Technical data Page 1 of 3

00-1

Technical data
Engine identification

The engine code and serial number are stamped on the left side on the
cylinder block above the oil filter.

A sticker with the engine code and serial number is attached to the
cylinder head cover.

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The engine code is also listed on the vehicle data label.

Note:

The engine identification is also stamped on the front engine mounting

bracket (visible after removing cover above fuel injectors).

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Technical data Page 2 of 3

00-2

Engine specifications

Engine code AEB ATW

Manufactured 11.94 tbd
Displacement liters 1.781 1.781
Output kW @ RPM 110/5700 110/5700

HP @ RPM 150/5700 150/5700

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Torque Nm @ RPM 210/1750 210/1750

Ft lb @ RPM 155/1750 155/1750

Bore diameter mm (in.) 81.0 (3.189) 81.0 (3.189)
Stroke mm (in.) 86.4 (3.402) 86.4 (3.402)
Compression ratio 9.5:1 9.5:1
RON minimum 95 tbd
Fuel injection and ignition system Bosch Motronic Bosch Motronic
Knock sensor control Yes Yes
On Board Diagnostic (OBD) OBD II OBD II
Oxygen sensor control Yes Yes
Three Way Catalytic Converter (TWC) Yes Yes
Turbocharger Yes Yes
Exhaust Gas Recirculation (EGR) No tbd
Intake manifold change-over valve No tbd

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Technical data Page 3 of 3

00-3

Engine code AEB ATW

Camshaft adjustment No No
Valve timing: at 1mm valve lift and 0 mm valve lash:
Intake valve opens after TDC 18 tbd
Intake valve closes after BDC 28 tbd
Exhaust valve opens before BDC 28 tbd

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Exhaust valve closes before TDC 8 tbd

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Engine, disassembling and assembling Page 1 of 38

13-1

Engine, disassembling and

assembling
Lock carrier, moving into service position

Special tools and equipment

3369 support tool

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1 - Bolts
45 Nm (33 ft lb)
2 - Bolts
45 Nm (33 ft lb)
3 - Bolts
10 Nm (7 ft lb)
4 - Bolts
10 Nm (7 ft lb)
5 - Bore
For 3369 support tool
6 - Lock carrier bore
7 - Fender bore

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Engine, disassembling and assembling Page 2 of 38

13-2

- Remove front bumper.

Repair Manual, Body Exterior, Repair Group 63

- Remove 3 quick-release screws on front of noise

insulation panel.
- Unbolt air guide between lock carrier and air filter
at lock carrier.

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- If installed, remove retaining clamps for wiring
harness on left side of radiator frame.
- Remove bolt -2- and install 3369 support tool.
- Install 3369 support tool into left bore -5-.
- Remove bolts -1- and -3-.
- Remove bolts -4- and pull lock carrier out to
stop.
- To secure lock carrier, install appropriate M6
bolts into rear bored holes of lock carrier -6- and
fender -7-.

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13-3

- After installing lock carrier, check wiring for

proper routing near coolant fan.
- Install front bumper.

Repair Manual, Body Exterior, Repair Group 63

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Engine, disassembling and assembling Page 4 of 38

13-4

Ribbed belt for power steering pump,

generator and viscous fan, and V-belt for
coolant pump

CAUTION!

Before removing ribbed belt, note direction of

rotation with chalk or felt-tip marker. Reversing
the direction of rotation of a used belt can
destroy the belt. When installing the ribbed belt,

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make sure it is seated correctly on the pulley.

1 - Fan wheel bolt

10 Nm (7 ft lb)
2 - Fan wheel
For viscous fan
Removing and installing Page 13-14 ,
Fig. 1
3 - Coolant pump pulley bolt
25 Nm (18 ft lb)
4 - Belt pulley
For coolant pump
V-belt design
Installed position: straight side toward
coolant pump

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13-5

5 - Ribbed belt
Removing and installing Page 13-15
Check for wear
6 - Special bolt
Tighten to 40 Nm (30 ft lb)
Only use VW bolts, bolt strength grade

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10.9 parts catalog
7 - Vibration damper
With pulley for ribbed belt
Installation only possible in one position
Page 13-14 , Fig. 2
8 - Bolt for ribbed belt tensioner
25 Nm (18 ft lb)
9 - Ribbed belt tensioner
To release tension on the ribbed belt, use
open-end wrench Page 13-15
Secure with appropriate hex socket or
3204 drift in positioning bore
10 - Belt pulley
For viscous fan
Removing and installing Page 13-14 ,
Fig. 1

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13-6

11 - Circlip
For viscous fan bearing
Removing and installing Page 13-20
12 - Bolt for belt pulley
10 Nm (7 ft lb)
13 - Bearing

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For viscous fan
Removing and installing Page 13-20
14 - T-head bolt
Insert before installing bracket for
generator, power steering pump and
viscous fan
15 - Nut
40 Nm (30 Nm)
16 - Bolt
25 Nm (18 ft lb)

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13-7

17 - Generator
Removing:
- Disconnect battery Ground (GND) strap.
- Loosen ribbed belt and remove from
generator Page 13-15 .
- Remove air guide at throttle body.
- Remove upper and lower threaded

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assemblies.
- Swing generator slightly to side and
remove lower bolt.
- Remove wiring from generator.
- Remove generator.

Note:

For easier installation of generator into the bracket,

push back lower bolt bushing slightly.

18 - Bolt
40 Nm (30 ft lb)
19 - Bolt
40 Nm (30 ft lb)
20 - Brace
To cylinder block

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21 - Bolt
25 Nm (18 ft lb)

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13-8

22 - Brace
For intake manifold
23 - Bolt
20 Nm (15 ft lb)
24 - Bolt
40 Nm (30 ft lb)

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25 - Bolt
25 Nm (18 ft lb)
26 - Bolt
25 Nm (18 ft lb)
27 - Bracket
For generator, power steering pump and
viscous fan
Removing and installing Page 13-22
Different length bolts
Arrangement and tightening sequence
Page 19-16
28 - Power steering pump
Removing and installing Repair Manual,
Suspension, Wheels, Steering, Repair
Group 48
29 - Bolt

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Engine, disassembling and assembling Page 10 of 38

25 Nm (18 ft lb)

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13-9

30 - Coolant pump
With coolant regulator
Removing and installing Page 19-13
31 - Belt pulley
For power steering pump
Designed for ribbed belt

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Install with bulged side facing in driving
direction
32 - Belt pulley
For power steering pump
Designed for ribbed belt
33 - Bolt
25 Nm (18 ft lb)
34 - V-belt
For coolant pump
Removing and installing Page 13-18
35 - Viscous clutch
Removing and installing Page 13-14 ,
Fig. 1

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13-10

Ribbed belt for air conditioning

CAUTION!

The A/C refrigerant circuit must not be

opened.
Before removing ribbed belt, note direction of
rotation with chalk or felt-tip marker.
Reversing the direction of rotation of a used

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belt can destroy the belt. When installing the
ribbed belt, make sure it is seated correctly
on the pulley.
1 - Bolt
25 Nm (18 ft lb)
2 - Refrigerant lines
Do not unbolt or separate
3 - Bushing
Verify proper seating in bracket
4 - Bolt
For bolt strength grade 8.8, tighten to 25
Nm (18 ft lb) parts catalog
For bolt strength grade 10.9, tighten to 30
Nm (22 ft lb) parts catalog

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13-11

5 - Bracket
For A/C compressor
6 - Ribbed belt tensioner
Removing and installing Page 13-15
7 - Washer
8 - Bolt

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20 Nm (15 ft lb)
9 - Ribbed belt
Removing and installing Page 13-15
Check for wear
10 - A/C compressor
After removing, secure A/C compressor to
long member (i.e. using wire).

CAUTION!

Do not let A/C compressor hang by refrigerant

lines.

11 - Washer

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13-12

V-belt and ribbed belt, routing overview

1 - Ribbed belt tensioner

2 - Generator
3 - Viscous clutch
4 - Coolant pump
5 - Power steering pump

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6 - V-belt
For coolant pump
Removing and installing Page 13-18
7 - Ribbed belt
For generator, power steering pump and
viscous fan
Removing and installing Page 13-15

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13-13

8 - Vibration damper
9 - Ribbed belt tensioner
For A/C compressor
10 - Ribbed belt
For A/C compressor
Removing and installing Page 13-15

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11 - A/C compressor

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13-14

Fig. 1 Viscous fan, removing and installing

Lock carrier in service position Page 13-1

Ribbed belt free of tension Page 13-15

- Secure belt pulley for viscous fan with 5 x 60 mm bolt and remove
using hex socket wrench.
- Remove viscous fan.

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- When installing viscous fan, tighten to 45 Nm (33 ft lb).

Fig. 2 Install vibration damper

Lock carrier in service position Page 13-1

Ribbed belt removed Page 13-15

- Install vibration damper using only original equipment bolts (bolt
strength grade 10.9) parts catalog.

Installation is only possible in one position: the bore hole of the vibration
damper (arrow) must align with raised portion of toothed belt gear.

- Tighten vibration damper bolts to 40 Nm (30 ft lb).

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13-15

Ribbed belt, removing and installing

Lock carrier in service position Page 13-1

CAUTION!

Before removing ribbed belt, note direction of

rotation with chalk or felt-tip marker.
Reversing the direction of rotation of a used

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belt can destroy the belt. When installing the
ribbed belt, make sure it is seated correctly
on the pulley.

Removing

- Remove noise insulation panel (arrows).

- Loosen bolts for ribbed belt tensioner for A/C compressor (arrows).
- Release tension on ribbed belt and remove belt.

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13-16

All models

- Move ribbed belt tensioner in direction of arrow to release tension on

ribbed belt.

Note:

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Ribbed belt tensioner can be locked in place by inserting a proper sized
angled hex socket wrench (arrow) or 3204 drift into locating bore.

- Remove ribbed belt and release tension on ribbed belt tensioner.

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13-17

Installing

Note:

When installing ribbed belt, make sure it is

seated correctly on the pulley.

- Place ribbed belt on belt pulleys for crankshaft,

viscous fan and power steering pump, (use tools
to pull up if necessary).

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- Move ribbed belt tensioner in direction of arrow.
- Install ribbed belt on belt pulley for generator last and release tension
on belt tensioner.
- Check ribbed belt for proper installation.
Ribbed belt routing Page 13-12
- Install ribbed belt for A/C compressor.
Ribbed belt routing Page 13-12

- Use torque wrench to pre-tighten belt tensioner hex screw to 25 Nm

(18 ft lb).
- Tighten bolts -A- to 20 Nm (15 ft lb) at same time.
- Start engine and check running of belt.

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13-18

V-belt, removing and installing

Lock carrier in service position Page 13-

17

Ribbed belt free of tension Page 13-15

Removing

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- Remove noise insulation panel (arrows).
- Remove viscous fan (with belt pulley) from bearing Page 13-14 , Fig.
1.

- Remove belt pulley for coolant pump. Use drift (arrow) to counterhold
at belt pulley for power steering pump.
- Remove V-belt.

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13-19

Installing

Installation is the reverse of removal, noting the

following:

- Install V-belt and loosely bolt both halves of belt

pulley to coolant pump.

- Slowly bring belt pulley halves together by

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turning coolant pump and tightening bolts for
belt pulley in stages.

While tightening pulley halves, the V-belt must

move outward and sit correctly on belt pulley.

- Tighten bolts to 25 Nm (18 ft lb).

Note:

Adjustment of V-belt tension for coolant pump is

not possible.

- Install ribbed belt and release tension on

tensioner.

- Start engine and check running of belt.

- Check tightening torque of bolts for coolant

pump belt pulley.

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13-20

Bearing for viscous fan in mounting

bracket, removing and installing

Lock carrier in service position Page 13-1

Special tools and equipment

Hex nut from 3301 assembly tool

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Extractor pipe from 3350 installation device

3367 press out tool for viscous clutch fan

bearing bushing

Removing

- Remove ribbed belt Page 13-15 .

- Remove viscous fan (together with belt pulley)

Page 13-14 , Fig. 1 .

- Remove circlip (arrow) from bearing bushing.

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13-21

- Pull bearing from bracket using hex nut from 3301 assembly tool, bolt
from 3367 press out tool for viscous fan bearing bushing and 3350
extractor pipe.

Installing

Installation is the reverse of removal, noting the following:

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- Press in bearing using 3367 press out tool for viscous fan and hex nut
from 3301 assembly tool.
- Using circlip pliers, install circlip in viscous fan bracket.
- Install viscous fan Page 13-14 , Fig. 1.

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13-22

Mounting bracket for generator, power

steering pump and viscous fan,
removing and installing

Lock carrier in service position Page 13-1

Removing

CAUTION!

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Before disconnecting the battery, determine
the correct coding for the anti-theft radio.

- Switch ignition off and disconnect battery Ground (GND) strap.

- Remove ribbed belt and ribbed belt tensioner Page 13-18 .

Note:

Ribbed belt for A/C remains installed.

Ribbed belt, removing Page 13-15 .

- Remove belt pulley for power steering pump.

- Unbolt power steering pump from mounting bracket for generator,
power steering pump and viscous fan and tie to side.
All lines remain connected

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13-23

- Follow procedures for "Coolant pump, removing

and installing" Page 19-13 .

Note:

Coolant pump is bolted to mounting bracket for

generator, power steering pump and viscous fan.

Installing

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Installation is the reverse of removal, noting the
following:

- Replace O-ring for coolant pump (to guard

against leakage).

Tightening torques

Component Tightening
torque
Belt pulley to power steering 25 Nm (18 ft
pump lb)
Power steering pump to mounting
bracket for generator, power
steering pump and viscous fan 25 Nm (18 ft
lb)

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13-24

Toothed belt, overview

CAUTION!

Before removing toothed belt, note direction of

rotation with chalk or felt-tip marker. Reversing
the direction of rotation of a used belt can
destroy the belt. When installing the ribbed belt,
make sure it is seated correctly on the pulley.

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1 - Bolt
10 Nm (7 ft lb)
2 - Bolt
10 Nm (7 ft lb)
3 - Bolt
10 Nm (7 ft lb)
4 - Bolt
20 Nm (15 ft lb)
5 - Upper toothed belt cover
To remove, unbolt ribbed belt tensioner
When installing, carefully hook into lower
toothed belt cover

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13-25

6 - Toothed belt
Before removing, note direction of rotation
using chalk or felt-tip marker
Check for wear
Removing Page 13-29
Installing (adjusting valve timing) Page
13-32

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7 - Bolt for tensioner
25 Nm (18 ft lb)
8 - Nut
10 Nm (7 ft lb)
9 - Washer
10 - Bolt
65 Nm (48 ft lb)
Use 3036 retainer for loosening and
tightening
11 - Washer
12 - Camshaft gear
For exhaust camshaft
For removing and installing, remove
toothed belt Page 13-29
Installation position Fig. 1

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13 - Tensioner

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13-26

14 - Connecting bolt
25 Nm (18 ft lb)
For tensioner
15 - Rear toothed belt cover
16 - Bolt
20 Nm (15 ft lb)

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17 - Intermediate shaft gear
18 - Washer
19 - Toothed belt gear for crankshaft
Contact surface between toothed belt gear
and crankshaft must be free of oil
Installation only possible in one position
20 - Bolt for toothed belt gear for crankshaft
Always replace
90 Nm (66 ft lb) + additional 1/4 turn (90 )
Do not oil
Use 3099 retainer for loosening or
tightening
Attach 3099 retainer Page 13-39
To secure retainer, remove torque support
bracket Page 17-2 , item 5

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13-27

21 - Bolt
65 Nm (48 ft lb)
Use 3036 retainer when loosening or
tightening
22 - Toothed belt tensioner
23 - Bolt

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10 Nm (7 ft lb)
24 - Idler pulley
25 - Bolt
25 Nm (18 ft lb)
26 - Lower toothed belt cover
To remove, remove vibration damper

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13-28

Fig. 1 Installation position for camshaft gear

Thin rib of camshaft gear points outward (arrows) and TDC Cyl. 1 marking
is visible.

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13-29

Toothed belt, removing and installing

Removing

Engine installed

Lock carrier in service position Page 13-1

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Special tools and equipment

V159 pin wrench

- Remove ribbed belt and ribbed belt tensioner

Page 13-15 .

- Remove viscous clutch (with belt pulley) Page

13-14 , Fig. 1 .

- Remove upper toothed belt cover.

CAUTION!

Before removing toothed belt, note direction

of rotation with chalk or felt-tip marker.
Reversing the direction of rotation of a used
belt can destroy the belt.

- Turn crankshaft at central bolt of toothed belt gear in direction of

engine rotation to TDC Cyl.1 marking (arrows).

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13-30

- Remove vibration damper.

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- Remove lower toothed belt cover (arrows).

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13-31

- Using Torx wrench T45, loosen toothed belt tensioner (lower arrow).
- Push toothed belt tensioner downward.
- Remove toothed belt.

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13-32

Installing (adjust valve timing)

Note:

Use the following procedure to adjust toothed

belt, even for repairs that only require removal
of toothed belt from camshaft gear.

Adjustments can be made on a hot or cold

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engine.

CAUTION!

When turning camshaft, crankshaft may not

be at TDC for any cylinder. Valves and/or
piston heads may be damaged.

- Align marking on camshaft gear to marking on cylinder head cover.

- Place toothed belt on crankshaft gear noting direction of rotation.
- Install lower toothed belt cover.
- Using a bolt, secure vibration damper/belt pulley (note locating point).
- Set crankshaft to TDC Cyl. 1 position.
- Place toothed belt on belt tensioner and camshaft gear.

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13-33

- Tighten toothed belt by turning tensioner -A- to right using 2 pin

spanner (i.e. Matra V159 pin wrench) until cylinder -1- is fully extended
and tensioner -2- is raised by approx. 1 mm.
- Tighten mounting bolt -3- hand tight.
- Turn crankshaft 2 rotations in running direction.

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- Check area -A- for proper alignment with the upper edge of piston -2-
(Fig. A13-0012) and adjust if necessary.
Area -A-: adjustment OK
Area -B-: wear limit
Area -C-: re-adjust and check belt drive including tensioner for
wear

Note:

If edge of piston is located in area -A-, measurement -D- is between 25-29

mm (0.984-1.142 in.).

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13-34

- Counterhold toothed belt tensioner using 2 pin spanner -B- and tighten
mounting screw -3-.

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- Turn crankshaft at central bolt for toothed belt gear two rotations in
direction of engine rotation, until camshaft and crankshaft markings
align with their respective reference points.
- Install vibration damper/belt pulley.
- Install upper toothed belt cover.
- Install ribbed belt and ribbed belt tensioner Page 13-17 .

Note:

When installing the ribbed belt, make sure it is seated correctly on the
pulley.

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Engine, disassembling and assembling Page 38 of 38

13-35

Tightening torques

Component Tightening
torque
Toothed belt tensioner to
tensioner assembly
25 Nm (18 ft
lb)
Lower toothed belt cover M6 10 Nm (7 ft lb)

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to

cylinder block
M8 20 Nm (15 ft
lb)
Vibration damper/belt pulley to
crankshaft
40 Nm (30 ft lb)
1)

Ribbed belt tensioner to

mounting bracket
25 Nm (18 ft
lb)
1) Bolt strength grade: 10.9

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Sealing flange and flywheel/drive plate, removing and installing Page 1 of 11

13-36

Sealing flange and

flywheel/drive plate, removing
and installing
Note:

Servicing clutch:

Repair Manual, 5 Spd. Manual Transmission

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012/01W Front Wheel Drive, Repair Group 30
Repair Manual, 5 Spd. Manual Transmission
01A All Wheel Drive, Repair Group 30
1 - Oil seal
To remove, remove oil seal carrier, item -
15 -
Install using 10-203
Lightly oil lip of seal
2 - Woodruff key
Check for proper installation
3 - Connecting bolt
25 Nm (18 ft lb)
4 - Front oil seal flange
Before installing oil pan, spread sealant
AMV174 004 01 on joint between oil seal
flange and cylinder block.

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13-37

5 - Gasket
Always replace
6 - Cylinder block
Crankshaft, removing and installing
Page 13-46
Pistons and connecting rods,
disassembling and assembling Page 13-

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53
7 - Mounting bolt for dual-mass
flywheel/drive plate
Always replace
Tightening torque for dual-mass flywheel:
60 Nm (44 ft lb) + additional 1/2 turn (180
)
Tightening torque for drive plate (vehicles
with automatic transmission): 60 Nm (44 ft
lb) + additional 1/4 turn (90 )
8 - Dual-mass flywheel or drive plate
Removing and installing Page 13-43
9 - Intermediate plate
Must fit on bushings
Do not damage or bend while performing
repairs

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13-38

10 - Bolt
10 Nm (7 ft lb)
11 - Rear oil seal flange
With oil seal
Replace as complete unit
Lightly oil lip of seal

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Before installing oil pan, spread sealant
AMV 174 004 01 on joint between oil seal
flange and cylinder block
12 - Oil seal
Replacing Page 13-39
13 - Intermediate shaft
Axial play, max: 0.25 mm (0.010 in.)
14 - O-ring
Always replace
15 - Oil seal carrier for intermediate shaft

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13-39

Crankshaft oil seal (toothed belt side),

replacing

Engine installed

Lock carrier in service position Page 13-1

Special tools and equipment

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2085 seal puller

3083 arbor

3099 spur belt spreading

Removing

- Remove ribbed belt and ribbed belt tensioner

Page 13-15 .

- Remove toothed belt Page 13-29 .

- Remove mounting bracket for torque arm

Page 17-2 , item - 5 -.

- Remove crankshaft toothed belt gear. Secure toothed belt gear using
3099 spur belt spreading.

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Note:

3415 special tool can also be used.

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13-40

- Before attaching seal puller, insert socket head cap bolt from 3083
arbor into crankshaft to stop.
- Unscrew inner part of 2085 seal puller two turns (approx. 3 mm 0.118
in.) and secure using knurled bolt.

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- Grease threaded head of 2085 seal puller, position and with forced
pressure screw into oil seal as far as possible.
- Loosen knurled bolt and turn inner part against crankshaft until oil seal
is removed.

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13-41

Installing

- Lightly oil lip of oil seal.

- Place guide sleeve from 3083 arbor on crankshaft.

- Slide oil seal over guide sleeve.

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- Press in oil seal to stop together with pressure bushing and bolt from
3083 arbor.
- Replace bolt for toothed belt gear.
- Install toothed belt gear for crankshaft and secure using 3099 spur belt
spreading.

Note:
Contact surface between toothed belt gear and crankshaft must be
free of oil.
Do not grease crankshaft bolt for toothed belt gear.
- Install toothed belt (adjust valve timing) Page 13-32 .

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13-42

- Place torque arm on rubber buffer for torque arm

and tighten bolts to 25 Nm (18 ft lb).

- Install ribbed belt and ribbed belt tensioner

Page 13-15 .

Note:

When installing the ribbed belt, make sure it is

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seated correctly on the pulley.

Tightening torque

Component Tightening torque

Toothed belt gear to 90 Nm (66 ft lb) +
crankshaft 90 1)2)
1) Replace bolt.
2) 90 are equivalent to 1/4 turn.

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13-43

Dual-mass flywheel/drive plate,

removing and installing

Special tools and equipment

10-201 flywheel retainer

Dual-mass flywheel

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- Relocate 10-201 flywheel retainer to loosen and tighten bolts.
- Mark installed position (flywheel to crankshaft) to reinstall in same
position.
- Always replace bolts.

Tightening torque

Component Tightening torque

Dual-mass flywheel to crankshaft 60 Nm (44 ft lb) + 180 1)
1) 180 are equivalent to 1/2 turn.

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13-44

Drive plate

Removing

- Relocate 10-201 flywheel retainer to loosen and tighten bolts.

- Mark drive plate to engine.

Installing

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- Install drive plate with shim -2- and mounting washer -1-. Lug (arrow)
must point toward torque converter.
- Insert at least three used mounting bolts and tighten.
Tightening torque: 30 Nm (22 ft lb)

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13-45

- Measure distance -a- at three places and calculate average.

Specification for Automatic Transmission 01V: 26-28 mm (1.024-1.102
in.).

If the specified value is exceeded:

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- Remove drive plate and reinstall without shim -2-.
- Re-tighten bolts to 30 Nm (22 ft lb).
- Repeat measurement procedure.

If specified value is obtained:

- Replace bolts and tighten.

Tightening torque

Component Tightening torque

Drive plate to crankshaft 60 Nm (44 ft lb) + 90 1)
1) 90 are equivalent to 1/4 turn.

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13-46

Crankshaft, removing and

installing
Note:

For engine disassembly and assembly, mount

engine to an assembly stand using VW540 holding
fixture.

1 - Main bearing shells 1, 2, 4 and 5

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Install shell without lubrication groove in
main bearing cap
Install shell with lubrication groove in
cylinder block
Do not interchange used main bearing
shells (mark accordingly)
2 - Main bearing cap bolts
Always replace
65 Nm (48 ft lb) + additional 1/4 turn (90 )
To measure radial play in crankshaft,
tighten to 65 Nm (48 ft lb) but not any
further
3 - Main bearing caps
Bearing cap 1: belt pulley side
Retaining tabs for cylinder block/bearing
cap must overlap

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13-47

4 - Main bearing shell 3

Install shell without lubrication groove in
main bearing cap
Install shell with lubrication groove in
cylinder block
Do not interchange used main bearing
shells (mark accordingly)

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5 - Thrust plates
For bearing cap, bearing 3
Check location point
6 - Sensor wheel
Always replace when bolts are removed
For engine speed (RPM) sensor -G28-
Installation only possible in one position;
bore holes are offset
Removing and installing Fig. 1
7 - Sensor wheel screws
Always replace
Always replace sensor wheel when bolts
are removed
10 Nm (7 ft lb) + additional 1/4 turn (90 )

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13-48

8 - Needle bearing
Removing and installing Page 13-50
9 - Crankshaft
Axial play when new: 0.07-0.23 mm (0.003-
0.009 in.)
Wear limit: 0.30 mm (0.012 in.)

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- Radial clearance is measured using
Plastigage
New: 0.02-0.04 mm (0.0008-0.0016 in.)
Wear limit: 0.15 mm (0.006 in.)
Do not turn crankshaft when measuring
radial play
Crankshaft dimensions Page 13-52

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13-49

Fig. 1 Removing and installing sensor wheel

- Always replace sensor wheel -2- when screws -1- are removed.

Note:
After tightening a second time, the attachment point of the
countersunk screws of the sensor wheel are so deformed that the
screw heads sit against crankshaft (arrows) -3- and the sensor wheel
is loose underneath the screws.

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Installation of the sensor wheel is only possible in one position; bore
holes are offset.

Tightening torque

Component Tightening torque

Sensor wheel to crankshaft 10 Nm (7 ft lb) + 90 1) 2)
1) Replace bolts.
2) 90 are equivalent to 1/4 turn.

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13-50

Crankshaft needle bearing, removing

and installing

Note:

A pilot needle bearing must be installed in the

crankshaft of engines for vehicles with manual
transmission. Install if necessary.

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A pilot needle bearing must not be installed in
the crankshaft of engines for vehicles with
automatic transmission. Remove if necessary.

Special tools and equipment

21/1 Kukko puller and 22/1 Kukko support

or

10-202 puller

VW207C drift

or

3176 centering mandrel

Removing

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Crankshaft, removing and installing Page 6 of 8

- Pull out using puller -A-, e.g. 21/2 Kukko extractor and 22/1 Kukko
support or 10-202 puller.

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13-51

Installing

- Drive in using VW207C drift and/or 3176 centering mandrel.

When needle bearing is installed, side with inscription must be visible.

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Installation of needle bearing:

Dimension -a- = 1.5 mm (0.059 in.)

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13-52

Crankshaft dimensions

Reconditioning dimension Crankshaft journal diameter - mm (in.) Connecting rod journal diameter - mm (in.)

maximum size (from nominal) -0.017 (0.0007) -0.022 (0.0009)

Basic dimension (nominal) 54.00 (2.126) 47.80 (1.882)

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minimum size (from nominal) -0.037 (0.0015) -0.042 (0.0017)
maximum size (from nominal) -0.017 (0.0007) -0.022 (0.0009)
1st undersize (nominal) 53.75 (2.116) 47.55 (1.872)
minimum size (from nominal) -0.037 (0.0015) -0.042 (0.0017)
maximum size (from nominal) -0.017 (0.0007) -0.022 (0.0009)
2nd undersize (nominal) 53.50 (2.106) 47.30 (1.862)
minimum size (from nominal) -0.037 (0.0015) -0.042 (0.0017)
maximum size (from nominal) -0.017 (0.0007) -0.022 (0.0009)
3rd undersize (nominal) 53.25 (2.096) 47.05 (1.852)
minimum size (from nominal) -0.037 (0.0015) -0.042 (0.0017)

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Cylinder head bolts, conversion from inner 12-point to Polydrive Page 1 of 1

15-1

Cylinder head bolts,

conversion from inner 12-
point to Polydrive
Conversion of cylinder head bolts from inner 12-point to Polydrive
bolts. Conversion is a running-change

A - Bolt with inner 12-point (old version). Remove and install using socket
insert 3410

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B - Bolt with Polydrive head (new version). Remove and install using
Polydrive key 3452

Note:

Before removing or installing the cylinder head bolts, check which version
of the bolt is installed.

Special tool -B- is inserted in a socket insert -A- for assembly.

A - 10 mm socket insert (locally available)

B - Polydrive key 3452

Cylinder head bolts tightening sequence and torques remain unchanged

Page 15-25 .

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15-2

Cylinder head, removing and

installing
Note:

Replace cylinder head bolts.

Always replace self-locking nuts, bolts as well

as gaskets and O-rings.

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After installing a replacement cylinder head with
camshafts attached, grease contact surfaces
between valve lifters and cam lubricating
surfaces.

Do not remove plastic covers protecting

exposed valves until immediately before
installing cylinder head.

When replacing the cylinder head or cylinder

head gasket, coolant must be completely
replaced.

Cylinder heads with small cracks between the

valve seats that are less than 0.3 mm (0.012
in.) wide and/or between one valve seat and
only the first 4 threads of the spark plug thread,
can continue to be used without reduced
service life.

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15-3

Part I

1 - Cylinder head gasket

Replacing page 15-20 cylinder head,
removing
Installed position: part number faces
cylinder head
After replacing, replace coolant

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2 - Cylinder head
Removing Page 15-20
Check for distortion Page 15-8 , Fig.
1
Refacing measurement Page 15-8 , Fig.
2
Installing Page 15-25
After replacing, replace coolant
3 - Oil deflector
Verify correct installation position above
intake camshaft between cylinders 1 and 2
4 - Cylinder head bolt
Always replace
Follow sequence of removal Page 15-20
Follow torque sequence Page 15-25

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15-4

5 - Gasket
For ignition coil
Replace if damaged
6 - Ignition Coil
Check

Repair Manual, 1.8 Liter 5V Turbo Fuel Injection

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& Ignition, Repair Group 28

7 - Bolt
10 Nm (7 ft lb)
8 - Oil filler cap
9 - Gasket
Replace if damaged or leaking
10 - Nut
10 Nm (7 ft lb)
11 - Cylinder head cover
Removing and installing Page 15-17

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15-5

12 - Cylinder head cover gaskets

Replace if damaged or leaking
Before installing, seal contact surfaces with
sealant D 454 300 A2 Fig. 3 and
Fig. 4

CAUTION!

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Part numbers are listed here for reference only.
Always check with your Parts department for
the latest information.

13 - Coolant flange
With coolant temperature sensor
14 - Bolt
10 Nm (7 ft lb)
15 - O-Ring
Always replace

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15-6

Part II

1 - Gasket
Always replace
2 - Nut
10 Nm (7 ft lb)
3 - Socket-head bolt

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10 Nm (7 ft lb)
4 - O-Ring
For injector
Always replace
5 - Fuel rail
With injectors
6 - Upper coolant line
7 - Socket-head bolt
10 Nm (7 ft lb)
8 - Bolt
10 Nm (7 ft lb)

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15-7

9 - O-Ring
For upper coolant line
Always replace
10 - Socket-head bolt
10 Nm (7 ft lb)
11 - Intake plenum

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Removing and installing Page 15-10
12 - Socket-head bolt
20 Nm (15 ft lb)
13 - Brace
For intake manifold

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15-8

Fig. 1 Check cylinder head for distortion

- Using straightedge and feeler gauge, check cylinder head for distortion
at multiple points.
Cylinder head distortion must not exceed 0.1 mm (0.004 in.)

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Fig. 2 Refacing cylinder head

Refacing cylinder head can only be done to a minimum dimension -a-.

Minimum dimension -a-: 139.25 mm (5.482 in.)

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15-9

Fig. 3 Sealing contact surfaces between double bearing cap and

cylinder head
- Using small screwdriver, carefully apply thin layer of sealant D 454 300
A2 to both corners of sealing surface between double bearing cap and
cylinder head (arrows).

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Fig. 4 Sealing contact surfaces between hydraulic chain
tensioner and cylinder head
- Using small screwdriver, carefully apply thin layer of sealant D 454 300
A2 to both corners of sealing surface between hydraulic chain
tensioner and cylinder head (arrows).

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15-10

Intake manifold, removing and installing

Removing

Note:

All tie wraps opened or cut during removal must

be reinstalled at the same locations.

CAUTION!

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BEFORE disconnecting the battery:

Stop the engine.

Be sure the ignition is switched OFF (also

applies when connecting the battery). Failure
to do so may damage the Engine Control
Module (ECM).

Determine the correct coding for the anti-

theft radio.

- Disconnect battery Ground (GND) strap.

- Remove engine covers.
- Drain coolant Page 19-4 .

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15-11

- Remove hose (arrow) for Leak Detection Pump (LDP) -V144-.

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15-12

- Disconnect Accelerator Pedal (AP) cable from throttle valve control

module -J338- and mounting flange (arrows) without removing
positioning clip.
- Remove air guide hose -6- at throttle valve control module.
- Remove vacuum hose -1-.
- Disconnect vacuum line -3- to Evaporative Emissions (EVAP) canister.
- Disconnect vacuum hose -2- at brake servo.

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Note:

For vehicles with automatic transmission, remove vacuum hose -2- from
behind vacuum booster.

- Disconnect the following harness connectors:

4 - For Intake Air Temperature (IAT) sensor -G42-
5 - For throttle valve control module -J338-

- Disconnect harness connector from Camshaft Position (CMP) sensor -

G40- (arrow).

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15-13

- Unbolt fuel supply rail retaining bolts and disconnect vacuum line at
fuel pressure regulator (arrows).
- Disconnect fuel supply rail with injectors from intake manifold and lay
aside in rear of engine compartment on clean cloth.
- Disconnect coolant hoses at upper coolant line.

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- Disconnect upper coolant line at intake line and rear coolant flange at
rear of cylinder head (arrows).

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15-14

- Disconnect crankcase ventilation hose -1- at intake manifold.

- Remove intake manifold brace (arrows).
- Remove dipstick.
- Unbolt intake manifold at flange and remove.

Note:

Stuff clean cloths into cylinder head intake ports.

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Cylinder head, removing and installing Page 14 of 35

15-15

Installing

Installation is the reverse of removal, noting the

following:

Note:

Replace gaskets and O-rings.

- Adjust Accelerator Pedal (AP) cable.

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Repair Manual, Fuel Supply System, Repair
Group 20

- Top up coolant Page 19-6 .

CAUTION!

Be sure the ignition is switched OFF. Failure

to do so may damage the Engine Control
Module (ECM).

- Switch ignition off and reconnect battery Ground

(GND) strap.

- After connecting battery, enter anti-theft code for

radio

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Cylinder head, removing and installing Page 15 of 35

Radio operating manual

- Fully close power windows to stop.

- Operate all power window switches again for at

least one second in "close" direction to activate
"one touch" opening/closing function.

- Set clock to correct time.

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15-16

- Perform throttle valve control module adaptation

to Engine Control Module (ECM).

Repair Manual, 1.8 Liter 5V Turbo Fuel

Injection & Ignition, Repair Group 24

Tightening torques

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Component Tightening
torques
Intake manifold to cylinder 10 Nm (7 ft lb)
head
Intake manifold brace to intake 20 Nm (15 ft lb)
manifold
Intake manifold to bracket 20 Nm (15 ft lb)
Fuel supply rail to intake 10 Nm (7 ft lb)
manifold
Coolant line to coolant flange 10 Nm (7 ft lb)
Coolant line to intake manifold 10 Nm (7 ft lb)

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15-17

Cylinder head cover, removing and

installing

Removing

- Remove engine covers.

- Unbolt crankcase ventilation line from heatshield and cylinder head

cover and disconnect line from front hose (arrows).

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- Swing crankcase ventilation line to side.
- Remove 2 retaining clamps for upper toothed belt cover.
- Disconnect harness connectors at ignition coils -1- and unbolt Ground
(GND) connection -2-.
- Unbolt ignition coils.

- Remove cylinder head cover nuts (arrows) and remove cylinder head
cover.

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15-18

Installing

Installation is the reverse of removal, noting the

following:

Note:

Replace cylinder head cover gaskets if damaged.

- Using small screwdriver, carefully apply thin layer of sealant D 454 300

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A2 to both corners of sealing surface between double bearing cap and
cylinder head (arrows).

CAUTION!

Part numbers are listed here for reference only. Always check with
your Parts department for the latest information.

- Using small screwdriver, carefully apply thin layer of sealant D 454 300
A2 to both corners of sealing surface between hydraulic chain
tensioner and cylinder head (arrows).
- Tighten cylinder head cover nuts alternately in diagonal sequence.
- Make sure toothed belt cover is installed properly.

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15-19

Tightening torques

Component Tightening
torques
Cylinder head cover to cylinder 10 Nm (7 ft lb)
head
Ignition coils to cylinder head 10 Nm (7 ft lb)
cover

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Crankcase ventilation line to 10 Nm (7 ft lb)
cylinder head cover

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Cylinder head, removing and installing Page 20 of 35

15-20

Cylinder head, removing

Engine installed

Lock carrier in service position Page 13-1

Note:

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Secure all hose connections with original
equipment clamps parts catalog.

All tie wraps opened or cut during removal must

be reinstalled at the same locations.

CAUTION!

BEFORE disconnecting the battery:

Stop the engine.

Be sure the ignition is switched OFF (also

applies when connecting the battery). Failure
to do so may damage the Engine Control
Module (ECM).

Determine the correct coding for the anti-

theft radio.

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15-21

- Remove Ground (GND) connection.

- Drain coolant Page 19-4 .
- Remove intake manifold Page 15-10 .
- Remove ribbed belt and ribbed belt tensioner Page 13-15 .

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- Remove the following lines/harness connectors:
1 - At Wastegate Bypass Regulator Valve -N75-
2 - At Evaporative Emission (EVAP) Canister Purge Regulator Valve -
N80-
3 - At Power outage stage -N122-
4 - At Mass Air Flow (MAF) sensor -G70-
- Pull off hose connections and remove air cleaner element housing
(arrows).

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15-22

- Disconnect harness connector -1- at Engine Coolant Temperature

(ECT) sensor -G2-/-G62-.
- Disconnect harness connector -2- at temperature sensor II -G18-.
- Unclip all connections from cylinder head and move clear.

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- Remove crankcase ventilation line -1-.
- Remove oil supply line at cylinder head -2-.
- Remove heat shield -3-.
- Unbolt turbocharger from exhaust manifold -4-.
- Disconnect coolant hose to heat exchanger at rear of cylinder head,
also detach retaining clamps at connecting flange.
- Remove upper toothed belt cover Page 13-29 .

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15-23

- Turn crankshaft at central bolt of toothed belt gear in direction of engine

rotation to TDC Cyl. 1 marking (arrows).

CAUTION!

Before removing toothed belt, note direction of rotation with chalk or

felt-tip marker. Reversing the direction of rotation of a used belt can
destroy the belt.

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15-24

- Using Torx wrench T45, loosen toothed belt tensioner (lower arrow).
- Push down on toothed belt tensioner.
- Remove toothed belt from camshaft gear.
- Remove TORX bolt and swing belt tensioner assembly bracket
forward.
- Remove cylinder head cover Page 15-17 .

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- Remove cylinder head bolts in sequential order as shown in illustration.
- Remove cylinder head.

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15-25

Cylinder head, installing

Note:

Always replace cylinder head bolts.

Note inner 12-point or Polydrive versions of

cylinder head bolts Page 15-1 .

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Always replace self-locking nuts, bolts, gaskets
and O-rings.

Carefully remove any sealant residue from

cylinder head or engine block repairs. Avoid
any scratches or scoring.

Thoroughly remove all sanding and grinding

residue.

Do not remove new cylinder head gasket from

package until immediately before installing.

Handle gasket with extra care. Silicon layer and

grooved areas can be damaged leading to
leakage.

Pocket holes in engine block for cylinder head

bolts must be free of oil and coolant.

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- Before installing cylinder head, set crankshaft and camshaft to TDC

Cyl. 1 marking (arrows).

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15-26

- Loosen bolts -1- and -2- at turbocharger bracket two turns to reduce
likelihood of any tension while installing cylinder head.

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- Install cylinder head gasket.

Note:
Pay close attention to pilot pins (arrows) in engine block.
Pay attention to installation position marking for cylinder head gasket:
Part number must be visible from intake side.
- Install cylinder head.

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15-27

- Insert cylinder head bolts and hand tighten.

- Tighten cylinder head bolts in sequential order, in two stages:

Step 1 = 60 Nm (44 ft lb)
Step 2 = additional 1/2 turn using rigid wrench (180 is equivalent
to two 90 turns)

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Note:

It is not necessary to re-tighten the bolts.

- Using new gasket, bolt turbocharger to exhaust manifold and bolt

bracket to engine block Page 21-24 .
- Install cylinder head cover Page 15-18 .
- Install toothed belt (adjust valve timing) Page 13-32 .

Note:

Follow all procedures for removing and installing toothed belt Page 13-
29 .

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15-28

- Install ribbed belt and ribbed belt tensioner

Page 13-15 .

Note:

When installing ribbed belt, make sure it is

seated correctly on the pulleys.

- Adjust Accelerator Pedal (AP) cable.

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Repair Manual, Fuel Supply System, Repair
Group 20

- Replace coolant Page 19-6 .

CAUTION!

Be sure the ignition is switched OFF. Failure

to do so may damage the Engine Control
Module (ECM).

- Switch ignition off and reconnect battery Ground

(GND) strap.

- After connecting battery, enter anti-theft code for

radio.

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Cylinder head, removing and installing Page 30 of 35

Radio operating manual

- Using power window switch, raise windows to

stop.

- Operate all power window switches again for at

least one second in "close" direction to activate
"one touch" opening/closing function.

- Set clock to correct time.

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Cylinder head, removing and installing Page 31 of 35

15-29

- Perform throttle valve control module adaptation

to Engine Control Module (ECM).

Repair Manual, 1.8 Liter 5V Turbo Fuel

Injection & Ignition, Repair Group 24

Tightening torques

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Component Tightening
torque
Intake manifold brace to intake 20 Nm (15 ft
manifold lb)
Intake manifold brace to bracket 20 Nm (15 ft
lb)
Turbocharger to exhaust 35 Nm (26 ft
manifold lb)
Turbocharger bracket to 40 Nm (30 ft
turbocharger (bolt and washer lb)
assembly M8)

Turbocharger bracket to cylinder 45 Nm (33 ft

block lb)
Retainer straps for oil supply line 20 Nm (15 ft
to cylinder head lb)

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15-30

Compression, checking

Special tools and equipment

VAG1381 or VAG1763 compression tester

3122B spark plug removal tool

Test condition

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Minimum engine oil temperature: 30 C (86
F)

Test procedure

- Remove engine covers.

- Switch ignition off and remove harness

connectors to ignition coils.

- Unbolt ignition coils (arrows).

- Remove all harness connectors to fuel injectors.
- Using 3122B spark plug removal tool, remove all spark plugs.
- Open throttle to Wide Open Throttle (WOT) position.
- Using VAG1381 or VAG1763 compression tester, test engine
compression.

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Note:

Use VAG1381 or VAG1763 compression tester user manual.

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Cylinder head, removing and installing Page 34 of 35

15-31

- Activate starter until no further pressure

increases are indicated by VAG1381 or
VAG1763 compression tester.

Compression pressure

Engine code New Wear limit

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AEB 10.0-13.0 bar 7.0 bar

(145-188.5 psi) (101.5 psi)

Permissible difference between all cylinders: 3

bar (43 psi)

- Install spark plugs and ignition coils.

- Check DTC memory.

Repair Manual, 1.8 Liter 5V Turbo Fuel

Injection & Ignition, Repair Group 01

Note:

Diagnostic Trouble Codes (DTCs) are stored

when harness connectors are disconnected.
After testing, check DTC memory and erase.

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Cylinder head, removing and installing Page 35 of 35

Tightening torques

Component Tightening
torques
Spark plugs into cylinder 30 Nm (22 ft lb)
head
Ignition coils to cylinder head 10 Nm (7 ft lb)
cover

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Pistons and connecting rods, disassembling and assembling Page 1 of 9

13-53

Pistons and connecting rods,

disassembling and assembling
1 - Nut for connecting rod bolt
30 Nm (22 ft lb) + additional 1/4 turn (90 )
Always replace connecting rod bolt -13-
Grease thread and contact surface

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To measure radial play, tighten to 30 Nm
(22 ft lb) but not any further
2 - Pressure relief valve
Tightening torque: 27 Nm (20 ft lb)
Opening pressure: 2.5-3.2 bar (36.25-46.4
psi)
3 - Oil spray nozzle
For piston cooling
4 - Connecting rod bearing cap
Mark -B- to indicate which cylinder each
cap belongs to
Installed position:
Marks -A- point toward belt pulley side

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13-54

5 - Bearing shell
Verify correct installation position
Do not interchange used connecting rod
bearing shells (mark accordingly)
Check for proper securing in retaining tabs
Axial play:

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New: 0.10-0.35 mm (0.004-0.014 in.)
Wear limit: 0.40 mm (0.016 in.)
Measure radial play using Plastigage :
New: 0.01-0.05 mm (0.0004-0.0020 in.)
Wear limit: 0.12 mm (0.0047 in.)
Do not turn crankshaft when measuring
radial play with Plastigage in place
- To measure radial play, tighten nut -1- to
30 Nm (22 ft lb) but not any further
6 - Cylinder block
Check bore Fig. 4
Piston and cylinder bore dimensions
Page 13-60

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13-55

7 - Bearing shell
With oil bore for piston pin lubrication
Verify correct installation position
Do not interchange used connecting rod
bearing shells (mark accordingly)
Axial play:

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New: 0.10-0.35 mm (0.004-0.014 in.)
Wear limit: 0.40 mm (0.016 in.)
Measure radial play using Plastigage :
New: 0.01-0.05 mm (0.0004-0.0020 in.)
Wear limit: 0.12 mm (0.0047 in.)
Do not turn crankshaft when measuring
radial play with Plastigage in place
To measure radial play, tighten nut -1- to
30 Nm (22 ft lb) but not any further

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13-56

8 - Connecting rod
Replace only as a set
Markings -B- indicate which cylinder each
rod belongs to
Installed position:
Marks -A- point toward belt pulley side

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With oil bore for piston pin lubrication
9 - Circlip
10 - Piston pin
If stiff, warm pistons to approx. 60 C
(140 F)
When removing and installing, use
VW222a pilot drift
11 - Piston rings
Offset by 120
Use piston ring pliers to remove and install
Marking "TOP" must point to piston head
Checking piston ring end gap Fig. 1
Checking piston ring side clearance Fig.
2

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13-57

12 - Pistons
Checking
Mark installation position and matching
cylinder
Arrow on piston head points toward belt
pulley side
Install using piston ring compressor

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13 - Connecting rod bolt
Always replace

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13-58

Fig. 1 Checking piston ring end gap

- Insert ring at right angle from top and slide down until approx. 15 mm
(19/32 in.) from lower edge of cylinder. To insert, use piston without
rings.

Piston ring End gap, new mm (in.) Wear limit

mm (in.)
1. Compression ring 0.20-0.40 0.8

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(0.0078-0.0157) (0.0315)
2. Compression ring 0.20-0.40 0.8

(0.0078-0.0157) (0.0315)
3. Oil scraper ring 0.25-0.50 0.8

(0.0098-0.0197) (0.0315)

Fig. 2 Checking piston ring side clearance

- Before checking, clean ring groove.

Piston ring Side clearance, new mm (in.) Wear limit

mm (in.)
1. Compression ring 0.06-0.09 0.20

(0.0023-0.0035) (0.0078)

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2. Compression ring 0.05-0.08 0.20

(0.0019-0.0315) (0.0078)
3. Oil scraper ring 0.03-0.06 0.15

(0.0011-0.0023) (0.0059)

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13-59

Fig. 3 Checking piston diameter

- Measure approx. 10 mm (3/8 in.) from bottom edge, at points offset by
90 from piston pin axis.
Deviation from nominal size: max. 0.04 mm (0.0016 in.)

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Fig. 4 Checking cylinder bore

Special tools and equipment

Inner bore gauge 50-100 mm (2-4 in.)

CAUTION!

DO NOT have the cylinder block mounted to the assembly stand

while measuring the cylinder bores. The block is deformed by its
own weight under these conditions and this stress will result in false
measurements that are not accurate after the tension has been
relieved.

- Measure at three locations diagonally in crosswise direction -A- and

lengthwise direction -B-.
Deviation from nominal size: max. 0.08 mm (0.0031 in.)

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13-60

Piston and cylinder bore dimensions

Reconditioning Piston Cylinder

dimension bore
diameter
diameter
Basic dimension 80.975mm1) 81.01 mm

(3.1180 in.) (3.1894 in.)

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Repair step 81.475mm1) 81.51 mm

(3.2076 in.) (3.2090 in.)

1)Measurement does not include graphite
coating, thickness 0.02 mm (0.0008 in.). The
graphite coating wears away.

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Valvetrain, servicing Page 1 of 51

15-32

Valvetrain, servicing
Note:

Cylinder heads with small cracks between the

valve seats that are less than 0.3 mm (0.012
in.) wide and/or between one valve seat and
only the first 4 threads of the spark plug thread,
can continue to be used without reduced
service life.

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Always replace gaskets, seals and O-rings.

CAUTION!

After installing the camshafts, the engine

must not be started for approx. 30 minutes.
The hydraulic valve lifters have to settle
(otherwise valves will strike the pistons).

After installing the valvetrain and lifters,

carefully rotate the crankshaft by hand at
least 2 full revolutions before starting to be
sure that valves do not strike the pistons.

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15-33

1 - Bolt
65 Nm (48 ft lb)
Use 3036 retainer when loosening or
tightening
2 - Camshaft gear
For exhaust camshaft

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Verify correct installation position: thin rib
of camshaft gear points forward and TDC
Cyl. 1 marking is visible from front Page
15-45
3 - Oil seal
For exhaust camshaft
Always replace Page 15-42
4 - Cylinder head
Note Page 15-32
Check valve guides, reface valve seats
Page 15-66
Bearing cap bushings must be installed in
cylinder head
Seal contact surfaces Page 15-9 , Fig.
3 and Fig. 4
Reface valve seats Page 15-71
5 - Valve guide

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Valvetrain, servicing Page 3 of 51

Check Page 15-66

Replace Page 15-67

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15-34

6 - Valve stem oil seal

Replace Page 15-62
7 - Valve spring
Removing and installing Page 15-62
8 - Valve spring retainer
9 - Valve keeper

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10 - Hydraulic valve lifter
Check Page 15-60
Removing and installing Page 15-62
Do not interchange
When removed, store with contact surfaces
facing down
Before installing, check axial play in
camshafts Page 15-41
Oil contact surface
11 - Intake camshaft
Using Plastigage check radial play (valve
lifters removed)
Wear range: 0.1 mm (0.004 in.)
Max. run-out: 0.01 mm (0.0004 in.)
Axial play, checking Page 15-41

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Camshafts, removing and installing

Page 15-50

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15-35

12 - Bearing cap for intake camshaft

Must fit on bushing
Bushings must be installed in cylinder head
Verify correct installation position
Installation sequence Page 15-50
13 - Double bearing cap

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Must fit on bushing
Bushings must be installed in cylinder head
Before installing, seal contact surfaces
lightly with sealant D 454 300 A2 Page
15-57
Sealing contact surfaces between double
bearing cap and cylinder head Page 15-
9 , Fig. 3
14 - Exhaust camshaft
Using Plastigage check radial play (valve
lifters removed)
Wear range: 0.1 mm (0.004 in.)
Max. run-out: 0.01 mm (0.0004 in.)
Axial play, checking Page 15-41
Camshafts, removing and installing
Page 15-50

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15-36

15 - Bearing cap for exhaust camshaft

Must fit on bushing
Bushings must be installed in cylinder head
Verify correct installation position
Installation sequence Page 15-50
16 - Bolt

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10 Nm (7 ft lb)
17 - Bolt
10 Nm (7 ft lb)
18 - Drive chain
Check for wear
Before removing, mark installed position
Page 15-52
Camshafts, removing and installing
Page 15-50

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15-37

19 - Hydraulic chain tensioner

Before removing, secure with VAG3366
chain tensioner bracket
Removing and installing Page 15-50
Seal contact surfaces between hydraulic
chain tensioner and cylinder head Page
15-9 , Fig. 4

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20 - Rubber/metal seal
Replacing Page 15-53
21 - Gasket
Always replace
22 - Exhaust valve
Sodium-filled
Follow disposal procedures for sodium-
filled valves Page 15-40
Do not reface by grinding, only hand
lapping is permitted
Valve dimensions Page 15-39 , Fig. 1
Checking valve guides Page 15-66
Refacing valve seats Page 15-71

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15-38

23 - Intake valve
Do not reface by grinding; only hand
lapping is allowed
Valve dimensions Page 15-39 , Fig. 1
Checking valve guides Page 15-66
Refacing valve seats Page 15-71

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24 - Oil seal
For intake camshaft
Replacing Page 15-42
25 - Shutter wheel for Camshaft Position
(CMP) sensor -G40-
Note position: insert lug in camshaft notch
26 - Washer
Conical
Note position
27 - Bolt
25 Nm (18 ft lb)
28 - Camshaft Position (CMP) sensor -G40-
housing
29 - Bolt
10 Nm (7 ft lb)

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15-39

Fig. 1 Valve dimensions

WARNING!

Valves must not be refaced by cutting or grinding.

Only hand lapping is permitted.

Dimension Intake valve Exhaust valve

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Diameter -a- mm 26.80-27.00(1.055- 29.80-30.00(1.173-
1.063) 1.181)
(in.)
Diameter -b- mm 5.95-5.97 5.94-5.95

(in.) (0.2339-0.2350) (0.2339-0.2343)

Length -c- mm 104.84-105.34 103.64-104.14

(in.) (4.127-4.147) (4.080-4.099)

Angle -a- 45 45

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15-40

WARNING!

Sodium-filled exhaust valves must not be

scrapped without first being properly treated.

The valves must be cut open using a

hacksaw, by hand, between the valve head
and the middle of the stem.

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The valves must not come into any contact
with water while being cut.

After cutting open the valves, throw not more

than 10 at a time into a bucket of water and
step back. A sudden chemical reaction will
occur during which the sodium filling is
consumed.

Valves that have been treated in this way can

be disposed of as normal waste.

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15-41

Camshafts axial play, checking

Special tools and equipment

VW387 dial gauge holder

Dial indicator

Measure with installed bearing cap on chain

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sprocket side and double bearing cap on
camshaft side with valve lifters removed.

- Secure VW387 dial gauge holder with dial

indicator to cylinder head.

Intake camshaft

Exhaust camshaft

Wear limit for intake and exhaust camshafts:

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Axial play max.: 0.20 mm (0.008 in.)

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15-42

Oil seals for camshafts, replacing

Cylinder head installed

Lock carrier in service position Page 13-1

Special tools and equipment

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2085 seal puller

3241 seal installer

3036 retainer

Replacing exhaust camshaft oil seal

Removing

- Remove ribbed belt and ribbed belt tensioner

Page 13-15 .

- Remove engine covers.

- Remove upper toothed belt cover Page 13-

29 .

- Turn crankshaft at central bolt of toothed belt gear in direction of

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engine rotation to TDC Cyl. 1 marking (arrows).

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15-43

CAUTION!

Before removing toothed belt, note direction

of rotation with chalk or felt-tip marker.
Reversing the direction of rotation of a used
belt can destroy the belt.

- Loosen tensioner (arrows) and lift toothed belt from camshaft gear.
- Use 3036 Retainer to loosen camshaft gear.

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- Remove camshaft gear.

- Thread camshaft gear retaining bolt (arrow) into camshaft by hand until
stop to guide 2085 seal puller.
- Unthread inner part of 2085 seal puller two turns (approx. 3 mm or 0.12
in.) and secure using knurled bolt.

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15-44

- Grease threaded head of 2085 seal puller, attach and with forced
pressure screw into oil seal as far as possible.
- Loosen knurled bolt and turn inner part against crankshaft until oil seal
is removed.
- Clamp 2085 seal puller in vise at flat surfaces. Remove oil seal using
pliers.

Installing

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- Lightly oil lip of oil seal.

- Place 3241/2 guide sleeve on end of camshaft.

- Slide oil seal over guide sleeve.

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15-45

- Using 3241/5 camshaft fitting tool and 3241/1 pressure sleeve, press
oil seal in to stop.

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- Install camshaft gear.
Note position: thin rib of camshaft gear points outward (arrows) and
TDC Cyl. 1 marking is visible from the front.
- Using 3036 retainer, install camshaft gear retaining bolt.

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15-46

- Align marking on camshaft gear with marking on cylinder head cover.

- Align marking on vibration damper to that on lower toothed belt cover.

Note:

While turning camshaft, valves could hit pistons that are at TDC. Verify
that no piston is at TDC. Valves and/or pistons may be damaged.

- Install toothed belt (adjust valve timing) Page 13-32 .

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Note:

Follow all procedures for removing and installing toothed belt Page 13-
29 .

- Install ribbed belt and ribbed belt tensioner Page 13-15 .

Note:

When installing the ribbed belt, make sure it is seated correctly on the
pulleys.

Tightening torques

Component Tightening torques

Camshaft gear to camshaft 65 Nm (48 ft lb)
Ribbed belt tensioner to mounting bracket 25 Nm (18 ft lb)

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15-47

Replacing intake camshaft oil seal

Removing

- Remove ribbed belt and ribbed belt tensioner

Page 13-15 .

- Disconnect harness connector from Camshaft Position (CMP) sensor -

G40-.

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- Remove upper toothed belt cover Page 13-29 .
- Remove housing for Camshaft Position (CMP) sensor -G40-.
- Remove shutter wheel and washer for Camshaft Position (CMP)
sensor -G40-.

- Insert 2085/1 adapter into camshaft by hand until stop to guide seal
puller.
- Unscrew inner part of 2085 seal puller two turns (approx. 3 mm or 0.12
in.) and secure using knurled bolt.

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15-48

- Grease threaded head of 2085 seal puller, attach and with forced
pressure screw into oil seal as far as possible.
- Loosen knurled bolt and turn inner part against crankshaft until oil seal
is removed.

Installing

- Lightly oil lip of oil seal.

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- Place 3241/2 guide sleeve on end of camshaft.
- Slide oil seal over guide sleeve.

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15-49

- Using 3241/3 camshaft fitting tool and 3241/1 pressure sleeve, press
oil seal in to stop.
- Install Camshaft Position (CMP) sensor -G40- Page 15-38 .
- Install upper toothed belt cover.
- Install ribbed belt and ribbed belt tensioner Page 13-15 .

Note:

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When installing ribbed belt, make sure it is seated correctly on the pulleys.

Tightening torques

Component Tightening
torques
Shutter wheel for Camshaft Position (CMP) sensor - 25 Nm (18 ft lb)
G40- to camshaft
Housing for Camshaft Position (CMP) sensor -G40- 10 Nm (7 ft lb)
to cylinder head

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15-50

Camshafts and hydraulic chain

tensioner, removing and installing

Cylinder head installed

Lock carrier in service position Page 13-1

Special tools and equipment

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3036 retainer

3366 bracket-tensioner

Removing

- Remove ribbed belt and ribbed belt tensioner

Page 13-15 .

- Remove engine covers.

- Remove upper toothed belt cover Page 13-

29 .

- Turn crankshaft at central bolt of toothed belt gear in direction of engine

rotation to TDC Cyl. 1 marking (arrows).
- Remove cylinder head cover Page 15-17 .

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CAUTION!

Before removing toothed belt, note direction of rotation with chalk or

felt-tip marker. Reversing the direction of rotation of a used belt can
destroy the belt.

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15-51

- Loosen tensioner (arrows) and remove toothed belt from camshaft

gear.
- Use 3036 retainer to loosen camshaft gear.
- Remove camshaft gear.
- Remove housing for Camshaft Position (CMP) sensor -G40-.
- Remove shutter wheel for Camshaft Position (CMP) sensor -G40-.

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- Secure hydraulic chain tensioner using 3366 bracket-tensioner.

CAUTION!

If over-tightened, the chain tensioner will be damaged.

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15-52

- Verify that camshafts are at TDC Cyl 1.

Both camshaft markings must align with arrows on bearing caps.

- Clean drive chain and camshaft chain gears opposite both arrows on
bearing caps. Mark installed position using paint.

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The distance between the two arrows/paint marks is equivalent to
16 drive chain rollers.
The notch on the exhaust camshaft is slightly offset inward toward
drive chain roller (arrow-1-).

Note:

Do not mark chain using punch, filing a notch or similar procedures.

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15-53

- First remove bearing caps -3- and -5- from intake and exhaust
camshafts.
- Remove double bearing cap.
- Remove both bearing caps from chain gears on intake and exhaust
camshafts.
- Remove hydraulic chain tensioner retaining bolts.
- Alternating in diagonal sequence, loosen bearing caps -2- and -4- of

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intake and exhaust camshafts and remove.
- Remove intake and exhaust camshafts with hydraulic chain tensioner.

Installing

- Replace rubber/metal chain tensioner gasket and spread sealant D 454

300 A2 on hatched surface.

CAUTION!

Part numbers are listed here for reference only. Always check with
your Parts department for the latest information.

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15-54

Install drive chain on camshaft chain gear as

follows:

- When installing old drive chain, line up paint markings (arrows).

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If a new drive chain is installed, distance between notches -A- and
-B- on camshafts must equal the distance between 16 drive chain
rollers. Illustration shows where first and sixteenth drive chain
rollers must be installed on chain gears.
Notch -A- is slightly offset inward toward drive chain roller -1-.
- Slide in hydraulic chain tensioner between drive chain.

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15-55

- Install camshafts with drive chain and hydraulic

chain tensioner into cylinder head.

- Oil camshaft contact surfaces.

Note:

Alignment bushings for bearing caps and

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hydraulic chain tensioner must be installed in
cylinder head.

When installing bearing caps, verify marking on

cap is readable from intake side of cylinder
head.

- Tighten hydraulic chain tensioner (pay attention

to alignment bushings).

- Tighten bearing caps -2- and -4- of intake and exhaust camshafts in
alternating diagonal sequence (pay attention to alignment bushings).
- Install both bearing caps on chain sprockets of intake and exhaust
camshafts.

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15-56

- Verify correct position of both camshafts.

Both camshaft markings must align with arrows on bearing caps

(arrows).

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The distance between the two arrows/paint markings is equivalent
to 16 drive chain rollers.
The notch on exhaust camshaft is slightly offset inward toward
drive chain roller -1-.

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15-57

- Remove 3366 bracket-tensioner.

- Lightly coat hatched surface of double bearing cap with sealant D 454
300 A2 and install bearing cap (pay attention to alignment bushings).

CAUTION!

Part numbers are listed here for reference only. Always check with
your Parts department for the latest information.

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- Install remaining bearing caps (pay attention to alignment bushings).
- Replace oil seals for intake and exhaust camshafts Page 15-42 .

- Install camshaft gear.

Note position: thin rib of camshaft gear points outward (arrows) and
TDC Cyl. 1 marking is visible from the front.
- Using 3036 retainer, install camshaft gear retaining bolt.
- Install Camshaft Position (CMP) sensor -G40- Page 15-38 .
- Install cylinder head cover Page 15-18 .

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15-58

- Align marking on camshaft gear with marking on cylinder head cover.

- Align marking on vibration damper with marking on lower toothed belt
cover.

Note:

When turning camshaft, crankshaft must not be at TDC Cyl. 1 for any
cylinder. Valves and/or pistons may be damaged.

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- Install toothed belt (adjust valve timing) Page 13-32 .

Note:

Follow all procedures for removing and installing toothed belt Page 13-
29 .

CAUTION!

After installing the camshafts, the engine must not be started for
approx. 30 minutes. The hydraulic valve lifters have to settle
(otherwise valves will strike the pistons).
After installing the valvetrain and lifters, carefully rotate the
crankshaft by hand at least 2 full revolutions before starting to be
sure that valves do not strike the pistons.
- Install ribbed belt and ribbed belt tensioner Page 13-15 .

Note:

When installing ribbed belt, make sure it is seated correctly on the pulleys.

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15-59

Tightening torques

Component Tightening
torques
Bearing cap to cylinder head 10 Nm (7 ft lb)
Hydraulic chain tensioner to 10 Nm (7 ft lb)
cylinder head
Shutter wheel for Camshaft 25 Nm (18 ft

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Position (CMP) sensor -G40- to lb)
camshaft
Housing for Camshaft Position 10 Nm (7 ft lb)
(CMP) sensor -G40- to cylinder
head
Ribbed belt tensioner to 25 Nm (18 ft
mounting bracket lb)
Camshaft gear to camshaft 65 Nm (48 ft
lb)

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15-60

Hydraulic valve lifters, checking

Special tools and equipment

Feeler gauge

Wood or plastic wedge

Note:

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Hydraulic valve lifters cannot be serviced.

Irregular valve noise when starting engine is

normal.

- Start engine and let run until coolant

temperature reaches at least 80 C (176 F).

- Increase RPM to 2500 for about 2 minutes; if

necessary test drive vehicle.

Note:

If irregular valve noises disappear but then

reappear during drive, replace oil retaining valve.
Oil retaining valve is located in oil filter bracket
Page 17-6 .

If hydraulic valve lifters are still loud, locate faulty

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valve lifter as follows:

- Remove cylinder head cover Page 15-17 .

- Turn crankshaft until cams of valve lifters to be

tested point up.

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15-61

Vehicles with manual transmission

- Switch ignition off, shift into fourth gear and push

vehicle forward.

Vehicles with automatic transmission

- Remove noise insulation panel and turn central

bolt of toothed belt gear for crankshaft in

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clockwise direction.

- Determine play between cams and valve

lifters.

- Push down on valve lifters using wood or plastic wedge. If 0.20 mm

(0.008 in.) feeler gauge can be inserted between camshaft and valve
lifter, replace valve lifter.
Valve lifter, replacing Page 15-50 .

CAUTION!

After installing the camshafts, the engine must not be started for
approx. 30 minutes. The hydraulic valve lifters have to settle
(otherwise valves will strike the pistons).
After installing the valvetrain and lifters, carefully rotate the
crankshaft by hand at least 2 full revolutions before starting to be
sure that valves do not strike the pistons.

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15-62

Valve stem oil seals, replacing

Cylinder head installed

Special tools and equipment

VW653/3 pressure hose

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3122B spark plug removal tool

3362 valve spring tool and 3362/1 pressure

piece

3364 valve seat tool

3365 valve stem seat fitting tool

Removing

- Remove camshafts and hydraulic chain

tensioner Page 15-50 .

- Remove valve lifters and lay aside with camshaft

contact surface facing down. Be careful not to
interchange valve lifters.

-
Using 3122B spark plug removal tool, remove all

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spark plugs.

- Move piston for individual cylinder to Bottom

Dead Center (BDC) position.

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15-63

- Thread VW653/3 pressure hose into spark plug

hole.

Note:

Lightly tap valve spring retainer to loosen stuck

valve keepers.

Intake and exhaust valves have different installation angles in cylinder

head. 3362 valve spring tool can be used in two different positions:

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1 - Top position for the center intake valve
2 - Lower position for both outer intake valves and both exhaust valves
3 - Threaded bores with M6 x 25 retaining bolts on the left and right are
used to secure the lower bracket to cylinder head

- Using retaining bolts bolted into tool, secure 3362 valve spring tool to
cylinder head.
- Adjust tool to correct position for corresponding valve.
- Attach pressure hose to compressor.
Minimum pressure: 6 bar (87 psi)
- Using threaded spindle and 3362/1 pressure piece, press valve springs
downward and remove.

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15-64

- Using 3364 valve seat tool, remove valve stem oil seals.

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15-65

Installing

- Place plastic sleeve -A- on valve stem to prevent damage to new valve
stem oil seals.
- Lightly oil lip of valve stem oil seal -B-.
- Insert valve stem oil seal into 3365 valve stem seal fitting tool and
carefully slide onto valve guide.
- Remove plastic sleeve.

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- Install camshafts Page 15-53 .

CAUTION!

After installing the camshafts, the engine must not be started for
approx. 30 minutes. The hydraulic valve lifters have to settle
(otherwise valves will strike the pistons).
After installing the valvetrain and lifters, carefully rotate the
crankshaft by hand at least 2 full revolutions before starting to be
sure that valves do not strike the pistons.

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15-66

Valve guides, checking

Special tools and equipment

VW387 dial gauge holder

Dial indicator

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- Install valve into guide so end of valve stem is flush with end of guide.

CAUTION!

Due to differences in valve stem diameter, make sure that only intake
valves are used to check intake guides, and only exhaust valves are
used to check exhaust guides.

- Measure side play.

Wear limit

Intake valve guide Exhaust valve guide

0.80 mm (0.031 in.) 0.80 mm (0.031 in.)

Note:
If wear limit is exceeded, remeasure using new valves. If wear limit is
still exceeded, replace valve guide.
If valve is replaced during repair, use new valve for measurement.

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15-67

Valve guides, replacing

Special tools and equipment

VW411 punch

3120 reamer (7mm) and cutting fluid

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3360 driver

3361 press-in pad

Removing

- Clean cylinder head and check.

Note:

Cylinder heads with valve seats that cannot be

refaced or cylinder heads that have been
resurfaced to the minimum dimension are not
suited for valve guide replacement.

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15-68

- Insert 3361 press-in pad as follows:

- Install mounting pins for cylinder head bolt holes -A- into threaded hole
position -2- and -3-.
- Install pin -B- into relevant hole for valve angle.
Outer intake valves: 21.5
Center intake valve: 15

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Exhaust valves: 20

- Using 3360 driver, press out worn valve guides as follows:

Valve guide without collar: from camshaft side
Valve guide with collar (replacement valve guide): from combustion
chamber side

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15-69

Installing

- Using 3360 driver, press new, oiled valve guides

from camshaft side to collar into cold cylinder
head.

Note:

After valve guide with collar is seated, insertion

pressure may not exceed 10kN (2248 lbs =

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approx 1.0t), as collar may break off.

- Using 3363 reamer -7 mm, ream valve guide.

Use cutting fluid.

- Reface valve seats Page 15-71 .

- Replace valve stem oil seals Page 15-62 .

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15-70

WARNING!

Valves must not be refaced by cutting or

grinding.

Only hand lapping is permitted.

WARNING!

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Sodium-filled exhaust valves must not be
scrapped without first being properly treated.

The valves must be cut open using a

hacksaw, by hand, between the valve head
and the middle of the stem.

The valves must not come into any contact

with water while being cut.

After cutting open the valves, throw not more

than 10 at a time into a bucket of water and
step back. A sudden chemical reaction will
occur during which the sodium filling is
consumed.

Valves that have been treated in this way can

be disposed of as normal waste.

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15-71

Valve seats, refacing

Note:

If a perfect contact pattern isn't obtained after

hand lapping valves, reface valve seats.

Special tools and equipment

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Depth gauge

Valve seat refacing tool

Note:

When servicing engines with low compression

due to leaking valves, it is not sufficient to
reface or replace the valve seats and valves. It
is especially important to check valve guides for
signs of wear on high-mileage engines Page
15-66 .

Only reface valve seats enough until a perfect

contact pattern is obtained.

Before refacing, determine maximum refacing

dimension.

If refaced dimension is exceeded, hydraulic

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valve lifter function is no longer guaranteed and

cylinder head must be replaced.

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15-72

Determining maximum allowable refacing

dimension

- Insert valve and press tightly against valve

seat.

Note:

If valve is replaced during repair, use new valve

for measurement.

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- Measure distance between end of valve stem
and camshaft center axis (camshaft center axis
is located at the level of cylinder head upper
edge).

- Determine maximum allowable refaced

dimension using distance measured and
minimum dimension.

Minimum dimensions
Outer intake Center intake Exhaust
valves valve valves
34.0 mm 33.7 mm 34.4 mm

(1.338 in.) (1.236 in.) (1.354 in.)

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15-73

Distance measured minus minimum dimension =

maximum allowable refacing dimension.

Example for outer intake valve:

Distance measured 34.4 mm (1.354
in.)
- Minimum dimension - 34.0 mm (1.338
in.)

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= maximum allowable = 0.4 mm (0.016
refacing dimension in.)

Note:

If the maximum allowed refaced dimension is 0

mm or less than 0 mm, repeat measurement
using new valve. If measurement is still 0 mm or
less than 0 mm , replace cylinder head.

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15-74

Valve seats, refacing

Intake valve seat

Diameter -a- = 26.2 mm (1.031 in.)
Dimension -b- = 1.5-1.8 mm (0.059-0.070 in.)
Z = Cylinder head lower edge
Angle -a- = 45 valve seat angle

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Angle -b- = 30 upper correction angle
Angle -g- = 60 lower correction angle
Exhaust valve seat
Diameter -a- = 29.0 mm (1.142 in.)
Dimension -b- = approx. 1.8 mm (0.070 in.)
Z = Cylinder head lower edge
Angle -a- = 45 valve seat angle
Angle -b- = 30 upper correction angle
Angle -g- = 60 lower correction angle

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17-1

Lubrication system
components, removing and
installing
WARNING!

Do not re-use any fasteners that are worn or

deformed in normal use.

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Some fasteners are designed to be used only
once, and are unreliable and may fail if used
a second time. This includes, but is not
limited to, nuts, bolts, washers, circlips and
cotter pins. Always follow the
recommendations in this manual-replace
these fasteners with new parts where
indicated, and any other time it is deemed
necessary by inspection.

CAUTION!

If large quantities of metal particles or other

deposits (caused, for example, by partial
seizure of the crankshaft or connecting rod
bearings) are found in the engine oil, the oil
passages must be cleaned thoroughly and
the oil cooler replaced in order to prevent
further damage from re-occurring.

Do not overfill with oil past the MAX mark on

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the oil dipstick. Damage to the Three Way

Catalytic Converter (TWC) could result.
Markings, refer to illustration Page 17-27 .

Viscosity classes and oil specifications Page

17-26 .

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17-2

Part I

CAUTION!

Part numbers are listed here for reference only.

Always check with your Parts department for
the latest information.

1 - O-ring

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Always replace
2 - Suction pipe
Clean strainer if dirty
3 - Bolt
10 Nm (7 ft lb)
4 - Baffle plate
5 - Bracket
For torque support
6 - Stop
For torque support
Adjusting:
- Place stop for torque support on rubber
buffer for torque support and tighten
bolts to 25 Nm (18 ft lb)
7 - Bolt

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Lubrication system components, removing and installing Page 4 of 33

25 Nm (18 ft lb)

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17-3

8 - Bolt
25 Nm (18 ft lb)
9 - Nut
25 Nm (18 ft lb)
10 - Brace
11 - Nut

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25 Nm (18 ft lb)
12 - Side brace
13 - Bolt
20 Nm (15 ft lb)
14 - Oil pump housing
15 - Gears
Backlash, checking Fig. 1
Axial clearance, checking Fig. 2
16 - Oil pump cover with pressure relief valve
Opening pressure: 5.7-6.7 bar (82.65-
97.15 psi)
17 - Bolt
25 Nm (18 ft lb)
18 - Bolt

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10 Nm (7 ft lb)

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17-4

19 - Bolt
45 Nm (33 ft lb)
20 - Oil drain plug
50 Nm (37 ft lb)
21 - Sealing washer
Always replace

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22 - Oil pan
Removing and installing Page 17-9
Clean contact surface before installing
When installing oil pan on removed engine,
note that oil pan is aligned with metal plate
on flywheel side (i.e. oil pan projects out
over engine block 0.8 mm 0.031 in.)
Before installing oil pan, spread thin coat of
sealant AMV 174 004 01 on sealing
surface between oil seal carrier and engine
block
23 - Bolt
10 Nm (7 ft lb)
Use 3249 hex ball socket to remove and
install two rear bolts on transmission
Tighten diagonally in sequence

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17-5

24 - Gasket
Always replace
25 - Bolt
10 Nm (7 ft lb)
26 - Oil return line
From turbocharger

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27 - Gasket
Always replace
Install dry
Only spread thin coat of sealant AMV 174
004 01 on front and rear sealing surfaces
between oil seal carrier and engine block

CAUTION!

Part numbers are listed here for reference only.

Always check with your Parts department for
the latest information.

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17-6

Part II

1 - Oil filter bracket

2 - Gasket
Always replace
3 - Oil retaining valve
8 Nm (71 in. lb)

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4 - Gasket
Always replace
5 - Coupling
30 Nm (22 ft lb)
6 - Oil feed line
25 Nm (18 ft lb)
To turbocharger
7 - Bolt
20 Nm (15 ft lb)
8 - Lower coolant pipe
9 - Sealing washer
If leaking, cut open and replace
10 - Oil pressure switch -F1-, 1.4 bar (20.3 psi)
25 Nm (18 ft lb)

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Black insulation
Check Page 17-22

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17-7

11 - Engine oil temperature sensor -G8-

10 Nm (7 ft lb)
12 - Sealing washer
If leaking, cut open and replace
13 - O-ring
Always replace

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Snap into grooves on oil cooler
14 - Oil cooler
Refer to "CAUTION!" Page 17-1
Coolant hose connection diagram Page
19-2
15 - Oil filter
Follow filter change intervals
Use 3417 oil filter wrench to remove
Follow installation notes found on oil filter
Tightening torque: 20 Nm (15 ft lb)
16 - Nut
25 Nm (18 ft lb)
17 - Hex socket bolt
25 Nm (18 ft lb)

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17-8

Fig. 1 Checking oil pump backlash

New: 0.05 mm (0.002 in.)
Wear limit: 0.20 mm (0.008 in.)

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Fig. 2 Checking oil pump axial clearance

Wear limit: 0.15 mm (0.006 in.)

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17-9

Oil pan, removing and installing

Special tools and equipment

10-222A engine support bridge with 10-222A/1

bracket for engine

2024A engine sling

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3249 puller

VAG1202A engine hoist

AMV 174 004 01 sealant

Note:

Always replace gaskets.

Removing

- Remove noise insulation panel (arrows).

- Drain engine oil.

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17-10

CAUTION!

Before removing ribbed belt, note direction of

rotation with chalk or felt-tip marker.
Reversing the direction of rotation of a used
belt can destroy the belt.

- Remove bolts for ribbed belt tensioner for A/C compressor (arrows).
- Release tension on ribbed belt and remove.

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- Remove belt pulley.

- Remove torque support stop (arrows).

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17-11

- Remove side brace from left side of torque

support bracket.

- Remove torque support bracket from engine (arrows).

Note:

Illustration is shown with engine removed.

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- Cut tie wraps (arrows), open bracket for starter wiring and remove
wiring.

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17-12

- Remove hose from turbocharger at air guide tube in lock carrier

(arrow).

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- Remove both nuts -1- from lower engine mount.

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17-13

- Remove engine covers.

- Set 10-222A engine support bridge on fender mounting edges.

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- Remove mounting eye from 2024A engine sling.
- Insert bolt -1- in center bore of 2024A engine sling and secure using
cotter pin.
- Attach 2024A engine sling bolt to 10-222A engine support bridge
spindle.
- Attach 2024A engine sling to mounting eyes at front and rear of engine.

WARNING!

Mounting hooks and pins on the engine sling must be secured with
the positioning lock (arrows).

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17-14

- Using 10-222A engine support bridge spindle, lift

up engine as far as possible.

Note:

Lift engine only as far as possible without over-

stretching or damaging any pipes or coolant
hoses. Check for clearance of viscous fan; if
necessary remove.

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- Release tension on ribbed belt Page 13-
15 .

- Secure belt pulley for viscous fan using M5 x 60 mm bolt and unbolt
using 8mm hex socket wrench.
- Remove viscous fan and place forward in fan frame.

- Use VAG1202A engine hoist to support subframe.

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17-15

- First remove front bolts -2- and -3- from subframe, then remove bolt -1-
.

Note:

Only loosen or lower subframe at front to avoid changing wheel

alignment.

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- Using VAG1202A engine hoist slowly lower subframe.
- Pull out VAG1202A engine hoist and swing stabilizer down.

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17-16

Vehicles with manual transmission

- Loosen left transmission mount nut (arrow) until it is aligned with lower
edge of bolt (approx. 4 turns).

Vehicles with automatic transmission

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- Loosen rear bolt -2- for left transmission mount several turns. Remove
front bolt -1- for left transmission mount.

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17-17

All models

- Loosen rear bolt -2- for right transmission mount several turns.
Remove front bolt -1- for right transmission mount.
- Remove oil return line for turbocharger at oil pan.
- Unbolt oil pan.

Note:

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For vehicles with manual transmission: both rear bolts on oil pan can
be reached through opening on flywheel (arrow). Turn flywheel as
needed.
Use 3249 hex ball socket to remove rear oil pan bolts.
- Remove oil pan (if necessary tap lightly using rubber hammer to
remove).

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17-18

Installing

Installation is the reverse of removal, noting the

following:

Note:

Replace gaskets and O-rings.

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When installing oil pan on removed engine,
note that oil pan is aligned with metal plate on
flywheel side (i.e. oil pan projects out over
engine block 0.8 mm, or 0.0315 in.).

- Clean sealing surfaces before installing oil

pan.

- Lightly spread AMV 174 004 01 sealant on front

and rear contact surfaces of oil seal carrier.

- Tighten bolts between oil pan and engine block

in 2 stages and diagonal sequence.

- Install oil pan and tighten all bolts between oil

pan and engine block to 5 Nm (44 in. lb) (stage
1).

- Tighten bolts between oil pan and

transmission.

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Tightening torque: 45 Nm (33 ft lb)

- Tighten M10 bolts between oil pan and engine

block.

Tightening torque: 45 Nm (33 ft lb)

- Tighten all M6 bolts between oil pan and engine

block to 10 Nm (7 ft lb) (stage 2).

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17-19

- Install subframe Repair Manual, Suspension,

Wheels, Steering,Repair Group 40.

- Place torque support on rubber buffer for torque

support and tighten bolts to 25 Nm (18 ft lb).

- Install ribbed belt Page 13-15 .

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Note:

When installing ribbed belt, check for correct

seating on belt pulley.

- Add engine oil and check oil level.

CAUTION!

Do not overfill with oil past the MAX mark on

the oil dipstick. Damage to the Three Way
Catalytic Converter (TWC) could result.

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17-20

Tightening torques

Component Tightening
torques
Oil pan to engine block M6 10 Nm (7 ft lb)
M10 45 Nm (33 ft lb)
Oil pan to transmission 45 Nm (33 ft lb)

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Engine mount to subframe 25 Nm (18 ft lb)
Torque support to bracket on 25 Nm (18 ft lb)
engine
Torque support bracket to
engine
25 Nm (18 ft lb)
Side brace to bracket for 25 Nm (18 ft lb)
torque support
Side brace to engine support 20 Nm (15 ft lb)
Oil drain plug 50 Nm (37 ft lb)
Oil return line to oil pan 10 Nm (7 ft lb)
Transmission mount to 23 Nm (17 ft lb)
subframe

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17-21

Oil pump, removing and installing

Removing

- Remove oil pan Page 17-9 .

- Unhinge baffle plate and remove.

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- Remove bolts (arrows).
- Press down on subframe and remove oil pump.

Installing

Installation is the reverse of removal, noting the following:

Installing oil pan Page 17-18 .

Tightening torque

Component Tightening torques

Oil pump to engine block 25 Nm (18 ft lb)

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17-22

Oil pressure and oil pressure switch,

checking

Function of dynamic oil pressure warning

system

Warning lamp, checking

With engine switched off and ignition on (terminal

15 on), oil pressure warning lamp will be lit (not

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for vehicles with Auto Check system).

Warning criteria

Engine switched off and oil pressure switch

closed.

Coolant temperature less than 60 C (140

F), engine speed higher than 300 RPM and
oil pressure switch open.

Coolant temperature greater than 60 C

(140 F).

At engine speeds greater than 5000 RPM,

an active oil warning won't be erased
independent of oil pressure switch setting.

A Diagnostic Trouble Code (DTC) is

recognized when oil pressure switch is open

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for more than 0.5 seconds at engine speeds

greater than 1500 RPM. If condition occurs
more than three times during a drive,
warning will remain active even at engine
speeds less than 1300 RPM.

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17-23

Special tools and equipment

VAG1342 oil pressure tester

VAG1527B voltage tester

VAG1594A measuring appliance adapter

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Test conditions

Oil level OK

Oil pressure warning light -K3- must light up

when ignition is switched on.

For vehicles with Auto Check system, "i.O"

indicator must be lit (call up symbol)

Engine oil temperature approximately 80 C

(176 F)

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17-24

Oil pressure switch, checking

- Disconnect line from oil pressure switch.

- Remove oil pressure switch and install VAG1342 oil pressure tester.
- Install oil pressure switch into VAG1342 oil pressure tester.
- Connect brown wire -1- of tester to Ground (GND).

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- Using VAG1594 adapter, connect VAG1527B voltage tester to oil
pressure switch and Battery Positive Voltage (B+).
LED must not be lit.
- If LED is lit, replace oil pressure switch.
- Start engine.

Note:

While starting engine, watch pressure tester and LED as oil pressure
switch may open during start.

At 1.2-1.6 bar (17.4-23.2 psi) LED must be lit.

- If LED does not light, replace oil pressure switch.

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17-25

Oil pressure, checking

- Disconnect line from oil pressure switch.

- Remove oil pressure switch and install VAG1342 oil pressure tester.
- Install oil pressure switch into VAG1342 oil pressure tester.
- Start engine.

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Engine oil temperature approximately 80 C (176 F).
Oil pressure at idle: 1.0-3.5 bar (14.5-50.75 psi)
Oil pressure at 3000 RPM: 5.0-7.0 bar (72.5-101.5 psi)

If specified values are not obtained, the pressure relief valve or the oil
pump is faulty.

- Replace oil pump Page 17-21 .

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17-26

Engine oil

Engine oil capacity (w/filter): 3.5 L (3.7 qt.).

The engine is factory-filled with a high quality

multi-grade oil that can be used as an all-season
oil, except in extremely cold climates.

Viscosity classes and oil specifications

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Select the viscosity according to the chart shown. The oil does not need
to be changed if the outside temperature only briefly exceeds the
specified ranges.

The specifications stated on these pages must be indicated on the

container either individually or in combination with other specifications.

A - Multi-grade oil, specification VW 500 001)

B - Multi-grade oil, specification VW 501 011)

- Multi-grade oil, specification API-SF- or -SG-2)

1) This VW specification must have a date of 10/91 or later.

2)These oils may only be used in exceptional cases if no approved

engine oil is available.

Mixing oils when topping up is permissible.

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17-27

Oil level, checking

Test conditions

Minimum engine oil temperature: 60 C

(140 F)

Vehicle on level ground

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After stopping engine, wait a few minutes to
allow oil to flow back into oil pan

- Withdraw dipstick, wipe off using clean cloth and

reinsert fully.

- Withdraw dipstick again and read oil level.

Range of markings on dipstick:

a - Oil MUST NOT be topped off.

b - Oil may be topped off. After topping off, oil may reach range -a-.
c - Oil MUST BE topped off. After topping off, it is sufficient if oil level is
somewhere in range -b- (shaded area).

CAUTION!

Do not overfill with oil past the MAX mark on the oil dipstick.
Damage to the Three Way Catalytic Converter (TWC) could result.

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19-1

Cooling system components,

removing and installing
WARNING!

The cooling system is pressurized when the

engine is warm. When opening the expansion
tank, wear gloves and other appropriate
protection, cover the cap using a cloth, and
open carefully to relieve system pressure

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slowly.

Note:

Cooling system is under pressure when engine

is warm. If necessary reduce pressure before
repair.

Secure all hose connections using production-

type clamps parts catalog.

VAG1921 pliers are recommended for installing

spring clips.

Always replace gaskets, seals and O-rings.

Arrows on coolant lines and hoses must

align.

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19-2

Cooling system components

Coolant hose connection diagram

1 - Heater core
After replacing, replace coolant
2 - Lower coolant line
Removing and installing Page 19-22

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3 - Expansion tank
With cap
Pressure relief valve in cap, checking
Page 19-30
4 - Oil cooler
Removing and installing Page 17-7 ,
item 14
5 - Intake manifold
6 - Lower coolant hose
7 - Upper coolant hose

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19-3

8 - Radiator
Removing and installing Page 19-24
After replacing, replace coolant
9 - Upper coolant line
10 - Coolant pump/coolant thermostat
Coolant pump, removing and installing

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Page 19-13
Check for ease of movement
Coolant thermostat, removing and installing
Page 19-20
Checking Page 19-21
11 - Turbocharger
12 - Cylinder head/cylinder block
After replacing, replace coolant
13 - Connector

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19-4

Cooling system, draining and filling

Special tools and equipment

VAG1306 drip tray

VAG1274/10 with VAG1274/1 adapter or

VAG1274/8

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T40007 refractometer

Draining

Note:

Drain coolant into a clean container for recycling

or reuse.

WARNING!

The cooling system is pressurized when the

engine is warm. When opening the expansion
tank, wear gloves and other appropriate
protection, cover the cap using a cloth, and
open carefully to relieve system pressure
slowly.

- Open coolant expansion tank cap.

- Remove noise insulation panel (arrows).

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19-5

- Place VAG1306 drip tray underneath engine.

CAUTION!

Observe disposal regulations for coolant!

- Remove retaining clip (arrow) from lower coolant hose and remove
coolant hose from radiator.

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Note:

With bumper removed, coolant can be drained through radiator drain plug
(arrow).

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19-6

- Remove drain plug from coolant pump (arrow).

Filling

Note:
The cooling system is filled year-round with frost and corrosion
protection additives.
Until 6/96, G 011 A8 C coolant (green color) was used.

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From 7/96 on, only G 012 A8 D coolant (red color) is used.

CAUTION!

Coolants G 011 A8 C and G 012 A8 D CANNOT be mixed. Mixing

them will cause severe engine damage.
Part numbers are for reference only. Always check with your Parts
department for the latest information.
If the fluid in the expansion tank is brown, G012 A8 D has been mixed
with other coolant. In this case, flush cooling system and change
coolant. To flush, fill cooling system with clear water and run engine
for approx. 2 minutes. Flushing the system should remove most of the
coolant residue.

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19-7

Note (continued from page Page 19-6 ):

G 011 A8 C or G 012 A8 D and coolant

additives marked with "according to TL VW
774C" or "according to TL VW 774 D", prevent
frost and corrosion damage as well as calcium
deposits. They also raise the boiling point.
Therefore, cooling system must be filled year-
round with frost and corrosion protection
additives.

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A higher boiling point improves engine reliability
under heavy load, particularly in countries with
tropical climates.

Frost protection additives must protect against

frost to about -25 C (-13 F) and to about -35
C (-31 F) in arctic climates.

The coolant concentration must not be reduced

by adding water even in warmer seasons and in
warmer countries. The anti-freeze ratio must be
at least 40%.

If for climatic reasons greater frost protection is

required, the amount of G 011 A8 C or G 012
A8 D can be increased, but only up to 60% to
obtain frost protection to about -40 C (-40 F).
Otherwise frost protection and cooling
effectiveness will be reduced.

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Cooling system components, removing and installing Page 8 of 34

If the radiator, heater core, cylinder head or

cylinder head gasket is replaced, completely
replace the engine coolant.

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Cooling system components, removing and installing Page 9 of 34

19-8

For coolant G 012 A8 D, use T40007 refractometer to test frost protection

in cooling system.

Recommended mixture ratios:

Frost protection to Anti-freeze amount G 012 A8 Water1)

D1)
-25 C 40 % 3.0 ltr. 4.0 ltr.

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(-13 F) (3.2 qts.) (4.2 qts.)

-35 C 50 % 3.5 ltr. 3.5 ltr.

(-13 F) (3.7 qts.) (3.7 qts.)

1)The quantity of coolant: 7.0 liters (7.4 qts.) can vary depending upon
vehicle options.
- Install lower radiator hose and secure.
- Replace O-ring and install coolant pump drain plug.
Tightening torque: 30 Nm (22 ft lb)

Vehicles with small cap

- Screw VAG1274/1 adapter onto coolant expansion tank.

- Attach VAG1274/10 special tool to VAG1274/1 adapter.

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19-9

Vehicles with large cap

- Screw VAG1274/8 adapter onto coolant expansion tank.

- Attach VAG1274/10 special tool to VAG1274/1 adapter.

All models

Note:

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To fill without using special tools, loosen coolant expansion tank and lift
approx. 100 mm (approx. 4 in.).

- Remove grommet holding clip at heater core and pull back grommet.

- Loosen coolant hose on heater core and pull back hose sufficiently so
that bleeder hole (arrow) is no longer sealed by connection.
- Top up coolant until it flows out of coolant hose bleeder hole.
- Push coolant hose on connection and tighten.
- Install coolant expansion tank cap.

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19-10

- Start engine and maintain an engine speed of

about 2000 RPM for approx. 3 minutes.

- Allow engine to idle until the lower radiator hose

is hot.Check coolant level and top up if
necessary. When engine is at normal operating
temperature, coolant level must be at max.
mark; when engine is cold, between min. and
max. marks.

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WARNING!

The cooling system is pressurized when the

engine is warm. When opening the expansion
tank, wear gloves and other appropriate
protection, cover the cap using a cloth, and
open carefully to relieve system pressure
slowly.

- Switch engine off.

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19-11

Coolant pump and coolant thermostat,

servicing

1 - Bolt
M6: 10 Nm (7 ft lb)
M8: 20 Nm (15 ft lb)
2 - Lower toothed belt cover

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Removing and installing Page 13-29
3 - Nut
10 Nm (7 ft lb)
4 - Coolant pump
Removing and installing Page 19-13
Check for ease of movement
5 - Gasket
Always replace
6 - O-ring
Always replace

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19-12

7 - T-head bolt
Insert before installation
8 - Coolant thermostat
Removing and installing Page 19-20
Checking Page 19-20
9 - Connector

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10 - Drain plug
30 Nm (22 ft lb)
11 - O-ring
Always replace
12 - Belt pulley
Installed position: flat pulley half faces
coolant pump
13 - Socket-head bolt
25 Nm (18 ft lb)

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19-13

Coolant pump, removing and installing

Note:

Coolant pump is bolted to bracket for generator,

power steering pump and viscous fan.

Lock carrier in service position Page 13-1

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Removing

CAUTION!

Before disconnecting the battery:

Stop the engine.

Determine the correct coding for the anti-

theft radio.

Switch the ignition off (also applies when

connecting the battery). Failure to do so may
damage the Engine Control Module (ECM).

- Switch ignition off and disconnect battery Ground (GND) strap.

- Remove ribbed belt Page 13-15 .
- Remove viscous fan (with belt pulley) Page 13-14 , Fig. 1.
- Remove V-belt Page 13-18 .

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Cooling system components, removing and installing Page 15 of 34

Note:

Ribbed belt for A/C compressor and torque support remains installed.

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Cooling system components, removing and installing Page 16 of 34

19-14

- Drain coolant Page 19-4 .

- Loosen clamps for coolant hoses -1- and -2-.

- Remove coolant hose to radiator at coolant line.
- Remove intake air duct between intake manifold and charge air cooler.
- Remove mounting bolts for generator.
- Remove generator toward front.

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- Disconnect wiring from removed generator.
- Unbolt following supports and braces from bracket for generator, power
steering pump and viscous fan:
Intake manifold support
Support for torque support bracket
Brace to cylinder block (remove completely)

- Remove bracket for generator, power steering pump and viscous fan
bolts -1- through -6-.
- Secure bracket for generator, power steering pump and viscous fan to
left side using wire.

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19-15

Note:

Power steering pump remains installed.

- Pull off coolant hoses from coolant pump and

coolant thermostat housing.

- Unbolt coolant pump housing from toothed belt cover (arrow).

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- Remove coolant pump.

- Unbolt impeller housing -1- from pump housing -4-.

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19-16

Installing

Installation is the reverse of removal, noting the

following:

- Clean sealing surfaces of both housings.

- Replace gasket and O-ring.

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- Insert T-head bolt into coolant pump bore.

- Mount bracket for generator, power steering pump and viscous fan with
coolant pump on cylinder block and tighten bolts in numerical
sequence.
1 - M8 x 70 bolt
2 - M8 x 110 bolt
3 - M8 x 50 bolt
4 - M8 x 90 bolt
5 - M8 x 70 bolt
6 - M8 x 100 bolt
- Install viscous fan Page 13-14 , Fig. 1.
- Install ribbed belt Page 13-17 .

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19-17

Note:

When installing ribbed belt, check for correct

seating on belt pulley.

- Install V-belt Page 13-18 .

- Fill up with coolant Page 19-6 .

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WARNING!

The cooling system is pressurized when the

engine is warm. When opening the expansion
tank, wear gloves and other appropriate
protection, cover the cap using a cloth, and
open carefully to relieve system pressure
slowly.

CAUTION!

Be sure the ignition is switched OFF. Failure

to do so may damage the Engine Control
Module (ECM).

- Switch ignition off and reconnect battery Ground

(GND) strap.

- After connecting battery, enter anti-theft code for

radio.

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Cooling system components, removing and installing Page 20 of 34

Radio Operating Manual

- Fully close power windows to stop.

- Operate all power window switches again for at

least one second in "close" direction to activate
"one-touch" opening/closing function.

- Set clock to correct time.

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Cooling system components, removing and installing Page 21 of 34

19-18

Tightening torques

Component Tightening
torques
Impeller to pump housing 10 Nm (7 ft
lb)
Pump housing to toothed belt 10 Nm (7 ft
cover lb)

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Bracket for generator, power 25 Nm (18 ft
steering pump and viscous fan to lb)
cylinder block
Left brace for cylinder
block/bracket for generator, power
steering pump and viscous fan
to cylinder block 25 Nm (18 ft
lb)
to bracket M10 40 Nm (30 ft
lb)
Brace for torque support/bracket
for generator, power steering
pump and viscous fan
to torque support 25 Nm (18 ft
lb)
to bracket 20 Nm (15 ft
lb)
Intake duct support

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Cooling system components, removing and installing Page 22 of 34

to intake duct 20 Nm (15 ft

lb)
to bracket 20 Nm (15 ft
lb)

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Cooling system components, removing and installing Page 23 of 34

19-19

Component Tightening
torques
Generator to bracket for
generator, power steering pump
and viscous fan
M8 25 Nm (18 ft
lb)
M10 40 Nm (30 ft

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lb)
Belt pulley to coolant pump 25 Nm (18 ft
lb)
Viscous fan to bearing 45 Nm (33 ft
lb)

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19-20

Coolant thermostat, removing, installing

and checking

Removing

- Drain coolant Page 19-4 .

- Remove bolts -4-, remove connector -3-, O-ring -2- and coolant
thermostat -1-.

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Installing

- Clean and/or smooth O-ring sealing surface.

- Install coolant thermostat.
- Fill up with coolant Page 19-6 .

WARNING!

The cooling system is pressurized when the engine is warm. When

opening the expansion tank, wear gloves and other appropriate
protection, cover the cap using a cloth, and open carefully to relieve
system pressure slowly.

Tightening torque

Component Tightening torque

Connector to pump housing 10 Nm (7 ft lb)

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19-21

Coolant thermostat, checking

- Warm thermostat in hot water bath.

Starts to Fully open Stroke

open
approx. 87 C approx. 102 C min. 8
1) mm

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(189 F)
(216 F) (0.315 in.)

1) Cannot be tested.

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19-22

Coolant line (lower), removing and

installing

Removing

- Drain coolant Page 19-4 .

- Remove intake air duct between intake manifold

and charge air cooler.

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- Remove hose -4- to oil cooler at lower coolant line -2-.
- Remove hose -5- to heater core at lower coolant line.
- Remove lower coolant line from hose -1- at coolant pump.
- Unbolt lower coolant line from oil filter bracket -3-.

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Cooling system components, removing and installing Page 27 of 34

19-23

Installing

Installation is the reverse of removal, noting the

following:

- Fill with coolant Page 19-6 .

WARNING!

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The cooling system is pressurized when the
engine is warm. When opening the expansion
tank, wear gloves and other appropriate
protection, cover the cap using a cloth, and
open carefully to relieve system pressure
slowly.

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19-24

Radiator, removing and installing

Special tools and equipment

VAG1306 drip tray

Removing

- Remove front bumper.

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Repair Manual, Body Exterior, Repair Group
63

- Unbolt cooling pipe for power steering hydraulic oil (arrows).

- Place VAG1306 drip tray underneath engine.

WARNING!

The cooling system is pressurized when the engine is warm. When

opening the expansion tank, wear gloves and other appropriate
protection, cover the cap using a cloth, and open carefully to relieve
system pressure slowly.

- Open coolant expansion tank cap.

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19-25

- Turn radiator drain plug (arrow) counterclockwise; if needed attach

accessory hose to connection flange.

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- Remove coolant hoses at radiator and remove clip from connecting
flange (arrow).

Vehicles with automatic transmission

- Remove ATF lines from radiator.

Repair Manual, 5 Spd. Automatic Transmission 01V, Repair Group 37

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19-26

- Remove bolts -4- for air guides at radiator on left and right sides.
- Remove retaining bolts -1- and -2- from condenser.
- Disconnect harness connector -3- at A/C pressure switch -F129-.
- Pull condenser upward, out of retaining bracket, swing to side and
hang at right-front wheel using wire loop.

Note:

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Make sure fender is protected against possible damage.

- Unlock both radiator retaining bolts and pull upward to remove

(arrows).
- Tilt radiator forward and remove toward top.

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19-27

Installing

Installation is the reverse of removal, noting the

following:

- Fill up with coolant Page 19-6 .

WARNING!

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The cooling system is pressurized when the
engine is warm. When opening the expansion
tank, wear gloves and other appropriate
protection, cover the cap using a cloth, and
open carefully to relieve system pressure
slowly.

Tightening torques

Component Tightening torques

Condenser to radiator 10 Nm (7 ft lb)
Coolant line to radiator 10 Nm (7 ft lb)

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19-28

Cooling system, pressure test

Special tools and equipment

VAG1274 cooling system tester

VAG1274/1 adapter or VAG1274/8 with

VAG1274/9

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Test condition:

Engine at operating temperature

WARNING!

The cooling system is pressurized when the

engine is warm. When opening the expansion
tank, wear gloves and other appropriate
protection, cover the cap using a cloth, and
open carefully to relieve system pressure
slowly.

- Open coolant expansion tank cap.

Vehicles with small cap

- Using VAG1274/1 adapter, attach VAG1274 cooling system tester to

coolant expansion tank.

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19-29

Vehicles with large cap

- Using VAG1274/8 adapter, attach VAG1274 cooling system tester to

coolant expansion tank.

All models

- Use tester hand pump to create approx. 1.0 bar (14.5 psi) pressure.
- If pressure drops, check for leaks and repair.

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19-30

Pressure relief valve in cap, checking

Vehicles with small cap

- Using VAG1274/1 adapter (2 parts), attach VAG1274 cooling system

tester to coolant expansion tank cap.
- Pump using hand pump.
Pressure relief valve must open at 1.2-1.5 bar (17.4-21.75 psi).

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Vehicles with large cap

- Using VAG1274/9 adapter attach VAG1274 cooling system tester to

coolant expansion tank cap.
- Pump using hand pump.
Pressure relief valve must open at 1.4-1.6 bar (20.3-23.2 psi).

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Turbocharger system Page 1 of 50

21-1

Turbocharger system
Note:

Observe rules of cleanliness Page 21-22 .

Charge air pressure control connection diagram

Page 21-2 .

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All hose connections are secured with hose
clamps:

parts catalog.

charge air pressure system must be free of

leaks.

Replace self-locking nuts.

Always replace gaskets.

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21-2

Charge air pressure control, system

overview

Vehicles with manual transmission

1 - PCV valve
For crankcase ventilation
2 - Evaporative Emission (EVAP) canister

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purge regulator valve -N80-
3 - To Evaporative Emission (EVAP) canister
4 - Check valve for Evaporative Emission
(EVAP) canister
Installed position (light/dark): as shown in
illustration
5 - Turbocharger
6 - Fuel pressure regulator
7 - Intake manifold
8 - To Leak Detection Pump (LDP) -V144-
9 - Crankcase ventilation

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21-3

10 - Check valve for Evaporative Emission

(EVAP) canister
Installed position (light/dark): as shown in
illustration
11 - Charge air cooler
12 - Vacuum diaphragm
For wastegate

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13 - Charge pressure bypass valve
Checking Page 21-4
14 - Wastegate bypass regulator valve -N75-

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Turbocharger system Page 4 of 50

21-4

Charge pressure bypass valve, checking

Note:

The charge pressure bypass valve is located in

front of the turbocharger. It is opened by
vacuum during deceleration and when under
partial load at idle. This reduces charge air
pressure in front of the throttle valve and keeps
the turbocharger spinning at higher RPMs.

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Check the charge pressure bypass valve if
experiencing reduced performance or turbo lag.

Special tools and equipment

VAG1390 hand vacuum pump

- Connect VAG1390 hand vacuum pump to vacuum connection on

recirculation valve.
- Operate hand vacuum pump.
Recirculation valve must open (arrow).
- After approx. 30 seconds, operate vent valve on hand vacuum pump.
Recirculation valve must close (arrow).

If valve does not open/close or valve plate does not seal correctly when
valve is closed:

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- Replace valve and secure recirculation shut-off valve connections

using hose clamps.

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Turbocharger system Page 6 of 50

21-5

Turbocharger and wastegate, checking

If special testing equipment is required during

test drive, heed the following WARNING:

WARNING!

When driving or riding in an airbag-equipped

vehicle, NEVER hold the scan tool or other
test equipment in your hands or lap while in

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motion. Objects between you and the airbag
increase the risk of injury in an accident.

During a test drive in an airbag-equipped

vehicle, test equipment must always be
fastened to and operated from the rear seat
by a second technician.

Special tools and equipment

VAG1397A turbocharger tester

VAG1551 scan tool with VAG1551/3 adapter

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Turbocharger system Page 7 of 50

21-6

Test conditions:

Check DTC memory Repair Manual, 1.8

Liter 4-Cyl. 5V Turbo Fuel Injection &
Ignition, Repair Group 01

Perform output diagnostic test mode

(function 03)

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Minimum engine oil temperature: 60 C
(140 F)

All vacuum connections are free of leaks

Test procedure

- Using T-fitting, connect VAG1397A turbocharger tester test hose to

front of intake manifold.
- Guide test hose over rear corner of hood through right window opening
into vehicle interior.

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21-7

- Turn turbocharger tester on and select measuring range -I- (absolute

pressure).
- Connect test hose to connection flange -I-.

Note:
Hoses must be connected so there is no possibility of leaks, otherwise
incorrect readings may result.
Ensure test hose is not pinched at the hood and/or window.

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By pressing the memory button "M" on the turbocharger tester, the last
test value is stored until either memory button "M" is pressed again or
the turbocharger tester is shut off.
A blinking comma in the display field indicates a value has been
stored.
An arrow appears in the top left corner of the display field if the
turbocharger tester battery voltage drops below the allowed
specification.
Before testing, drive vehicle briskly for at least 3 km (approx. 2 miles)
without frequent stops.

WARNING!

Always use a second technician to take measurements via the

VAG1397A turbocharger tester when test-driving vehicle for this
test.
Follow "WARNING!" Page 21-5 .

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Turbocharger system Page 9 of 50

21-8

Vehicles with manual transmission:

- Accelerate vehicle in 3rd gear at full throttle from

2000 RPM and watch tachometer.

- At 3000 RPM press memory button "M" on turbocharger tester.

Specification: 1.37-1.47 bar (19.865-21.315 psi)

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Vehicles with automatic transmission:

- Drive with selector lever in range 2.

- Accelerate to 3000 RPM and wait for transmission to shift into 2nd
gear.
- Press accelerator pedal to kickdown position (transmission will not shift
down at this vehicle/engine speed).
- At 4500 RPM, press memory button "M" on turbocharger tester.
Specification: 1.3-1.4 bar (18.85-20.30 psi)

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Turbocharger system Page 10 of 50

21-9

Note:

For vehicles with automatic transmission the

charge air pressure test may not always provide
a definitive reading of proper charge air pressure
regulation. If pressure readings are at the lower
end of the specified range, measure charge air
pressure control via load signal Page 21-10 .

All vehicles:

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If measured value is above or below specification
Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel
Injection & Ignition, Repair Group 24.

Note:

If no charge air exists and a rumbling sound is

heard from the engine compartment, the causes
are as follows:

Charge pressure bypass valve

malfunctioning.

Vacuum line to charge pressure bypass valve

leaking or disconnected.

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Turbocharger system Page 11 of 50

21-10

Charge air pressure control (via load

signal), checking

WARNING!

Always use a second technician to take

measurements via the VAG1397A
turbocharger tester when test-driving vehicle
for this test.

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Follow "WARNING!" Page 21-5 .

Note:

If VAG1551 scan tool is not available, use

VAG1552 mobile scan tool instead.

- Unclip Data Link Connector (DLC) cover.

- Using VAG1551/3 adapter, connect VAG1551 Scan Tool (ST) or

VAG1552 mobile scan tool.

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Turbocharger system Page 12 of 50

VAG - ON BOARD DIAGNOSTIC HELP Indicated on display1)

1 - Rapid data transfer

2 - Blink code output 1) Operating modes 1 and 2 are displayed alternately

Note:

If nothing appears on display:

Scan tool operating instructions

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21-11

- Press button 1 to select "Rapid data transfer"

operating mode 1.

- Start engine.

Rapid data transfer HELP Indicated on display

Select function XX

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Rapid data transfer Q
- Press buttons -0- and -1- to insert "Engine Electronics" address word
01 - Engine Electronics 01.
- Press -Q- button to confirm input.

06A906018.. 1.8l R4/5T MOTR HS 0.. VAG1551 scan tool display indicates control module coding.
Coding 04000 WSC 12345
- Press button.

Rapid data transfer HELP Indicated on display

Select function XX
- Press buttons -0- and -8- to select "Read Measuring Value Block"
function 08.
- Press -Q- button to confirm input.

Read Measuring Value Block HELP Indicated on display

Input display group number XXX
- Press buttons -1-, -1- and -4- to input display group number 114 (114).
- Press -Q- button to confirm input.

Read Measuring Value Block 114 The "Read Measuring Value Block" displays four display fields.

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Interpreting values 1-4 in each display field Page 21-12 .

1 2 3 4

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21-12

Interpreting display fields

Read Measuring Value Block 114 Indicated on display:

1 2 3 4
Display Description
field
1 Not applicable
2 Specified engine load (after correction)

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3 Current engine load
4 Duty cycle (actuation of wastegate bypass regulator valve
-N75-)
- Note values in display field 2 and 3 while vehicle is under steady
acceleration.

Specification

Deviation between display field 2 and 3: 0.3 ms (max.)

Note:

If the OBD for the Engine Control Module (ECM) recognizes Diagnostic
Trouble Codes (DTCs) in charge air pressure regulation, duty cycle
(display field 4) will indicate a constant 5%.

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21-13

Diagnostic Trouble Codes (DTC) for charge air pressure regulation

Diagnostic VAG1397A Display VAG1551 Display Possible causes

Trouble Code
(DTC)
Charge air Measured value below 1.37 Current engine load Wastegate bypass regulator valve
pressure too bar (19.9 psi) (vehicles with (display field 3) less than -N75- malfunctioning
low manual transmission) specified engine load
(display field 2) Wiring to wastegate bypass

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Measured value below 1.30 regulator valve -N75-
bar (18.9 psi) (vehicles with Duty cycle (display field 4) malfunctioning
automatic transmission) close to 99%
Wastegate in turbocharger stuck
in open position
Leak between turbocharger and
intake manifold
Turbocharger malfunctioning

Charge air
Measured value above 1.47 Current engine load Vacuum diaphragm for wastegate
pressure too bar (21.3 psi) (vehicles with (display field 3) higher malfunctioning
high 1) manual transmission) than specified engine load
(display field 2) Hoses to vacuum diaphragm (for
Measured value above 1.40 wastegate) over wastegate
bar (20.3 psi) (vehicles with Duty cycle (display field 4) bypass regulator valve -N75-
automatic transmission) close to 0% leaking
Vacuum diaphragm wastegate in
turbocharger stuck in closed
position
1)If charge air pressure is too high, the fuel supply is shut off to protect the engine. The engine misfires at high engine
speeds.

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21-14

Charge pressure leak test with VAG

1687

Intake system, checking for leaks using VAG

1687 Diagnostic Tool

Diagnostic trouble codes (DTCs) related to fuel

trim, charge pressure or mass air flow (MAF)
may be caused by:

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Leaking (worn/torn) intake hoses during charge
conditions

Incorrectly torqued or improperly placed clamps

on intake hoses etc. causing leaks during
charge conditions

Check the charge air pressure system using the VAG 1687 Charge air
system tester.

Special tool VAG 1687 Charge air system tester preliminary set-up

- Back off pressure regulator knob -2- of VAG 1687 fully to protect gauge
when shop air supply is applied to assembly.

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- Close valve -3- before gauge.

- Close valve -4- after gauge.

The shop air supply line will later be attached to the inlet of VAG 1687.

- Remove female fitting from tester (arrow) and install an appropriate

"male" air fitting that will connect to your shop air supply line (
WARNING!).

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21-15

WARNING!

Use only approved air fittings to adapt shop

air supply line to VAG 1687 tester.

Special tool VAG 1687/1 pressure adapter,

installing (1.8L Turbo)

- Separate intake hose from Mass Air Flow (MAF)

sensor assembly.

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- Insert VAG 1687/1 pressure adapter in intake hose -black arrow- using
existing clamp (as shown).
- Remove crankcase ventilation tube from intake hose at -white arrow-.

Special tool VAG 1687/1 pressure adapter, installing (2.7L BiTurbo)

- Remove upper air cleaner housing and hoses to intake manifold as

necessary

Repair Manual, Maintenance; Air cleaner housing, cleaning; Air cleaner

element, replacing

- Insert VAG 1687/1 pressure adapter in intake hose -white arrow- using
existing clamp (as shown).
- Disconnect engine crankcase ventilation hose from intake manifold -
black arrow-.
-
Plug intake manifold fitting (for crankcase ventilation hose) with
appropriate hose and metal plug using clamps supplied with VAG

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1687/1 special tool kit.

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21-16

Note:

To help find small leaks, BEFORE pressurizing

the system fill system with smoke using special
tool KLI9210 and adapter KLI9210/50 as
described on page Page 21-16 .

An ultrasonic detector may also be used to

detect extremely small leaks where smoke may

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not be visible.

Special tool KLI9210 (Evaporative system

leak detector), connecting to 1.8L Turbo

- Install optional fitting LKI9210/50 on hose of

special tool KLI9210.

- Connect KLI9210 to VAG 1687/1 adapter (KLI9210 is shown attached

to VAG 1687/1 at arrow on 1.8L Turbo).

Special tool KLI9210 (Evaporative system leak detector), connecting

to 2.7L BiTurbo

- Install optional fitting LKI9210/50 on hose of special tool KLI9210.

-
Connect KLI9210 to VAG 1687/1 adapter (KLI9210 is shown attached

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to VAG 1687/1 at arrow on 2.7L BiTurbo).

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21-17

Special tool LKI9210 (Evaporative system

leak detector), preliminary set-up

- Connect smoke generator leads to vehicle

battery.

- Turn valve to test -black arrow-.

- Press smoke generator button to fill system with smoke (see

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instructions printed on tester).

With system filled with smoke:

- Remove smoke generator hose and connect VAG1687 quickly to

prevent smoke from leaking out Page 21-17 .

Special tool VAG 1687, connecting to pressure adapter VAG 1687/1

(1.8L Turbo)

For illustrations purposes VAG is shown lying in the engine compartment.

In practice the tool should be hung from the hood.

- Connect VAG 1687 quickly to prevent smoke from leaking out.

VAG 1687 is shown connected to VAG 1687/1 -black arrow-

Shop air supply will be connected to VAG 1687 -at white arrow-

- Perform pressure test Page 21-19 .

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21-18

Special tool VAG 1687, connecting to

pressure adapter VAG 1687/1 (2.7L BiTurbo)

For illustrations purposes VAG is shown lying in

the engine compartment. In practice the tool
should be hung from the hood.

- Connect VAG 1687 quickly to prevent smoke

from leaking out.

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VAG 1687 is shown connected to VAG 1687/1 -black arrow-

Shop air supply will be connected to VAG 1687 -at white arrow-

- Perform pressure test Page 21-19 .

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21-19

Performing pressure test:

- With outlet hose -1- of VAG 1687 connected to air pressure adapter:
- Attach shop air supply line to previously installed male fitting ( Page
21-14 .

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- Open valve -3- between regulator valve and gauge.
- Adjust test pressure up to 0.5 bar ( CAUTION below) by turning
regulator valve -2-.

CAUTION!

DO NOT pressurize the system above 0.5 bar!

Doing so may force oil into the intake system which can damage
the engine.
- Slowly open outlet valve -4- (after gauge) to test hose connections.
- Observe pressure gauge for a drop in pressure.

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21-20

Note:

Some pressure will be lost past the throttle plate.

- Readjust test pressure to 0.5 bar ( CAUTION

above) by turning regulator valve -2-.

- Listen for any very large intake leaks.

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If smoke generator was used to fill the system
with smoke:

- Inspect intake system connections for smoke at

leaks.

Note:

An ultrasonic detector may also be used to

detect extremely small leaks where smoke may
not be visible.

- Repair any leaks found.

- Remove tester.

- Remove plug from crankcase ventilation hose.

- Remove air pressure adapter.

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With VAS 5051 diagnostic tool connected:

- Erase DTC memory.

If smoke generator was not used to fill the

system with smoke:

- Apply soapy water solution or equivalent to

intake system connections.

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21-21

Note:

An ultrasonic detector may also be used to

detect extremely small leaks.

- Inspect intake system connections for leaks.

- Repair any leaks found.

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- Remove tester.

- Remove plug from crankcase ventilation hose.

- Remove air pressure adapter.

With VAS 5051 diagnostic tool connected:

- Erase DTC memory.

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21-22

Rules of cleanliness

CAUTION!

Whenever carrying out any work on the fuel

supply or fuel injection systems, always
observe the following rules of cleanliness.

1. Thoroughly clean fuel system line and hose

connections and the surrounding area before

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disconnecting.

2. Place removed components on a clean

surface and cover. Use plastic sheeting or paper.
Do not use fluffy rags that could leave lint!

3. Carefully cover over or seal any components

that have been opened if repairs are not carried
out immediately.

4. Install only clean parts:

Do not remove replacement parts from the

packaging until immediately before they are
to be installed.

Do not use parts that have been stored

without packaging (e.g. in toolboxes, etc.).

5. When the fuel system is opened:

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Avoid working with compressed air

whenever possible.

Avoid moving the vehicle if possible.

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21-23

Note:

Observe rules of cleanliness Page 21-22 .

Charge air pressure control connection diagram

Page 21-2 .

All hose connections are secured with hose

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clamps that comply with factory specifications
parts catalog.

Charge air pressure system must be free of

leaks.

Always replace gaskets and self-locking nuts.

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21-24

Turbocharger, removing, installing and

overview

Part I

1 - Bolt with collar

40 Nm (30 ft lb)
Only use genuine equipment bolts parts

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catalog
2 - Gasket
Always replace
3 - Three Way Catalytic Converter (TWC)
4 - Nut
Always replace
30 Nm (22 ft lb)
5 - Connection
30 Nm (22 ft lb)
6 - Connection
35 Nm (26 ft lb)

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21-25

7 - Bolt
20 Nm (15 ft lb)
8 - Oil supply line
Tightening torque for union nut: 25 Nm (18
ft lb)
From oil filter bracket item - 1 -, page
Page 17-6

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9 - Heat shield
10 - Exhaust manifold
11 - Bolt
Always replace
35 Nm (26 ft lb)
Coat thread and bolt head seating surface
with "G 052 112 A3" hot bolt paste.

CAUTION!

Part numbers are listed here for reference only.

Always check with your Parts department for
the latest information.

12 - Bolt
10 Nm (7 ft lb)

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21-26

13 - Gasket
Always replace
Note installed position
14 - Coolant return line
Union nut tightening torque: 30 Nm (22 ft
lb)

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15 - Nut
Always replace
25 Nm (18 ft lb)
16 - Gasket
Always replace
Note installed position
17 - Banjo bolt
25 Nm (18 ft lb)
18 - Coolant supply line
19 - Fuse
20 - Vacuum diaphragm
For wastegate
21 - Bolt
10 Nm (7 ft lb)

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22 - Bolt
10 Nm (7 ft lb)
Install with D 000 600

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21-27

23 - Gasket
Always replace
24 - Oil return line
To oil pan
25 - Gasket
Always replace

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26 - Bolt
10 Nm (7 ft lb)
27 - Bolt
10 Nm (7 ft lb)
28 - Nuts
10 Nm (7 ft lb)
Install with D 000 600
Do not change adjustment
29 - Turbocharger
Check Page 21-5
30 - Bolt
45 Nm (33 ft lb)
31 - Bracket

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21-28

Part II

1 - Vacuum hose
To intake manifold
2 - Charge pressure bypass valve
Check Page 21-4
3 - Hose

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To charge pressure bypass valve
4 - Intake air duct
To connection at turbocharger
5 - Hose
To Evaporative Emissions (EVAP) purge
regulator valve
6 - Line
To crankcase ventilation
7 - Socket-head bolt
10 Nm (7 ft lb)

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21-29

8 - Sheet metal screw

9 - Hose
To crankshaft ventilation line
10 - PCV valve
For crankcase ventilation
11 - Hose

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To turbocharger
12 - Hose
To vacuum diaphragm for wastegate
13 - Wastegate bypass regulator valve -N75-
14 - Elbow
15 - Hose
To turbocharger

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21-30

Turbocharger, removing and installing

Note:

Replace gaskets and self-locking nuts.

Removing

- Remove noise insulation panel (arrows).

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- Unbolt A/C compressor.

WARNING!

Do NOT open A/C refrigerant circuit.

- Unbolt turbocharger bracket -2-.

- Disconnect oil return line -1- at turbocharger and lay aside.
- Remove air guide ducts -4- and -5- at turbocharger.
- Remove pressure line banjo fitting -3-.
- Disconnect hose from support for charge air pressure regulation valve
vacuum diaphragm.
- Unbolt bracket for coolant supply line at charge air pressure regulation
valve vacuum diaphragm.

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- Use 3094 hose clamp to pinch off coolant supply hose.

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21-31

- Remove intake air duct between cowl and air

cleaner housing.

- Remove air cleaner housing cover.

- Remove the following lines/harness connectors:

1 - At wastegate bypass regulator valve -N75-

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2 - At Evaporative Emissions (EVAP) purge regulator valve -N80-
3 - At power output stage -N122-
4 - At Mass Air Flow (MAF) sensor -G70-
- Remove hose connections and remove air cleaner housing (arrows).
- Remove engine covers.

- Unbolt crankcase ventilation hose -1- at cylinder head cover and heat
shield.
- Unbolt both oil supply line bolts -3-.
- Remove heat shield -4-.
- Remove sleeve -2- from coolant return hose.

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- Use 3094 hose clamp to pinch off coolant return hose.

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21-32

- Remove coolant return hose at line to

turbocharger. Line remains bolted to
turbocharger.

- Unbolt oil supply line -7- at turbocharger.

Note:

The exhaust flexpipe must not be bent more than

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10 , otherwise it may be damaged.

- Unbolt Three Way Catalytic Converter (TWC)

from turbocharger -6-.

- Unbolt turbocharger from exhaust manifold -5-

.

- Move turbocharger to side and remove coolant

supply line banjo fitting.

- Remove turbocharger.

Installing

Installation is the reverse of removal, noting the

following:

- Perform the following steps before tightening

turbocharger:

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- Loosely bolt coolant supply line to vacuum

diaphragm for charge air pressure regulation
valve.

- Tighten banjo fitting, then tighten mounting

bolt for bracket to proper torque.

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21-33

Note:

Add oil to turbocharger through oil supply line

connection flange.

- Fill up coolant Page 19-4 .

WARNING!

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The cooling system is pressurized when the
engine is warm. When opening the expansion
tank, wear gloves and other appropriate
protection, cover the cap with a cloth and
open carefully to relieve system pressure
slowly.

Note:

After installing the turbocharger, let engine idle

for approx. 1 minute without increasing engine
speed. This ensures adequate oil supply to the
turbocharger.

- Check engine oil level Page 17-27 .

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21-34

Tightening torques

Component Tightening
torques
Oil return line to turbocharger 10 Nm (7 ft
lb)
Turbocharger bracket to 40 Nm (30 ft
turbocharger (bolt and washer lb)
assembly M8)1)

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Turbocharger bracket to cylinder 45 Nm (33 ft
block lb)
Oil feed line to turbocharger 25 Nm (18 ft
lb)
Coolant supply pipe bracket to 10 Nm (7 ft
turbocharger lb)
Oil supply line bracket to cylinder 20 Nm (15 ft
head lb)
Coolant supply line to 25 Nm (18 ft
turbocharger lb)
Crankcase ventilation line to 10 Nm (7 ft
cylinder head lb)
Coolant return line to 30 Nm (22 ft
turbocharger lb)
Turbocharger to exhaust 35 Nm (26 ft
manifold lb)
Three Way Catalytic Converter 30 Nm (22 ft

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(TWC) to turbocharger lb)

1) Bolt strength: 10.9

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21-35

Charge air cooler components, removing

and installing

Note:
All hose connections are secured with hose
clamps parts catalog.
charge air pressure system must be free of
leaks.

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1 - Air duct
2 - Grommet
3 - Hose
Between charge air cooler and air guide in
cowl
4 - Hose
Between intake manifold and charge air
cooler

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21-36

5 - Bracket
Riveted to body
6 - Grommet
With sleeve
7 - Charge air cooler
Removing and installing Page 21-37

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21-37

Charge air cooler, removing and

installing

Lock carrier in service position Page 13-

1.

Removing

- Remove upper air duct at charge air cooler.

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- Remove noise insulation panel (arrows).
- Disconnect air guide at charge air cooler.
- Remove lower air duct at charge air cooler.
- Remove charge air cooler from below.

Installing

Installation is the reverse of removal.

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21-38

Vacuum control system

(engine code ATW)
Notes:

Observe rules for cleanliness Page 21-39

Observe safety precautions Page 21-40

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Always replace gaskets, O-rings and self-
locking nuts and bolts.

Secure all hose connections using original

equipment type hose clamps:

Parts catalog

Before performing a test or repair, check all

hoses and wires for proper seating and seal.

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21-39

Rules of cleanliness

When working on the vacuum control system,

charge air pressure regulation or at the
secondary air system hoses, always observe the
following rules of cleanliness:

Thoroughly clean all connections and the

surrounding area before disconnecting.

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Place parts that have been removed on a clean
surface and cover. Use lint-free cloths only!

Carefully cover over opened components or

seal, if repairs are not carried out immediately.

Only install clean components: Only remove

replacement parts from packaging immediately
prior to installation. Do not use parts that have
been stored loose (in tool boxes etc.)

If possible, do not work with pressurized air. Do

not move vehicle unless absolutely necessary.

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21-40

Safety precautions

If special testing equipment is required during

test drive, note the following:

Do not operate test and measuring equipment

from the passenger seat. In the event of an
accident involving deployment of the passenger-
side airbag, the person seated there could be
injured.

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WARNING!

When driving or riding in an airbag-equipped

vehicle, NEVER hold the scan tool or other
test equipment in your hands or lap while in
motion. Objects between you and the airbag
increase the risk of injury in an accident.

During a road test in an airbag-equipped

vehicle, test equipment must always be
fastened to and operated from the rear seat
by a second technician.

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Vacuum control system (engine code ATW) Page 4 of 8

21-41

Charge air pressure regulation and

secondary air system vacuum control
system

1 - EVAP canister
2 - From fuel tank
3 - Evaporative Emission (EVAP) canister
purge regulator valve -N80-

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4 - Check-valve for EVAP canister
Between EVAP canister and intake
manifold before turbocharger
Installation position (light/dark side): Arrow
points in direction of flow, as shown
5 - Air cleaner

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Vacuum control system (engine code ATW) Page 5 of 8

21-42

6 - Turbocharger
Check charge air pressure Page 21-54
7 - Combination valve for secondary air
injection (AIR)
8 - Fuel pressure regulator
9 - To power brake booster
10 - Check valve

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Installation position (light/dark side): Arrow
points in direction of flow, as shown
11 - Vacuum booster
12 - To Leak Detection Pump (LDP)
13 - Vacuum reservoir

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Vacuum control system (engine code ATW) Page 6 of 8

21-43

14 - Distributor piece
15 - Check valve
Installation position (light/dark side): Arrow
points in direction of flow, as shown
16 - Secondary Air Injection (AIR) solenoid
valve -N112-
17 - Crankcase vent

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18 - Check valve
Installation position (light/dark side): Arrow
points in direction of flow, as shown
19 - To tank Leak Detection Pump (LDP) -
V144-

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Vacuum control system (engine code ATW) Page 7 of 8

21-44

20 - Check valve
Installation position (light/dark side): Arrow
points in direction of flow, as shown
21 - Charge air cooler
With charge air pressure sensor -G31-
22 - Throttle valve control module -J338-
23 - Recirculating valve for turbocharger -

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N249-
Checking Page 21-48
24 - Intake manifold
With Intake Air Temperature (IAT) sensor -
G42-

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Vacuum control system (engine code ATW) Page 8 of 8

21-45

25 - Pressure unit for charge air pressure

regulation
26 - Wastegate bypass regulator valve -N75-
27 - Mechanical recirculation valve
Checking Page 21-46
28 - Pressure control valve for crankcase
ventilation

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29 - Secondary Air Injection (AIR) pump motor
-V101-

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Charge air system with turbocharger (engine code ATW) Page 1 of 42

21-46

Charge air system with

turbocharger (engine code
ATW)
Checking mechanical recirculation valve

Notes:

The mechanical recirculation valve is located in

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front of the turbocharger. It is opened by
vacuum via the recirculating valve for
turbocharger -N249- during deceleration, idle
and part throttle. This produces a reduction of
the charge air pressure in front of the throttle
valve which keeps the turbocharger spinning at
a higher RPM.

Check the recirculation valve in case of reduced

performance or part throttle hesitation.

Special tools and equipment

VAG1390

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21-47

Test sequence

- Attach VAG1390 vacuum pump to recirculation valve.

- Operate vacuum pump.
Recirculation valve must open (arrow)
- After approx. 30 seconds, operate vent valve on vacuum pump.
Recirculation valve must close (arrow)

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If recirculation valve does not open or close or valve plate does not seal
correctly when valve is closed:

- Replace recirculation valve. Secure connections of recirculation valve

using screw type clamps.

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21-48

Recirculating valve for turbocharger -

N249-, checking

Special tools and equipment

VAG1526A
VAG1527B
VAG1594A

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VAG1598/31
VAS5051 with VAG5051/1
- or
VAG1551 with VAG1551/3A

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21-49

Note:

The recirculating valve for turbocharger -N249-

and wire connections are monitored by the
Engine Control Module (ECM).

- Connect VAS5051 tester or VAG1551 scan tool

and select control module for engine electronics
using "address word 01". Engine must run at idle
for this:

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Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel
Injection & Ignition, Repair Group 01

If a malfunction relating to the recirculating valve

for turbocharger -N249- is displayed:

- Disconnect hoses from valve; harness connector

remains connected.

- Attach assisting hose to one connection of

valve.

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21-50

- Initiate output Diagnostic Test Mode (DTM) and

activate the recirculating valve for turbocharger -
N249-:

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel

Injection & Ignition, Repair Group 01

Indicated on display

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Output Diagnostic Test Mode

Recirc. valve for turbocharger -N249

Valve must click...
...and must open and close (can be tested by blowing into assisting
hose).

If valve does not click:

- Check internal resistance of valve.

If valve does not open and close properly:

- Replace recirculating valve for turbocharger -N249-.

Checking internal resistance

- Disconnect harness connector at valve.

- Connect multimeter at valve for resistance measurement.

Specified value: 27-30

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If specified value is not obtained:

- Replace recirculating valve for turbocharger -N249-.

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21-51

If the specified value is attained:

- Check voltage supply

Checking voltage supply

Note:

Voltage is supplied to the recirculation valve via

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the Fuel Pump (FP) relay.

Test requirement

Fuse for recirculation valve OK

- Disconnect harness connector at valve.

- Connect VAG1527B voltage tester as follows:

Harness connector Measure to

terminal
1 Engine Ground (GND)
- Operate starter briefly.
LED must light.

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21-52

If LED does not light:

- Check wire connection from terminal 1 to Fuel

Pump (FP) relay via fuse for an open circuit":

Electrical Wiring Diagrams, Troubleshooting &

Component Locations

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- Repair open circuit if necessary.

If wire connection is OK:

- Check Fuel Pump (FP) relay:

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel

Injection & Ignition, Repair Group 24

If LED lights:

- Check activation:

Checking activation

- Connect VAG1527B voltage tester to connector terminals 1 (B+) and 2.

-
Initiate output Diagnostic Test Mode (DTM) and activate the

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Charge air system with turbocharger (engine code ATW) Page 9 of 42

recirculating valve for turbocharger -N249-:

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel Injection & Ignition,
Repair Group 01

LED must blink.

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21-53

If LED does not blink or if it remains constantly

lit:

- Connect VAG1598/31 test box at wiring harness

to ECM, do not connect ECM:

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel

Injection & Ignition, Repair Group 24

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- Check the following wire connection for open circuit and short circuit to
Ground (GND) and B+:

Harness connector VAG1598/31 test box

terminal socket
2 105
- Repair open circuit or short circuit if necessary.

If wire connection is OK:

- Replace Engine Control Module (ECM):

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel Injection & Ignition,
Repair Group 24

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21-54

Turbocharger and charge air pressure

regulator valve, checking

Special tools and equipment

VAG1397A

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VAS5051 with VAG5051/1
or
VAG1551 with VAG1551/3A

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21-55

Test requirements

All hoses and wires have been checked for

proper seating and seal.

DTC memory checked

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Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel
Injection & Ignition, Repair Group 01

Output Diagnostic Test Mode (DTM)

performed

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel

Injection & Ignition, Repair Group 01

Vehicle tester VAS 5051 or VAG 1551

connected.

Test sequence

WARNING!

To reduce the risk of accident or injury while

carrying out tests and measurements during
a road test, observe safety precautions
Page 21-40 .

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- Using T-piece connect test hose from VAG1397A Turbocharger Tester

between intake manifold and fuel pressure regulator.
- Guide test hose over rear corner of hood, through passenger side
window and into vehicle interior.

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21-56

- Turn turbocharger tester on and select measuring range -I- (absolute

pressure).
- Connect test hose to connection barb -I-.

Notes:
Hoses must be properly connected and there must be no possibility of
leaks, otherwise incorrect readings may result.
Make sure that the test hose is not pinched at the hood or at the side

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window.
By pressing memory button "M" on turbocharger tester, the last test
value is saved until either memory button "M" is pressed again or the
turbocharger tester is shut-off.
A blinking comma in the display field indicates that a value has been
saved.
An arrow appears in the top left corner of the display field if the
turbocharger tester battery voltage drops below the permitted
threshold.
Before testing, drive vehicle rapidly for at least 3 km on a road that
does not require stopping (i.e. traffic lights or similar).
A second technician is required because the indicated values must be
read out while the vehicle is being driven.

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21-57

Rapid data transfer When indicated on display:

Select function XX
- Press buttons -0- and -8- to select "Read Measuring Value Block" and
press -Q- button to confirm input.

Read Measuring Value Block Q When indicated on display:

Input display group number XXX
- Press buttons -0-, -0- and -4- to select "display group number 004" and
press -Q- button to confirm input.

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Read Measuring Value Block 4 Indicated on display
1 2 3 4
Do not continue with test until intake air temperature in display field 4 is
20-50 C if necessary, warm up vehicle by driving.

- Press -C- button.

Read Measuring Value Block Q When indicated on display:

Input display group number XXX
- Press buttons -1-, -1- and -5- to select "display group number 115" and
press -Q- button to confirm input.

Read Measuring Value Block 115 Indicated on display (1-4 = display fields)
1 2 3 4
- Accelerate vehicle in 3rd gear at full throttle from 2000 RPM and
observe tachometer.
- At approx. 3000 RPM, press the print button on the VAS5051 or
VAG1551 and simultaneously press the memory button -M- on the
VAG1397A.

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21-58

Note:

The height of the charge air pressure should be

determined using the VAG1397/A turbocharger
test tool, the VAS5051 tester or the VAG1551
Scan Tool is used to determine whether the
charge air pressure is also being recognized in
the control module.

Specification on VAG1397A: 1.450-1.700 bar

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Read Measuring Value Block 115
Specified value on VAS 5051 or VAG 1551 Display field 4: 1450-1700
3000 RPM 42% 1770 mbar 1770 mbar mbar

If the specification is exceeded or not met:

- Check DTC memory of Engine Control Module (ECM):

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel Injection & Ignition,
Repair Group 01

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21-59

charge air pressure regulation Diagnostic Trouble Codes (DTC)

Diagnostic Trouble Charge air pressure Possible causes

Code (DTC)
Charge air pressure Measured value below Wastegate bypass regulator valve -N75- faulty
too low 1.450 bar or 1450 mbar
Wire to wastegate bypass regulator valve -N75- faulty
Charge air pressure regulator valve in turbocharger is stuck in

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open position
Leak between turbocharger and intake manifold
Mechanical recirculation valve faulty
Turbocharger malfunctioning

Charge air pressure Measured value above Vacuum diaphragm for charge air pressure regulator valve
too high 1) 1.700 bar or 1700 mbar faulty
Hoses to vacuum diaphragm for charge air pressure regulation
valve (via wastegate bypass regulator valve -N75-) leaky
Charge air pressure regulator valve in turbocharger is stuck in
closed position

1)If charge air pressure is too high, the fuel supply is shutoff to protect the engine. The engine misfires at high engine
speeds.

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21-60

Wastegate bypass regulator valve -N75-,

checking

Special tools and equipment

VAG1526A
VAG1527B
VAG1594A

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VAG1598/31
VAS5051 with VAG5051/1
- or
VAG1551 with VAG1551/3A

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21-61

Note:

The wastegate bypass regulator valve -N75- and

wire connections are monitored by the Engine
Control Module (ECM).

- Connect VAS5051 tester or VAG1551 scan tool

and select control module for engine electronics
using "address word 01". Engine must run at idle
for this:

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Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel
Injection & Ignition, Repair Group 01

- Check DTC memory of Engine Control Module

(ECM):

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel

Injection & Ignition, Repair Group 01

If a malfunction relating to the wastegate bypass

regulator valve -N75- is indicated:

- Disconnect hoses from valve; harness connector

remains connected.

- Attach assisting hose to one connection of

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valve.

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21-62

- Initiate output Diagnostic Test Mode (DTM) and

activate the wastegate bypass regulator valve -
N75-.

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel

Injection & Ignition, Repair Group 01

Indicated on display

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Output Diagnostic Test Mode

Wastegate Bypass Regulator Valve -N75

Valve must click...
...and must open and close (can be tested by blowing into assisting
hose).

If valve does not click:

- Check internal resistance of valve.

If valve does not open and close properly:

- Replace wastegate bypass regulator valve -N75-.

Checking internal resistance

- Disconnect harness connector at valve.

- Connect multimeter at valve for resistance measurement.

Specified value: 25-35

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21-63

If specified value is not obtained:

- Replace wastegate bypass regulator valve -N75-

.

If the specified value is met:

Checking voltage supply

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- Connect VAG1527B voltage tester as follows:

Harness connector Measure to

terminal
1 Engine Ground (GND)
- Operate starter briefly.
LED must light.

If LED does not light:

- Check wire connection from terminal 1 to Fuel Pump (FP) relay via
fuse for open circuit:

Electrical Wiring Diagrams, Troubleshooting & Component Locations

- Repair open circuit if necessary.

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21-64

If wire connection is OK:

- Check Fuel Pump (FP) relay:

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel

Injection & Ignition, Repair Group 24

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If LED lights:

Checking activation

- Connect VAG1527B voltage tester to harness connector terminals 1

(B+) and 2.
- Initiate output Diagnostic Test Mode (DTM) and activate the wastegate
bypass regulator valve -N75-.

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel Injection & Ignition,
Repair Group 01

LED must blink.

If LED does not blink or if it remains constantly lit:

- Connect VAG1598/31 test box at wiring harness to ECM, do not

connect ECM:

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel Injection & Ignition,
Repair Group 24

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21-65

- Check the following wire connection for open circuit and short circuit to
Ground (GND) and B+:

Harness connector VAG1598/31 test box

terminal socket
2 104
- Repair open circuit or short circuit if necessary.

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If wire connection is OK:

- Replace Engine Control Module (ECM):

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel Injection & Ignition,
Repair Group 24

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21-66

Charge air pressure sensor -G31-,

checking

Special tools and equipment

VAG1526A
VAG1594A
VAG1598/31

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VAS5051 with VAG5051/1
- or
VAG1551 with VAG1551/3A

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21-67

Note:

The charge air pressure sensor -G31- and wire

connections are monitored by the Engine Control
Module (ECM).

- Connect VAS5051 tester or VAG1551 scan tool

and select control module for engine electronics
using "address word 01". Engine must run at idle
for this:

cardiagn.com
Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel
Injection & Ignition, Repair Group 01

- Check DTC memory of Engine Control Module

(ECM):

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel

Injection & Ignition, Repair Group 01

If a malfunction relating to the charge air

pressure sensor -G31- is indicated:

Checking voltage supply

- Disconnect harness connector at charge air

pressure sensor.

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- Connect multimeter between terminals 1 and 3 of harness connector

for voltage measurement.

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21-68

- Switch ignition on.

Specified value: approx. 5 V

If specified value is not obtained:

- Connect VAG1598/31 test box to wiring harness -2- for Engine Control
Module (ECM), also connect ECM -1-. Connect Ground (GND) clamp -

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3- to negative battery post.

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel Injection & Ignition,
Repair Group 24

- Check the following wire connections for open circuit and short circuit
to Ground (GND) and B+:

Harness connector VAG1598/31 test box

terminal socket
1 108
3 98
- Repair open circuit or short circuit if necessary.

If the specified value is met:

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21-69

Checking signal wire

- Connect harness connector at charge air

pressure sensor.

- Connect multimeter to socket 101 and socket

108 of test box for voltage measurement.

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- Start engine and run at idle.

Specified value: approx. 1.90 V

- Bring up engine RPM by suddenly depressing

pedal.

Specified value: 2.00-3.00 V

If specified values are not obtained:

- Check the following wire connection for open circuit and short circuit to
Ground (GND) and B+:

Harness connector VAG1598/31 test box

terminal socket
4 101

- Repair open circuit or short circuit if necessary.

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If wire connection is OK:

- Replace charge air pressure sensor -G31-.

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21-70

Charge pressure leak test with VAG

1687

Intake system, checking for leaks using VAG

1687 Diagnostic Tool

Diagnostic trouble codes (DTCs) related to fuel

trim, charge pressure or mass air flow (MAF)
may be caused by:

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Leaking (worn/torn) intake hoses during charge
conditions

Incorrectly torqued or improperly placed clamps

on intake hoses etc. causing leaks during
charge conditions

Check the charge air pressure system using the VAG 1687 Charge air
system tester.

Special tool VAG 1687 Charge air system tester preliminary set-up

- Back off pressure regulator knob -2- of VAG 1687 fully to protect gauge
when shop air supply is applied to assembly.

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- Close valve -3- before gauge.

- Close valve -4- after gauge.

The shop air supply line will later be attached to the inlet of VAG 1687.

- Remove female fitting from tester (arrow) and install an appropriate

"male" air fitting that will connect to your shop air supply line (
WARNING!).

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21-71

WARNING!

Use only approved air fittings to adapt shop

air supply line to VAG 1687 tester.

Special tool VAG 1687/1 pressure adapter,

installing (1.8L Turbo)

- Separate intake hose from Mass Air Flow (MAF)

sensor assembly.

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- Insert VAG 1687/1 pressure adapter in intake hose -black arrow- using
existing clamp (as shown).
- Remove crankcase ventilation tube from intake hose at -white arrow-.

Special tool VAG 1687/1 pressure adapter, installing (2.7L BiTurbo)

- Remove upper air cleaner housing and hoses to intake manifold as

necessary

Repair Manual, Maintenance; Air cleaner housing, cleaning; Air cleaner

element, replacing

- Insert VAG 1687/1 pressure adapter in intake hose -white arrow- using
existing clamp (as shown).
- Disconnect engine crankcase ventilation hose from intake manifold -
black arrow-.
-
Plug intake manifold fitting (for crankcase ventilation hose) with
appropriate hose and metal plug using clamps supplied with VAG

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Charge air system with turbocharger (engine code ATW) Page 34 of 42

1687/1 special tool kit.

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21-72

Note:

To help find small leaks, BEFORE pressurizing

the system fill system with smoke using special
tool KLI9210 and adapter KLI9210/50 as
described on Page 21-72 .

An ultrasonic detector may also be used to

detect extremely small leaks where smoke may

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not be visible.

Special tool KLI9210 (Evaporative system

leak detector), connecting to 1.8L Turbo

- Install optional fitting LKI9210/50 on hose of

special tool KLI9210.

- Connect KLI9210 to VAG 1687/1 adapter (KLI9210 is shown attached

to VAG 1687/1 at arrow on 1.8L Turbo).

Special tool KLI9210 (Evaporative system leak detector), connecting

to 2.7L BiTurbo

- Install optional fitting LKI9210/50 on hose of special tool KLI9210.

-
Connect KLI9210 to VAG 1687/1 adapter (KLI9210 is shown attached

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to VAG 1687/1 at arrow on 2.7L BiTurbo).

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21-73

Special tool LKI9210 (Evaporative system

leak detector), preliminary set-up

- Connect smoke generator leads to vehicle

battery.

- Turn valve to test -black arrow-.

- Press smoke generator button to fill system with smoke (see

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instructions printed on tester).

With system filled with smoke:

- Remove smoke generator hose and connect VAG1687 quickly to

prevent smoke from leaking out Page 21-73 .

Special tool VAG 1687, connecting to pressure adapter VAG 1687/1

(1.8L Turbo)

For illustrations purposes VAG is shown lying in the engine compartment.

In practice the tool should be hung from the hood.

- Connect VAG 1687 quickly to prevent smoke from leaking out.

VAG 1687 is shown connected to VAG 1687/1 -black arrow-

Shop air supply will be connected to VAG 1687 -at white arrow-

- Perform pressure test Page 21-75 .

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21-74

Special tool VAG 1687, connecting to

pressure adapter VAG 1687/1 (2.7L BiTurbo)

For illustrations purposes VAG is shown lying in

the engine compartment. In practice the tool
should be hung from the hood.

- Connect VAG 1687 quickly to prevent smoke

from leaking out.

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VAG 1687 is shown connected to VAG 1687/1 -black arrow-

Shop air supply will be connected to VAG 1687 -at white arrow-

- Perform pressure test Page 21-75 .

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21-75

Performing pressure test:

- With outlet hose -1- of VAG 1687 connected to air pressure adapter:
- Attach shop air supply line to previously installed male fitting Page
21-70 .

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- Open valve -3- between regulator valve and gauge.
- Adjust test pressure up to 0.5 bar ( CAUTION below) by turning
regulator valve -2-.

CAUTION!

DO NOT pressurize the system above 0.5 bar!

Doing so may force oil into the intake system which can damage
the engine.
- Slowly open outlet valve -4- (after gauge) to test hose connections.
- Observe pressure gauge for a drop in pressure.

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21-76

Note:

Some pressure will be lost past the throttle plate.

- Readjust test pressure to 0.5 bar ( CAUTION

above) by turning regulator valve -2-.

- Listen for any very large intake leaks.

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If smoke generator was used to fill the system
with smoke:

- Inspect intake system connections for smoke at

leaks.

Note:

An ultrasonic detector may also be used to

detect extremely small leaks where smoke may
not be visible.

- Repair any leaks found.

- Remove tester.

- Remove plug from crankcase ventilation hose.

- Remove air pressure adapter.

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With VAS 5051 diagnostic tool connected:

- Erase DTC memory.

If smoke generator was not used to fill the

system with smoke:

- Apply soapy water solution or equivalent to

intake system connections.

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21-77

Note:

An ultrasonic detector may also be used to

detect extremely small leaks.

- Inspect intake system connections for leaks.

- Repair any leaks found.

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- Remove tester.

- Remove plug from crankcase ventilation hose.

- Remove air pressure adapter.

With VAS 5051 diagnostic tool connected:

- Erase DTC memory.

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Exhaust system components, removing and installing Page 1 of 35

26-1

Exhaust system components,

removing and installing
WARNING!

Do not re-use any fasteners that are worn or

deformed in normal use.

Some fasteners are designed to be used only

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once, and are unreliable and may fail if used
a second time. This includes, but is not
limited to, nuts, bolts, washers, circlips and
cotter pins. Always follow the
recommendations in this manual-replace
these fasteners with new parts where
indicated, and any other time it is deemed
necessary by inspection.

Note:

Always replace gaskets and self-locking nuts.

After exhaust system repairs, make sure

exhaust system is not under stress and that it
has sufficient clearance from the bodywork. If
necessary, loosen double clamps and align
muffler and exhaust pipe so that sufficient
clearance is maintained to the bodywork and
the support rings are evenly loaded.

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Exhaust system components, removing and installing Page 2 of 35

The exhaust flexpipe must not be bent more

than 10 , otherwise it may be damaged.

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Exhaust system components, removing and installing Page 3 of 35

26-2

Front-wheel-drive vehicles

1 - Nut
40 Nm (30 ft b)
2 - Double clamp
Before tightening, ensure exhaust system
is free of stress Page 26-24

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Installation position: bolt ends point toward
left
Installation position of bolt ends Page
26-13 , Fig. 3
Tighten bolts evenly
3 - Nut
40 Nm (30 ft b)
4 - Double clamp
Used when front or rear muffler is replaced
separately
Before tightening, ensure exhaust system
is free of stress Page 26-24
Installation position: bolt ends point toward
rear
Installation position of bolt ends %page
Page 26-13 , Fig. 3
Tighten bolts evenly

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Exhaust system components, removing and installing Page 4 of 35

26-3

5 - Bolt
25 Nm (18 ft lb)
6 - Mount
7 - Gasket
Always replace
8 - Nut

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Always replace
30 Nm (22 ft lb)
9 - Gasket
Always replace
10 - Turbocharger
Removing and installing Page 21-30
11 - Three Way Catalytic Converter (TWC)
Protect from damage
Removing and installing Page 26-21
Disconnect Heated Oxygen Sensor
(HO2S) harness connector Page 26-21

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26-4

12 - Heated Oxygen Sensor (HO2S)

50 Nm (37 ft lb)
Only grease threads with "G 052 112 A3."
Do NOT allow grease to get into slots on
sensor body

CAUTION!

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Part numbers are listed here for reference only.
Always check with your Parts department for
the latest information.

Checking Repair Manual, 1.8 Liter 4-Cyl. 5V

Turbo Fuel Injection &Ignition, Repair Group 24
13 - Nut
Always replace
25 Nm (18 ft lb)
14 - Bolt
25 Nm (18 ft lb)
15 - 16Mount
Different versions for manual and automatic
transmissions
Manual transmission Page 26-12 , Fig.
1

Automatic transmission Page 26-13 ,

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Exhaust system components, removing and installing Page 6 of 35

Fig. 2

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Exhaust system components, removing and installing Page 7 of 35

26-5

17 - Front exhaust pipe

With flexpipe
Flexpipe must not be bent more than 10 ,
otherwise it may be damaged
To remove, unbolt floor crossmember (20
Nm/15 ft lb)
Align exhaust system free of stress

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Page 26-24
18 - Mount
19 - Bolt
25 Nm (18 ft lb)
20 - Rear muffler
Factory-installed with front muffler as one
unit. If repair is necessary, replace
separately
Separating point Page 26-14
Align exhaust system free of stress
Page 26-24
21 - Front muffler
Factory-installed with rear muffler as one
unit. If repair is necessary, replace
separately
Separating point Page 26-14

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Exhaust system components, removing and installing Page 8 of 35

Align exhaust system free of stress

Page 26-24

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Exhaust system components, removing and installing Page 9 of 35

26-6

22 - Support ring
23 - Bolt
25 Nm (18 ft lb)

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Exhaust system components, removing and installing Page 10 of 35

26-7

All-wheel-drive vehicles

1 - Front muffler
Factory-installed with rear muffler as one
unit. If repair is necessary, replace
separately
Separating point Page 26-16
Align exhaust system free of stress

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Page 26-24
2 - Gasket
Always replace
3 - Nut
Always replace
30 Nm (22 ft lb)
4 - Gasket
Always replace
5 - Turbocharger
Removing and installing Page 21-30
6 - Three Way Catalytic Converter (TWC)
Protect from damage
Removing and installing Page 26-21

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Exhaust system components, removing and installing Page 11 of 35

26-8

7 - Heated Oxygen Sensor (HO2S)

50 Nm (37 ft lb)
Only grease threads with "G 052 112 A3."
Do NOT allow grease to get into slots on
sensor body
Checking Repair Manual, 1.8 Liter 4-Cyl.
5V Turbo Fuel Injection &Ignition, Repair
Group 24

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Disconnect Heated Oxygen Sensor
(HO2S) harness connector Page 26-21
8 - Nut
Always replace
25 Nm (18 ft lb)
9 - Bolt
25 Nm (18 ft lb)
10 - Mount
Different versions for manual and automatic
transmissions
Manual transmission Page 26-12 , Fig.
1
Automatic transmission Page 26-13 ,
Fig. 2

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Exhaust system components, removing and installing Page 12 of 35

26-9

11 - Front exhaust pipe

With flexpipe

CAUTION!

Flexpipe must not be bent more than 10 ,

otherwise it may be damaged.

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To remove, unbolt floor crossmember (20
Nm/15 ft lb)
Align exhaust system free of stress Page 26-
24
12 - Double clamp
Before tightening, ensure exhaust system
is free of stress Page 26-24
Installation position: bolt ends point toward
left
Installation position of bolt ends Page
26-13 , Fig. 3
Tighten bolts evenly
13 - Nut
40 Nm (30 ft lb)
14 - Mount
15 - Bolt

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Exhaust system components, removing and installing Page 13 of 35

25 Nm (18 ft lb)

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Exhaust system components, removing and installing Page 14 of 35

26-10

16 - Rear muffler
Factory-installed with front muffler as one
unit. If repair is necessary, replace
separately
Separating point Page 26-16
Align exhaust system free of stress
Page 26-24

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17 - Mount
18 - Bolt
25 Nm (18 ft lb)
19 - Bolt
25 Nm (18 ft lb)
20 - Mount
21 - Nut
40 Nm (30 ft lb)
22 - Double clamp
Used when front or rear muffler is replaced
separately.
Before tightening, ensure exhaust system
is free of stress Page 26-24
Installation position: bolt ends point toward
left

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Installation position of bolt ends Page

26-13 , Fig. 3
Tighten bolts evenly

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Exhaust system components, removing and installing Page 16 of 35

26-11

23 - Support ring
24 - Bolt
25 Nm (18 ft lb)

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Exhaust system components, removing and installing Page 17 of 35

26-12

Fig. 1 Individual mounting components for vehicles with manual

transmission
1 - Buffer
2 - Spacer sleeve
3 - Washer
4 - Strap, right
5 - Washer

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6 - Bolt (25 Nm/18 ft lb)
7 - Spacer sleeve
8 - Strap, left
9 - Compression spring
10 - Bolt (25 Nm/18 ft lb)
11 - Self-locking nut (25 Nm/18 ft lb)

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26-13

Fig. 2 Individual mounting components for vehicles with

automatic transmission
1 - Washer
2 - Buffer
3 - Strap
4 - Spacer sleeve
5 - Bolt (25 Nm/18 ft lb)

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6 - Bolt
7 - Washer
8 - Compression spring
9 - Spacer sleeve
10 - Self-locking nut (25 Nm/18 ft lb)

Fig. 3 Double clamp installation position

- Install double clamp so bolt ends do not project over lower edge of
double clamp.

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Exhaust system components, removing and installing Page 19 of 35

26-14

Front and rear muffler, separating

Connecting pipe has a designated separating

point on connecting pipe for separate
replacement of front and/or rear muffler.

Separating point is marked by a depression in

the pipe.

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Special tools and equipment

VAG1523 saw

Front-wheel-drive vehicles

- Using VAG1523 saw, cut exhaust pipe at separating point (arrow) at

right angle.

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26-15

- When installing, center double clamp over

separating point.

Double clamp -1- installation position: level, bolt ends pointing

downward
Install double clamp so that bolt ends don't project over lower edge
of double clamp Page 26-13 , Fig. 3
- Install exhaust system free of stress Page 26-24 .

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- Tighten double clamp bolts evenly to 40 Nm (30 ft lb).

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Exhaust system components, removing and installing Page 21 of 35

26-16

All-wheel-drive vehicles

- Using VAG1523 saw, cut exhaust pipe at separating point (arrow) at

right angle.
- When installing, center double clamp over separating point.

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Double clamp installation position: level with bolts in clamp -1- pointing
toward left-rear wheel
- Install double clamp so that bolts don't project over lower edge of
double clamp Page 26-13 , Fig. 3 .
- Align exhaust system free of stress Page 26-24 .
- Tighten double clamp bolts evenly to 40 Nm (30 ft lb).

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Exhaust system components, removing and installing Page 22 of 35

26-17

Exhaust manifold, removing and

installing

Removing

Note:

Replace gaskets and self-locking nuts.

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Flexpipe in front exhaust pipe must not be bent
more than 10 , otherwise it may be damaged.

- Remove air guide duct between cowl and air

cleaner housing.

- Remove air cleaner housing cover.

- Remove the following lines/harness connectors:

1 - At wastegate bypass regulator valve -N75-
2 - At Evaporative Emissions (EVAP) purge regulator valve -N80-
3 - At power output stage -N122-
4 - At Mass Air Flow (MAF) sensor -G70-
- Pull off hose connections and remove air cleaner housing (arrows).

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26-18

- Remove noise insulation panel (arrows).

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- Unthread bolts -1- and -2- several turns.

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26-19

- Remove engine covers.

- Unbolt crankcase ventilation hose -1- at cylinder head cover and heat
shield.
- Unbolt both oil supply line bolts -2-.
- Remove heat shield -3-.
- Remove bolts -4-.

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- Remove seal between turbocharger and exhaust manifold.
- Seal opening in turbocharger using clean cloth.

- Remove all nuts (arrows) from exhaust manifold.

- Remove washers and exhaust manifold.

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26-20

Installing

Installation is the reverse of removal, noting the

following:

- Install in sequential order as follows:

Exhaust manifold to cylinder head

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Turbocharger to exhaust manifold

Turbocharger bracket to cylinder block

Tightening torques

Component Tightening
torques
Turbocharger bracket to 40 Nm (30 ft
turbocharger (bolt and washer lb)
assembly M8)
Turbocharger bracket to cylinder 45 Nm (33 ft
block lb)
Turbocharger to exhaust 35 Nm (26 ft
manifold lb)
Exhaust manifold to cylinder 25 Nm (18 ft
head lb)
Oil supply line to cylinder head 20 Nm (15 ft

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Exhaust system components, removing and installing Page 26 of 35

lb)
Crankcase ventilation line to 10 Nm (7 ft
cylinder head lb)

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26-21

Three Way Catalytic Converter (TWC),

removing and installing

Removing

Note:

Replace gaskets and self-locking nuts.

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Flexpipe in front exhaust pipe must not be bent
more than 10 , otherwise it may be damaged.

- Disconnect harness connector for heated oxygen sensor (arrow) and

set aside.

- Remove coolant expansion tank -2- (arrows)

- Remove wiring from Engine Coolant Level (ECL) warning switch -F66-
and lay coolant expansion tank to side.

Note:

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Exhaust system components, removing and installing Page 28 of 35

Coolant hoses -1- and -3- remain connected.

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26-22

- Remove air guide duct between cowl and air

cleaner housing.

- Remove air cleaner housing cover.

- Remove the following lines/harness connectors:

1 - At wastegate bypass regulator valve -N75-

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2 - At Evaporative Emissions (EVAP) purge regulator valve -N80-
3 - At power output stage -N122-
4 - At Mass Air Flow (MAF) sensor -G70-
- Pull off hose connections and remove air cleaner housing (arrows).
- Remove Heated Oxygen Sensor (HO2S) from Three Way Catalytic
Converter (TWC).
- Remove bolts between front exhaust pipe and Three Way Catalytic
Converter (TWC).
- Unbolt transmission mount for exhaust system at exhaust system.
- Remove bolts between three Three Way Catalytic Converter (TWC)
and turbocharger.
- Remove Three Way Catalytic Converter (TWC) toward top.

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26-23

Installing

Installation is the reverse of removal, noting the

following:

Only grease threads of oxygen sensor with

"G 052 112 A3." Do NOT allow grease to get
into slots on sensor body.

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Align exhaust system free of stress Page
26-24 .

Tightening torques

Components Tightening
torques
Front exhaust pipe to three way 25 Nm (18 ft
catalytic converter lb)
Front exhaust pipe to 25 Nm (18 ft
transmission mount lb)
Three way catalytic converter to 30 Nm (22 ft
turbocharger lb)
Heated oxygen sensor to three 50 Nm (37 ft
way catalytic converter lb)

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26-24

Exhaust system, aligning free of stress

Align exhaust system when cold

Front-wheel-drive vehicles

- Remove double clamp bolts Page 26-2 , item

2.

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- Push exhaust system forward (arrow) until tension on rear mount
equals dimension -a-.
Dimension -a- = 7-9 mm (0.275-0.354 in.)
- Tighten double clamp bolts evenly to 40 Nm (30 ft lb).

Aligning tailpipes:

- Align tailpipes so distance -a- on left and right side is equal.

- Distance -b- between bumper cutout and tailpipes must equal
specification.
Distance -b- = 40-46 mm (1.57-1.81 in.)

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26-25

All-wheel-drive vehicleswithout double clamp

between front and rear mufflers

- Remove double clamp bolts Page 26-9 , item

- 12 -.

- Push exhaust system forward (arrow) until initial preload on right rear
mount equals dimension -a-.

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Dimension -a- = 7-11 mm (0.275-0.433 in.)
- Tighten double clamp bolts evenly to 40 Nm (30 ft lb).

Aligning tailpipes:

- Align tailpipes so distance -a- on left and right-sides is equal.

- Distance -b- between bumper cutout and tailpipes must equal
specification.
Distance -b- = 41-47 mm (1.614-1.850 in.)

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26-26

All-wheel-drive vehicleswith double clamp

between front and rear mufflers

Note:

Only for vehicles with double clamp between

front and rear mufflers: also align front muffler.

- Remove double clamp bolts Page 26-9 , item

- 12 - and Page 26-10 , item - 22 -.

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- Push exhaust system forward (arrow) until initial preload on left rear
mount equals dimension -a-.
Dimension -a- = 7-9 mm (0.275-0.354 in.)
- Tighten front double clamp bolts evenly to 40 Nm (30 ft lb) Page 26-
9 , item - 12 -.

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26-27

- Push exhaust system forward (arrow) until initial preload on right-rear

mount equals dimension -a-.
Dimension -a- = 7-11 mm (0.275-0.433 in.)
- Tighten rear double clamp bolts evenly to 40 Nm (30 ft lb) Page 26-
10 , item - 22 -.

Aligning tailpipes:

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- Align tailpipes so distance -a- on left and right side is equal.

Distance -b- between bumper cutout and tailpipes must equal

specification.

Specification:

Distance -b- = 41-47 mm (1.614-1.850 in.)

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Exhaust system, checking for leaks

- Start engine and run at idle.

- Seal tailpipes with cloths or equivalent for

duration of leak test.

- Listen for leaks at following connections:

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cylinder head/exhaust manifold, exhaust
manifold/turbocharger, turbocharger/Three Way
Catalytic Converter (TWC), etc.

- Repair leaks.

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Secondary air system, checking

(engine code ATW)
Following a cold start, the secondary air system
helps to quickly heat the catalytic converter for
quicker operating readiness.

Principle

Due to over-enrichment of the mixture during the

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cold start phase, there is an increased amount of
uncombusted carbon monoxide in the exhaust.
Secondary Air Injection (AIR) improves secondary
oxidation in the catalytic converter and therefore
reduces emissions. The heat produced by
secondary oxidation greatly reduces start-up time
for the catalytic converter which significantly
improving exhaust quality during the cold start
phase.

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Function:

In the cold start phase, the ECM -2- activates

the secondary air pump -12- via the relay for
secondary air pump -1-. Air is supplied to the
combination valve for Secondary Air Injection
(AIR) -10-.
The Secondary Air Injection (AIR) valve -3- is
activated in parallel, which allows the vacuum to

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reach the combination valve for Secondary Air
Injection (AIR) -10- and the vacuum diaphragm
for charge air pressure regulation -7-. The
combination valve for Secondary Air Injection
(AIR) thereby opens the path for secondary air
to the exhaust channels of the cylinder head.

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To prevent unnecessary heating, the secondary

air is diverted past the turbocharger -7-. For
this, the charge air pressureregulation pressure
unit opens the charge air pressure valve. The
pressure unit, designed as a double reservoir,
has a vacuum connection for this on the intake
side.
1 - Secondary Air Injection (AIR) pump relay -
J299-

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2 - Motronic Engine Control Module (ECM) -
J220-
3 - Secondary Air Injection (AIR) solenoid
valve -N112-
4 - Intake manifold
5 - Check valve
Installation position (light/dark side): Arrow
points in direction of flow, as shown

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6 - Vacuum reservoir
7 - Pressure unit for charge air pressure
regulation
8 - Turbocharger
9 - Cylinder head
10 - Combination valve for secondary air
injection (AIR)

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11 - Air cleaner
12 - Secondary Air Injection (AIR) pump motor
-V101-

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Secondary Air Injection (AIR) solenoid

valve -N112-, checking

Special tools and equipment

VAG1526A
VAG1527B
VAG1594A

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VAG1598/31
VAS 5051
- or
VAG1551 with VAG1551/3A

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Test requirement

Output Diagnostic Test Mode (DTM)

performed

Checking internal resistance

- Disconnect green harness connector from

Secondary Air Injection (AIR) solenoid valve -

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N112-.

- Connect multimeter at valve for resistance measurement.

Specified value: 25-35
- If specified value is not obtained, replace Secondary Air Injection (AIR)
solenoid valve -N112-.

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Checking voltage supply

- Disconnect harness connector from Secondary

Air Injection (AIR) solenoid valve -N112-.

- Connect VAG1527B voltage tester as follows:

Harness connector Measure to

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terminal
1 Engine Ground (GND)

- Operate starter briefly.

LED must light.

If LED does not light:

- Perform the following tests marked with dots:

Check fuse S234 (in fuse holder, position 34).

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Check wire connection from terminal 1 of connector via fuse S234 (in
fuse holder, socket 34) to Fuel Pump (FP) relay for open circuit:

Electrical Wiring Diagrams, Troubleshooting & Component Locations

Check Fuel Pump (FP) relay

Repair Manual, Fuel Supply System, Repair Group 20

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Checking activation

- Connect VAG1527B voltage tester between terminals 1 and 2 using

test leads from VAG1594A.
- Connect VAG1551 scan tool.
- Initiate output Diagnostic Test Mode (DTM) and activate Secondary Air
Injection (AIR) solenoid valve -N112-.

Output Diagnostic Test Mode Indicated on display

Secondary Air Inj. Solenoid Valve -N112
LED must blink.

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If LED does not blink or if it remains constantly

lit:

- Connect VAG1598/31 test box at wiring harness

to ECM, do not connect ECM.

- Check the following wire connections for open circuit and short circuit
to Ground (GND) and B+:

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Harness connector VAG1598/31 test box

terminal socket
2 44
- Repair open circuit or short circuit if necessary.

If wire connection is OK:

- Replace Engine Control Module (ECM).

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Secondary Air Injection (AIR) pump relay -

J299-, checking activation

Special tools and equipment

VAG1526A
VAG1527B
VAG1594A

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VAG1598/31

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Installation location:

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel

Injection & Ignition, Repair Group 24

- Initiate output Diagnostic Test Mode (DTM) and

activate Secondary Air Injection (AIR) pump
relay -J299-.

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The Secondary Air Injection (AIR) pump relay (in 3-socket relay
carrier in the E-box, at left in plenum chamber, position 2) must
trigger and the Secondary Air Injection (AIR) pump motor -V101-
must run in intervals

A - If relay does not trigger:

- Check voltage supply of Secondary Air Injection (AIR) relay Page

26-40 .
- Checking activation of Secondary Air Injection (AIR) relay Page 26-
42 .

B - If relay triggers, but Secondary Air Injection (AIR) pump does not run:

- Check voltage supply for Secondary Air Injection (AIR) pump Page
26-43 .

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Checking voltage supply of Secondary Air

Injection (AIR) pump relay

- Remove Secondary Air Injection (AIR) pump

relay.

- Connect multimeter for voltage measurement as follows.

3-socket relay carrier in E-box, plenum Measure to

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chamber, position 2

terminal
8 Engine Ground
(GND)

Specified value: approx. battery voltage

If specified value is not obtained:

- Perform the following tests marked with dots:

Check fuse S130 (40 A) in 3-socket relay carrier in E-Box, plenum

chamber, position 7.
Check wire connection from Battery (B+) (terminal 30) to Secondary
Air Injection (AIR) pump relay -J299- (in 3-socket relay carrier in E-
Box, plenum chamber, position 2) for open circuit.

Electrical Wiring Diagrams, Troubleshooting & Component Locations

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- Connect multimeter for voltage measurement as follows.

3-socket relay carrier in E-box, plenum Measure to

chamber, position 2

terminal
4 Engine Ground
(GND)

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- Operate starter briefly.
Specified value: approx. battery voltage

If specified value is not obtained:

- Perform the following tests marked with dots:

Check fuse S234 (in fuse holder, position 34).

Check wire connection from Secondary Air Injection (AIR) pump relay
-J299- (in 3-socket relay carrier in E-box, plenum chamber) via fuse
S234 (in fuse holder, position 34) to Fuel Pump (FP) relay for open
circuit:

Electrical Wiring Diagrams, Troubleshooting & Component Locations

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Checking activation of the Secondary Air

Injection (AIR) pump relay

- Switch ignition off.

- Remove Secondary Air Injection (AIR) pump

relay.

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- Connect VAG1527B voltage tester as follows:

3-socket relay carrier in E-box, plenum Measure to

chamber, position 2

terminal
6 Engine Ground
(GND)

- Initiate output Diagnostic Test Mode (DTM) and activate Secondary Air
Injection (AIR) pump relay -J299-.
LED must blink.

If LED does not blink:

- Switch ignition off.

- Connect VAG1598/31 test box at wiring harness to ECM, do not
connect ECM.

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- Check the following wire connection for open circuit and short circuit to
Ground (GND) and B+:

3-socket relay carrier in E-box, plenum VAG1598/31 test

chamber, position 2 box

terminal socket
6 46

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- Repair open circuit or short circuit if necessary.

If no malfunctions are detected:

- Replace Secondary Air Injection (AIR) pump relay -J299-.

Checking voltage supply of the Secondary Air Injection (AIR) pump

motor

- Remove harness connector for Secondary Air Injection (AIR) pump

motor -V101-.
- Connect VAG1527B voltage tester between terminals 1 and 2.
- Initiate output Diagnostic Test Mode (DTM) and activate Secondary Air
Injection (AIR) pump relay -J299- Page 26-42 .
LED must light.

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If LED does not light:

- Perform the following tests marked with dots:

Check wire connection from harness

connector at Secondary Air Injection (AIR)
pump motor -V101- to Secondary Air
Injection (AIR) pump relay -J299- (in 3-
socket relay carrier in E-Box, plenum

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chamber, position 2) for open circuit.

Electrical Wiring Diagrams, Troubleshooting &

Component Locations

Check wire connection from harness

connector at Secondary Air Injection (AIR)
pump motor -V101- to Ground (GND)
connection 1 in engine compartment wiring
harness for open circuit:

Electrical Wiring Diagrams, Troubleshooting &

Component Locations

If no malfunctions are detected:

- Replace Secondary Air Injection (AIR) pump

motor -V101-.

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