S01AAHW8820-4 Cyl Injection Engine (4V) Mechanics

Service
Toledo 1999 , León ➤

4 cyl. injection engine (4V), mechanics
Engine ID AHW APE AXP AUS AZD
Edition 10.2001
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
4 cyl. injection engine (4V), mechanics
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, Valve gear
17 - Lubrication
19 - Cooling system
20 - Fuel supply system
26 - Exhaust system
Technical information should always be available to the foremen and mechanics, because their careful
and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In
addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course,
be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 Seat S.A S01AAHW8820

4 cyl. injection engine (4V), mechanics - Edition 10.2001
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Engine characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1 Engine: removing and install-ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.1 Engine: removing and install-ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.2 Removing: instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.3 Installing: instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.4 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.5 Engine unit supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.6 Vehicles with air conditioning: additional instructions and installation work . . . . . . . . . . . . . .10
1.7 Align the set of supports for the engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

1 Engine: disassembly and as-sembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.1 Engine: disassembly and as-sembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.2 Poly-V belt: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
1.3 Distribution timing: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
1.4 Toothed belt: removing and installing, tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
1.5 Semiautomatic tensioning roller for the toothed belt: testing . . . . . . . . . . . . . . . . . . . . . . . .31
1.6 Testing the tensioning roller of the main belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
2 Piston and connecting rod: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
2.1 Piston and connecting rod: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
2.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
3 Engine block, sealing flange and engine flywheel: removing and installing . . . . . . . . . . . . . .44
3.1 Engine block, sealing flange and engine flywheel: removing and installing . . . . . . . . . . . . . .44
3.2 Clutch plate: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
3.3 Crankshaft seal, pulley side: re-placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
3.4 Crankshaft sealing flange, eng-ine flywheel side: replacing . . . . . . . . . . . . . . . . . . . . . . . . . .54
3.5 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

1 Cylinder head: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
1.1 Cylinder head: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
1.2 Camshaft housing: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
1.3 Cylinder head: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
1.4 Remove the camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
1.5 Compression: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
2 Valve control: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
2.1 Valve control: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
2.2 Valve seats: re-cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
2.3 Camshaft seals: replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
2.4 Valve guides: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
2.5 Valve guides: replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
2.6 Valve stem seals: replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
1 Lubrication system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . .95
1.1 Lubrication system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . .95
1.2 Oil sump: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Contents i
1.3 Oil pump: removing and install-ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

1.4 Oil pressure and oil pressure switch: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

1 Cooling system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
1.1 Cooling system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
1.2 Cooling system components, bodywork side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
1.3 Cooling system components, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
1.4 Cooling system components, coolant pump side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
1.5 Coolant hose connections diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
1.6 Coolant: draining and toppingup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
1.7 Radiator: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
1.8 Coolant pump: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
1.9 Radiator fans -V7- and -V35-: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

1 Fuel supply system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . .125
1.1 Fuel supply system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . .125
1.2 Fuel tank with accessory parts and fuelfilter: removing and installing . . . . . . . . . . . . . . . . . .126
1.3 Safety rules for work on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
1.4 Cleaning rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
1.5 Fuel supply unit: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
1.6 Fuel level sender: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
1.7 Fuel tank: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
1.8 Fuel pump: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
1.9 Accelerator control: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
1.10 Accelerator control cable: adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
2 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
2.1 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
2.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
2.3 Active charcoal filter system components: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
2.4 Servicing parts of the activated charcoal filter system: repairing . . . . . . . . . . . . . . . . . . . . . .147
2.5 Deaeration of the fuel tank: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
3 Electronic engine output control (electronic accelerator) . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
3.1 Electronic engine output control (electronic accelerator) . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
3.2 Electronic accelerator system operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
3.3 Electronic engine output control(electronic accelerator) components: repairing . . . . . . . . . .152
3.4 Electronic accelerator drive fault lamp: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
3.5 Accelerator position senders: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157

1 Exhaust system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
1.1 Exhaust system components: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
1.2 Catalytic converter Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
1.3 Exhaust manifold, front exhaust pipe with catalyst and accessory parts . . . . . . . . . . . . . . . .161
1.4 Silencer with fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
1.5 Front exhaust pipe with catalyst: replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
1.6 Catalyst: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
2 Exhaust recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
2.1 Exhaust recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
2.2 Exhaust recirculation system components: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
2.3 Exhaust recirculation valve: testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
ii Contents
00 - Technical data
1 - Technical data
1.1 - Technical data
1.2 - Engine number
-> The engine number ("code letters" and "correlative number") is stamped on the front of the engine block,
gearbox side below the thermostat housing.
There is also a sticker "the engine code letters" and "correlative number" on the toothed belt shield.
The engine code letters can also be found in the vehicle information file.
The engine number consists of up to nine symbols (alphanumeric). The first part (maximum three code letters)
represents the "engine code letters". The second (six digits) is the "correlative number". After 999,999 engines
manufactured with the same code letters, the first digit is replaced with a letter.
1.3 - Engine characteristics
Code letters AHW APE AXP AZD AUS

Exhaust emissions in accord‐ Standard Standard D4 Norma EU4 Standard EU4 Standard EU4
ance with MVEG II
Cubic capacity cm3 1390 1390 1390 1597 1597
Valves per cylinder 4 4 4 4 4
Power output kW a 1 rpm 55/5000 55/5000 55/5000 77/5700 77/5700
Engine torque Nm a 1 rpm 126/3800 126/3800 126/3300 148/4500 148/4500
Cylinder diameter mm 76,5 76,5 76,5 76,5 76,5
Stroke mm 75,6 75,6 75,6 86,9 86,9
Compression 10,8 10,8 10,5 11,5 11,5
Research Octane mín. 95 lead-free1) 95 lead-free1) 95 lead-free1) 98 lead-free2) 98 lead-free2)
Injection, ignition 4CV ME 7.5.10 ME 7.5.10 4MV 4LV
Knocking control Yes Yes Yes Yes Yes
Self-diagnosis Yes Yes Yes Yes Yes
1.1 - Technical data 1

Lambda control Yes Yes3) Yes3) Yes3) Yes3)

Exhaust recirculation Yes Yes Yes Yes Yes
Catalyst Yes Yes Yes Yes Yes
Turbo-charging No No No No No
1) In exceptional cases, min. octane 91 ROZ, but with power loss.
2) In exceptional cases, min. octane 95 ROZ, but with power loss.
3) With 2 lambda probes.
2 00 - Technical data
10 - Removing and installing engine
1 - Engine: removing and install-ing

1.1 - Engine: removing and install-ing
Special tools, work shop equipment, tes-ting and measuring equipment and auxiliary devices required
◆ Tray V.A.G. 1306

◆ Pliers for strip clamps T20029
◆ Suspension unit U-30034
◆ Workshop lift V.A.G. 1202 A
◆ Lubricating grease G 000 100
◆ Dynamometric spanners SAT 8010
◆ Wire holder
1.1 - Engine: removing and install-ing 3

If engine must be disassembled:
◆ -> Engine support Ar-2204 A
◆ -> Holding flanges T20082
1.2 - Removing: instructions
Note:
In order to carry out these operations, the battery earth strap must be removed. In doing so, check to see if a
coded radio is installed on the vehicle, and if so consult the anti-theft coding.
- The engine is removed upwards along with the gearbox.

- With the ignition off, disconnect the battery earth strap.
Note:
All wire holders that come loose or are cut while removing the engine must be replaced in the same place when
reinstalling.
- Remove front bumper:
=> Bodywork-installation work; Rep. Group 63; Front bumper: removing and installing. Front bumper: removing
and installing.
- Set the lockholder cover in service position:
=> Bodywork-installation work; Rep. Group 50; Bodywork, front; Lockholder cover service position. Bodywork,
front Lockholder cover service position.
4 10 - Removing and installing engine

- Open the cap of the compensation tank to release the cooling system pressure.
- -> Remove battery and battery support.

- Detach wiring from battery to dash panel insert.
- Leave out in the open the positive wire from battery to starting motor (it is removed along with the engine
unit).
- Separate the accelerator control cable from the upper part of the air filter (AHW engines only).
- Separate the accelerator control cable from the support and from the throttle valve control unit (without
removing the regulating clamp) (AHW engines only).
- Remove the air filter:
=> Rep. Group 24; Injection: repairing; Air filter: disassembly and assembly. Injection: repairing Air filter: dis‐
assembly and assembly.
- -> Separate the fuel supply and return hoses -1 and 2- (press release button).
Attention!
The fuel supply hose is under pressure. Before loosening the hose connections put a cloth around the con‐
nection. Then release the pressure carefully removing the hose.
- Separate from their holders the following components:
◆ the hose from the intake manifold to the active charcoal filter system
◆ the decompression hose from the intake manifold to the brake servo
◆ the engine speed sender connector under the support of the guide pipe for the oil dipstick and extract the
connector from its housing on the support
◆ the connector of the ignition transformer, from the Hall sender and the throttle valve control unit
◆ the coolant temperature sender connector, oil pressure switch and exhaust recirculation valve
◆ the connectors of the injectors.
- Remove the gearbox change control:
=> 5 speed manual gearbox 02K; Rep. Group 34; Gear control: repairing Gear control: repairing
- Remove the soundproofing sump:
1.2 - Removing: instructions 5

=> Bodywork-installation work; Rep. Group 50; Bodywork, front; Soundproofing sump: removing. Bodywork,
front Soundproofing sump: removing.
- Separate from their holders the following components:
◆ Lambda probe connector

◆ the double connector of the knocking sensor (engine block, rear part) and quadruple connector of the intake
manifold pressure sender under the front right part of intake manifold.
- Drain the coolant => page 11 .

- Loosen the strip clamps and extract coolant hoses from the thermostat housing.
- Loosen the bolts holding the power assisted steering vane pump pulley.
- Remove the Poly-V belt => page 21 .
- Remove the power assisted steering vane pump and secure it with a wire to the engine unit carrier; the
hoses are to remain connected:
=> Running gear; Rep. Group 48; Assembly chart: vane pump, reserve tank, hydraulic hoses; Power assisted
steering vane pump: removing and installing. Assembly chart: vane pump, reserve tank, hydraulic hoses Power
assisted steering vane pump: removing and installing.
Vehicles with air conditioning
- Remove the air conditioning compressor:
- Follow the additional indications and assembly work sequences=> page 10
Continue for all vehicles

- Hydraulic clutch slave cylinder (pump): removing
=> 5 speed manual gearbox 02K; Rep. Group 30; Clutch control: repairing. Clutch control: repairing.
Note:
Clutch pedal must not be pressed.

- Separate radiator coolant hoses from the engine with clamp pliers T20029.
- -> Separate swing reaction arm -arrows-.
- Separate the decompression and breather/deaeration hoses from the engine.
- Separate all wiring from the gearbox, alternator and starting motor and leave them in the open.
- Remove the front exhaust pipe from the exhaust manifold => page 161 , Exhaust manifold, front exhaust
pipe with catalyst and accessory parts.

- Separate the holding clamps for the power assisted steering pressure hose.
- Disconnect all necessary wiring from the engine and leave it in the open.
- Separate the articulated half shafts from the gearbox and secure them above.
=> Running gear; Rep. Group 40; articulated half shaft: removing and installing. articulated half shaft: removing
and installing.
- -> Attach the suspension unit U-30034 as shown in the illustration and raise slightly with the workshop lift.
- Remove the cooling system expansion tank and put it to one side.
- Loosen and secure the power assisted steering reserve tank above.
- Loosen the active charcoal filter.
- -> Remove the engine support -A- and the gearbox -B-. To do so, remove bolts -1 ... 3-.
Turn the engine unit slightly to the left (engine towards the front, gearbox towards the back) and carefully push
upwards.
Note:
The engine unit must be handled with great care when removing the vehicle so as to avoid damaging the
bodywork.
When carrying out installation work, the engine must be secured to the mounting trestle using engine support
Ar-2204 A along with flanges T20082.
1.2 - Removing: instructions 7

1.3 - Installing: instructions
Carry out operations described for removing in reverse order, taking into account the following:
- -> Check that the clutch drive plate is correctly centred with the U-30004 tool.
- Check wear on the disengagement collar and replace it if necessary.
- Apply a thin layer of G 000 100 to the disengagement collar, the guide sleeve for the collar and primary shaft
spline.
- Make sure that the centring bushings for the engine/gearbox group on the engine block are aligned; align
them if necessary.
- -> Attach the intermediate plate to the sealing flange and install it on the adjustment hoses -arrows-. Make
sure that the intermediate plate is correctly seated on the engine.
- When lowering the engine unit make sure there is enough play with the articulated half shafts.
- Install the hydraulic clutch slave cylinder (pump):
=> 5 speed manual gearbox 02K; Rep. Group 30; Clutch control: repairing. Clutch control: repairing.
- Install the gear changing mechanism on the gearbox:
=> 5 speed manual gearbox 02K; Rep. Group 34; Gearbox control: repairing. Gearbox control: repairing.
- Align the set of supports for the engine and the gearbox
=> page 11 .
- Install the articulated half shafts:
=> Running gear; Rep. Group 40; articulated half shafts: removing and installing. articulated half shafts: re‐
moving and installing.
- Install the front exhaust pipe => page 161 , Exhaust manifold, front exhaust pipe with catalyst and accessory
parts.
- Install the power assisted steering vane pump:
=> Running gear; Rep. Group 48; Installation chart: vane pump, filler tank, hydraulic hoses. Installation chart:
vane pump, filler tank, hydraulic hoses.
- Install the air conditioning compressor.

- Electrical connections and wiring harnesses:
=> Electrical system; Rep. Group 97;
- Install the Poly-V belt => page 21 .
- Adjust the accelerator cable (AHW engines only) => page 144 .
- Fill coolant => page 11 .
- Adapt the control unit to the engine electronics:

=> Rep. Group 24; Engine control unit; Engine control unit: adapting to the throttle valve control unit. Engine
control unit Engine control unit: adapting to the throttle valve control unit.
- Do a road test and consult the fault memory:
=> Rep. Group 01; Self-diagnosis; Fault memory: consulting and erasing. Self-diagnosis Fault memory: con‐
sulting and erasing.
1.4 - Tightening torques
Connection to bolts Tightening torque

Bolts, nuts M6 10 Nm
M8 20 Nm
M10 45 Nm
M12 60 Nm
1.5 - Engine unit supports
Tightening torques
-> Engine unit supports, engine
A1) - 40 Nm + 90° (1/4turn)

B - 25 Nm
C1) - 60 Nm + 90° (1/4 turn)
1) - Expansion bolts, replacing
1.3 - Installing: instructions 9

-> Engine unit supports, gearbox
A1) - 40 Nm + 90° (1/4 turn)

B - 25 Nm
C1) - 60 Nm + 90° (1/4 turn)
1) - Expansion bolts, replacing
-> Swing support
A1) = 40 Nm + 90° (1/4 turn)

B1) = 20 Nm + 90° (1/4 turn)
1) Expansion bolts, replacing
1.6 - Vehicles with air conditioning: additional instructions and installation work
Attention!
Do not open the air conditioning coolant circuit.
Note:
To avoid damage to the condenser and the coolant pipes/hoses take care not to bend, twist or stretch exces‐
sively the pipes/hoses.
In order to remove and install the engine without opening the coolant circuit:
- Remove the clamp(s) of the coolant hoses.

- Remove the air conditioning compressor:
=> Heating, air conditioning; Rep. Group 87; Compressor support: removing and installing. Compressor sup‐
port: removing and installing.
- Secure the air conditioning compressor to the towing ring in such a way that the coolant pipes/hoses are
not stressed.
Note:
Protect the bumper with adhesive tape.

1.7 - Align the set of supports for the engine and gearbox
Attention!
Before loosening the bolts, immobilise the supports with the U-30025B.
-> Set of engine supports:
a = 14,0 mm
b = 10,0 mm minimum
The two bolt heads -1- must be flush with the edge -c-.
-> Set of gearbox supports:
The edges -a- and -b- must be in parallel.
1.7 - Align the set of supports for the engine and gearbox 11
13 - Crankshaft group
1 - Engine: disassembly and as-sembly

1.1 - Engine: disassembly and as-sembly
I =>page 13
II =>page 18
12 13 - Crankshaft group
Part I
1 Upper shield of the toothed belt

2 20 Nm
3 Tensioning roller of the return belt
◆ Testing => page 31
◆ Tightening the toothed belt => page 24
4 Toothed return belt
◆ Mark direction of rotation before removing
◆ Check wear
◆ Do not bend
◆ Routing of the toothed belt => fig. 1
◆ Removing and installing, tightening=> page 24
5 20 Nm
6 Rear shield of the toothed belt
7 12 Nm
1.1 - Engine: disassembly and as-sembly 13

8 20 Nm
9 Ring for hanging
10 25 Nm
11 Return roller
12 Support
13 50 Nm
14 Gasket
◆ Replace
15 Coolant pump
◆ In case of fault or leakage, replace completely
◆ Removing and installing => page 18
16 Tensioning roller of the main belt
◆ Tightening the toothed belt
=> page 24
17 Return roller for the main toothed belt

18 50 Nm
19 Pinion of the toothed belt-crankshaft
◆ Check the position when installing the toothed belt => page 24
20 20 Nm
21 Main toothed belt
◆ Check wear
◆ Do not bend
◆ Routing of the toothed belt=> fig. 1
◆ Removing and installing, tightening => page 24

22 Pulley
◆ Check fastening when installing
◆ Removing and installing => page 24 ; Toothed belt: removing and installing, tightening
◆ Removing and installing the Poly-V belt => page 21
23 90 Nm + 1/4 turn (90°)
◆ Replace
◆ Apply lubricant
◆ Tightening may be done in several stages
◆ The tightening angle can be measured with the T20030
24 Poly-V belt
◆ Routing of the Poly-V belt => page 22
◆ Vehicles with air conditioning have an additional return roller
25 Lower toothed belt shield
26 50 Nm
27 Support

Part II
Note:
Clutch repairs:
=> 5 speed manual gearbox 02K; Rep. Group 30; Clutch: repairing; Clutch: removing and installing. Clutch:
repairing Clutch: removing and installing.
1 Engine block
◆ Piston and connecting rod: disassembly and assembly=> page 35 .
2 50 Nm
◆ Tightening order: First tighten the upper right bolt, then the lower right and last of all, the left bolts (seen
in direction of travel)
3 M8: 20 Nm + 1/4 turn (90o)
M10: 45 Nm
4 10 Nm
5 Mount
6 Clip
7 25 Nm
8 Oil radiator (according to model)
◆ Check for sufficient clearance with adjacent parts
◆ Apply AMV 188 001 02 to the contact surfaces outside the seal.
◆ Check note => page 95 .
Coolant hose connection diagrams => page 10 .
9 O-ring
◆ Replace
◆ Fit in oil radiator before installation
◆ Oil before fitting
10 Oil filter
◆ Loosen by the hexagon or with a universal filter extractor (U-40078)
◆ Hand tighten
◆ Follow assembly instructions on the filter

11 Support
◆ For the vane pump and the alternator
◆ For vehicles without air conditioning
◆ Removing and installing the support for vehicles with air conditioning:
=> Heating, air conditioning; Rep. Group 87; Air conditioning with manual control; Support for air conditioning
compressor: re-moving and installing. Air conditioning with manual control Support for air conditioning com‐
pressor: re-moving and installing.
12 13 Nm
◆ Loosening and tightening the steering wheel-side bolts with box spanner U-40051A
13 Oil sump
◆ Removing and installing => page 101 .
14 Oil bleed screw, 30 Nm
◆ With safety ring gasket
◆ Replace
15 Tightening element
-> Fig.1 Routing of the toothed belt
A - Toothed return belt
B - Main toothed belt
1.2 - Poly-V belt: removing and installing
Note:
Before removing the Poly-V belt, mark the direction of rotation. When installing the belt, make sure that it is
seated properly on the pulleys.
Removing
- Remove the Poly-V belt shield.

- -> With a spanner on the securing bolt of the tensioning roller, move the roller in the direction of the arrow.
- Remove the Poly-V belt.
Installing
- First put the Poly-V belt on the crankshaft pulley and then on the tensioning roller.

Note:
When installing the Poly-V belt, make sure that it is correcting seated on the pulleys.
- Start the engine and check the correct functioning to the belt.
Poly-V belt routing
-> Belt routing on versions with air conditioning compressor
1- Pulley-vane pump for power assisted steering

2- Return roller
3- Pulley-alternator
4- Air conditioning compressor
5- Crankshaft
6- Tensioning roller
-> Belt routing on versions without air conditioning compressor
1- Antivibrator/pulley
2- Tensioning roller
3- Pulley-alternator
4- Poly-V belt
5- Pulley-vane pump for power assisted steering
1.3 - Distribution timing: testing
- Remove the upper toothed belt shield.

- -> Situate the crankshaft at TDC for cylinder 1. The mark on the pulley must coincide with the mark -O-.
- -> The locking holes on the camshaft pinions must coincide with the holes on the camshaft housing -arrows-.
Note:
If the holes are on the opposite side from the pinions, turn the crankshaft over once.
1.3 - Distribution timing: testing 23

1.4 - Toothed belt: removing and installing, tightening
◆ Holding tool U-30025B
◆ Countersupport T20018A
◆ Camshaft locking tool T10016
Removing
- -> Remove the upper cover of the camshaft housing -arrows-.

- Remove the upper element of the air filter.
=> Rep. Group 24; Injection: repairing; Air filter: removing and installing Injection: repairing Air filter: removing
and installing
- Remove the upper shield of the toothed belt.
- -> Situate the crankshaft at TDC for cylinder 1. The mark on the pulley must coincide with the mark -O-.
- Remove the fasteners of the power assisted steering tank and secure it to one side.
- -> The locking holes on the camshaft pinions must coincide with the holes on the camshaft housing -arrows-.
Note:
If the marks are on the opposite side from the pinions, turn the crankshaft over once.
Lock the camshaft pinions with the camshaft locking tool T10016, as follows:
1.4 - Toothed belt: removing and installing, tightening 25

- -> Introduce the locking pins T10016 in the locking holes in the camshaft pinions and in the holes in the
camshaft housing (the support in front of the pinion must be removed).
Note:
Both locking pins are correctly placed if the end pieces -D- are aligned with the line -A-.
- Introduce the support T10016 -B- as far as it will go into the camshaft pinion -C-.
In order to remove the crankshaft pulley the engine must be lowered slightly as follows:
- -> Attach the support device U-30025B.

- Remove the upper bolt (under the engine support) and secure the lower shield of the toothed belt.
- Pretighten the engine slightly with the U-30025B and remove the right engine support, as shown in the
illustration.
- -> Unscrew the securing bolts of the engine support unit and remove the engine support completely.
- Remove the engine support from its fastening to the cylinder head.
- Remove the right soundproofing sump.
- If necessary, lower the engine in order to gain access to the bolt holding the crankshaft pulley.
- Mark the direction of rotation of the Poly-V belt and remove it as follows:
- -> Put a spanner of the bolt holding the tensioning roller and move the roller in the direction of the arrow.
- -> Loosen the bolt holding the pulley and the pinion of the toothed belt; to do so, hold the pulley with coun‐
tersupport T20018A.
- Remover the pulley. Screw the bolt back in with two washers to hold the toothed belt pinion.
- On vehicles with air conditioning, the return roller and the tensioning roller for the Poly-V belt must be re‐
moved.
- Remove the lower shield of the toothed belt.
- Mark the direction of rotation of both belts before removing them.
Removing the main toothed belt:
- -> Loosen the securing bolt of the tensioning roller of the main belt -1- and loosen the toothed belt turning
the tensioning roller counter-clockwise -arrow-.
- Remove the toothed belt.
Removing the toothed return belt:

- -> Loosen the securing bolt of the tensioning roller of the toothed return belt -1- and loosen the toothed belt
turning the tensioning roller clockwise -arrow-.
- Separate the tensioning roller of the toothed return belt.
- Remove the toothed belt.
Installing
Test conditions
• The crankshaft pinion must be fixed to the crankshaft with the bolt and two washers.
• The camshaft pinions must be set with the T10016 in the holes in the cylinder head and locked to prevent
involuntary turning.
• The pistons must not be at TDC.
Note:
When the camshaft is turned the valves can hit the pistons if they are at TDC.
Work sequence
- -> Situate the crankshaft at TDC for cylinder 1. The shortened tooth must coincide with the mark on the oil
seal holder cover.
Note:
Note that the oil pump/oil seal holder cover has two TDC marks, a short one for 4V engines (right side) and
another longer one for 2V engines (left side); do not confuse the marks when putting the crankshaft at TDC;
this can cause grave damage to the engine.
- Install the toothed return belt. The loose part of the toothed belt should be on the down side. In case of a
used belt, check the mark for rotation direction.
Install the tensioning roller of the toothed return belt as follows:
- -> Turn the tensioning roller of the toothed return belt by the inner hexagon -1- clockwise towards the mark
window (the tensioning roller is loose).
- Press upwards on the lower part of the toothed return belt with the tensioning and put the securing bolt in
the tensioning roller.
- Hand tighten the securing bolt of the roller. The projection on the base plate must be in the hole on the
cylinder head -2-.
- -> Next tighten the toothed belt; to do so turn the tensioning roller counter-clockwise by the inner hexagonal
-pos. 1-, until the indicator arm -2- coincides with the projection on the mark window -arrow-.
- Tighten the securing bolt on the tensioning roller. Tightening torque: 20 Nm.
Note:
The camshafts must be held with the T10016 until the main toothed belt principal is installed.
- Install the main toothed belt working counter-clockwise, starting with the water pump, tensioning roller,
crankshaft, return roller and the camshaft pinion. In the case of a used toothed belt, check the direction of
rotation mark.
If the tensioning roller was previously removed, the following operation must be carried out:
- -> Turn the tensioning roller of the main toothed belt; to do so turn the roller counter-clockwise by the inner
hexagonal to the position indicated -arrow-.
- -> Install the tensioning roller and hand tighten the nut; the bolt -2- of oil seal holder cover should be inside
the groove on the support plate -1- of the tensioning roller.

- Turn the roller with an Allen key in the direction of the arrow until the indicator arm -3- coincides with the
mark on the tensioning support plate -arrow-.
- Tighten the securing bolt on the tensioning roller. Tightening torque: 20 Nm.
- Remove the tool T10016 from the camshaft pinions.
- Turn the crankshaft over twice in the direction of engine revolutions over until it is back at TDC for cylinder
1.
- Next, check the adjustment of the toothed belt and the position of the tightening rollers.
- If necessary, repeat tightening of the toothed belts.
- Install the toothed belt shield.
- Reinstall the pulley crankshaft pulley, taking into account the following:
◆ Replace the bolt that secures the pulley/pinion of the crankshaft.

◆ When installing the pulley, check that it is secured to the pinion.
◆ Tighten the new, oiled securing bolt to 90 Nm + 1/4 turn (90°).
- Install the engine supports on the cylinder head, right side.

Tightening torque: 50 Nm.
- Install the engine support unit.
Tightening torques
Note:
The expansion bolts cannot be reused.
-> Engine unit supports, engine.
A1) = 40 Nm + 90° (1/4 turn)
B = 25 Nm
C1)=60 Nm + 90° (1/4 vuelta)
1) T Expansion bolts, replacing
- Install the power assisted steering tank.

Note:
- Install the soundproofing sump.

- Consult the fault memory:
=> Rep. Group 01; Fault memory; Fault memories: consulting and erasing. Fault memory Fault memories:
consulting and erasing.
1.5 - Semiautomatic tensioning roller for the toothed belt: testing
Special tools, work shop equipment, testing and measuring equipment and auxiliary devices required

1.5 - Semiautomatic tensioning roller for the toothed belt: testing 31

1.6 - Testing the tensioning roller of the main belt
Test process
- Remove the upper part of the air filter.
=> Rep. Group 24; Injection: repairing; Air filter: removing and installing Injection: repairing Air filter: removing
and installing
- Remove the upper toothed belt shield.
In order to remove the crankshaft pulley the engine must be lowered slightly as follows:
- -> Attach the support device U-30025B.

- Remove the fasteners of the power assisted steering tank and secure it to one side.
- Remove the upper bolt (under the engine support) and secure the lower shield of the toothed belt.
- Pretighten the engine slightly with the U-30025B and remove the right engine support as follows:
- -> Unscrew the securing bolts of the engine support unit and remove the engine support completely.
- Remove the engine support from its fastening to the cylinder head.
- Remove the right soundproofing sump.
- If necessary, lower the engine in order to gain access to the bolt holding the crankshaft pulley.
Mark the direction of rotation of the Poly-V belt and remove it as follows:
- -> With a spanner on the securing bolt of the tensioning roller, move the roller in the direction of the arrow.
- -> Loosen the bolt holding the pulley and the pinion of the toothed belt; to do so, hold the pulley with coun‐
tersupport T20018A.
- Remover the pulley. Screw the bolt back in with two washers to hold the toothed belt pinion.
- Turn the crankshaft over twice in the direction of engine revolutions over until it is back at TDC for cylinder
1.
- Separate the lower shield of the toothed belt; on vehicles with air conditioning the return roller and the
tensioning roller for the Poly-V belt must be removed.
- -> Memorise the position of the indicator arm of the tensioning roller -arrow-.
- Press down hard on the toothed belt with your thumb. The indicator arm should move.
- Take pressure off the toothed belt.
- Turn the crankshaft over twice in the direction of engine revolutions.
- Check the position of the indicator arm; it should have returned to its original position
1.6 - Testing the tensioning roller of the main belt 33

If the indicator arm does not return to its original position:
- Replace the tensioning roller.
Check the tensioning roller of the return belt
- -> Memorise the indicator arm position -arrow- (use a mirror to see the marks).
- Press down hard on the toothed belt with your thumb. The indicator arm should move.
- Take pressure off the toothed belt.
- Turn the crankshaft over twice in the direction of engine revolutions.
- Check the position of the indicator arm; it should have returned to its original position.
If the indicator arm does not return to its original position:
- Sustituir el rodillo tensor.
If both tensioning rollers are OK:
- Install the toothed belt shield.

- Reinstall the pulley crankshaft pulley, taking into account the following:
◆ Replace the bolt that secures the pulley/pinion of the crankshaft.

◆ When installing the pulley, check that it is secured to the pinion.
◆ Tighten the new, oiled securing bolt to 90 Nm + 1/4 turn (90°).
- -> Install the engine supports on the cylinder head, right side.
Tightening torque: 50 Nm.
- Install the engine support unit.
Tightening torques
Note:
The expansion bolts cannot be reused.
Engine unit supports, engine

A1) = 40 Nm + 90° (1/4 turn)
B = 25 Nm
C1) = 60 Nm + 90° (1/4 turn)
1) Expansion bolts, replacing
- Install the power assisted steering tank.

Note:
2 - Piston and connecting rod: disassembly and assembly

2.1 - Piston and connecting rod: disassembly and assembly
1 Safety key
2 Piston pin
◆ If difficult to move, heat piston to 60°C
1.6 - Testing the tensioning roller of the main belt 35

◆ Removing and installing with the tool T20019

3 Piston
◆ Testing => fig. 3
◆ Mark the installation position and the position on the respective cylinder
◆ The arrow of the piston head must point towards the pulley
◆ Install with casing for ring installation
4 Piston ring
◆ Stagger the cuts by 120°
◆ Removing and installing compression rings using ring pliers
◆ By hand carefully remove and install the 3 oil-scraping parts of the rings
◆ The word "TOP" indicates the head of the piston
◆ Check the play between the ends of the rings => fig. 1
◆ Check the play between piston rings and piston grooves => fig. 2
5 Connecting rod
◆ Only replace the unit
◆ Mark the position on cylinder -A-
◆ The marks -B- should point towards the pulley
◆ Axial guided by piston
6 Connecting rod caps

◆ If the connecting rods are cracked, the cap can only be placed in one position, and only on a given
connecting rod
7 Connecting rod bolt, 30 Nm + 1/4 turn (90°)
◆ Replace
◆ Lubricate the thread and contact surface
◆ To measure radial play tighten to 30 Nm without retightening
◆ The retightening angle can be measured with the T20030
8 Engine block
◆ Check the interior diameter of the cylinders => fig. 4
◆ Piston and cylinder dimensions => page 43
2.1 - Piston and connecting rod: disassembly and assembly 37

9 Piston rings
◆ Offset gaps by 120°
◆ Remove and install piston rings with piston ring pliers
◆ Carefully remove and replace the three parts of the oil scraper rings by hand
◆ "TOP" faces towards piston crown-
◆ Checking ring gap => fig. 1
◆ Checking ring to groove clearance => fig. 2
10 Conrod
◆ Only renew as a set
◆ Mark cylinder number -A-
◆ Marking -B- faces towards pulley end
◆ Guided axially via piston
11 Conrod bearing cap

◆ The caps only fit in one position and only on the appropriate conrod, this is due to the breaking procedure
(cracking) separating the cap from the conrod
12 Conrod bolt, 30 Nm +1/4turn (90°) turn
◆ Replace
◆ Oil threads and contact surface
◆ To measure radial clearance tighten to 30 Nm but not further
◆ Tightening can be done in several stages
◆ The angle of tightening can be measured with protractor T20030
13 Cylinder block
◆ Checking cylinder bores => fig. 4
◆ Piston and cylinder dimensions => page 43

14 Halfshell bearing
◆ Do not interchange used bearing shells
◆ Measure pretension => fig. 5
◆ Place shell bearings in correct position
◆ Check radial clearance with Plastigage:
New: 0,020 ... 0.061 mm
Wear limit: 0.091 mm
Do not rotate crankshaft when checking radial clearance
-> Fig. 1 Piston ring ends: checking the play

- Install the ring from above, so that it is at a straight angle to the lower cylinder opening, and separated
approximately 15 mm from the cylinder edge.
Piston ring Dimensions in mm New Wear limit

1.er compression ring 0,20...0,50 1,0
2.o compression ring 0,40...0,70 1,0
Oil scraper ring 0,40...1,40 --1)
1) It is not possible to make an indication as to wear limit
-> Fig. 2 Check the play between piston rings and piston grooves
First clean the piston ring grooves.
Piston ring Dimensions in mm New Wear limit

1.er compression ring 0,04...0,08 0,15
2.o compression ring 0,04...0,08 0,15
Oil scraper rings Not measured

-> Fig. 3 Check the pistons
◆ Exterior micrometer 75...100 mm
- Measure approximately 10 mm from the lower edge, staggering 90° from the piston pin shaft. Divergence
over nominal dimensions
max. 0.04 mm
Nominal dimension => page 43 ; Piston and cylinder dimensions
-> Fig. 4 Check cylinder diameters
◆ Interior gauge 50...100 mm
- Measure at three points, crosswise -A- and lengthwise -B-. Variations in nominal dimension
0.08 mm max.
Nominal dimension => page 41 ; Pistons and cylinder dimensions.
Nota:
The cylinder bore should not be measured when the engine block is fixed to the assembly trestle by engine
mount Ar-2204 A, as erroneous measurements can result.
-> Fig. 5 Measure the half-bearing pre-tension
◆ Calliper
The pre-tension of the half bearing is calculated as follows:

dimension -a- of the half bearing
- diameter of the connecting rod -b-
= pre-tension
Minimum dimension: 1.5 mm
If the pre-tension is not reached:
- Replace the half bearing.
2.2 - Piston and cylinder dimensions
Re-cutting dimension ø piston ø interior cylinder

Basic dimension mm 76,470 76,51
I re-cutting mm 76,720 76,76
II re-cutting mm 76,970 77,01

3 - Engine block, sealing flange and engine flywheel: removing and installing
3.1 - Engine block, sealing flange and engine flywheel: removing and installing
Aluminium block engine
Attention!
Do not remove the crankshaft. Loosening the main bearing caps bolts damages the main bearing caps, thus
reducing play in the bearings and if the half bearings are not changed the bearings can be damaged due to
incorrect play.
If the cap bolts are loosened, the entire engine block with crankshaft must be replaced.
Main crankshaft bearing play cannot be measured with equipment available in a workshop.
Note:
Clutch repairs:
=> Rep. Group 30; Clutch: repairing; Clutch: removing and installing Clutch: repairing Clutch: removing and
installing
1 10 Nm
2 Breather pipes
3 10 Nm
4 Aluminium block engine
5 Knock sensor
6 20 Nm
◆ The tightening torque influences the functioning of the knock sensor
7 60 Nm + 1/4 turn (90°)
◆ Replace
3.1 - Engine block, sealing flange and engine flywheel: removing and installing 45
8 Plate
◆ Check installing position
9 Clutch plate
◆ For removing and installing, immobilise the clutch plate with the U-40009
◆ Clutch plate: removing and installing=> page 51 .
10 Intermediate plate
◆ It must be positioned in adjustment sleeves
◆ Do not bend or damage while installing
11 Generator wheel
◆ For the engine RPM sender
◆ Replace only along with the sealing flange
◆ Removing and installing the generator wheel => page 54 .
12 Sealing flange with seal
◆ Replace only complete unit with seal and generator wheel
◆ Removing and installing the sealing flange => page 54 .
13 Gasket
◆ Replace
14 Oil pump
◆ Always replace the unit
◆ When installing, take into accountthe crankshaft drive element, pos. 17
◆ It must be positioned in adjustment sleeves
◆ Removing and installing => page 104 , lubrication system components: removing and installing
15 20 Nm
◆ Replace
16 Seal
◆ Replacing => page 52
17 Drive element
◆ Apply oil before installing oil pump
18 Gasket
◆ Replace
Grey cast iron engine block
1 Half-bearings 1, 2, 4 and 5
◆ Do not swap used half-bearings (mark them)
2 65 Nm
3 Caps
◆ Do not swap caps (mark them)
◆ Cap 3 is grooved for drive washers
◆ The tabs of the engine block half-bearings must coincide with the tabs of the caps
4 Half-bearing 3
5 Drive washer
◆ For cap 3
◆ Check that it is secured correctly
6 Crankshaft
◆ Axial play, new: 0.07 ... 0.18 mm Wear limit: 0.17 mm
◆ Do not turn crankshaft while measuring radial play
◆ Crankshaft dimensions => page 63 .
7 10 Nm
8 Sealing flange with seal
◆ Only replace complete unit with seal and generating wheel
◆ Remove and fit the sealing flange=> page 54
9 Intermediate plate
◆ Must fit into adjustment sleeves
◆ Do not bend or damage during fitting work
10 Clutch plate
◆ Clutch plate: removing and fitting => page 51
11 60 Nm + 1/4 turn (90o)
◆ Replace
12 Plate
◆ Check the fitting position
13 Drive washer
◆ For engine block, bearing 3
14 Gasket
◆ Replace
15 Sealing flange for Duocentric oil pump
◆ Duocentric oil pump: removing and fitting => page 104 .
16 10 Nm
◆ Replace
17 Seal
◆ Replace => page 52 .
18 Gasket
◆ Replace
19 Intake line
20 10 Nm
3.2 - Clutch plate: removing and installing
◆ -> Countersupport U-40009
Loosening and tightening the clutch plate
- -> Secure the countersupport to the clutch plate.

- Tighten or loosen the bolts that fix the clutch plate to the crankshaft.
3.2 - Clutch plate: removing and installing 51

3.3 - Crankshaft seal, pulley side: re-placing
◆ Seal extractor T20031B
◆ Pressure piece T20081B/1 and T20081B/2
◆ Torque spanners SAT 8010
Removing
- First remove the toothed belt=> page 24 .

- Remove the toothed belt pinion from the crankshaft.
- -> Oil the threaded head of the extractor T20031B, apply it and, pressing hard, thread it all the way onto the
seal.
- Turn the bolt against the crankshaft until the seal comes free.
Installing
- Lightly oil the sealing side of the seal.

- Place the seal in the guide sleeve T20081B/2 and place the unit over the crankshaft journal.
- -> Use tappet T20081B/1 and press the guide sleeve-oil seal unit until the oil seal is seated. To do so, use
the old vibration damper securing bolt.
- Remove guide sleeve T20081B/2.
- Install the crankshaft pinion and immobilise it with countersupport T20018A.
- Installing the toothed belt => page 24 .
3.3 - Crankshaft seal, pulley side: re-placing 53

3.4 - Crankshaft sealing flange, eng-ine flywheel side: replacing
◆ Installing tool T10017
◆ Closed ring spanner SAT 8010/24CC
◆ Three hexagonal bolts M6 * 35 mm
◆ Feeler gauge
◆ Caliper
Remove the sealing flange with the generator wheel

Note:
In order to facilitate comprehension, the work sequence will be carried out with the engine removed.
Work sequence
- Remove the clutch plate => page 51 .
- Remove the engine flywheel. To do so, immobilise it with the countersupport T20075A.
- Remove the intermediate plate.
- Set the engine at TDC cyl. 1 => page 23 ,Distribution timing: testing.
- Remove the oil sump => page 101 .
- -> Remove the engine RPM sender -arrow-.

- Screw the securing bolts of the sealing flange.
- -> Put three bolts M6 * 35 mm in the threaded hole in the sealing flange -arrows-.
- Screw in the bolts alternately (max. 1/2 turn (180°) per bolt), in the sealing flange and remove it from the
crankshaft along with the generator wheel.
Press the sealing flange in with the generator wheel
Notes:
◆ Progressive use of the new generation of sealing flanges with PTFE seal (Teflon). The sealing flange with
elastic washer is still available as a replacement part.
When installing a new sealing flange use only the type of flange previously installed.
◆ The sealing flange with PTFE seal has a support ring on the sealing lip. This support ring acts as an installing
sleeve and cannot be removed before installing.
◆ Once disassembled, do not separate the sealing flange and the generator wheel or change their position.
◆ The sealing surface of the sealing flange with elastic washer for the crankshaft has an elastomeric coating.
This coating must always be kept free of dirt and grease.
◆ The generator wheel finds its installation position when placed over the positioning pin of installing device
T10017.
◆ The sealing flange and seal are a single unit and can only be replaced along with the generator wheel.
◆ The installation position of the device T10017 with regards to the crankshaft is determined by the guide pin
that goes into the threaded hole in the crankshaft.
3.4 - Crankshaft sealing flange, eng-ine flywheel side: replacing 55

A- Hexagonal nut
B- Contact surface
C- Installation bell
D- Allen bolt
E- Guide pin
F- Positioning pin
A -Installing the sealing flange with generator wheel on the installing device T10017
- -> Loosen or tighten the hexagonal nut -A- as far as the holding surface -B- of the threaded shaft.
- -> Fix the installation device T10017 in a bench vice by the surface -B- of the threaded shaft.
- Press the installation bell -C- downwards such that it rests on the hexagonal nut -A- (arrow).
Note:
The inner part of the installation device and the installation bell must be at the same level.
- -> Remove the safety clip -A- and the new sealing flange.
Note:
Do not remove the generator wheel from the sealing flange and do not change their respective positions.
- -> The securing hole -B- of the generator wheel -C- must coincide with the mark -A- on the sealing flange
- -> Place the sealing flange by the front part on a flat, clean surface.
- Press the generator wheel (support ring of the sealing lip along with the PTFE seal) -A- in the direction of
the arrow downwards until it rests on the flat surface

- -> The upper edge of the generator wheel and the front edge of the sealing flange must coincide -arrows-.
- -> Situate the front part of the sealing flange over the installation device T10017 such that the positioning
pin -A- fits into the hole -B- in the generator wheel.
Note:
Make sure that the sealing flange rests fully on the installation device.
- -> When tightening the three knurled bolts -A- on the surface of the installation device, press the generator
wheel (support ring of the sealing lip along with the PTFE seal) -B- such that the positioning pin cannot come
out of the generator wheel.
Note:
Make sure that the generator wheel is held in the installation device when installing the sealing flange.
B -nstalling the installation device T10017 with sealing flange in the crankshaft flange
Conditions
• The crankshaft flange must be clean (free of oil and grease).
• The engine at TDC cyl. 1.
Work sequence
- -> Loosen the hexagonal nut -A- as far as the end of the threaded shaft.
- Press the threaded shaft of the installation device in the direction of the arrow until the hexagonal nut -A-
touches the installation bell -C-.
- Orientate the flat part of the installation bell towards the sealing surface of the engine sump directing it
towards the oil sump.
- -> Fix the installation device with the Allen bolts -A- to the crankshaft flange.
Note:
Fix the Allen bolts -A- approx. 5 turns into the crankshaft flange.
- -> Screw the bolts M6 * 35 mm -A- into the engine block to guide the sealing flange.

C -Bolt the installation device T10017 to the flange of the crankshaft
- -> With your hand slide the installation bell -A- in the direction of the arrow until the generator wheel (support
ring of sealing lip along with PTFE seal) -B- rests on the crankshaft flange -C-.
Note:
The guide pin -D- of the installation device is introduced into a threaded hole in crankshaft during installation.
In this way the definitive installation position of the generator wheel is determined.
- Maintain the installation bell in this position and hand tighten the two Allen bolts of the installation device.
- Hand thread the hexagonal nut -E- onto the threaded shaft until it touches the installation bell -A-.
D -Press the generator wheel with the installation device T10017 onto the crankshaft flange
- -> Tighten the hexagonal nut of the installation tool with the dynamo-metric spanner SAT 8010 and the ring
spanner SAT 8010/24C. Tightening torque: 35 Nm
Note:
After tightening the hexagonal nut to 35 Nm there should be a small gap between the engine block and the
sealing flange.
E -Check the installation position of the generator wheel in the crankshaft
- -> Loosen the hexagonal nut -A- as far as the end of the threaded shaft.
- Unscrew the two bolts M6 * 35 mm -B- from the engine block.
- Unscrew the three knurled bolts -C- from the sealing flange.
- Move the installation bell of the installation device rearwards -D- to the hexagonal nut -A- (only for the sealing
flange with elastic washer).
-> The installation position of the generator wheel on the crankshaft is exact if there is a distance -a- of 0.5 mm
between the crankshaft flange -A- and the generator wheel -B-.
Nota:
On the sealing flange with PTFE seal, completely unbolt the installation device T10017 and remove the support
ring of the sealing lip.
In order to facilitate the identification of the dimension -a- the crankshaft flange is shown without the installation
device T10017 bolted.
- -> Place the calliper against the crankshaft flange -A- (marked surface).
- -> Measure with a feeler gauge -A- the distance -a- between the calliper and the generator wheel.

If the distance -a- is too narrow:

- Press again on the generator wheel => page 60 .
If the distance is achieved -a-:

- Remove the installation device.
- Screw in the new securing bolts of the sealing flange alternating in a cross pattern.
Tightening torque: 12 Nm
- -> Install the engine RPM sender -arrow-.Tightening torque: 5 Nm

- Install the oil sump => page 101 .
- Install the intermediate plate.
- Install the engine flywheel with new bolts, immobilising the flywheel with the countersupport T20075A.
Tightening torque
60 Nm + 1/4 turn (90°)
F -Rectify the position of the generator wheel

- -> Move the installation bell -A- by hand towards the sealing flange -B-
- Screw the two bolts M6 * 35 mm -C- into engine block to guide the sealing flange -B-.
- Thread the hexagonal nut -D- by hand onto the threaded shaft until it touches the installation bell -A-.
- -> Tighten the hexagonal nut of the installation tool with the dynamometric spanner SAT 8010 and the ring
spanner SAT 8010/24C.
Tightening torque 40 Nm
- Recheck the installation position of the generator wheel on the crankshaft=> page 60 .
If the distance -a- is still too narrow:
- Tighten the hexagonal nut of the installation device to 45 Nm.

- Recheck the installation position of the generator wheel on the crankshaft => page 60 .
3.5 - Crankshaft dimensions
Re-cutting di‐ ø connecting rod bear‐ ø crankshaft

mensions Di‐ ing journals bearing jour‐
mensions in nals
mm For AUS en‐
gines only
Basic dimen‐ -0,022 -0,017
sion 47,80 54,00
-0,037 -0,032
I re-cut -0,022 -0,017
47,55 53,75
-0,037 -0,032
II re-cut -0,022
47,30
-0,037
III re-cut -0,022
47,05
-0,037

15 - Cylinder head, Valve gear
1 - Cylinder head: removing and installing

1.1 - Cylinder head: removing and installing
Check the compression=> page 75

Notes:
◆ When a new cylinder head is installed, oil all contact surfaces between support elements, rocker arms and
the cam slide tracks before installing the camshaft housing.
◆ Do not remove the protective plastic bases that come with the open valves until you are ready to install the
cylinder head.
◆ After replacing the cylinder all coolant should be changed.
1 Upper toothed belt shield

2 Main toothed belt
◆ Check wear
◆ Do not twist
64 15 - Cylinder head, Valve gear

◆ Removing and installing, tightening=> page 24 .

◆ Check wear
◆ Do not twist
4 10 Nm + 1/4 turn (90°)
◆ Replace
◆ Tighten from inside outwards
5 Ignition wiring guide
6 Camshaft housing
◆ Eliminate all residues of sealant
◆ Before installing smear with D 188 003 A1
◆ For installing, potion vertically from above over the studs and pins
7 10 Nm
8 Pin
9 Rocker arm
◆ Carefully check that rotation
◆ Carefully check that the roller bearings turn
◆ Lubricate the slip surface
◆ For installation, fasten with the safety clip to the support element
10 Support element
1.1 - Cylinder head: removing and installing 65

◆ Do not swap
◆ With hydraulic compensation of the valve set
◆ Before installing, check the axial play of the camshaft=> pages 83 , fig. 3
◆ Lubricate the slip surfaces
11 Cylinder head bolt
◆ Replace
◆ Follow the installation instructions and the established order when loosening and tightening => page
70
12 Cylinder head
◆ Check for deformation=> fig 1
◆ After replacing, change all the coolant
13 Cylinder head gasket
◆ Metal gasket
◆ Replace
14 Tensioning roller of the return belt
◆ Testing => page 31 .
◆ Tightening the toothed belt => page 24 .
15 20 Nm
16 Protector trasero de la correa dentada
17 20 Nm

18 Ring for hanging
-> Fig. 1 - Check the cylinder head for deformations

Max. allowable deformation: 0.05 mm
1.2 - Camshaft housing: removing and installing

Special tools, workshop equipment, testing and measuring equipment, and auxiliary devices required
◆ Two rods (M6 * 70)
◆ Sealant D 188 003 A1
Removing
Notes:
◆ The camshafts on this engine are located in the camshaft housing. Thus the camshaft housing should only
be removed after removing the two toothed belts.
◆ Removing and installing the camshafts => page 77 , valve control: repairing.
◆ Do not work the contact surfaces of the camshaft housing.
Work sequence
- First check if the vehicle has a coded radio installed, and if necessary, check the anti-theft coding.
- With the ignition off, detach the battery earth strap.
- First remove the two toothed belts => page 24 .
- Remove the connections of the sparkplugs and the ignition wires.
- Extract the 4-pin connector from the ignition transformer.
- Extract the 3-pin connector from the Hall transmitter.
- -> Remove the securing bolts from the exhaust recirculation valve -1- and from the wiring support -2-.
- Unscrew the securing bolt from the rear shield of the toothed belt, near the right ring of the tow hook.
- Unscrew the camshaft housing bolts in a cross pattern starting with the outer bolts and working inwards.
- Carefully remove the camshaft housing.
Installing
Conditions
• The crankshaft pinion must be fixed to this by means of a bolt with two washers.
• The camshaft pinions fitted in the housing with the tool T10016 and locked against involuntary turning.
Note:
When turn the camshafts the valves can hit the pistons when the latter are at TDC.

- Eliminate all remains of sealant from the cylinder head and camshaft housing with a flat scraper or com‐
mercial sealant remover.
- Avoid dirt or sealant getting into the cylinder head.
- The contact surfaces should be free of oil and grease.
- -> Apply a thin, even coat of sealant on the clean sealing surface of the cylinderhead housing: see shaded
area of the illustration.
Note:
Do not spread sealant to thickly, since it could get into the oil holes and damage the engine.
- -> Check that all the rocker arms are seated correctly on the ends of the valve stems -1- and that they are
fastened to their respective support elements -2-.
- Screw two rods (M6 * 70) on the cylinder head before installing the camshaft housing.
- -> Carefully free the camshaft housing vertically from above over the rods and pins of the cylinder head -
arrows-.
- Tighten the new camshaft housing bolts evenly, crosswise, working from inside out.
Check that the camshaft housing is not tilted.Tightening torque: 10 Nm + re-tightening 1/4 of a turn (90o).
Note:
After installing the camshaft housing, let the sealant dry for about 30 minutes.
Continue the installation in the opposite order of removal.
1.2 - Camshaft housing: removing and installing 69

1.3 - Cylinder head: removing and installing

◆ Tray V.A.G. 1306

◆ -> Support T10014
◆ -> Toothed spanner set U-40020

◆ Sealant D 188 003 A1
Conditions
• Engine temperature, maximum warm.

Removing
- -> Remove the cover on the top of the camshaft housing -arrows-.
- Open the plug on the expansion tank to release cooling system pressure.
- Drain the coolant => page 11 .
- Loosen the strip clamps and extract the coolant hoses from the thermostat housing. Separate the hoses
from their fastening to the cylinder head and the intake manifold.

-> Remove the plug -1-.
- Detach accelerator drive cable -2- from the upper part of the air filter (AHW engines only).
- Separate the engine sump deaeration hose from the upper part of the air filter -3-.
- Separate the hot air breather hose from the hot air pick-up plate -4-.
- Loosen the bolts marked with arrows to remove the air filter and intake hose.
- Disassemble air filter.
Note:
In manufacture, self-threading bolts are used for fixing the air filter to the plastic intake manifold and the upper
part of the air filter to the lower part. When loosening or tightening these bolts with a screwdriver the thread in
the intake manifold or lower part of the air filter can be damaged. For this reason, for loosening and tightening
the bolts only use an electric/pneumatic screwdriverrespecting the following conditions:
◆ maximum screwdriver revolutions, 200/min.

◆ maximum tightening torque 3 Nm.
- Remove the oil dipstick guide pipe.
- On AHW engines, detach the accelerator drive cable from the mount and from the throttle valve control unit
(without removing the securing clip).
Attention!
The fuel supply hoses are under pressure. Before loosening the hose connections wrap a cloth around the
connection. Then release the pressure carefully removing the hose.
- -> Now detach the fuel supply hose and the return hose (press the lock button).
- Separate the following components from their fastenings and place them to one side:
◆ the hose from the intake manifold to the active charcoal filter system
◆ the decompression hose from the intake manifold to the brake servo
◆ exhaust recirculation decompression valve hose

◆ the 2-pin connector of the knock sensor (rear part of engine block) and the 4-pin connector of the pressure
sender of the intake manifold, under the intake manifold, front right part
◆ the connector of engine RPM sender under the support of the oil dipstick guide pipe, and extract the con‐
nector from its housing on the support
◆ the connector of the ignition transformer, from the Hall sender and the throttle valve control unit
◆ the connector of the coolant temperature sender, oil pressure switch and exhaust recirculation valve
◆ the connectors of the injectors
1.4 - Remove the camshaft housing
Notes:
◆ On this engine the camshafts are located in a housing. Before removing the housing the main toothed belt
must be removed.
◆ Removing and installing the camshafts => page 77 , valve control: repairing.
Work sequence

- Remove the front exhaust pipe from the exhaust manifold.

- Extract the Hall transmitter connector.
- -> Remove the bolts from the exhaust recirculation valve -1- and from the wiring support -2-.
- Unscrew the securing bolt from the rear shield of the toothed belt, near the right ring of the tow hook.
- Unscrew the camshaft housing bolts in a cross pattern starting with the outer bolts and working inwards.
- Carefully remove the camshaft housing.
- Remove the rocker arms along with the support elements and put them on a clean surface. Make sure not
to swap the rocker arms and support elements.
- -> Place the holding tool U-30025B and raise the engine slightly with the shaft -B-.

Note:
Both hanging rings are located on the cylinder head; for this reason it is necessary to fix an additional support
to hold the engine by the block.
- Place the support T10014 in the threaded hole by the water pump on the block as shown in the illustration.
- Raise the engine slightly with the shaft -A- until the shaft -B- is free of tension.
- Remove the shaft -B-.
Remove the cylinder head

- From the thermostat housing, extract the fastening clip of the coolant hose coming from the coolant pump.
- -> Loosen the cylinder head bolts in the order shown and extract them with the spanner M12 of the toothed
spanner set U-40020.
- Carefully remove the cylinder head.
Note:
To remove the cylinder head on versions with air conditioning, it is necessary to remove rapidly the vane pump-
alternator-compressor support.
Installing
Notes:
◆ Do not remove the new cylinder head gasket from its packaging until you are ready to install it.
◆ Handle the new gasket with extreme care. If damaged, leaks may result.
- Plug the cylinders with clean cloths to keep dirt and abrasive particles from entering between the inner wall
of the cylinder and the piston.
- Ensure that no dirt or particles get into the coolant.
- Carefully clean the contact surfaces of the cylinder head and engine block. Avoid scratching (if sandpaper
is used, the grain must be at least 100).
- Carefully eliminate abrasive particles and remove the cloths.
- Place the cylinder 1 piston at TDC and turn the crankshaft slightly back.
- Install the new cylinder head gasket such that the part number is visible.
- Install the cylinder head checking the centring pins on the engine block.
- Install new securing bolts for the cylinder head and hand tighten.

- -> Tighten the cylinder head bolts with the spanner M12 of the toothed spanner set U-40020 following the
order shown, as follows:
- Tighten all the bolts to a torque of 30 Nm.
- Then, retighten all the bolts 1/4 of a turn (90o) with a rigid spanner.
- Finally, retighten the bolts 1/4 of a turn (90o).
- Loosen the support elements on the cylinder head and rest the respective rocker arms on the ends of the
valve stems or on the support elements.
- Install the camshaft housing => page 68 .
Continue assembly in the reverse order of disassembly.
Adding new coolant => page 11 .
1.5 - Compression: checking
◆ Sparkplug spanner T20028

◆ Compression gauge V.A.G. 1763 or V.A.G. 1381
Test conditions
• Engine oil temperature, min. 30 oC
1.4 - Remove the camshaft housing 75

Work sequence

- Unscrew the sparkplugs with the spanner T20028.
- -> Extract the 4-pin connector from the ignition transformer -arrow-.
- Have another mechanic press on the accelerator pedal such that the throttle valve is fully open.
- Test the compression with the compression gauge V.A.G. 1381 or V.A.G. 1763.
Note:
The tester comes with instructions for use.
- Turn on the starter motor until the tester no longer shows an increase in pressure.
Compression values
New: 10...15 bar
Wear limit: 7 bar
Allowable difference between cylinders: 3 bar.
- Install the sparkplugs with the spanner T20028 and tighten to a torque of 30 Nm.
=> Rep. Group 01; Fault memory; Fault memory: consult and erase. Fault memory Fault memory: consult and
erase.

2 - Valve control: repairing

2.1 - Valve control: repairing
1 20 Nm + 1/4 turn (90o)

◆ Replace
◆ For loosening and tightening use the tool T10016=> page 83 , fig. 1
2 Camshaft pinion
◆ Check the installation position when installing the toothed belt => page 24 .
3 Seal
◆ Lightly lubricate the sealing lip
◆ Replacing => page 87 .
◆ Check wear
◆ Do not bend
2.1 - Valve control: repairing 77

5 Camshaft housing
◆ Eliminate all residues of sealant
◆ Before installing smear with D 188 003 A1
◆ For installing, potion vertically from above over the studs and pins
6 6 Nm +1/4 turn (90o)
◆ Replace
◆ Tighten from inside outwards
7 Cap/support for ignition transformer
8 10 Nm

9 Rocker arm
◆ Carefully check that the roller bearings turn
◆ Lubricate the slip surface
◆ For installation, fasten with the safety clip to the support element
10 Half cones
11 Plug
12 20 Nm
13 Ring for hanging
14 Retaining valve, 6 Nm
◆ Install with D 154 102 A1
◆ Do not tighten more, the valve could get jammed
15 Support element
◆ Do not swap
◆ With hydraulic compensation of the valve set
◆ Before installing check the axial play of the camshaft => page 83 , fig. 3
◆ Lubricate the slip surfaces

16 Valve spring plate

17 Valve spring
◆ Removing and installing:
Cylinder head removed with
T20034B/1
Cylinder head installed => page 92 , replacing the valve stem seals
18 Valve stem seal
19 Valve guide for repair
◆ With collar
20 Valve guide
21 Valves
◆ Do not re-cut them, they may only be ground
◆ Valves dimensions =>fig. 5

22 Cylinder head
◆ Re-cut the valve seats=> page 85
◆ Re-cut the sealing surfaces => fig. 2
23 20 Nm
24 Tensioning roller
◆ Tightening the toothed belt => page 24 .
25 Support
26 Lock bolt, 45 Nm
◆ Install with D 154 102 A1
◆ Do not screw in too far
◆ Maximum depth of entrance under the support surface of the camshaft housing: 2 mm

27 Camshafts
◆ Check the axial play => fig. 3
◆ Identification and distribution timing=> page 84 , fig. 4
28 O-ring
◆ Replace
◆ Oil before installing

-> Fig.1 Immobilise the camshaft pinions with the camshaft pin tool T10016
- Introduce the pins of the T10016 in the lock holes of the camshafts and in the holes in the camshaft housing.
Note:
Both locking pins are correctly placed if the end pieces -D- are aligned with the line -A-.
- Introduce the support T10016 -B- as far as it will go into the camshaft pinion -C-.
- Once immobilised both pinions, proceed to loosening or tightening of camshaft pinions.
-> Fig.2 Re-cut the sealing surface of the cylinder head
Cylinder head re-cutting dimension: a = at least 108.25 mm
Note:
When cutting the sealing surface, the valves should be cut down to the same dimension (re-cut the valve seating
rings). If not, the valves will hit the pistons. Check that it is not below the minimum allowable dimension =>
page . 85
-> Fig.3 Camshaft: checking the axial play
◆ Universal support for dial gauge T20020

◆ Dial gauge
Carry out the measurement with the camshaft housing removed and the cover installed.
Wear limit: max. 0.40 mm

-> Fig.4 Identification of camshafts, distribution timing
Identification between the pairs of cams - Cyls. 1 and

2
Engine code AHW APE-AXP AUS
Intake shaft -E- 036 AC 036 CG 036 BQ
036 BD
Exhaust shaft -A- 036 AA 036 AA 036 AA
036 BE 036 BE
Distribution timing for 1 mm of valve stroke
Engine code AHW-APE-AXP AUS

Intake opens after TDC 19,1° 16,3°
Intake closes after BDC 15,1° 21,2°
Exhaust open before BDC 20,2° 20,2°
Exhaust closer before TDC 15,3° 15,3°
-> Fig.5 Valve dimensions
Note:
Do not re-cut the valves, they can only be ground.
Dimension Intake valve Exhaust valve

ø a mm 29,5 26,0
ø b mm 5,973 5,953
c mm 100,9 100,5

α<° 45 45
2.2 - Valve seats: re-cutting
◆ Depth calliper
◆ Valve seat re-cutter
Notes:
◆ When repairing engines with non-hermetic valves, it is not enough to re-cut the valve seats, seat the valves
or replace both. Especially with engines with high mileage it is important to check the valve guide wear =>
page 89 .
◆ Re-cut the valve seats just to the point where a perfect contact is achieved. Before re-cutting, the maximum
allowable re-cut dimension must be calculated. If the re-cut dimension is surpassed, the hydraulic compen‐
sation function of the valve play will not be ensured, and the cylinder head must be replaced.
Calculate the maximum allowable re-cut dimension
- Introduce the valve and press it hard against the seat.
Note:
If the valve is replaced during a reparation, use the new valve for measurement.
- -> Measure the distance -a- between the end of the stem and the upper edge of the cylinder head.
- Calculate the maximum allowable re-cut dimension starting from the measured distance and from the min‐
imum dimension.
Minimum dimensions:
Intake valve 7.6 mm
Exhaust valve 7.6 mm
Distance measured less the minimum dimension = maximum allowable re-cut dimension.
Example:
Distance measured 8,00 mm

- Minimum dimension 7,6 mm
= Re-cut dimension max. allowable* 04,mm

*)The max. allowable re-cut dimension is referred to in the illustrations as dimension "b".
-> Intake valve seat: re-cutting
a = ø 28,7 mm
b = max. allowable re-cut dimension*
c = 1,5...1,8 mm
Z = lower edge of the valve
α = 45o valve seat angle
β = 30o upper correction angle
γ = 60o lower correction angle
Exhaust valve seat: re-cutting
a = ø 25,0 mm
b = max. allowable re-cut dimension*
c = approx. 1,8 mm
Z = lower edge of the valve
α = 45o valve seat angle
β = 30o upper correction angle
γ = 60o lower correction angle
*) Calculation of the max. allowable re-cut dimension => page 85

2.3 - Camshaft seals: replacing

◆ Pressure piece T20081B/1
◆ Guide sleeve T20081B/5
◆ Extractor T20031B ø 27
Removing

- Turn the crankshaft back slightly.
Note:
The camshaft pinions must be secured with the pin tool T10016, which should be fitted all the way in the holes
in the camshaft housing.
2.3 - Camshaft seals: replacing 87

- Remove the camshaft pinions. To loosen the bolts, hold the pinions with pin tool T10016.
- Lubricate the threaded head of the extractor T20031B, position it and, pressing hard, thread it all the way
into the seal.
- -> Turn the inner part against the camshaft until the seal comes out.
- Fit the extractor in the bench vice. Extract the seal with pliers.
Installing
- Lightly oil the sealing lip of the seal.

- -> Fit the seal in the guide sleeve T20081B/5 and fit the unit over the camshaft.
- Use the tappet T20081B/1 and press the guide sleeve-seal unit all the way on using the pinion bolt.
- Remove the guide sleeve T20081B/5.
- Install the camshaft pinions.
Note:
Check the position of the pinions with respect to the camshaft keys.
- Immobilise the respective pinion with the T10010 locking tool and tighten the new bolts to 10 Nm. Tighten
another 1/4 turn (90°).

2.4 - Valve guides: testing
◆ -> Universal support for dial gauge T20020

◆ Dial gauge
Test process
- -> Fit a new valve in the guide. The end of the valve stem should be flush with the guide. Given the different
stem diameters, always fit intake valves in intake guides and exhaust valves in exhaust guides.
- Measure tilting play.
Wear limit: 0.8 mm
2.4 - Valve guides: testing 89

2.5 - Valve guides: replacing
◆ Tool T20035
◆ Manual reamer T20036
◆ Base T20037

Removing
- Before carrying out this operation, check whether the valve seat rings can still be re-cut and, if necessary,
the cylinder head sealing surface. If not, the valve guides cannot be replaced either.
-> First adjust the base T20037 as follows:
- Insert the angular supports that correspond to the valve angle T20037/21.5 <°.
- -> Unseat the worn valve guides from the camshaft side with the tool T20035.
Note:
If the cylinder head already has guides with collars (reparation), these should be unseated from the combustion
chamber side.
Installing
Note:
Once the guide with collar is seated in the cylinder head, do not increase the seating pressure more than 10
kN (approx. 1.0 t) as this could break the collar.
- Oil the new guides and, with the tool T20035 from the camshaft side, seat them up to the collar in the cold
cylinder head.
- Ream the valve guides with the manual reamer T20036, making sure to use water soluble cooling oil.
- Re-cutting the valve seats => page 85
2.5 - Valve guides: replacing 91

2.6 - Valve stem seals: replacing
◆ Sparkplug spanner T20028
◆ Pressure hose T20033
◆ Installation tool T20034B with pressure element T20034B/27
◆ Fitting tool T20039
◆ Extractor T20058

◆ -> Torque spanners SAT 8010
◆ -> Holding tool U-30025B
Removing (with cylinder head installed)
- First remove the main toothed belt => page 24 .

- Remove the camshaft housing => page 68 .
- Remove the rocker arms together with the support elements, and place them on a clean surface.
- Make sure not to swap the rocker arms and support elements.
- Remove the sparkplugs with the T20028.

- Put the piston of the respective cylinder at BDC.
- -> Fit the installation tool T20034B with the pressure elementT20034B/27.
- Thread the pressure hose T20033 onto the sparkplug.
- Attach the pressure hose to compressed air at a minimum of 6 bar and remove the valve springs.
- Remove the valve stem seals with the tool T20058.
2.6 - Valve stem seals: replacing 93

Installing
- To avoid damage to the valve stem seals, fit the plastic sleeve other the valve stem (the sleeve comes with
the replacement part).
- -> Fit the new valve stem seal on the fitting tool T20039.
- Oil the sealing lip of the valve stem seal and carefully slide the seal over the valve guide.

17 - Lubrication
1 - Lubrication system components: removing and installing

1.1 - Lubrication system components: removing and installing
Notes:
◆ When repairing the engine, if significant quantities of metal shavings and particles due to wear or abrasion,
e.g. damage to the mount or connecting rod bearings are found in the oil, in order to avoid further damage,
not only must the oil lines be cleaned carefully but the oil radiator must also be replaced.
◆ The oil level must not be over the max. mark - danger of damaging catalyst! Marks=>page 101 , fig. 1 .
Checking the oil pressure: => page 106 .

Oil capacities:
With oil filter: 3.2 l
Engine oil specifications:
Use VW 500 00, VW 501 01 or VW 502 00 standard oils. Only under exceptional circumstances: API-SF or SG
standard multigrade oils.
1.1 - Lubrication system components: removing and installing 95

1 Oil pressure switch of 0.30 bar (F1), 25 Nm

◆ Identification: green
◆ Verificar => page 106 .
◆ En caso de inestanqueidad cortar y sustituir el anillo junta
2 10 Nm
3 Oil separator
4 Towards the air filter
5 20 Nm
6 Plug
◆ Replace the gasket if damaged
7 Oil dipstick
◆ Oil level must not be over max. mark!
◆ Marks => fig. 1
8 Filling funnel
◆ Remove it for draining oil by absorption
9 Guide pipe
◆ Check wear
◆ Do not bend
11 Return roller
96 17 - Lubrication
12 Oil filter
◆ On AUS engines, secured to the oil radiator.
◆ Loosen by the hexagon or with a universal filter extractor (U-40078)
◆ Hand tighten
◆ Follow assembly instructions on the filter
13 Oil pump
◆ When installing, take into account the crankshaft drive element
=> page 100 , pos. 32
◆ It should be positioned on the setting
14 12 Nm
17 Pulley
◆ Removing and installing the Poly-V belt=> page 21
18 20 Nm

19 90 Nm + 1/4 turn (90o)

◆ Replace
◆ Apply lubricant
20 Toothed belt wheel-crankshaft
21 Seal
22 Gasket
◆ Replace
◆ It should be positioned on the setting pins
23 O-ring
◆ Replace
98 17 - Lubrication
24 10 Nm
25 Breather pipes
◆ Clean the filter if dirty
26 Tensioning roller
◆ Tighten the toothed belt => page 24 .
27 Oil sump
◆ Before installing, clean the sealing surface
◆ Install with silicone-base sealant D 176 404 A2 => page 101 .

28 O-ring
◆ Replace
29 Oil bleed screw, 30 Nm
30 13 Nm
◆ Loosening and tightening the steering wheel-side bolts with box spanner U-40051A
31 45 Nm
32 Drive element
◆ Apply oil before installing oil pump
100 17 - Lubrication
-> Fig. 1 Oil dipstick marks

1 - Max. mark
2 - Min. mark
a - Area between the upper edge of the marked area and the max. mark: do not top up.
b - The level is within the marked area: oil can be topped up.
c -Area between the min. mark and the lower edge of the marked area: top with max. 0.5 l of oil.
1.2 - Oil sump: removing and installing
◆ -> Spherical Allen key U-40051A

◆ Hand drill with plastic brush
◆ Flat scraper
◆ Sellante a base de silicona D 176 404 A2

◆ -> Torque spanners SAT 8010
Work sequence
- Remove the soundproofing sump.
=> Bodywork-exterior installation work; Rep. Group 50; Bodywork, front; Installation chart Bodywork, front In‐
stallation chart
- Drain the engine oil.

- Remove the front exhaust pipe from the exhaust manifold.
- Remove the bolts holding the gearbox housing to the oil sump.
- Remove the engine flywheel cover.
- Remove the oil sump securing bolts with liquid seals.
- Remove the oil sump. If necessary, loosen the sump by lightly tapping with a rubber hammer.
- Eliminate remains of sealant from the engine block, with the help of a flat scraper.
- -> Eliminate remains of sealant from the oil sump, with the help of a rotary brush, e.g. a hand drill fitted with
a plastic brush (use protective eyewear).
- Clean the contact surfaces so that they are free off oil and grease.
Installing
Notes:
◆ Check the sealant expiration date.

◆ The oil sump must be installed within 5 minutes of applying the silicone-based sealant.
◆ To expedite the installation of the oil sump, threaded cotter pins M6 can be placed at two points of the engine
block flange.
- -> Cut the tip of the tube at the forward mark (tip diameter: approx.3 mm).
- Spread the silicone-base sealant on the clean contact surface of the oil sump, as shown in the illustration.
The bead should:
◆ be 2...3 mm thick
◆ run by the bolt holes along the inner surface -arrows-.
Note:
The sealant bead should be no thicker, otherwise it can get into the oil sump, obstructing the oil breather pipe
filter.
- Immediately fit the oil sump and lightly tighten all bolts.
- Tighten all the oil sump bolts to a torque of 15 Nm.
- Tighten the oil sump/gearbox bolts to 45 Nm.
Note:
After installing the oil sump the sealant should dry for about 30 minutes, after which oil can be added.
=> Bodywork-exterior installation work; Rep. Group 50; Bodywork, front; Installation chart. Bodywork, front
Installation chart.
1.3 - Oil pump: removing and install-ing
1.2 - Oil sump: removing and installing 103

◆ Pressure piece T20081B/1
◆ Sleeve T20081B/2
◆ Flat scraper
Removing
- Remove the toothed belt => page 24 , Toothed belt: removing and installing, tightening.
- -> Fix the crankshaft pinion -1- with the used securing bolt -2-.
- Set the crankshaft at TDC cyl. 1:The shortened tooth of the toothed belt pinion should coincide with oil pump
mark -arrow-.
Note:
Take into account that the oil pump/seal-holder cover has two TDC marks, a short one for 4V engines 4V (right
side) and another longer one for 2V engines (left side). Do not confuse the marks when setting the crankshaft
at TDC as this could cause major damage to the engine.
- -> Turn the crankshaft or the toothed belt pinion three teeth counter-clockwise from TDC. The third tooth
should coincide with the third tooth to the right of the shortened tooth -A-, with the TDC mark on the oil pump
housing -arrow-.
Note:
This setting establishes the crankshaft installation position for fitting the oil pump. One of the crankshaft drive
cams is up.
- Remove the toothed belt pinion from the crankshaft and the tensioning roller from the toothed belt. To do
so, immobilise the pinion with the countersupport T20018A.
- Remove the oil sump => page 101 .
- Remove the breather pipe=> page 99 , pos. 25 .
- Remove the oil pump.
Note:
To remove the oil pump on vehicles with air conditioning, the vane pump-compressor-alternator support must
be partially separated.
- Remove the gasket.
- With a flat scrapper, eliminate any remains of sealant from the engine block.
- Clean the contact surfaces of any oil or grease.
Installing
Condition
• -> One of the drive cams -arrow- in the upper part of the crankshaft.
Work sequence
- Fit the new gasket over the guide pins.
- Oil the crankshaft drive cams.
- -> Set the mark -arrow A- of the interior oil pump rotor to coincide with the assembly position mark -B- on
the cover of the oil pump housing.
- Lightly oil the sealing lip of the oil pump seal.
1.3 - Oil pump: removing and install-ing 105

- -> Fit the sleeve T20081B/2 over the oil pump seal and carefully guide the pump over the crankshaft drive
cams.
- In the case of an interior rotor, align it, lightly withdrawing it from the crankshaft drive cam.
- Next carefully fit the oil pump over the guide pins.
- Install the oil pump => page 104 .
- Remove the sleeve T20081B/2.
- Install the breather pipe => page 99 , pos. 25 .

- Install the oil sump => page 101 .
- Install the vane pump-compressor-alternator support, following the tightening order => page 20 , pos.
11 .
- Install the toothed belt pinion and the tensioning roller, Toothed belt, installing, tightening => page 24 ,
Toothed belt: removing and installing, tightening.
1.4 - Oil pressure and oil pressure switch: testing
◆ Oil pressure gauge V.A.G. 1342

◆ Diode lamp V.A.G. 1527 B
◆ Auxiliary measurement set V.A.G. 1594 A or V.A.G. 1594 C
Note:
Operation inspection and repair of visual and acoustic oil pressure indicators:
=> Wiring diagrams, location of electrical faults and positioning places.
Test process
- -> Remove the oil pressure switch (F1) and thread it onto the tester.
- Thread the tester onto the cylinder head in the place of the oil pressure switch.
- Connect the brown wire of the tester to earth (-).
- Connect diode lamp V.A.G. 1527 B with auxiliary leads V.A.G. 1594 A or V.A.G. 1594 C to battery positive
(+) and to the oil pressure switch. The diode lamp should not light up.
- If the diode lights up, replace the oil pressure switch.
If the diode does not light up:
- tart the engine and accelerate slowly. Between

0.3...0.7 bar of pressure
the diode should light up. If not replace the oil pressure switch.
- Continue to increase the engine revs.
At 2000/min and with an oil temperature of 80 oC, oil pressure should be at least 2.0 bar.
At higher revs, oil pressure should not be over 7.0 bar. If necessary, replace the oil pump cover with the bleed
valve.
1.4 - Oil pressure and oil pressure switch: testing 107

19 - Cooling system
1 - Cooling system components: removing and installing

1.1 - Cooling system components: removing and installing
Notes:
◆ The cooling system is under pressure when the engine is warm. For this reason, the pressure must be
reduced before repairing.
◆ The hose connections are secured with strip clamps. In the event of reparation, only strip clamps may be
used.
◆ For installing strip clamps, pliers T20029 are recommended.
◆ The coolant hoses should hang free without touching other components during assembly. (Check the iden‐
tification mark on coolant connection and on the hose.)
Carry out the cooling system leakage test with the V.A.G. 1274 or SAT 1274 and the adapter V.A.G. 1274/8.
Cooling system components, bodywork => page 2 .
Cooling system components, engine => page 5 .
Coolant hose connection diagram 10 .
Draining and refilling coolant => page 11 .
Instructions for coolant mixture => page 11 , Líquido refrigerante: evacuar y cargar.
108 19 - Cooling system

1.2 - Cooling system components, bodywork side
1 Radiator
2 O-ring
◆ Replace
3 Upper coolant hose
◆ It is secured to the radiator with a clip
◆ Coolant hose connection diagram => page 10 .
4 Air baffle
5 10 Nm
6 Secondary fan
◆ On vehicles with optional equipment
1.2 - Cooling system components, bodywork side 109

7 Fan screen
8 Securing clip
◆ Check firm seating
9 Connector
10 Radiator fan
11 Towards the upper coolant hose
◆ => page 2 , pos. 3
◆ Coolant hose connection diagram => page 10 .
12 Expansion tank
13 Plug
◆ Test with tester V.A.G. 1274 or SAT 1274 and adapter V.A.G. 1274/9
◆ Test pressure 1.4...1.6 bar
14 Support
◆ For fan connector

15 Lower coolant hose

◆ It is secured to the radiator with a clip
◆ Coolant hose connection diagram
=>page 10 .
16 O-ring
◆ Replace
17 Heat switch (F18), 35 Nm
◆ For electric fan
◆ Switch temperatures
1st gear
- on: 92...97 oC
- off: 84...91 oC
2nd gear
- on: 98...105 oC
- off: 91...98 oC
18 Support
◆ For radiator
◆ Check installing position
◆ Note that there are different versions
19 15 Nm
1.2 - Cooling system components, bodywork side 111

1.3 - Cooling system components, engine side
Thermostat side
1 Support
2 Bolt with cutting thread
3 From the radiator down
◆ => page 2 , pos. 3
4 Connecting tube
5 O-ring
◆ Replace
6 Coolant thermostat
◆ Test operation: Heat the thermostat in water. The tip of the heat element should emerge
◆ Temperature test: Opening initiation (approx. 84oC) and end (approx. 98oC) not feasible

7 Plug
8 Towards the heat exchanger
9 From the expansion tank
◆ => page 3 , pos. 11
10 Securing clip
◆ Check firm seating
11 From the heat exchanger
12 Coolant pump housing on engine block
13 O-ring
◆ Sustituir
14 Coolant tube
15 Thermostat housing
16 10 Nm
1.3 - Cooling system components, engine side 113

17 Coolant temperature sender -G62-

◆ For engine control unit
◆ With coolant temperature indicator sender -G2-
◆ Before removing, reduce the cooling system pressure
18 Plug
◆ Before removing, reduce the cooling system pressure
19 Towards the radiator, upper part
◆ => page 2 , pos. 3

1.4 - Cooling system components, coolant pump side
1 Main toothed belt

◆ Check wear
◆ Do not bend
◆ Removing and installing, tightening => page 24 .
◆ Toothed belt routing => page 21 , fig. 1
2 Gasket
◆ Replace
◆ In some cases, the pump comes with the silicone gasket incorporated
3 Coolant pump
◆ In event of fault or leakage: replace completely
◆ Removing and installing=> page 18 .
4 10 Nm
5 Rear shield of the toothed belt
1.4 - Cooling system components, coolant pump side 115


8 10 Nm
9 Pulley
◆ Removing and installing the Poly-V belt => page 21 .
10 90 Nm + 1/4 turn (90o)
◆ Replace
◆ Apply lubricant
11 10 Nm
12 20 Nm
13 Pinion of the toothed belt-crankshaft

1.5 - Coolant hose connections diagram
1 Expansion tank
2 Heat exchanger for heating
3 Coolant hose
4 Lower coolant hose
5 Radiator
6 Upper coolant hose
7 Thermostat housing
8 Engine block
9 Coolant pump
10 Intake manifold
1.5 - Coolant hose connections diagram 117

1.6 - Coolant: draining and toppingup
◆ Anti-freeze tester T10017

◆ Tray V.A.G. 1306

Bleed
- Open the cap of the coolant expansion tank.
=> Bodywork-installation work; Rep. Group 50; Bodywork, front; Assembly chart. Bodywork, front Assembly
chart.
- -> To drain coolant, loosen the drain bolt -arrow- on the radiator.
Note:
Observe the rules for waste disposal!
Top up
Notes:
◆ Only TL VW 774 D standard anti-freeze -G12- may be used. It can be distinguished by the red colour.
◆ In no case can -G12- be mixed with other anti-freeze additives.
◆ If the liquid in the expansion tank is brown, that means that the -G12- has been mixed with another anti-
freeze additive, in which case all the coolant must be changed.
◆ G12 and the anti-freeze additives labelled "TL VW 774 D" prevent damage due to corrosion, freezing and
lime sediment. They also raise the boiling point of the coolant. For these reasons, the cooling system must
always be filled with the prescribed mixture of anti-freeze and anti-corrosion product.
◆ Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly in
countries with tropical climates.
◆ Freeze protection should be ensured down to approx. -25 oC (in countries with arctic climate to approx. -35
oC).
◆ The coolant concentration must not be reduced by adding water even in warmer seasons and warmer
countries. The anti-freeze ratio must be at least 40 %.
◆ If for climatic reasons, a greater freeze protection is required, the amount of G12 can be increased, but only
up to 60 % (freeze protection up to -40 oC), as otherwise freeze protection is reduced again and cooling
effectiveness is also reduced.
◆ Do not use the used coolant, if any of the following has been replaced: the radiator, the heat exchanger, the
cylinder head or the cylinder head gasket.
Proporciones de mezcla recomendadas:
Freeze protection Proportion anti‐ -G12-1) Water1)

to freeze
-25 °C 40% 2,41 3,61
-35°C 50% 3,01 3,01
1) The quantity of coolant may vary according to the equipment on each vehicle.
- Close the coolant drain bolt.
- -> Top up with coolant to the max. mark in the expansion tank.
- Close the expansion tank.
- Run the engine until the fan comes on.
1.6 - Coolant: draining and toppingup 119

- Check the coolant level, and top up if necessary. With the engine at service temperature, the coolant level
must at the maximum mark, and with the engine cold, between the minimum and maximum marks.
- Installing the soundproofing sump:
chart.
1.7 - Radiator: removing and installing

◆ Strip clamp pliers T20029
◆ Tray V.A.G. 1306
Removing

chart.
- Draining the coolant => page 11 .

- Removing the front bumper:
=> Bodywork-installation work; Rep. Group 63; Front bumper: removing and installing. Front bumper: removing
and installing.
- Remove the coolant hoses from the radiator.

- Remove the connector from the heat switch and the fan.
- Set the lockholder cover in service position:
=> Bodywork-installation work; Rep. Group 50; Bodywork, front; Lockholder cover service position. Bodywork,
front Lockholder cover service position.
- Remove the radiator securing bolts and pull the radiator out downwards.
Vehicles with air conditioning.
- Follow the additional instructions and assembly work=> page 17
Installing
Carry out assembly in the opposite order from removal, as follows:
- Top up with new coolant => page 11 .

- Installing the soundproofing sump:
chart.
Additional instructions and assembly work for vehicles with air conditioning
Attention!
Do not open the AC cooling agent circuit.
Note:
To avoid damage in the condenser and in the cooling agent tubes/hoses, be sure not to excessively bend, twist
or stretch the tubes/hoses.
- Remove the cooling agent hose clamp(s).

- Remove the condenser from its fastening and secure it to the lockholder.
1.7 - Radiator: removing and installing 121

1.8 - Coolant pump: removing and installing

◆ Tray V.A.G. 1306
Notes:
◆ The coolant pump may have a silicone gasket. In the event of breakage or leakage, replace the whole pump.
◆ The lower toothed belt shield must be removed.
◆ The main toothed belt shield must be removed.
◆ To protect the toothed belt from the coolant, cover it with a cloth before removing the coolant pump.

- Draining the coolant => page 11 .

- Removing the main toothed belt shield => page 24 .
- -> Remove the return roller -6- by removing the securing bolt -5- of the return roller.
- Remove the fixing bolts -1 and 4- from the coolant pump, remove the rear toothed belt shield -2- and remove
the coolant pump -4-.
Installing
Carry out assembly in the opposite order from removal, as follows:

- On engines without gasket integrated in the pump, fit a new gasket.
- -> Fit the coolant pump -3- on the engine block with the rear toothed belt shield and tighten the fixing bolts
-4-.
- Fit the fixing bolt -1- and tighten to 10 Nm.
- Install the return roller -6- and tighten the securing bolt -5-.
- Installing the Poly-V belt => page 21 .
- Refilling with coolant => page 11 .
1.9 - Radiator fans -V7- and -V35-: testing
1.8 - Coolant pump: removing and installing 123

Special tools, shop equipment, test and measurement units and auxiliary devices required
◆ -> Auxiliary measurement set V.A.G. 1594 A or V.A.G. 1594 C

◆ Wiring diagram
Test conditions
• -> Basic fuses must be OK.

• Radiator fan heat switch -F18-, OK.
Test procedure
- -> Detach the triple connector from the radiator fan heat switch -F18-.
- Bridge contacts -1- and -2- of the terminal connector with auxiliary leads V.A.G. 1594 A.
The radiator fans (V7) and (V35) should come on at speed 1.
- Switch on the ignition.
- Bridge contacts -2- and -3- of the terminal connector with auxiliary leads V.A.G. 1594 A or V.A.G. 1594 C.
The radiator fans (V7) and (V35) should come on at speed 2.
If the fans do not come on at speed 1 or 2:
- Find and eliminate the open circuit in the wiring following the wiring diagram:
=> Wiring diagrams.
If no open circuit is found in the wiring:
- Replace the radiator fans -V7- or -V35-.

20 - Fuel supply system
1 - Fuel supply system components: removing and installing

1.1 - Fuel supply system components: removing and installing
Notes:
◆ The hoses connections are fixed with strip or tightening clamps.

◆ Always replace tightening clamps with strip clamps.
◆ For fixing the fuel hoses to the engine only strip clamps may be used; do not use tightening or screw clamps.
◆ For installing strip clamps, pliers T20029 are recommended.
Follow safety rules=> page 132 .
Follow cleaning rules => page 132 .
Removing and installing the fuel tank with accessory parts and fuel filter=> page 126 .
Accelerator control: repairing => page 143 .
Adjusting the accelerator control => page 144 .
Electronic engine output control (electronic accelerator): repairing: reparar => page 152 .
Repairing the active charcoal filter components=> page .
1.1 - Fuel supply system components: removing and installing 125

1.2 - Fuel tank with accessory parts and fuelfilter: removing and installing
1 O-ring
◆ Replace
2 Gravity valve
◆ For removal, expel upwards from the filler hole
◆ Test the continuity of flow from the valve
Perpendicular valve: open
Inclined valve 45°: closed
3 Deaeration line
◆ Check for firm seating
◆ Fixed to the upper part of the fuel tank
4 Cap
5 O-ring
◆ Replace if worn
126 20 - Fuel supply system

6 Securing bolt
7 Tank cap unit
◆ With dust boot
8 Deaeration valve
◆ For removal, expel laterally from filler hole
◆ Before assembly, unscrew the cap pos pos. 4
◆ Testr =>page 131 , fig. 2
9 Connection to earth
10 10 Nm
11 Breather pipe
◆ Black
◆ Fixed laterally to the fuel tank
◆ Immobilise with strip clamps
1.2 - Fuel tank with accessory parts and fuelfilter: removing and installing 127
12 Fuel tank
◆ When removing, hold with engine and gearbox lift SAT 1001
13 Catch pin, 2 Nm
◆ Remove: turn to the left
14 Heat shield
◆ For fuel tank
15 25 Nm
16 Catch nut, 2 Nm
17 Fuel tank protector
18 Securing strap
◆ Check the different lengths
◆ Assembly position: the arrow (hole) indicates direction of travel

19 Supply line
◆ Black
◆ To fuel distributor
=> Rep. Group 24; Injection system: repairing; Injection system components: re-moving and installing Injection
system: repairing Injection system components: re-moving and installing
20 Fuel filter
◆ Assembly position: the arrow indicates direction of flow
21 Clamp
22 O-ring
◆ Replace if faulty
◆ Wet with fuel for assembly
23 Fuel supply unit
◆ Removing and installing=> page 132 .
◆ Testing fuel pump=> page 136 .
◆ Clean the filter if dirty
24 Cap nut
◆ Remove and install with the spanner U-40055 A
25 Supply line
26 Return line
◆ Blue or blue mark
◆ Fixed laterally to the fuel tank
◆ From the fuel distributor return line
=> Rep. Group 24; Injection system: repairing; Injection system components: re-moving and installing Injection
system: repairing Injection system components: re-moving and installing

-> Fig. 1 Assembly position for the fuel supply unit flange
The marks on the sender and the fuel tank should coincide.
Return line blue or blue mark -1- to the connection marked -R-.
Supply line black -2- to the connection marked -V-.
Note:
Once the fuel supply unit flange is installed, check that the supply, return and deaeration lines are still attached
to the fuel tank.
-> Fig. 2 Check the deaeration valve
Lever in rest position: closed
Lever in direction of arrow: open
Note:
Before installing the deaeration valve, remove the fuel tank cap.
1.3 - Safety rules for work on the fuel supply system
Attention!
When removing or installing the fuel level indicator sender or the fuel pump (fuel supply unit) with the fuel tank
partially or completely full, do the following:
◆ Before beginning work, the vacuum tube of a working extractor must be close at hand, near the fuel tank
assembly opening, to absorb the gases given off by the fuel.
If an extractor is not available, a radial fan can be used (the engine must be kept out of the flow of air) with
an air flow above 15 m 3/h.
◆ Avoid contact between skin and fuel. Use fuel-resistant gloves!
1.4 - Cleaning rules

For work on the fuel supply/injection system, carefully follow the "5 rules" of cleaning:
◆ Thoroughly clean the connections and their surrounding areas before releasing them.
◆ Deposit the parts removed over a clean surface and cover them. Do not use cloths that release fibres!
◆ If the repair work is not carried out immediately, the open components should be covered or carefully stored.
◆ Only install clean components:
Remove the renewal parts from their wrapping right before carrying out assembly.
Do not install components that have been stored without wrapping (e.g. in the toolbox, etc.).
◆ As the system is open:
Avoid the use of compressed air when possible.
Do not move the vehicle if possible.
1.5 - Fuel supply unit: removing and installing
◆ -> Dynamometric spanners SAT 8010

◆ -> Union nut spanner U-40055 A
Removing
- Check safety rules before starting assembly work => page 132 .
- With the ignition off, remove the battery earth strap.
- Remove the cover under the seat.
- Remove the flange: the 4-pin terminal connector and supply and return lines.
Attention!
- -> Remove the union bolt with the spanner U-40055 A.

- Remove the fuel supply unit and the ring gasket from its housing in the opening in the fuel tank.
Note:
In the event of supply unit replacement, the old unit should be emptied before disposal.
Installing
- Supply unit assembly is carried out in the reverse order from removal.
Notes:
◆ Make sure not to bend the fuel level sender during assembly.
◆ Before assembly, wet the ring gasket of the flange with fuel.
◆ Ensure firm seating of the fuel hoses.
◆ Secure the fuel hoses with strip clamps.
◆ -> Check the assembly position of the fuel supply unit flange: The mark on the flange should coincide with
the mark on the fuel tank -arrows-.
1.5 - Fuel supply unit: removing and installing 133

◆ Once the fuel supply unit is installed, check that supply, return and deaeration hoses are still connected
properly to the fuel tank.
1.6 - Fuel level sender: removing and installing
Removing
- Remove the fuel supply unit => page 132 .
- -> Unlock and detach the terminal tabs from the connector, the wiring -3- and -4-.
- Raise the securing lugs -1- and -2- with a screwdriver and detach the fuel level sender downwards -arrows-.
Installing
- Position the fuel level sender in the supply unit guides and press upwards until it is seated.
1.7 - Fuel tank: removing and installing
◆ -> Engine and gearbox lift SAT 1001

◆ -> Dynamometric spanners SAT 8010
Removing
- Before starting assembly work, check the safety rules => page 132 .
Note:
For this work the battery earth strap must be disconnected. For this, check whether the vehicle has a coded
radio installed and, if so, the anti-theft code.
- Open the tank cover.

- Remove the right rear wheel arch protector:
=> Bodywork-exterior assembly work; Rep. Group 66, Wheel arch cover: removing and installing.
- Empty the fuel tank and clean around the mouth of the fuel filler hole.
- Remove the securing bolt and remove tank cover with dust boot.
- Remove the securing bolt in the filler hole.
- Fold the rear seat forward.
- Remove the fuel level sender cover plate and remove the connector.
- Remove the protectors under the fuel tank.
- Remove the rear axle:
=> Running gear; Rep. Group 42; Rear axle: repairing; Rear axle: removing and installing. Rear axle: repairing
Rear axle: removing and installing.
- -> At the connection point, remove the return line -2- (blue), the supply line -1- (black) and the breather pipe
-3- (white).
1.7 - Fuel tank: removing and installing 135

Note:
To do so press the lock button on the hoses.
Attention!
- Remove the fastening straps which fix the fuel tank using the engine and gearbox lift SAT 1001.
- Lower the fuel tank.
Installing
Assembly is carried out in the reverse order from removal, as follows:
◆ Install the deaeration and fuel hoses without crimps.

◆ Secure the fuel hoses with strip clamps.
◆ Check that the fuel hoses are firmly seated.
◆ Do not confuse the fuel supply hose with the return hose (return line blue or with blue mark, supply line,
black).
Note:
After installing the fuel tank, check that the fuel, return and deaeration lines are still properly connected to the
fuel tank.
1.8 - Fuel pump: testing
Special tools, work shop equipment, test-ing and measuring equipment and auxiliary devices required
◆ Multi-metre V.A.G. 1715

◆ Remote control V.A.G. 1348/3A with adapter lead V.A.G. 1348/3-2
◆ Diode lamp V.A.G. 1527 B
◆ Auxiliary measuring set V.A.G. 1594 A or V.A.G. 1594 C
◆ Spanner U-40055 A union bolts

◆ Pressure gauge V.A.G. 1318

◆ Adaptor V.A.G. 1318/1
◆ Measuring glass
◆ Wiring diagram
1.8 - Fuel pump: testing 137

Test conditions
• Battery voltage, min. 11.5 V

• -> Fuse num. 28, OK
Test operation and voltage supply
- Remove the protector from the fuel elevation unit.

- Switch ignition on. The fuel pump should be heard to come on (if repeating the test, allow at least 10 sec.
to pass).
- Switch off ignition.
If the fuel pump does not start up:
- Remove the fuse-holder cover.

- -> Remove fuse num. 28 from the holder.
- Connect the remote control V.A.G. 1348/3A with adapter lead V.A.G. 1348/3-2 to contact 28a towards the
fuel pump and the battery, positive terminal (+).
- Activate the remote control.
The fuel pump works:
- Check the excitation of the fuel pump relay with the wiring diagram:
=> Wiring diagrams, Location of electrical faults, Positioning places.
The fuel pump does not work:
- Disconnect the 4-pin connector from the fuel supply unit flange.
- -> Connect the diode lamp V.A.G. 1527 B with auxiliary leads of V.A.G. 1594 A or V.A.G. 1594 C to the
exterior contacts of the connector.
- Activate the remote control.
The diode lamp should light up.

The diode lamp does not light up:
- Find and eliminate the open circuit in the wiring with the wiring diagram:
=> Wiring diagram, Location of electrical faults, Positioning places.
The diode lamp lights up (voltage supply OK):
- -> Remove the union bolt with the spanner U-40055 A.

- Check that the wiring from the flange to the fuel pump is connected.
If no open circuit is found in the wiring:
- Faulty fuel pump, replace fuel supply unit => page 132 ; Fuel supply unit: removing and installing.
Check fuel flow
Test conditions
• Voltage supply, OK
• Remote control V.A.G. 1348/3A, connected
Test process
- Remove plug from fuel filler hole.
Attention!
The fuel system is under pressure. Before opening it, place a cloth around the connection point, then release
the pressure by carefully loosening the connection.
- -> Remove the supply line -1- (black) and wipe up any spilt fuel with a cloth.

- -> Connect the pressure gauge V.A.G. 1318 with adapter V.A.G. 1318/23 and V.A.G. 1318/17 to the fuel
supply line.
- Connect the hose V.A.G. 1318/1 to the adapter V.A.G. 1318/11 of the pressure test gauge and put the end
in a measuring glass.
- Open the valve of the pressure test gauge. The needle will show the direction of flow -A-.
- Activate the remote control V.A.G. 1348/3A, slowly closing the valve until the pressure gauge shows a
pressure of
3 bar
From this moment, do not change the position of the valve.
- Empty the measuring glass.
- The fuel pump flow depends on battery voltage. Thus the multi-metre must be connected to the battery of
the vehicle with the auxiliary leads of the V.A.G. 1594 A or V.A.G. 1594 C.
- Activate the remote control for
30 seconds, measuring battery voltage.
- -> Compare fuel flow with the target value.
*) Minimum flow cm3/30 s.

**) Fuel pump voltage with engine off and the pump running (approx. 2 volts less than battery voltage).
Example reading:
During the test, the battery voltage was 12.5 volts. Given that at the pump there are about 2 volts less than at
the battery, the resulting minimum fuel flow is 200 cc/30 s.
If minimum flow is not achieved:

- Check the fuel lines for kinks (folds) and clogging.

- -> Remove the fuel hose from the fuel filter intake.
- Connect the hose to the pressure test gauge V.A.G. 1318 with the adapter V.A.G. 1318/17.
- Re-check the flow.
If minimum flow is now achieved:
- Replace the fuel filter.
If minimum fuel flow is still not achieved:
- Remove the fuel supply unit and check the filter for dirtiness.
Only if up to this point no fault has been found:
- Replace the fuel supply unit.
If, despite achieving the fuel flow, it can been assumed that the fuel supply is faulty (e.g. a momentary fault in
fuel supply):
- Test the power consumption of the fuel pump, as follows:

- Reconnect the fuel lines.
- -> With a current detector, attach the multi-metre V.A.G. 1715 to one of the fuel pump power cables (contacts
outside the flange connector).
- Start the engine and run at idle.
- Measure the power consumption of the fuel pump.
Target value: 8 amperes max.
Note:
If If there is a temporary fault in the fuel system, the verification can also be made during a test run, in which
case the aid of a second person is needed.
If the power consumption is surpassed:

Check the fuel pump non-return valve
Test conditions
• Remote control V.A.G. 1348/3A, connected.
• Pressure gauge device V.A.G. 1318, connected.
Test process
Note:
This test also checks for leakage in the fuel supply hose connections, from the supply unit to the point of
connection for the pressure gauge V.A.G. 1318.
- -> Close the flow valve of the pressure gauge (lever perpendicular to flow -position B-).
- Operate the remote control in successive brief pulses until the pressure gauge shows a pressure of
approx. 3 bar.
Attention!
Danger of splashing when opening the flow valve; place a receptacle in front of the open connection of the
pressure gauge.
- Release possible excess pressure carefully opening the flow valve.

- Check pressure drop in the pressure gauge. After 10 minutes it should not drop below
2.5 bar
.If pressure continues to drop:
- Check connections for leakage.
If no fault is found in the wiring:

1.9 - Accelerator control: repairing
1 Accelerator cable
◆ Adjusting => page 144 .
◆ A damaged accelerator cable cannot be reused; it must be replaced
2 Securing clip
◆ Adjust the accelerator control cable => page 144 .
3 Vibration damper counterweight
4 Accelerator pedal
5 Spacer bushing
6 Bearing
7 Washer
8 Stop screw
9 20 Nm
1.9 - Accelerator control: repairing 143

1.10 - Accelerator control cable: adjusting
◆ -> Pedal actuator V.A.G. 1788/10
Work sequence
- Connect the accelerator cable to the accelerator pedal and to the throttle valve control unit cam disk.
- Remove the securing ring for the accelerator cable.
- Depress accelerator pedal to full gas.
Note:
For this work, a second mechanic is needed or the accelerator pedal must be depressed with pedal actuator
V.A.G. 1788/10 against the steering column.
- -> Adjust accelerator cable modifying the position of the regulation element in the clip fastener so that the
throttle valve reaches this position at full gas.

2 - Activated charcoal filter system

2.1 - Activated charcoal filter system
2.2 - Function
Depending upon the air pressure and ambient temperature, fuel vapour will form above the level of fuel in the
tank.
The activated charcoal filter system prevents these HC emissions escaping to the atmosphere.
The reduced fuel vapours reach the activated charcoal filter from the highest point of the fuel tank through the
gravity/overflow valve (closes on tilting 32o) and through the breather valve.
The activated charcoal stores these vapours like a sponge.
Running, with the Lambda regulation active (engine hot), the control unit will excite the fuel tank breather valve
(N80), also known as regeneration valve, according to engine load and engine revolutions. The opening period
is dependent on the input signals.
During the sweeping process (regeneration of the activated carbon) the air that goes through the ventilation
casing at the top of the activated carbon filter is drawn by depression into the inlet manifold. The temporarily
accumulated uel vapours and the air in the activated carbon are added in a controlled fashion to the combustion.
The pressure retention valve avoids the vapours being drawn into the fuel tank if the fuel tank breather valve
is open and the adjacent inlet manifold has a depression. Thus a prior emptying of the activated carbon filter
is guaranteed.
Without current (e.g. a cable breakage) the breather valve will remain closed. The activated charcoal filter will
not be purged.
The vacuum pipe from the throttle valve control part to the activated charcoal filter has an additional by-pass
which is connected with the crankcase breather valve. The non-return valve integrated in the crankcase breath‐
er valve prevents the intake air gassing into the crankcase during some partial load ranges. This improves the
overall crankcase breathing. The by-pass guarantees the crankcase breathing.
Notes:
◆ Hose connections are secured with either spring-type or clamp-type clips.

◆ Always replace clamp-type clips with spring-type clips.
◆ To mount spring type clips use pliers T20029.
Observe safety precautions=> page 132
Observe rules for cleanliness => page 132
2.1 - Activated charcoal filter system 145

2.3 - Active charcoal filter system components: repairing
1 Active charcoal filter

◆ Location: in the engine compartment, right side
◆ Fixed to the bodywork
◆ With solenoid valve 1 for active charcoal filter -N80-
◆ The valve is activated (cadenced) by the engine control unit when the engine is at service temperature
◆ Testing:
=> Rep. Group 01; Actuator diagnosis; Actuator diagnosis: carrying out Actuator diagnosis Actuator diagnosis:
carrying out
2 Connector
◆ Black, bipolar
◆ For solenoid valve 1

2.4 - Servicing parts of the activated charcoal filter system: repairing
3 Activated charcoal filter canister

◆ Fitting location: in engine compartment, right
◆ Secured to body
◆ With solenoid valve 1 for activated charcoal filter -N80-
◆ When the engine is warm the valve will be activated from the engine control unit (pulsed)
◆ Checking:
=> Repair group 01; Final control diagnosis; final control diagnosis: carry out. Final control diagnosis final control
diagnosis: carry out.
4 Pressure retention valve with connection hose

◆ Close the fuel tank ventilation closes when the solenoid valve -N80- is opened and there is a vacuum in
the intake manifold
2.4 - Servicing parts of the activated charcoal filter system: repairing 147
5 Deaeration line
◆ White
◆ From the gravity valve in the fuel tank => page 126 , pos. 2
6 Throttle valve control unit
7 10 Nm

2.5 - Deaeration of the fuel tank: testing
◆ Manual vacuum pump SAT 1390

◆ Vacuum tester V.A.G. 1368
◆ Adapter SAT 1368/1
2.5 - Deaeration of the fuel tank: testing 149

Test process
- -> Remove the deaeration line -2- of the active charcoal filter -1- from the throttle valve control unit -3-.
- Connect the manual vacuum pump SAT 1390 to the line -2-.
- Remove the ventilation pipe -5- that goes from the fuel tank to the active charcoal filter and connect it to the
decompression tester V.A.G. 1368 -intake A-; use the adapter SAT 1368/1.
- Connect the decompression tester V.A.G. 1368 -intake B- to the ventilation pipe -4- to the active charcoal
filter; use the adapter SAT 1368/1.
- Set the decompression tester at position -B-.
- Start the actuator diagnosis and select the solenoid valve for active charcoal filter -N80-:
=> Rep. Group 01; Actuator diagnosis; Actuator diagnosis: carrying out. Actuator diagnosis Actuator diagnosis:
carrying out.
- Activate the manual vacuum pump SAT 1390 several times. No decompression should occur.
If decompression occurs:
- Check the breather connection -6- of the active charcoal filter -1- for dirt; if necessary, clean it.
If no decompression occurs:
- Unscrew the fuel filler cap.

- -> Connect the manual vacuum pump SAT 1390 to the decompression tester V.A.G. 1368 -intake B-.
- Set the decompression tester at position -A/B-.
- Activate the SAT 1390 several times. No decompression should occur.
- Check the gravity valve => page 126 , pos. 2

- Check the continuity of flow in the line -1- from the fuel tank.
If no decompression occurs:
- Screw the fuel filler cap back on.

- Operate the manual vacuum pump SAT 1390 several times. No decompression should occur.
Note:
If the level in the fuel tank is low, the manual vacuum pump must be operated approx. 20...30 times.
- Replace the fuel filler cap.

3 - Electronic engine output control (electronic accelerator)

3.1 - Electronic engine output control (electronic accelerator)
3.2 - Electronic accelerator system operation
With the electronic accelerator, the throttle valve is not activated by a drive cable from the accelerator. There
is no mechanical connection between the accelerator and the throttle valve.
The accelerator position is sent to the engine control unit via two accelerator position senders (variable resistors;
housed in the housing) that are connected to the accelerator.
The accelerator position (driver's intentions) is a basic entry magnitude for the engine control unit.
Activation of the throttle valve is produced by an electric motor (throttle valve actuator), incorporated in the
throttle valve control unit, throughout the range of revs and loads.
The throttle valve is activated by the throttle valve actuator in function of the data supplied by the engine control
unit.
With the engine running (with load), the engine control unit can open or close the throttle valve, independently
of the accelerator position sender.
In this way, the throttle valve can, for example, be already open fully although the accelerator is only depressed
half way. The advantage of this is that losses due to choking caused by the throttle valve are avoided.
Moreover, in this way, in certain load states, much better emission and fuel consumption values are achieved.
The necessary engine torque can be generated by the engine control unit via an optimum throttle valve opening
angle and the supercharging pressure.
It would be a mistake to believe that the "electronic accelerator" is made up of only one or two components.
The electronic accelerator is a system containing all those components which take part in determining the
throttle valve position, regulating and monitoring it, e.g. the accelerator position sender, the throttle valve control
unit, the EPC warning lamp, the engine control unit, etc.
3.1 - Electronic engine output control (electronic accelerator) 151

3.3 - Electronic engine output control(electronic accelerator) components: repairing
Engine codes letters: APE, AXP, AUS
1 Mount
◆ Remove and fit
◆ Running gear; Rep. Group 46; Brake, mechanics, Fitting chart for brake pedal mount
2 Connector
◆ Black, 6-pin
3 10 Nm
4 Accelerator position sender -G79-
◆ Test => page 154 .
5 Mount
◆ For footwell cover
◆ Fitted in the position sender

3.4 - Electronic accelerator drive fault lamp: testing
Note:
The electronic accelerator drive fault lamp is also called the EPC warning lamp.
-> Location of the EPC warning lamp.

Test of operation
The EPC warning lamp should light up.

- Start the engine and let it idle
The warning lamp should go off if no fault has been found in the electronic accelerator.
If the warning lamp does not go off:

=> Electrical system; Repair Group 01; Instrument panel; self-diagnosis of instrument panel with CAM BUS.
Instrument panel self-diagnosis of instrument panel with CAM BUS.
3.5 - Accelerator position senders: testing
3.4 - Electronic accelerator drive fault lamp: testing 153

◆ Hand-held multimeter V.A.G. 1526 A

◆ Auxiliary measurement set V.A.G. 1594 A or V.A.G. 1594 C
◆ Test box V.A.G. 1598/22
◆ Test box V.A.G. 1598/31 (for engines AUS only)
◆ Fault reader V.A.G. 1551 or vehicle systems checker V.A.G. 1552 with cable V.A.G. 1551/3B
◆ Wiring diagrams
Operation
The two accelerator pedal position senders -G79- and -G185- are on the accelerator and send complete driver
intentions to the engine control unit independently of each other. Both senders are located in the housing.
Test conditions
• The fuses must be OK.

• Minimum battery voltage, 11.5 V.
Test procedure
- Connect the V.A.G. 1551 (V.A.G. 1552), switch on the ignition and enter the "address code 01" to select the
engine control unit.
=> Self-diagnosis; Rep. Group 01; Fault reader V.A.G. 1551: connecting and selecting the engine control unit.
Fault reader V.A.G. 1551: connecting and selecting the engine control unit.
-> Reading on display:

Rapid data transmission HELP
Select function XX
- Press 0 and 8 for function "Read measurement value block" and press Q to confirm the entry.
Reading on display:
- ->
Read measurement value block HELP
Enter value group number XXX
Press 0, 6 and 2 for "Display group number 62" and press Q to confirm the entry.
-> Reading on display:

(1...4 = display fields)
Read measurement value block 62
⇒
1 2 3 4
- Check the target value for sender 1 (G79) at idle in display field 3.
Target value: 10...97% (engines AHW, APE, AXP)
Target value: 0...100% (engines AUS)
- Check the target value for sender 2 (G185) at idle in display field 4.
Target value: 4...49% (engines AHW, APE, AXP)
Target value: 0...100% (engines AUS)
Note:
The engine control unit converts the angle sender voltage values expressed into percentages referring to 5
volts and displays these percentages (5 volts of supply equals 100%).
- ctivate the accelerator slowly to full gas and watch the percentages in the display fields 3 and 4.
The percentage in display fields 3 and 4 should rise steadily. The complete tolerance range is not used:
10...97% (engines AHW, APE, AXP)
0...100% (engines AUS)

If the messages described are not displayed:

- Test the voltage supply and the wiring connections of the accelerator pedal position senders =>page
155 .
Test the voltage supply and wiring to the engine control unit
- Remove the driver side parcel tray:
=> Bodywork - interior fitting work; Rep. Group 70; Dash panel; Driver side parcel tray: removing. Dash panel
Driver side parcel tray: removing.
- Detach the 6-pin connector for the accelerator pedal position sender.
- -> Connect the multimeter to measure the voltage at the following connector contacts:
Contact 1 + Earth
Contact 1 + 5
Contact 2 + Earth
Contact 2 + 3
Target value: minimum 4.5 V
- Switch off the ignition.
If the target values are not reached:

- -> Connect test box V.A.G. 1598/22 to the control unit wiring harness without connecting the control unit (on
AUS engines use test box V.A.G. 1598/31).
3.5 - Accelerator position senders: testing 155

- -> Test for open circuits in the wiring between the test box and the connector following the wiring diagram.
AHW-APE-AXP AUS
Contact 1 Female contact 6 Female contact 72
Contact 2 + Female contact 8 Female contact 73
Contact 4+ Female contact 33 Female contact 35
Wire resistance: 1.5 ωmax.
- Test the wiring for short circuits to battery positive or earth.

- Also test for short circuits between wires.
- If no faults are found in the wiring:
- Replace the accelerator position sender=>page 152 . pos. 4 .

26 - Exhaust system
1 - Exhaust system components: removing and installing

1.1 - Exhaust system components: removing and installing
1.2 - Catalytic converter Checking
Engine codes: AZD
Special tools, workshop systems, testers, measuring instruments and auxiliary items required
◆ V.A.G 1551 fault reader or V.A.G 1552 vehicle system tester

◆ V.A.G 1551/3B Cable
1.1 - Exhaust system components: removing and installing 157

◆ V.A.G 1788/10 Engine speed adjuster
Note:
If system tester V.A.G 1552 is used the results cannot be printed
Check conditions
• -> Fuse no. 43, OK.

• Vehicle stationary
• All electric consumers, e.g.: lights and rear window heater must be switched off.
• If the vehicle is equipped with an air conditioner, this must be switched off.
• Exhaust system between catalytic converter and cylinder head must be free of leaks.
• Coolant temperature minimum 80oC => display group 04, display zone 3
• Coolant temperature minimum 60oC => display group 04, display zone 4
Functional check
- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and use address code 01 to select engine
control unit. Connecting fault reader and selecting engine control unit
=> Repair group 01; Self-diagnosis; V.A.G 1551 Fault reader: connecting and selecting engine electronics
control unit. Self-diagnosis V.A.G 1551 Fault reader: connecting and selecting engine electronics control unit.
Lambda probe ageing diagnostic (period monitoring)
-> Indicated on display:

Rapid data transfer HELP
Select function XX
- Press keys 0 and 4 for the function "Begin basic setting" and confirm entry with the Q key.

Basic setting
Input display group number XXX
- Press keys 0, 3 and 4 for "Display group number 34" and confirm entry with Q key.

(1...4 = Display fields)
System in basic setting 34
⇒
1 2 3 4
- Give two throttle bursts, raising RPMs over 5000.

- Operate the brake pedal with the help of engine speed adjuster V.A.G 1788/10 to keep engine speed at
2500...4000/min.
158 26 - Exhaust system

- Leave the engine at a high speed until field 4 on the display jumps from "Test OFF" to "Test ON". The catalyst
temperature in display zone 2 must be at least de 300ºC.
Note:
This process can take a few minutes.
- Leave the engine at a high speed until the specification "F1-S1 OK" appears in display zone 4.
If the display does not indicate as described:
- Press ⇒key.
- Interrogate fault memory=>Repair Group 01; Self-diagnosis; Fault memory: consulting and erasing.
- Read out readiness code:
=> Repair group 01; Readiness code: consulting Readiness code: consulting
- If the fault memory has been erased or the voltage supply cut to the engine control unit the readiness code
must be generated again.
=> Repair group 01; Readiness code; readiness code: generating: Readiness code readiness code: generating:
If the display indicates as described:
- Press C key.
- Remove engine speed adjuster V.A.G 1788/10 and engine speed falls until the idling speed is reached.
- Proceeding with catalytic converter diagnosis.
Catalytic converter diagnosis
Note:
This diagnosis will only be terminated if the Lambda probe ageing diagnosis is first successfully completed.
- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and use address code 01 to select engine
control unit. Connecting fault reader and selecting engine control unit
=> Repair group 01; Self-diagnosis; V.A.G 1551 Fault reader: connecting and selecting engine electronics
control unit. Self-diagnosis V.A.G 1551 Fault reader: connecting and selecting engine electronics control unit.

Rapid data transfer HELP
Select function XX
- Press keys 0 and 4 for the function "Begin basic setting" and confirm entry with the Q key.

Basic setting
Input display group number XXX
- Press keys 0, 4 and 6 for "Display group number 46" and confirm entry with Q key.

(1...4 = Display fields)
System in basic setting 46
⇒
1 2 3 4
- Operate the brake pedal with the help of engine speed adjuster V.A.G 1788/10 to keep engine speed at
about 2500... 4000 RPM.
- Leave the engine at a high speed until field 4 on the display jumps from "Test OFF" to "Test ON". The catalyst
temperature in display zone 2 must be at least de 300ºC.
1.2 - Catalytic converter Checking 159

Note:
This process can take a few minutes.
- Leave the engine at a high speed until the theoretical value "Cat F1 OK" appears in field 4 on the display.
If the display indicates as described:
- Press ⇒key.
- Remove engine speed adjuster V.A.G 1788/10 and engine speed falls until the idling speed is reached.
- Press keys 0 and 6 for the "End output" function and confirm input with the Q key.
- Switch off ignition.
If the display does not indicate as described:
- Interrogate fault memory.
Note:
If "Cat F1 no OK" is displayed, the catalytic converter need not always be renewed, but only if the next emissions
test is not passed or if visible damage to catalytic converter can be determined.
If the emissions test is not passed or if damage to catalytic converter can be determined:
- Renew catalyst.
- Read out readiness code:
=> Repair group 01; Readiness code: consulting Readiness code: consulting
- If the fault memory has been erased or the voltage supply cut to the engine control unit the readiness code
must be generated again.
=> Repair group 01; Readiness code; readiness code: generating: Readiness code readiness code: generating:

1.3 - Exhaust manifold, front exhaust pipe with catalyst and accessory parts
Engine code letters AHW
1 Hot air pick up plate

2 10 Nm
◆ Bear in mind the tightening order
=>page 168 , fig. 5
3 Exhaust manifold
4 Gasket
◆ Replace
5 Washer
6 Safety nut, 25 Nm
7 Exhaust recirculation valve flange
◆ => page 174 , pos. 9
8 Mark
◆ Three times around the perimeter
9 Toward the presilencer
1.3 - Exhaust manifold, front exhaust pipe with catalyst and accessory parts 161
10 Protective plate
11 Front exhaust pipe with catalyst
12 Microcatalyst
◆ According to versions
13 Lambda probe, 55 Nm
◆ Grease threads only with "G5". The "G5" should not get in the grooves in body of the probe
◆ Remove and install with U-40080
◆ Testing:
=> Rep. Group 24; Functions: testing, Lambda control: testing Functions: testing, Lambda control: testing
14 40 Nm
15 Gasket
◆ Replace
16 Support

Engine code letters: APE, AXP, AUS
1 Hot air intake flap

2 10 Nm
◆ Bear in mind the tightening order
=>page 168 , fig. 5
3 Exhaust manifold with pre-catalyst
4 Gasket
◆ Replace
5 Lock nut, 25 Nm
6 Lambda probe after the catalyst,
50 Nm
◆ Grease thread with "G5" only. The "G5" must not get into the grooves in the probe body
◆ Remove and fit with U-40080
◆ Test:
=> Rep. Group 24; Functions: testing; Lambda regulation: testing Functions: testing Lambda regulation: testing
1.3 - Exhaust manifold, front exhaust pipe with catalyst and accessory parts 163
7 Towards the presilencer

8 Mark
◆ Three times around the perimeter
9 Main catalyst
10 Front exhaust pipe
11 Shield
12 40 Nm
13 Gasket
◆ Replace
14 Lambda probe before the catalyst,
50 Nm
◆ Grease thread with "G5" only. The "G5" must not get into the grooves in the probe body
◆ Remove and fit with U-40080
◆ Test:
=> Rep. Group 24; Functions: testing; Lambda regulation: testing Functions: testing Lambda regulation: testing
15 Mount

1.4 - Silencer with fasteners
1 From front exhaust pipe with catalyst

2 Double clamp
◆ Check assembly position=> fig. 1
3 40 Nm
◆ Replace
4 Suspension element
◆ Check assembly position=> fig. 2
5 25 Nm
6 Rear silencer
◆ Install and adjust the silencer without stress points=> fig. 4
1.4 - Silencer with fasteners 165

7 Cutting point
◆ The middle silencer and rear silencer come as a single piece. For repairs, the middle and rear silencers
are supplied separately with a double clip to hold them together
◆ Cut the union pipe perpendicularly along the marked area with the U-40075 => fig. 3
◆ For repairs
◆ Marked with three marks around the perimeter of the union pipe
8 25 Nm
9 Tunnel bridge
10 Suspension element

-> Fig. 1 Double clamp assembly position
- Place the double clamp some 5 mm from the mark -A- -arrow 1-.
-> Fig. 2 Suspension element assembly position
- The L-shaped part of the suspension element -arrow- indicates the direction of travel.
-> Fig. 3 Cutting point on the exhaust pipe
- Cut the exhaust pipe perpendicularly at the point indicated with-arrow 2-; use the U-40075.
- When installing the double repair clamp -4-place it between thelateral marks -arrows 1 and 3-.
1.4 - Silencer with fasteners 167

-> Fig. 4 Align the silencer without stress
- The holding pin of the centre silencer must be parallel to the tunnel bridge (dimensions -X- same at both
sides).
-> Fig. 5 Tightening order: hot air intake flap to intake manifold.
- Tighten bolt -1- and then -2- and finally -3- to 10 Nm.
1.5 - Front exhaust pipe with catalyst: replacing
- -> Remove the fixing bolt from the articulated shaft and remove the crosshead.
- Remove the soundproofing tray from the engine.
- Separate the front exhaust pipe from the manifold.
- Loosen the double clip holding the catalyst to the middle presilencer.
- Disconnect the lambda probe.

- Remove the bolts holding the gearbox lever mount to the engine unit crossmember.
- Remove the front heat shield and catalyst shield.

- Remove the bolts holding the swing support to the gearbox.
- -> Partially lower the engine unit crossmember with hydraulic jack SAT 1001. To do so, remove bolts 2 and
3.
- Remove forwards the front exhaust pipe with catalyst.
Refit in the reverse order.
1.6 - Catalyst: testing
Engine code letters: APE, AXP, AUS

◆ Fault reader V.A.G. 1551 or vehicle systems checker V.A.G. 1552 with lead V.A.G. 1551/3B
◆ -> Pedal actuator V.A.G. 1788/10
1.5 - Front exhaust pipe with catalyst: replacing 169

Test conditions
◆ -> Fuse no. 43, OK.

◆ Vehicle stopped.
◆ All electrical consumers, e.g. lights and heated rear window, must be off.
◆ On vehicles with air conditioner, the AC must be off.
◆ Exhaust system, airtight between the catalyst and cylinderhead.
◆ Coolant temperature minimum 80 °C =>display group 04, display field 3.
◆ Intake air temperature below 60°C=>display group 04, display field 4.
Operating test
- Connect the V.A.G. 1551 (V.A.G. 1552). Start the engine and select the engine control unit with "address
code 01". Connect the fault reader and select the engine control unit.
=> Rep. Group 01; Self-diagnosis; Fault reader V.A.G. 1551: connecting and selecting the engine electronics
control unit. Self-diagnosis Fault reader V.A.G. 1551: connecting and selecting the engine electronics control
unit.
Lambda probe ageing diagnosis (lasting cycle monitoring)
-> The display reads:

Select function XX
- Press 0 and 4 for the function "start basic settings" and press Q to confirm the entry.

Start basic settings
- Press 0, 3 and 4 for "Display group number 34" and press Q to confirm the entry.

System in basic settings 34
1 2 3 4
Code letters APE, AXP
- Depress the brake pedal and hold it with the V.A.G. 1788/10, engine revs are raised to about 1100 ... 1400
rpm by the engine control unit.
Code letters AUS
- Hold revs at 1500 ... 3900 rpm, depressing the accelerator pedal with the V.A.G. 1788/10.
- Let the engine run at high revs until the reading in display field 4 changes from "Test OFF" to "Test ON".
The catalyst temperature in display field 2 should reach at least 300 °C.
Note:
This process may take a few minutes.
- Let the engine run at high revs until display field 4 shows the target value "F1-S1 OK".
If this message does not appear:
- Press ⇒.
=> Rep. Group 01; Self-diagnosis; Fault memory: consulting and clearing. Self-diagnosis Fault memory: con‐
sulting and clearing.

Code letters AXP and AUS only
- Consult the conformity code:
- If the fault memory has been cleared or there has been an interruption in the continuous positive voltage
supply of the engine control unit, regenerate the conformity code:
=> Rep. Group 01; Conformity code; Conformity code: generating. Conformity code Conformity code: gener‐
ating.
If the message described appears:
- Press C.
- Engine revs fall to idling revs, remove actuator V.A.G. 1788/10.
Code letters AUS
- Remove actuator V.A.G. 1788/10 and engine revs fall to idling revs.
Catalyst diagnosis
Note:
This diagnosis concludes only after the lambda probe ageing diagnosis has been carried out successfully.
- Connect the V.A.G. 1551 (V.A.G. 1552). Start the engine and select the engine control unit with "address
code 01". Connect the fault reader and select the engine control unit.
=> Rep. Group 01; Self-diagnosis; Fault reader V.A.G. 1551: connecting and selecting the engine electronics
control unit. Self-diagnosis Fault reader V.A.G. 1551: connecting and selecting the engine electronics control
unit.

Select function XX
- Press 0 and 4 for the function "start basic settings" and press Q to confirm the entry.

Start basic settings
- Press 0, 4 and 6 for "Display group number 46" and press Q to confirm the entry.

System in basic settings 46
1 2 3 4
- Depress the brake pedal and hold it with the V.A.G. 1788/10, engine revs are raised to about 1100 ... 1400
rpm by the engine control unit.
Code letters AUS
- Hold revs at 1500 ... 3900 rpm, depressing the accelerator pedal with the V.A.G. 1788/10.
1.6 - Catalyst: testing 171

- Let the engine run at high revs until the reading in display field 4 changes from "Test OFF" to "Test ON".
The catalyst temperature in display field 2 should reach at least 300 5C.
Note:
This process may take a few minutes.
- Let the engine run at high revs until display field 4 shows the target value "Cat F1 OK".
If the message described appears:

- Press ⇒.

- Engine revs fall to idling revs, remove actuator V.A.G. 1788/10.
Code letters AUS

- Remove actuator V.A.G. 1788/10 and engine revs fall to idling revs.
- Press 0 and 6 for the function "End transmission" and press Q to confirm the entry.
- Switch off the ignition.
If the message described does not appear:

Code letters AXP and AUS only
Note:
Is display reads "CatF1no OK" that does not necessarily mean that the catalyst must be replaced completely;
only when the vehicle has not passed emissions inspection or there is visible damage to the catalyst.
If the vehicle does not pass emissions inspection or the catalyst is damaged:
- Replace the catalyst.
- Consult the conformity code:
=> Rep. Group 01; Conformity code; Conformity code: consulting. Conformity code Conformity code: consulting.
- If the fault memory has been cleared or there has been an interruption in the continuous positive voltage
supply of the engine control unit, regenerate the conformity code:
=> Rep. Group 01; Conformity code; Conformity code: generating. Conformity code Conformity code: gener‐
ating.
2 - Exhaust recirculation system

2.1 - Exhaust recirculation system
Engine code letters AHW: => page 173 .

Engine code letters APE, AXP, AUS: => page 176 .
Notes:
◆ The control unit 4AV (J448) excites the exhaust recirculation system via the recirculation solenoid valve
(N18) and the latter activates the exhaust recirculation valve.

◆ Exhaust recirculation valve (N18): testing
=> Rep. Group 01; Actuator diagnosis; Actuator diagnosis: carrying out. Actuator diagnosis Actuator diagnosis:
carrying out.
◆ The mechanical valve for exhaust recirculation with conical tappet permits different aperture sections ac‐
cording to valve strokes.
◆ Because of the cadenced activation, any valve position can be obtained.
2.2 - Exhaust recirculation system components: repairing
Engine code letters: AHW

1 Exhaust recirculation valve -N18-
◆ Testing
2 Throttle valve control unit -J338-

3 Gasket
◆ Replace
4 Breather hole
5 Ring gasket
2.1 - Exhaust recirculation system 173

◆ Replace
6 10 Nm
7 Union pipe
8 35 Nm
9 Exhaust recirculation valve
10 Filter
11 Connector
◆ Bipolar

2.3 - Exhaust recirculation valve: testing
◆ -> Manual vacuum pump SAT 1390
Test process
- Detach the decompression hose from the exhaust recirculation valve.

- Connect the manual vacuum pump SAT 1390 to the valve.
- Start the engine and run at idle.
- -> Operate the vacuum pump. The idling speed should change. When the valve is completely open the
engine stops.
If idling speed does not change:
- Remove the exhaust recirculation valve.

- Operate the decompression pump. The valve should open.
- Eliminate the decompression. The valve should open.
- Also check for clogging in the exhaust recirculation system.
2.3 - Exhaust recirculation valve: testing 175

Engine code letters: APE-AXP-AUS
1 Gasket
◆ Replace
2 10 Nm
3 Connecting line
4 Filter
5 20 Nm
6 Exhaust recirculation valve -N18- with pot. for exhaust recirculation -G212-
◆ Test
=> Rep. Group 01; Final control diagnosis: carrying out Final control diagnosis: carrying out
◆ If the valve has been replaced, it must be adapted with measurement value block 75
=> Rep. Group 01; Conformity code; Conformity code: consulting Conformity code Conformity code: consulting

7 Seal
◆ Replace
8 Intake hole
9 Throttle valve control unit -J338-
2.3 - Exhaust recirculation valve: testing 177

S01AAHW8820-4 Cyl Injection Engine (4V) Mechanics

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S01AAHW8820-4 Cyl Injection Engine (4V) Mechanics

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Service

Toledo 1999 , León ➤

Service Department. Technical Information

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Copyright © 2010 Seat S.A S01AAHW8820

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

1.3 Oil pump: removing and install-ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157

1.2 - Engine number

1.3 - Engine characteristics

Code letters AHW APE AXP AZD AUS

1.1 - Technical data 1

Lambda control Yes Yes3) Yes3) Yes3) Yes3)

1) In exceptional cases, min. octane 91 ROZ, but with power loss.

2) In exceptional cases, min. octane 95 ROZ, but with power loss.

3) With 2 lambda probes.

10 - Removing and installing engine

1 - Engine: removing and install-ing

◆ Tray V.A.G. 1306

1.1 - Engine: removing and install-ing 3

If engine must be disassembled:

◆ -> Engine support Ar-2204 A

◆ -> Holding flanges T20082

1.2 - Removing: instructions

- The engine is removed upwards along with the gearbox.

- Remove front bumper:

- Set the lockholder cover in service position:

4 10 - Removing and installing engine

- -> Remove battery and battery support.

- Separate from their holders the following components:

- Remove the gearbox change control:

- Remove the soundproofing sump:

1.2 - Removing: instructions 5

◆ Lambda probe connector

- Drain the coolant => page 11 .

Continue for all vehicles

Clutch pedal must not be pressed.

6 10 - Removing and installing engine

1.2 - Removing: instructions 7

1.3 - Installing: instructions

- Install the hydraulic clutch slave cylinder (pump):

- Install the gear changing mechanism on the gearbox:

- Install the air conditioning compressor.

=> Electrical system; Rep. Group 97;

- Install the Poly-V belt => page 21 .

8 10 - Removing and installing engine

- Do a road test and consult the fault memory:

1.4 - Tightening torques

Connection to bolts Tightening torque

1.5 - Engine unit supports

-> Engine unit supports, engine

A1) - 40 Nm + 90° (1/4turn)

1.3 - Installing: instructions 9

-> Engine unit supports, gearbox

A1) - 40 Nm + 90° (1/4 turn)

-> Swing support

A1) = 40 Nm + 90° (1/4 turn)

- Remove the clamp(s) of the coolant hoses.

Protect the bumper with adhesive tape.