching pressure tester V.A.G 1318.
Microsoft
Fig. 251: Identifying Fuel Supply Hose And Fuel Filter

 Pull fuel supply hose - 2 - from right fuel delivery unit off fuel filter - 1 -.
 Let fuel from connecting piece - 1 - flow back into tank.

 Close pressure gauge shut-off tap - arrow - (lever perpendicular to direction of flow).
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 Connect pressure tester V.A.G 1318 with adapter V.A.G 1318/7 , hose adapter V.A.G 1318/13 and
Adapter For VAG1318 V.A.G 1318/17 as shown.
NOTE:  Ensure that fuel supply line connection engages audibly when joined.
 Attach connectors to filter housing and flange again.
- arrow - for fuel pump relay for right fuel delivery unit.
 Watch pressure drop on gauge. After 10 minutes the pressure must not drop below a 3.0 bar decrease.
If pressure drops:
 Right fuel pump is faulty. Replace fuel delivery unit --> Fuel delivery unit, fuel gauge sensor and
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To change pressure tester set-up for left fuel pump:

 Open lever of pressure tester and let fuel flow back to fuel tank through hose V.A.G 1318/13.
Check left pump check valve

 Pull fuel supply hose - 2 - from left fuel delivery unit off fuel filter - 1 -.
 If necessary, disconnect connectors from flange and filter housing and then attach pressure tester V.A.G
1318.
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 Close pressure gauge shut-off tap - arrow - (lever perpendicular to direction of flow).

 Connect pressure tester V.A.G 1318 with adapter V.A.G 1318/7 , hose adapter V.A.G 1318/13 and
adapter V.A.G 1318/24 as shown.
NOTE:  Ensure that fuel supply line connection engages audibly when joined.
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- arrow - for fuel pump relay for left fuel delivery unit.
 Watch pressure drop on gauge. After 10 minutes pressure must not drop below a 3.0 bar decrease.
If pressure drops:
 Left fuel pump is faulty. Replace left fuel delivery unit --> Fuel delivery unit, fuel gauge sensor and

 Open lever of pressure tester and let fuel flow back to fuel tank through hose V.A.G 1318/13.
 Remove pressure gauge V.A.G 1318 with adapters.
ELECTRONIC ENGINE POWER CONTROL (EPC)
Electronic Engine Power Control (EPC)
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Fig. 261: Electronic Engine Power Control (EPC) Components

1 - Bracket
2 - Connector
 Black, 6-pin
3 - 10 Nm
4 - Throttle Position (TP) Sensor G79 with Accelerator Pedal Position Sensor 2 G185
 Not adjustable
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 Remove footwell cover to remove sensor
Function of EPC system
The position of the accelerator pedal is transmitted to the engine control module via two accelerator pedal
position sensors (adjustable resistances, accommodated in one housing), that are connected to accelerator pedal.
The position of accelerator pedal (driver controlled) is a main input for engine control module.
Operation of throttle valve occurs via an electric motor (throttle valve actuator) in throttle valve control module.
This is true across entire engine speed and engine load spectrum.
The throttle valve is operated by the throttle drive according to instructions of Engine Control Module (ECM).
With engine at standstill and ignition switched on, the Engine Control Module (ECM) activates throttle valve
actuator precisely according to specifications of Throttle Position (TP) Sensor. This means, if the accelerator
pedal is depressed half way, the throttle drive opens the throttle valve to the same degree; i.e. throttle valve is
then opened approx. half way.
With engine running (under load) the engine control module can open and close the throttle valve independently
of the accelerator pedal position sensor.
That way e.g. the throttle valve can already be completely opened, although accelerator pedal is only depressed
half-way. An advantage of this is that throttle losses at throttle valve are avoided.
Aside from that, it results in clearly better pollutant output and consumption values under certain load
conditions.
According to torque requirement outputs from the various components (e.g. air conditioning, automatic
transmission, ABS/ESP...), the engine control module calculates a throttle valve open angle that is optimal for a
respective situation.
EVAPORATIVE EMISSION (EVAP) CANISTER PURGE SOLENOID VALVE SYSTEM
Evaporative emission (EVAP) canister purge solenoid valve system
EVAP canister system components, assembly overview --> Evaporative emission (EVAP) canister purge
solenoid valve system, assembly overview
Checking fuel supply system for leaks --> Evaporative Emission (EVAP) Canister Purge Regulator Valve
N80 system, checking for leaks
Function
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Depending on air pressure and ambient temperature, varying quantities of fuel vapors form above fuel surface
in fuel tank.
The EVAP canister system prevents these HC emissions from entering the atmosphere.
Fuel vapors travel from the highest point of the fuel tank (at filler tube) via expansion tank into EVAP canister.
The activated charcoal in canister stores these gases like a sponge.
While driving, with oxygen sensor control active (engine warm), the Evaporative Emission (EVAP) Canister
Purge Regulator Valve N80 is activated by Engine Control Module (ECM) J623 in pulses dependent on load
and engine speed. The opening time is dependent on input signals.
During cleansing process (regeneration of active charcoal), intake manifold vacuum sucks fresh air through
breather connection of the EVAP canister. The fuel vapors stored amongst activated charcoal and fresh air are
proportionately supplied to be burned.
Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 is closed without current (e.g. open
circuit). The EVAP canister is not purged.
Function description of leak diagnosis
The EVAP system (including fuel tank) is equipped with leak diagnosis. The leak diagnosis will detect whether
system is leaking.
The diagnosis operates by pressurizing system and should detect leaks where damage exceeds 0.5 mm in
diameter.
During diagnosis, positive pressure is created in EVAP system by Leak Detection Pump (LDP) V144. To do
this, the Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 N115 is closed. The pump will switch
off when pressure is attained. When pressure falls to below a certain figure, pump will switch on again. On
Board Diagnostic monitors the switch intervals and stores a DTC in DTC memory if intervals are too short.
NOTE:  Hose connections are secured with either spring-type or clamp-type clips.
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Fig. 262: Identifying Spring-Type Clip Pliers VAS 6340

 For installing spring-type clips, the Spring-Type Clip Pliers VAS 6340
Fig. 263: Clamp Pliers VAS 6362

 Or the Space-saving Clip Pliers VAS 6362 are recommended.
Evaporative emission (EVAP) canister purge solenoid valve system, assembly overview
Microsoft
Fig. 264: Evaporative Emission (EVAP) Canister Purge Solenoid Valve System, Assembly Overview
1 - Expansion tank
 Right side
2 - Gravity valve
3 - Fuel filler tube
4 - 5 Nm
5 - Bracket
6 - Vacuum line
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 For Leak Detection Pump (LDP) V144 vacuum supply

7 - Leak detection pump (LDP) V144
 Checking fuel supply system for leaks --> Evaporative Emission (EVAP) Canister Purge Regulator
Valve N80 system, checking for leaks
 Black connector, 3-pin
8 - Connecting hose
 Between air filter, leak detection pump V144 and Evaporative emission (EVAP) canister purge solenoid
valve N115
9 - 5 Nm
10 - Air filter housing
 Clean if soiled
11 - Rubber bushing

12 - Evaporative emission (EVAP) canister purge solenoid valve N115
13 - EVAP canister
 Component location: In right front wheel housing
14 - Screws
 3 pieces
 9 Nm
15 - Vent line
16 - Connector
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 Black, 2-pin
17 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve N80
18 - Rubber bracket
19 - Vent line
20 - Pressure retention valve
 Function Pressure retention valve function
Pressure retention valve function
Fig. 265: Pressure Retention Valve Function

The pressure retention valve is opened via gravity valve (on expansion tank) for flow in both directions. -
Arrow 1 - is the side toward expansion tank.
On the other side, it is only open to one direction of flow. - Arrow 2 - is side toward EVAP canister.
Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 system, checking for leaks
 Evaporative Emissions Tester KLI 9210 (smoke tester)

 Hose adapter KLI 9210/55-2
 Vehicle Diagnosis, Testing and Info. System VAS 5051B , VAS 5052 or VAS 5053
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 Hose Clamps Up to 25 mm dia. 3094
Test conditions:
 A leak was detected by Leak Detection Pump (LDP) V144.

 Guided Fault Finding was performed with Vehicle Diagnosis, Testing and Info. System.
Evaporative Emissions Tester KLI 9210 preparation:
NOTE:  Depending on the version, the appearance of the Evaporative Emissions

Tester KLI 9210 may vary.
 Check on Evaporative Emissions Tester KLI 9210 whether there is enough fluid in smoke generator.
Fig. 266: Identifying Evaporative Emissions Tester KLI 9210 Components

 Set valve - D - to "Hold".

 Open nitrogen bottle - H -.
 Connect measuring hose - G - on self-test connection - B -.
 Set valve - D - to "Test".
 Using pressure reducer - J - , adjust pressure to 25 mbar (10 in. H 2 O).

 Set valve - D - to "Hold".
 The pressure must now be maintained min. 2 minutes. If pressure is not maintained, check tester.
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Fuel system, checking for leaks:
 Disconnect breather line - arrow - to Evaporative emission (EVAP) canister purge regulator valve N80 in
engine compartment.
Fig. 268: Identifying Adapter Hose KLI 9210/55-2

 Connect Adapter Hose KLI 9210/55-2 as shown between Evaporative Emission (EVAP) Canister Purge
Regulator Valve N80 and ventilation line.
 Connect measuring hose - G - on Evaporative Emissions Tester KLI 9210 to Adapter Hose KLI 9210/55-
2.
 Connect Evaporative Emissions Tester KLI 9210 to vehicle battery.
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Fig. 269: Connecting Connector Of Diagnosis Cable VAS 5051/1 Or VAS 5051/3 To Data Link Connector
 Connect evaporative emissions tester to vehicle.

 Select OBD operating mode on evaporative emissions tester.
 Now select diagnostic mode 8 "Tank leak test".
 Mark "Tank leak test" entry and press right arrow button --> to activate test.
NOTE:  When diagnostic mode 8 "Tank leak test" is activated, leak detection pump
and Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 N115
are closed for a maximum of 1000 seconds. The Evaporative Emission
(EVAP) Canister Purge Regulator Valve N80 is not activated. The entire
system is now closed.
 If the engine control module stops the test, it can be reactivated by
stopping the engine and restarting.
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 Set valve - D - to "Test". The fuel system is now filled with nitrogen.
 Observe pressure gauge - C - and flow meter - E -. If the flow quantity decreases and pressure climbs to
25 mbar (10 in. H 2 O), the fuel system is full.
NOTE:  Depending on the level in the fuel tank, this procedure may take up to 3
minutes.
 After pressure has stabilized, set valve - D - to "Hold".
 The pressure must not drop below 20 mbar (8 in. H 2 O) after 5 minutes.
If no pressure decrease can be determined, end diagnostic mode 8 and check Leak Detection Pump (LDP) V144
pressure buildup.
If pressure does not build up or if positive pressure is not maintained for at least 5 minutes, locate leak as
follows:
Allow engine to continue running at idle with diagnostic mode 8 activated.
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Fig. 271: Clamping Off Hose To Evaporative Emission (EVAP) Canister Purge Regulator Valve N80
With Hose Clamp
 First check Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 for leaks. Clamp off hose
to Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 with hose clamp - arrow -.

 Repeat pressure test by resetting valve - D - to "Test".

 Observe pressure gauge and flow meter. If flow quantity decreases and pressure climbs to 25 mbar (10 in.
H 2 O), the fuel system is full.
 After pressure has stabilized, set valve - D - to "Hold".
 If pressure now no longer falls, replace Evaporative Emission (EVAP) Canister Purge Regulator Valve
N80.
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If pressure still drops:
 Reset valve - D - to "Test".

 While fuel system is being filled, press smoke generator button - I - for approx. one minute.
The fuel system is now under pressure and filled with smoke.
 Check all visible fuel system lines and hoses for escaping smoke. Also check fuel tank sealing cap.
NOTE:  Illuminate components and hoses with a strong flood light, the smoke will
be more visible.
 To check for leaks at accessible locations, also use ultrasonic measuring
device or commercially available leak detection spray.
 Depending on how long fault finding lasts, smoke generator button may
have to be pressed again. This ensures there is enough smoke present in
the fuel system.
If no malfunctions are detected:
 Remove right rear wheel housing liner.
If smoke comes out of air filter :
Fig. 273: Clamping Off Hose Between Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2
N115 And Air Filter
 Clamp off hose between Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 N115 and air
filter - arrow -.
 Observe air filter. If no smoke comes out of it now, Evaporative Emission (EVAP) Canister Purge
Solenoid Valve 2 N115 leaks. Replace Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2
N115.
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If smoke still comes out of air filter:
Fig. 274: Clamping Off Hose Between Leak Detection Pump (LDP) V144 And Air Filter
 Clamp off hose between Leak Detection Pump (LDP) V144 and air filter - arrow -.
 Observe air filter. If no smoke comes out of it now, shut-off valve in Leak Detection Pump (LDP) V144
leaks. Replace Leak Detection Pump (LDP) V144.
If no smoke comes out of air filter :
 Check all fuel system components and hoses for escaping smoke.
To check fuel pump and fuel filter flange, the assembly opening in vehicle interior must be opened.
 Replace leaking hoses or components.
After completing the work, perform "Check tank ventilation system for leaks" Guided Function using.
Evaporative emissions (EVAP) system, overview
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Fig. 275: Evaporative Emissions (EVAP) System, Overview

1 - EVAP canister
2 - Adapter Hose KLI 9210/55-2 installation location
 With leak test in fuel system
3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve N80
4 - Vent line
 To Intake manifold
5 - Solenoid valve
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 For Leak detection pump (LDP) V144
6 - Vacuum line
 To Intake manifold
7 - Air filter housing
 For Leak detection pump (LDP) V144
8 - Leak detection pump (LDP) V144
9 - Fuel tank
10 - Cap
11 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 N115
12 - Pressure retention valve
A - Clamp off here

 To check Evaporative Emission (EVAP) Canister Purge Regulator Valve N80
B - Clamp off here

 To check Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 N115
C - Clamp off here

 To check Leak Detection Pump (LDP) V144
Leak Detection Pump (LDP) V144 pressure buildup, checking
Test conditions:
 Evaporative Emissions Tester KLI 9210 with Adapter Hose KLI 9210/55-2 connected to vehicle
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 Valve - D - is at "Hold"
 Diagnostic mode 8 ended and vehicle running at idle
Fuel system must have no pressure for test. To release residual pressure, proceed as follows:

 Briefly open quick-release coupling - arrow - on Adapter Hose KLI 9210/55-2 to release pressure in fuel
system. The pressure gauge - D - must drop to 0 in. H 2 O.
 Select Guided Functions operating mode on evaporative emissions tester.
 Select "Check tank ventilation system for leaks" Guided Function.
 Activate test.
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 Observe pressure gauge while test is running.

 The Leak Detection Pump (LDP) V144 must pump fuel system up to min. 18 mbar (7 in. H 2 O).
 If pressure is not reached, check Leak Detection Pump (LDP) V144 vacuum supply.
 If fuel system has no leaks and Leak Detection Pump (LDP) V144 vacuum supply is OK, replace Leak
Detection Pump (LDP) V144.
Leak Detection Pump (LDP) V144 vacuum supply, checking
Fig. 278: Identifying Turbocharger Tester V.A.G 1397A

 Turbocharger tester V.A.G 1397A

 T-piece 251 201 346
 Hose dia. 6 mm
NOTE:  Leak Detection Pump (LDP) V144 installation location. Under wheel
housing liner in right rear wheel housing.
 Remove right rear wheel and wheel housing liner.

 Loosen EVAP canister mounting bolts and lower it so vacuum line is more easily accessible.
CAUTION: Support EVAP canister so it does not hang by the hoses and lines. This
prevents damage.
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Fig. 279: Connecting Turbocharger Tester V.A.G 1397A With T-Piece And 6 mm Dia. Hose Between
Vacuum Line And Leak Detection Pump (LDP) V144
 Remove vacuum line - 1 - from Leak Detection Pump (LDP) V144.

 Connect Turbocharger Tester V.A.G 1397A with T-piece and 6 mm dia. hose between vacuum line - 1 -
and Leak Detection Pump (LDP) V144 - 2 -.
 Switch on measuring range I (absolute pressure measurement).
 Connect vehicle tester and start engine.
 Select Guided Function operating mode on vehicle diagnostic tester.

 Select "Check tank ventilation system for leaks" Guided Function.
 While test is running, observe display on Turbocharger Tester V.A.G 1397A.
 The pressure must pulsate and must not rise above 0.700 bar during test.
 If pressure rises above 0.700 bar during test, vacuum supply is too low. Check vacuum line to intake
manifold for kinks or blockages.
24 - MULTIPORT FUEL INJECTION (MFI)

FUEL INJECTION SYSTEM, SERVICING
Fuel injection system, servicing
General notes on fuel injection
 Fuel hoses in engine compartment must only be secured with spring-type clips. The use of clamp or screw
type clips is not permissible.
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 Spring-type clip pliers VAS 5024 A or hose clip pliers V.A.G 1921 are recommended for installing
spring-type clips.
 For trouble-free operation of electrical components a voltage of at least 11.5 V is necessary.
 Do not use sealants containing silicone. Traces of silicone components which are sucked into engine are
not burned there, and they damage the oxygen sensors.
Intake manifold, assembly overview --> Intake manifold, assembly overview
Fuel rail, assembly overview --> Fuel rail, assembly overview
Air filter, assembly overview --> Air filter, assembly overview
Safety precautions --> Safety precautions.
Rules for cleanliness --> Rules for cleanliness.
Technical data --> Technical data.
Intake manifold, assembly overview
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Fig. 281: Intake Manifold, Assembly Overview

1 - Intake manifold
2 - To cylinder head cover
3 - Seal
 Replace
4 - Crankcase vent valve
 With Positive Crankcase Ventilation (PCV) Heating Element N79
5 - 10 Nm
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6 - Bearing cap
 For change over roller of intake manifold change over
7 - 20 Nm
8 - Vacuum connection
 For brake servo or Brake system vacuum pump V192 for vehicles with automatic transmission
 For leak detection pump V144 on vehicles with engine code BAA and BMX
 Closed with plugs on vehicles with engine code AZZ, BKJ, BMV and BRJ
 For Secondary Air Injection (AIR) solenoid valve N112 and Intake Manifold Tuning (IMT) Valve N156
 For evaporative emission (EVAP) canister purge regulator valve N80
12 - 20 Nm
13 - Throttle valve control module J338
 Terminals of harness connector are gold-plated

 Adapt to throttle valve control module when replacing Engine Control Module (ECM) "Guided
Functions".
14 - 10 Nm
15 - Vacuum actuator
 For variable intake manifold
16 - To Intake Manifold Tuning (IMT) Valve N156
17 - 10 Nm
18 - Control lever
 For change over roller

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19 - Change over roller
20 - Gasket

21 - Dowel sleeve
 For intake manifold mount

 For attaching seal
22 - 13 Nm
Fuel rail, assembly overview
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Fig. 282: Fuel Rail, Assembly Overview

1 - 10 Nm
2 - Protective cap
3 - Breather valve
 For checking fuel pressure

 For bleeding fuel system
4 - Cylinder 6 Fuel Injector N84
 Checking --> Fuel injectors, checking
5 - Seal
 Replace
6 - Retaining clip
7 - Supply line connection
8 - Fuel rail
9 - Connector
 Black, 2-pin
10 - Wiring harness
 With harness connectors for fuel injectors

 Clipped into wiring channel
Air filter, assembly overview
Connection to compressor for air suspension , separating
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Fig. 283: Air Filter, Assembly Overview

1 - Air duct
 Secured to lock carrier
2 - Protective grommet
3 - Air filter lower part
 To remove air filter lower part, remove bracket Removing bracket for engine cover
4 - 10 Nm
5 - Filter element
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6 - Air filter upper part
7 - Seal
8 - Mass Air Flow (MAF) Sensor G70 with Intake Air Temperature (IAT) Sensor G42
 Sensor contacts and connector contacts gold plated

9 - 6 Nm
10 - Spring-type clip
11 - Intake tube
12 - To Throttle Valve Control Module J338
13 - To compressor for air suspension
 Separating connection
 Depending on optional equipment, connection may be sealed with a blanking plug.
14 - Heat shield
 For upper part of air filter
15 - 6 Nm
16 - To Secondary Air Injection (AIR) Pump Motor V101
Removing bracket for engine cover
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Fig. 284: Removing Bracket For Right Engine Cover

 Press in retaining tab - 1 - from below and pull out bracket in direction of - arrow -.
Connection to compressor for air suspension, separating
Fig. 285: Identifying Connecting Wire To Air Suspension Compressor

 Separate connecting line at air filter - arrow - as follows:

 Carefully pry off green circlip - 1 - using a screwdriver. Then press clamping ring - 2 - in direction of -
arrow -.
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Fig. 286: Identifying Sealing Ring, Line Flange, Securing Sleeve, And Air Filter Connection
 Pull only loosened line - B - from connection - A - at air filter.
Safety precautions

 For safety reasons, fuses - 13 - and - 14 - - arrow - must be removed before opening fuel system because
fuel pumps can be activated by door contact switch in drivers door.
 Fuses - 13 - and - 14 - are located in fuse holder of electric box in plenum chamber on left.
To reduce risk of personal injury and/or damage to fuel injection and ignition system, always observe the
following:
 Only disconnect and reconnect wires for injection and ignition system, including test leads, when ignition
is switched off.
 Do not touch or remove ignition wires when engine is running or turning at starter speed.
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If test and measuring equipment is required during road test, note the following:
 Test and measuring instruments must be secured to rear seat and operated by a 2nd person from this
location.
If test and measuring instruments are operated from front passengers seat and vehicle is involved in an accident,
there is a possibility that the person sitting in this seat may receive serious injuries when airbag is triggered.
 If engine is to be turned at starter speed, without starting:
 Disconnect connector from ignition coils 1 to 6.
Fig. 288: Identifying Assembly Tool T10118 On Release Button

 To do so, place assembly tool T10118 on locking button - arrow - and carefully pull down harness
connector.
Rules for cleanliness
When working on fuel supply/injection system, pay careful attention to the following "5 rules" of cleanliness:
 Thoroughly clean all connections and surrounding area before disconnecting.

 Place parts that have been removed on a clean surface and cover them. Use lint-free cloths.
 Carefully cover over opened components or seal, if repairs are not performed immediately.
 Only install clean components: Only unpack replacement parts immediately prior to installation. Do not
use parts that have been stored loose (e.g. in tool boxes etc.).
 When system is open: Avoid working with compressed air if possible. Do not move vehicle unless
absolutely necessary.
Technical data
Engine code BAA BMX
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Idle check
Engine idle speed * See note RPM 650 to 750 650 to 750
Engine control module
System designation Motronic ME7.1.1 Motronic ME7.1.1
Replacement part number
Engine speed (RPM) limitation RPM from approx. 6500 from approx. 6500
*Not adjustable
COMPONENTS, CHECKING
Fuel injectors, checking
Checking for leaks
Checking injection quantity

 Adapter cable, 121-pin V.A.G 1598/31
 Injector quantity testing device V.A.G 1602
 Connector test set V.A.G 1594C
Test conditions
 Fuel pressure must be OK, check --> Fuel pressure regulator and residual pressure, checking , fuel
pressure regulator and retaining pressure, checking.
Test sequence
 Remove intake manifold --> Cylinder head cover, removing and installing , Cylinder head cover,
 Remove complete fuel rail (fuel lines remain attached) --> Fuel rail, assembly overview , Fuel rail,
disassembling and assembling.
Checking for leaks
 Remove cover over fuse holder.
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 Pull fuel pump relays - 1 - and - 2 - out of their sockets.
 Connect remote control for VAG 1348 V.A.G 1348/3A with the adapter cable V.A.G 1348/3-3 - arrow -
to connection for fuel pump relay for right fuel delivery unit.

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 Connect second connection of adapter cable V.A.G 1348/3-3 - arrow - to connection to fuel pump relay
for left fuel delivery unit.
 Operate remote control.
If fuel pumps run:
 Check injectors for leaks (visual inspection). Only 1 to 2 drops per minute may escape from each valve
when fuel pump is running.
If fuel loss is greater:
 Replace faulty fuel injector.
Perform installation of injectors in reverse order. When doing this note the following:
 Replace O-rings on all injectors and lightly moisten with clean engine oil.
 Insert fuel injectors into fuel rail perpendicular and in correct position, and secure them with retaining
clips.
 Position fuel distributor with secured fuel injectors on cylinder head and apply uniform pressure to press
it in.
Injection quantity, checking
Test conditions
 Fuel pump relays and fuses 13 and 14 are in their sockets.
Test sequence
Fig. 292: Connecting VAG 1598/31 Test Box At Control Module Wiring Harness
 Connect adapter cable, 121-pin V.A.G 1598/31 and bridge text box sockets 1 and 65 using adapter leads
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from connector test set V.A.G 1594C.

 Place a fuel injector to be tested into a graduated measuring glass of injection rate tester V.A.G 1602.
 Using adapter cables from connector test kit V.A.G 1594/C , connect one terminal of fuel injector to be
checked to engine Ground (GND).
Fig. 293: V.A.G 1348/3 A And V.A.G 1348/3-2

 Connect second fuel injector terminal with adapter cable to remote control for VAG 1348 V.A.G
1348/3A using adapter cable V.A.G 1348/3-2.
 Connect alligator clip to battery (+) terminal in engine compartment.
 Operate remote control for 30 seconds.
 Repeat check on other injectors. To do this use new measuring beakers.
 After all injectors have been activated, place measuring glasses on a horizontal surface and compare
injected quantity. Specified value: 128 to 140 ml per injector
If measured value of one or more fuel injectors is below or above indicated specified value:
 Replace faulty fuel injector.
Perform installation of injectors in reverse order. When doing this note the following:
 Replace O-rings on all injectors and lightly moisten with clean engine oil.
 Insert fuel injectors into fuel rail perpendicular and in correct position, and secure them with retaining
clips.
 Position fuel distributor with secured fuel injectors on cylinder head and apply uniform pressure to press
it in.
Fuel pressure regulator and residual pressure, checking
The fuel pressure regulator maintains fuel pressure at a constant 4.0 bar.
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Fig. 294: Identifying Special Tools - Fuel Pressure Regulator And Residual Pressure, Checking
 Pressure gauge V.A.G 1318

 Multimeter V.A.G 1715
 Pliers for spring type clips VAS 5024 A

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Test conditions
 Fuel pumps delivery rate OK., checking: --> Fuel pumps, checking Fuel pumps, checking.
Test sequence

 Thread adapter V.A.G 1318/20-1 onto adapter V.A.G 1318/20.

 Turn valve on T-piece of adapter V.A.G 1318/20 counter-clockwise until completely open.
Fig. 296: Connecting Pressure Tester V.A.G 1318 To Breather Valve Using Adapter V.A.G 1318/20 ,
V.A.G 1318/20-1 , V.A.G 1318/9 And Diesel Extractor VAS 5226
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 Connect pressure tester V.A.G 1318 to breather valve - 1 - as shown using adapter V.A.G 1318/20 ,
V.A.G 1318/20-1 , V.A.G 1318/9 and Diesel Extractor VAS 5226.

 Cut-off tap of pressure tester - arrow - must be close.

 Install valve on T-piece of adapters V.A.G 1318/20 clockwise into bleed valve to stop.
 Open cut-off tap of pressure tester briefly and close again to bleed line to pressure tester.
 Measure fuel pressure. Specified value: approx. 4.0 bar positive pressure
If specification is not obtained:
 Check delivery rate of fuel pumps: --> Fuel pumps, checking. Checking fuel pumps
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Fig. 298: Individual Components Of Flange, Right Side

 If necessary, replace fuel pressure regulator - 2 -.
If specified value is achieved:
 Switch off ignition.

 Check for leaks and residual pressure. Observe pressure drop on pressure gauge. After 10 minutes there
must be a residual pressure of at least 3.0 bar.
The holding pressure drops below 3 bar:
 Check pressure gauge for leaks.

 Check fuel pump non-return valve --> Fuel pumps, checking.
When removing pressure gauge after completing test:

 Open cut-off valve of pressure tester to release fuel pressure.
 Remove pressure gauge with adapters.
ENGINE CONTROL MODULE
Engine Control Module
Removing and installing Engine Control Module (ECM) --> Engine Control Module (ECM), removing and
installing
Engine Control Module (ECM) secured with anti-theft immobilizer, removing and installing --> Engine
Control Module (ECM) (secured with anti-theft immobilizer), removing and installing
Engine Control Module (ECM), removing and installing
If Engine Control Module (ECM) will be replaced, connect Vehicle Diagnosis, testing info. system VAS 5051B
and perform Guided Function "Replace control module".
Removing

 Remove windshield wiper motor on right side: --> 92 - WINDSHIELD WIPER AND WASHER
SYSTEM
 Release both connectors from control module and disconnect them.
 Control module can now be removed.
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Installing
 Set control module into mounting frame.

 Connect harness connectors and engage them.
 Install windshield wiper motor on right side: --> 92 - WINDSHIELD WIPER AND WASHER
SYSTEM
 Install plenum chamber cover.
 Adapt new Engine Control Module (ECM): "Guided Functions"
Engine Control Module (ECM) (secured with anti-theft immobilizer), removing and installing
NOTE:  If it is desired to replace Engine Control Module (ECM), connect Vehicle

Diagnosis, Testing and Information System VAS 5051B and perform
Guided Function "Replace Engine Control Module (ECM)".
Fig. 299: Wiring Harness Repair Kit V.A.S 1978

 Hot air gun from wiring harness repair kit VAS 1978
 Attachment nozzle from wiring harness repair kit VAS 1978
Removing

 Remove windshield wiper arms --> 92 - WINDSHIELD WIPER AND WASHER SYSTEM .
 Remove plenum chamber cover --> 64 - GLASS, WINDOWS .
NOTE:  Thread of shear bolts is equipped with locking compound. By heating the
shear bolts using a hot air gun, inhibition effect of the locking compound
is lowered.
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CAUTION: Cover wires, harness connectors and control modules in the close vicinity
of Engine Control Module (ECM) to prevent damage from burning.
Perform adjustments on hot air gun - 4 - as shown:
Fig. 300: Performing Adjustments On Hot Air Gun

 Turn potentiometer for temperature adjustment - 2 - to maximum heat output (600°C).

 Move two stage switch for air quantity - 3 - to position 3.
CAUTION: By heating the shear bolts, parts of the protective housing are heated
intensely. Wear protective gloves to prevent injuries.
 Guide nozzle of hot air gun on to shear bolts.

 Switch on heat gun and heat bolt head for approx. 20 to 25 seconds.
 Remove shear bolt - 2 - using pliers on bolt head.
Procedure for second shear bolt is exactly the same.
Fig. 301: Lifting Cover

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 Remove cover - 1 - downward from control module.
Fig. 302: Identifying Slide Release Catches

 Slide connector release catches - 1 - on Engine Control Module (ECM) outward and disconnect both
harness connectors.
 Remove Engine Control Module (ECM).
Installing
 Insert engine control module in frame in plenum chamber.
Fig. 303: Identifying Slide Release Catches

 Connect harness connectors to Engine Control Module (ECM) and slide release catches - 1 - inward.
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Fig. 304: Identifying Bolt Head And Cover

 Place cover - 1 - over ECM and position new shear bolts - arrows - by hand.
 Tighten new shear bolts uniformly until bolt heads shear off.
 Install plenum chamber cover --> 64 - GLASS, WINDOWS .
 Install windshield wiper arms --> 92 - WINDSHIELD WIPER AND WASHER SYSTEM .
26 - EXHAUST SYSTEM, EMISSION CONTROLS

EXHAUST SYSTEM COMPONENTS, REMOVING AND INSTALLING
Exhaust system components, removing and installing
Exhaust manifolds with primary catalytic converters and attachments, assembly overview --> Exhaust
manifolds (with primary catalytic converters and attachments), assembly overview
Muffler with mountings --> Muffler with mountings
Exhaust manifolds and exhaust pipes with primary catalytic converters, removing and installing --> Exhaust
manifolds and exhaust pipes (with primary catalytic converters), removing and installing
NOTE:  After working on the exhaust system ensure that the system has sufficient
clearance from the bodywork. If necessary, loosen the flange on the
catalytic converter and realign mufflers and exhaust pipes Aligning
exhaust system
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Fig. 305: Identifying Special Tools -- Exhaust System Components

 Ring spanner 7-piece set for oxygen sensor 3337

Exhaust manifolds (with primary catalytic converters and attachments), assembly overview
NOTE:  Disconnect the batteries before removing front exhaust pipes with
catalytic converters. --> 27 - BATTERY, STARTER, GENERATOR, CRUISE
CONTROL
 When installing exhaust pipes, ensure that the flange connection after the
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catalytic converter seals tightly. Leaks in this area produce pulsations in

the exhaust. This allows ambient air to reach the lambda probe after
catalytic converter and the lambda regulation will be disturbed.
 Replace self-locking nuts.
Fig. 306: Exhaust Manifolds (With Primary Catalytic Converters And Attachments), Assembly Overview
1 - Cylinder head
2 - Gasket
 Replace
3 - Securing nut
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 M8: 25 Nm
 M10: 40 Nm
4 - Exhaust manifold
5 - Gasket
 Locating tabs face downward

 Replace
6 - Primary catalytic converter
 Installed in exhaust gas stream of cylinders 1, 2 and 3
7 - Primary catalytic converter
8 - Heated Oxygen Sensor (HO2S) G39 , 50 Nm

 Grease thread only using G 052 112 A3 ; do not let G 052 112 A3 get onto slits of oxygen sensor body
 Use ring spanner set for oxygen sensor 3337 for removal and installation
9 - Heated Oxygen Sensor (HO2S) 2 G108 , 50 Nm

10 - Catalytic converter
11 - 25 Nm
12 - Oxygen sensor (O2S) behind three way catalytic converter (TWC) G130 , 50 Nm

13 - Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131 , 50 Nm

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14 - Heat shield
 With intake manifold support
15 - 23 Nm
16 - 20 Nm
17 - Bracket
18 - 23 Nm
Muffler with mountings
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Fig. 307: Muffler With Mountings, Components

1 - Double clamp, 40 Nm
2 - Center muffler
3 - Bolt, 25 Nm
4 - Suspended mount
 Installed location Installation position of double clamps in direction of travel
5 - Separating point
 For repairs
 Identified on exhaust pipe by an impression
 As standard, center and rear mufflers are installed as a single component. For cases of repair, middle and
rear mufflers are supplied individually and with a double clamp for connecting.
 Cut through connecting pipe at right angles at separating point using body repair saw V.A.G 1523A.
 Notches left and right of separating point must still be visible after installing double clamps
6 - Rear muffler
 Installing muffler free of tension
7 - Suspended mount
 Installed location Aligning exhaust system

8 - Double clamp
 Installed location Installation position of double clamps in direction of travel

 Must be slid to its center onto front exhaust pipe.
9 - Suspended mount
 Installed location Aligning exhaust system

10 - Double clamp
 Must be slid to its center onto front exhaust pipe.

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Installation position of double clamps in direction of travel
Fig. 308: Installation Position Of Double Clamps In Direction Of Travel

1 - The end of bolt must not project beyond lower edge of clamp.
2 - Angle 10° + 5°
Aligning exhaust system
Fig. 309: Aligning Exhaust System

Conditions
 Exhaust system, cold
Work procedure
 Press exhaust system in direction of travel - 1 - and tighten double clamps tightly until dimension - a - at
suspensions is reached.
Center muffler: Dimension - a - = 10 mm

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Rear muffler Dimension - a - = 15 mm
Exhaust manifolds and exhaust pipes (with primary catalytic converters), removing and installing
Removing
 Disconnect batteries --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL
NOTE:  The procedure must be strictly followed!
Fig. 310: Identifying Vacuum Hoses Of Intake Manifold


 Pull pressure hose off secondary air injection pump - arrow -.

 Remove air filter housing complete.
 Remove intake manifold --> Cylinder head cover, removing and installing , Cylinder head cover,
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 Remove heat shield with intake manifold support from cylinder head.
Fig. 312: Identifying Connectors For Oxygen Sensors

 Separate connectors - 1 to 4 - for lambda probes unclip wires from wiring guides.
 Remove lambda probes from catalytic converters using open wrench set 3337.
 Raise vehicle.
 Remove securing nuts from main catalytic converter flange.
 Remove support to transmission.

 Remove flange to exhaust manifold.
 Remove exhaust manifold.
 Now carefully remove exhaust pipe with catalytic converters.
Installing
NOTE:  When installing exhaust pipes, ensure that the flange connection after the
catalytic converter seals tightly. Leaks in this area produce pulsations in
the exhaust. This allows ambient air to reach the lambda probe after
catalytic converter and the lambda regulation will be disturbed.
 Adjust the exhaust system so that there is sufficient clearance to the
transmission and subframe.
SECONDARY AIR INJECTION (AIR) SYSTEM
Secondary air injection (AIR) system
Secondary air injection (AIR) system components, assembly overview --> Secondary Air Injection (AIR)
Pump Motor V101 system components, assembly overview
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Function
During cold start (+15°C to +35°C coolant temperature), air is blown behind exhaust valve by Secondary Air
Injection (AIR) system for 65 seconds. This produces an oxygen rich exhaust gas, causes after burning and
reduces heating-up phase of catalytic converter. Activation is triggered by Motronic Engine Control Module
(ECM) J220 via Secondary Air Injection (AIR) Pump Relay J299 to Secondary Air Injection (AIR) Solenoid
Valve N112 , (change-over valve) and combination valve. In addition, the Secondary Air Injection (AIR)
system is switched on with a delay of approx. 20 seconds during idle for 5 seconds after every subsequent
engine start (up to max. 85°C engine temperature) and is checked via On Board Diagnostic (OBD).
Secondary Air Injection (AIR) Pump Motor V101 system components, assembly overview
Combination valve, checking --> Combi-valve, checking
NOTE:  Secondary Air Injection (AIR) pump relay J299 Secondary Air Injection
(AIR) Pump Relay J299
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Fig. 313: Secondary Air Injection (AIR) Pump Motor V101 System Components, Assembly Overview
1 - Combi-valve
 Checking --> Combi-valve, checking
3 - Gasket
 Replace
4 - Connection
5 - 10 Nm
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6 - Pressure pipe
7 - Bracket
8 - Stud, 8 Nm
 Installed into intake manifold
9 - To Intake manifold
10 - To combi-valve
11 - to vacuum actuator
 for variable intake manifold
12 - Non-return valve

 White connector faces vacuum reservoir
13 - Intake Manifold Tuning (IMT) Valve N156
14 - 8 Nm
15 - Secondary air injection (AIR) solenoid valve N112
16 - To vacuum reservoir
17 - Pressure hose

 Press together at front to release
18 - Secondary Air Injection (AIR) Pump Motor V101
19 - 10 Nm
20 - Bracket
 For Secondary Air Injection (AIR) pump motor V101
21 - Intake tube
 From upper air filter housing

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 Press together at front to release
Secondary Air Injection (AIR) Pump Relay J299
Fig. 314: Component Location For Secondary Air Injection (AIR) Pump Relay J299
NOTE:  Secondary air injection pump relay J299 - 1 - is inserted in socket A4.
 If tools are necessary to pull relays or control modules out of the relay
plate, first disconnect battery Ground (GND) strap. --> 27 - BATTERY,
STARTER, GENERATOR, CRUISE CONTROL
Combi-valve, checking
Fig. 315: Hand Vacuum Pump V.A.G 1390

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 Hand vacuum pump V.A.G 1390
Test conditions
 Vacuum lines and hose connections free of leaks

 Vacuum lines not blocked or kinked
Test sequence
Fig. 316: Locating Vacuum Hose At Combi-Valve

 Pull vacuum hose from Secondary Air Injection (AIR) solenoid valve N112 off combination valve -
arrow -.
NOTE:  Do not use compressed air during following check!
Fig. 317: Hand Vacuum Pump VAG 1390 Connected To Vacuum Hose From Combi-Valve
 Connect hand vacuum pump V.A.G 1390 to vacuum hose from combi-valve - arrow -.
Microsoft
 Pull off pressure hose to combination valve at coupling - arrow - , push auxiliary hose onto end of pipe
and pressurize slightly by blowing into hose. Combi-valve must be closed.
 Operate hand vacuum pump. Combi-valve must open.
If combi-valve does not open:
Replace combi-valve.
28 - IGNITION/GLOW PLUG SYSTEM

IGNITION, SERVICING
Ignition, servicing
Safety precautions --> Safety precautions.
Test Data, Spark Plugs --> Technical data, spark plugs.
Ignition system components, assembly overview --> Ignition system components, assembly overview
Ignition coils with power output stages, removing and installing --> Ignition coils with power output stage,
Ignition system, general information
 Only components which specifically relate to ignition system are dealt with here. The other components
of the injection and ignition system --> Fuel injection system, servicing.
 For trouble-free operation of the electrical components a voltage of at least 11.5 V is necessary.
 It is possible that the control module will recognize a malfunction and store a DTC during some tests.
After completing all tests and repairs, DTC memory should therefore be checked and erased if necessary
"Guided Functions".
Microsoft
 If the engine only starts briefly and then turns off again after troubleshooting, repair or checking of the
components, it may be that the immobilizer is blocking the Engine Control Module (ECM). Control
module must then be adapted if necessary "Guided Functions".
Ignition system components, assembly overview
Fig. 319: Ignition System Components, Assembly Overview

1 - Ignition coil with power output stage N70, N127, N291, N292, N323, N324
 Remove and install using Puller For Ignition Coil T10095 A
2 - Connector
 Black, 4-pin
Microsoft
 Use assembly tool T10118 to pull off
3 - Bracket
 For harness connector of Knock Sensor (KS) 1 G61
4 - 10 Nm
5 - Connector
 Black, 3-pin
6 - Knock Sensor (KS) 1 G61
7 - 20 Nm
 Torque setting influences function of knock sensor
 With sensor wheel for Camshaft Position (CMP) Sensor 2 G163
 If camshaft adjuster has been removed, adjust valve timing after installation --> Valve timing, adjusting.
9 - Cover
 Removing and installing --> Cover, removing and installing, assembly overview.
10 - Seal
 Replace

12 - 10 Nm
13 - Connector
 Black, 3-pin
Microsoft

 Mark connector before removing

15 - Knock Sensor (KS) 2 G66

16 - Connector
 Black, 2-pin
 With sensor wheel for Camshaft Position (CMP) Sensor G40
 If camshaft adjuster has been removed, adjust valve timing after installation --> Valve timing, adjusting.
18 - Spark plug, 20 Nm
 Removing and installing with spark plug removal tool 3122B

 Type and electrode gap --> Technical data, spark plugs
19 - Control housing
 Camshaft adjustment valves, removing and installing --> Camshaft adjustment valves, removing and
installing
Safety precautions
To reduce risk of personal injury and/or damage to fuel injection and ignition system, always observe the
following:
 Only disconnect and reconnect wires for injection and ignition system, including test leads, when ignition
is switched off.
 Do not touch or remove ignition wires when engine is running or turning at starter speed.
Microsoft
If test and measuring equipment is required during road test, note the following:
 Test and measuring instruments must be secured to rear seat and operated by a 2nd person from this
location.
If test and measuring instruments are operated from front passengers seat and vehicle is involved in an accident,
there is a possibility that the person sitting in this seat may receive serious injuries when airbag is triggered.
If engine is to be turned at starter speed, without starting: Disconnect connectors from ignition coils 1 to 6.
Assembly tool T10118 can be used to release locking mechanism.

 Place assembly tool T10118 against release button - arrow - , and carefully remove connector from
respective ignition coil with power output stage.
Technical data, spark plugs
Engine code BAA/BMX

Ignition sequence 1-5-3-6-2-4
Spark plugs * See note
VW/Audi 101 905 606 A
Manufacturers designation IZKR 7B
Electrode gap max. 1.1 mm
Torque specifications 20 Nm
* Use Spark plug removal tool 3122B to remove or install spark plugs
Ignition coils with power output stage, removing and installing
Microsoft
Fig. 321: Identifying Puller For Ignition Coil T10095 A

 Puller For Ignition Coil T10095 A
Fig. 322: Identifying Assembly Tool T10118

Removing
Microsoft

 Place assembly tool T10118 against release button - arrow - , and carefully remove connector from
respective ignition coil with power output stage.
Fig. 324: Identifying Puller T10095A, Ignition Coils And Spark Plugs
 From straight side of connector, push Puller For Ignition Coil T10095 A on in direction of - arrow - , and
pull out ignition coil with power output stage.
Installing
Fig. 325: Identifying Removed Ignition Coils, Power Output Stages & Connectors
 To install, insert ignition coil with power output stage into corresponding spark plug shaft so that straight
connector sides fit with each other - arrows -.
Microsoft
Fig. 326: Identifying Puller T10095A, Ignition Coils And Spark Plugs
 Slide on Puller For Ignition Coil T10095 A from straight connector side in direction of - arrow - and
press ignition coil with power output stage on to spark plugs.
Microsoft

3.2L Engine Part2

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2004 Volkswagen Touareg

00 - GENERAL, TECHNICAL DATA

Engine specifications --> Engine data

Fig. 1: Identifying Engine Number Located On Vibration Damper

The engine code is also included on vehicle data plate.

Engine code BAA BMX

Displacement ltr. 3.2 3.2

*VR = V-Arrangment in compact in-line design

*In exceptional circumstances min. 95 RON, however with reduced performance

*Two independently variable camshafts.

Engine, removing and installing

Engine, removing --> Engine, removing

Securing engine to engine stand --> Engine, securing to assembly stand

Installing engine --> Engine, installing

Fig. 2: Identifying Special Tools - Engine, Removing And Installing (1 Of 2)

Special tools, testers and auxiliary items required

 Lifting tackle 3033

 Torque wrench (5 to 50 Nm) V.A.G 1331

Fig. 3: Identifying Special Tools - Engine, Removing And Installing (2 Of 2)

Special tools, testers and auxiliary items required

 Engine/transmission jack V.A.G 1383 A

 Shop crane VAS 6100

 Adapter V.A.G 1318/20-1

 Left suspension support VAS 6131/6-3

 Transmission support VAS 6131/6-7

The engine with transmission is removed downward.

 Check DTC memories of all control modules, before removing engine:

The procedure must be strictly followed!

 Switch off ignition and all electrical consumers.

Fig. 4: Identifying Covers In Engine Compartment And For Plenum Chamber

 Remove covers - A - , - B - and - C - in engine compartment and - D - for plenum chamber.

Fig. 5: Identifying V.A.G 1318/20-1 & V.A.G 1318/20

 Install adapter V.A.G 1318/20-1 on to adapter V.A.G 1318/20.

 Remove breather valve.

Fig. 7: Identifying Fuel Supply Line

Fig. 8: Identifying Breather Line To Solenoid Valve

Fig. 10: Identifying Connectors In Fuse Box

Fig. 11: Identifying Starter Wire And Generator Wire

Fig. 12: Identifying Vacuum Hoses Of Intake Manifold

Courtesy of VOLKSWAGEN UNITED STATES, INC.

 Pull vacuum hoses - 1 - from intake manifold.

Vehicles with engine code BAA

 Pull vacuum hose - 4 - from intake manifold.

Continuation for all vehicles

 Pull pressure hose off secondary air injection pump - arrow -.

Fig. 14: Identifying Connectors For Oxygen Sensors

 Disconnect connectors - 1 to 4 - for oxygen sensors and place connectors on engine.

Fig. 15: Identifying Connecting Wire To Air Suspension Compressor

 Pull only loosened line - B - from connection - A - at air filter.

 Remove sound insulation tray: --> 50 - BODY - FRONT

 Drain coolant --> Cooling system, draining and filling.

NOTE:  Observe disposal regulations!

Fig. 17: Identifying Line From Transmission Oil Cooler

Fig. 18: Identifying Connectors At Transmission And Transfer Case

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:  Observe disposal regulations!

Fig. 19: Identifying Transmission Transverse Support

 Remove transmission transverse support - A -.

Fig. 20: Securing Suspension Struts Using Spring Compressor VW 552

 Secure suspension struts using Tensioner Hooks (2) VW 552 as shown.

Fig. 21: Preparing Scissor Lift Table VAS 6131

 Left support - 1 - : A5, B4 and B5

 Left axle support - 3 - : A6 and C6