Technical data. Engine number. Engine data

X€r,i6q I qr6 I

Engine numb€r

Engine number

The engine number (engine code and serial nlmber) isengEved on the front of the engine block, gearbox side, -anow- below the themosht hou6ing.

Additionally ther€ is a Bticker on tho toothed belt guard withEngihe code and S€rial number -arow-.

The enging code also app€a6 In the vehicle docurnentF.

The angine numb€r@nsists ofup to nine symbols(alphanumeric). The fr8t part (a maximum ot 3 aode leter9)repres€ntl thg'€ngins code'and the 6€cond part (six{igit)the "serialnumbe/. lf rnoro than 999,999 engines haveb€en produc€d wilh he ssme €ngine code, the first numberb subetituted by a l€tter.

Eslidq I on6 I

Engirc data t€)"i6a I orlo t

Engine data

ldontffcation lottgra AUA BBY aaiz BKY

Exhaust emissions tulfil

Displacem6nt

Powar ouhutEngine toqu€CylindergStrokeCompressionValvea pgr cylinderRON

Injoc'tiqn, ignitionKnock controlS€lf.dlegnosisLEmbda regulation

Catalytic conveder

Exhgugt gas r€circulatlon

qn3

kwmin

Nm at lhingmm

mm

mtn,

EU 4 standard

1390

Z416000

124t4400

76,5

75,6

10,5

98 lead fee

4MV

Ye8

Ye8

2 probes

2 catalytlcconv€rterg

Yes

EU 4 stiandard

1390

55/50001mrc800

76,575,6,10,5

495 loed free

4MVYesYe8

2 pfob€s

2 c€t€lytlcconv€ngls

Yr6

EU4standard

1390

7416000124t4400

76,575,610,54

98 leed freef t : .1. ,

4MV

YerYes

2 probes

2 catalytic@nveneEr

Yes

EU 4 standard

1390

55/5000126/3800

75,010,5

95 lead free

4TVYesYes

2 pobes

2 catalydc@nveateft|

Y6/No l':1'r'l

1) Excrptlonally, mlnlmun odina, 95 OCT, but wlii soma powd lo.r

4 Era.Diionally, mininum ocianc. 91 OcT, bul witi iom! powor lcaa

3) ltlhoul axh.u{ ga! iaclrcuLllon br anolnat wllh coda BKY. nanuLclu.ad trom05t2005

Engine: removing and installing

Engine: removing and installing. Enolno: dismounling , Chaple.. Englne: Sccur€ b lho lngine $a€mbly brnch 'Chapler. Enginc: .&€mbly - chapter. Englno br.ck€ts - chapier. Vohlcl.a with gir cgnditioning/hodting: addlllon€l iNtruciions and

alllmbly information . Chapter

lelioc I ot6 I

60...3d, m

20...im Nm

5..,25 m

i_Ugtuc I

sp.cLl toob .nd rc*.hop oqulpmont riaquhd

. TorqG wtlnch -SAT 801G

. Cank€ gukle -T20O7G

. Countedold -T20127-

. T€y -T20173-

. Locldng tool -T20174. or pli€B -T20029.a Work8hop cren€. Lubricatin! gr6a.q G 000 100 (vrhldc! with manud ggsrbox) + ETKA (electronic catalogue of sparc parts)

. Csbb tie

I

Engine: dismounting

Engine: dismounting

disposal or rccwing.

Wth ignition switched off, disconnect battery earth strap.

Remov€ bEttery and battery retainer -anows.. . RepGt 2l

Renove enginE protEcllon together with air fiiter -anows-

Separats exhaust bresthgr pipe from engine-

Open the expension tank, sealing cap to releasepressu.e in cooling system.

Remove the lowerengine proteclion ' Rep Gr 50.

Romove frcnt exhaust pipe from 6xh6ust maniicld

ffi rvorTo aarry out this wotk it ls ,€cessary to disconrect baftery edfth slrap.Io t is en4 ff,s ,ecessary to check whether the vehicle haa a codedndlo. lf so, rofer to the anti-theft cgding.The engina is rcngved foNatda bgcther with lhe gqatuox and wiingllart6ss.All th6 cabla fixings that arc apened or c!1t dudng @moval of theengine nusl bo fifted in the sane placa when rcinstalting the engino.The extQcled coolant nust go into a clean rccaptacle, whathar for

Eel,i6s 1 o716 5

i

E10'CC77

hng|ne: dismounting

- Separate pehdular support -arrows-.- Remov-e,teft and right_hand drive sh6ft from the gearboxano support in a rdised position _ t.i,,l (, ,rrr

- Empty coolaht

- S€parate the upper and lower coolant hoses fiom theraorator

' Separate lhe Larnbda prob€ _G3g-conneqor unoemeathrne 9taft€r motor supporl.

Remove the reveBe gear swilch from the ge€rbox.Removo the front bumper . 1rr:r. r:r i I.

Remove the headlamp and fog tight connectors.ohlclgs with air condlfioning/herdhg

Observo additional infomation and Inslallauonrnsructtons

Remove Poty-V belt

Separate the air conditioner compressor and secure tl ljome boatylvofi.

Intinuod for r[ v€hicto.

Place the lock c€nier plate into Eervice position , pe;l

Remove the starter motor and altemator eleclnc€lconneclons

Iel.lio 2 q7lo 5

W:Jdwontndh..dng cootant circuit musa not b

:"_:!?!o_! i! " q".. rh e c o nden aer a n d ret d se 6 n trpevsaeov€s, arto crne not to bend, twist or stre,chne ptpas/steevea excasalvety.

Engine: dismounting

- Extract the connectoG from the engine control unit.

- Remove the 14-contacl connector on the left-hand sideofthe engine block and plac€ the cEble harness towardsthe engine.

Vohlclsr wlth m.nual grarbox

- Remove the clutch masler cylinder without op€ning thehydraulic circuit, and leave to one side (the clutch pedalshould not bs dop|essed) Rep cr30

- Disconn€ct g€l€ctor mechanism from gearbox and l6aveto on€ side ' ll.ro Gr 14

Vlhlcl.! wlth automrtlc garrbox

- Remove the cabl$ from the gearbor B6lec{or lever andleave to one side Reo cr37

Continuod fo. all vohlclo!

- Remove the 6ar$ cablE ftom its fxing in thg gear box.

- Lo@en spring clips and and remove the cootant hosepip€s tO the hsat oxchanger and to the expansion tankfrom their fixjng to the €ngin6.

- Separate the tuel distributor ieeder pipe from theconnector besido the shock absorber turret, -arow-,press buttons on hose couplings to do lhis

. | . wAR VrrvcFuel system la undor presaurql Wetr satotl glovesand glassaa b ayold lnjury tnd cqract wttt sktn.Bslarc opaning tho systam plrce a cloth aroun.t ,heconnactlon, fhan raLasa pnasura by caralulypu ing tuel hoga lrcm cqrnectlon.

Xe),i6o 3 o16 5

Engine: dismounting

Fit suspension tool -T20127- as indicated in theillwtfation and lifr slightly with the workshop crane.

Pullvacuum and bfeather fexible hoses ofthe engine.

Disconnect all other el€ctrical connections as necessaryfrom engane and l8y to on6 side.

Remove the fixing boits from tho ongine mounting -A-and -B-, lo do so, partially separdte the coolantexpansion tank.

t€1i6o, 4 0r.o 5

tTrotrls I

- Removo bolts from the gearbox mounting -A- and -B-.

Engine: disnounting

- Lo|lr end rr'nqra ha dElns a!!6nDly ugrads by

f ,v"oUlhan tlr€^aleni/'y.k.lit|Ed on if nurtr b Cr'rol'llty gtutlrcda p|pwnt damaga b b{dywlr*_

I€e,Inc 5 0r!6 5

lTfial

Engine: Secue to the engine assembly bench

Engine: Secure to the engine assembly bench

Spscisl tool8 rnd worishop .qulpmont roquirsd

. Counteftold -T20127-

. Support tool -T20172- with Adsptsr -T20172/3-

. \^rorkshop crane

lryorklcquonc.

. Gsarbox is separated ftom sngine.

@ ror"To align the assenbly ctntrc frt ttt6 countethold -720127- tothc cgreaponding anchoage o@,ints.

- lnsert Blruts ot the retaining device -T20127. into theconggpond ing anchorage points.

/ I , DANGERIEnsui.,h.t tho h@kt ara clos.al wlth ,he securltylnnga.

Bn*. lf opefttiana arc to be caried out on the qankshaft or on

the sealing f,enge, th6 engine flWhoel and intemedhteplate nust ba rcnowd belo€ attachnent to thecountehold -720172- .

. h vohicles fitted with an autonath gadtbox, aftersepdrcting the goaftox ftun its mounting to the engine,the totque cgnvefter must bo fixed to prcwnt it frcmfa ing.

Es)'i6o 1 o?!6 2

T2A127

lffi;l

T20172

K;t2

t1w00.2941

Engine: Secur€ to the engine ass€mbly bench

To porform rspalr8 tlt the englnc with th6 adspler -T2017213- b the locldng tool -T20172-.

Xsl"{60 2 q?r6 2

v.A.G 1202 A

7]20172r3Ertr10@5

Engine: assemblyIs),i6o I on6 2

Engine: assemblylnsiallation is canied out in the reveEe order to removal, obsorving thefollot,vingi

. t,, Cau{adWh*t doing aoy rcpat wo''., espgcialty in tho enginocompertmant pay ttlEnton to the fo owing due b ha clElmpcdconctldons:

ll!:!!ulq (to!.exanet. for fuet, h@autics, catuon frtft,r, tiqut.,coolor ancl.cooting atenl brake fluid, low pressure) and theerecldc caDres rrust bo placad ln such a way that ahE, tdum aothelr orrglnal posldon,

Ensuro turllclant ctaaanco rga all movtng or hot comr/anon&'.

Vehlclor wlth m.nuat ga.rbor

- Check wear to the clutch retease bearing and .€plac6 if necessary.- L ight ly grease . t tvt t - . , o, : . , r ,oJ.n thectutch releage

Deanng. retoase b€aring guide st9eve and th€ input shaft te€th.V.hlclor wlth .utom.flc gorrbox

- Orly us€ bolts suthorised a9 spare parts i fEstenhg the torqueconveder to the drive plate, E IKA letectron c parts-cataLlqLre).

Contlnuod for lll vghlcle6

- Check whether the dowel slsev.s br c€ntring engine/gearbox are inthe cylinder block, install if n€cessary.

- Fit intgrmediate ptate ontio s€ahng fiange and stide ontooowet s|€eves-€taows-

- l/lhen inserling th9 €ngine, ensure that €noughcleeranae cxtsts with the drive shafts.

- Fil thg €ngln€ 6nd the engine bEck€ts. and tighten boltsto thg specified toroue

- Fit thg drive shafrs . Reo Gr 4l

,ohlclg! s'lth alr condtdonlngrhedlng

- hstalling aif conditioning/heating cornpr6ssor:

:ontlnuod igr rlt vchlclo!

- Electrical connections and routjng: .Rep cr97

/9hlclo. wtth mlr!{|al gortbqx

" hstallth€ clutch mastar cylinder , Rep cr 30. Installgearbox selector m€chanism .Re[, cr34

/ehiclos wlth iutomatic aordox

- Chgck the fastening of the tcrque converter.. Rsplac€ the cables of the g€arbox selector lever and

adjust wlrere neces8ary , Rep Gr 37

;onthuod tor all vehicls6

Fngine: assenrblyIrj.ifu,2rrtr62

- Fl[ coollng rystom -.Chapter- Adapt thc engil|o cootrot unit b thc thrat{6 cootFt unitano grr exhrugt 916 rgcitqrLti'l valv€ , Chapteq

Funcqiona and componcnb adapdaE

- In whid€3itbd wih 8n aubrrEtic aoarbox, it i! allof:?9ry rD adapt the gsaroox contrct unit _Chapte[Funcront and componenb: sdapting

- Cary o!t-a bst ddw and Inbmgsi! fautt rFmory.' unapler

nght.olng io{quar

conrponant NmBolts rnd nub It'18

M8

Mt0

M12

2045

00Exc.pt lhr thc lbllowing:

' ChapterBolb Fining ltpnt o(hru|t dpq b a(h.ud mtl trotd 40 Nm

f-

Engine brackets

Engine brackets

@ rvot"The a€aembly mounting s€crning bofts arB 6tstcl, bolts and must bercplaced - ETKA (electrcnic pans catalague).

Engln! bnckat!, englno iido

A" r . . . 20 Nm + 90. (rL tum)

B- f.r rl . 30 Nm + 90" (t/. turn)

Englnc brlctrtr, gcrrbox 3ldo

A - . i,. ,, S0 Nm + 90" (1L tum)B- rr .40 Nm + 90. (1/. tum)

Pgnduhr!upport

A _ Ni,.,,, 30 Nm + 90. (14 tumB _ r.., ..40 Nm + 90" (11 tum

I€),16(t I om 2

B

o-\@UU

l' 'rcG]

Enginc bracketsEa)'i6a 2 ar!6 2

F.

Vehicles with air conditiooing/heating: additioral instructions and sssembly information E€,,i6a I 016 I

Vehicbs with air conditioningrheating: additionalinstructions and assembly information

I c.,ru"r,Atr oo''drdot'/f'offi'o M a,rritlt m.d rct b gF|t.,t

lo.wld.tun'oa b,tn @n bt'tr 3t t r*le..uta W/.lav-,trft. carf ||oa to larfd, ffi or rtu6,h tha plrylt/fivr.axcarrrnfy.

To bdllbta n pvlne 8nd lnablllng lha cminc wlthout opanlng thaEfitgc nt clrcult

- Unbolt |tiilning cl!mp(r) for coolrnt tubo8.

- Rrmorc Poly-V bclt -- Chapte(

- Pffdrilly rlrrovr th! ah oonditonlng (hrsnrB) comgnuor -

Rep.Gr.87

- Sqrlt t|a como|€alor b th! aro6 mGmhar |o hat all 0r€tubrJhoeaa fbr tha cooh ar! not ln trnrlon.

r-

Engine: ass€mbly and disnan itrg

Engine: assembly and dismanflingI Componcnb ovlwiqr

- chapter

r Pad li N,otn€d b€tt machanbm - Compo|tant3 owrview -

Chapter. p|n ll; Cl nd.r block - Conpomnb or,.rviorr - chapterr Rqm\,lng end Inltellng Poly-V bdt - ChapterI ChGcklng dittlDqtlon timing - Chapterr Ramo\rlng ard Inrtrlllr€, bnsloning no6l.d balt - Chapterr Chccklng noElcd brlt tanlloi r!lr| - Chapter

L€fr{6q 1 ord I

f-

Compon€nts overview

Components overview

. ff laoe quAntfties of rned shavlng' or pafticles arc fwM in the enginecil when rcpaitng the engine, fre or7 passsgcs musf De cr€aredcarctuIy, and the oil filter Enewed in oder to ptownt fwther damageocaltup lat .

a BefotB catrying wt as6€lmbly wottt oil 'houtd

be awlied to the suppottand sride sudbcse

Part l; Notchsd belt mechanlsm - Componqnts ov€wi€w . Chapier

part ll; Cyllnder block - Compon€nt8 owrviow . Chapter

!el,i6c I oro I

ll

C

TN{-357it1

Pan l: Notched belt mechanism - Componenls overview

Part l; Notched belt mechanism - Components overviewI . Notchod bclt gurrd - upper

pan

2 - 20 Nm + r/. turn (90")

o Renewo Use lcrcking spanner _

T10016- to toosenand tighten

3 - Crmlh.fr gg.ro Note th6 position when

fitfing the toothed belt

'l " ftnglon roll9r ol tho dorlygdb]inch of ih9 notchod bctt,o Testingq Tsnsion the notched belt.

5 - Sgcorda.y brrnch notchedb.lio Ma.k D.O.R. before

removingq Check forwearo Do not kinko Removing, installing end

t6nsioning

6 - Sqppo.t

7.10 Nm

I - Front of coolant pumpq Completely replace in cagc

of fault or le€kageo Removing and installing

I . Ro., notchod bolt guard

10.20 Nm

11 .50 Nm

12 - ldlar ro e. tor prhclpat notched bolr13 - Prlnclprt notchod belt i.naion ro{.r

tr Tgstingo Notched b€tt, fitting, tensioning

14 - C|anklhafr toorhod bett wheelo Obs€rv9 positior when fitting the bothed bett

15. Princlpal notchod bottlB Mark D.O.R. beioro removingo Chock for wear

I

Xei,i6o I aa6 2

1 2 3 4 5 23 6 7

,-1.:-..'' '.,m,d*l' i j

j. .*t"'{1\Q,ffi,,'}iii

' ''*Y, ,r"'*-il[t,uii - *-- 3;'=";"\.:'|. H22 - - s:.o iu r .i' :l?

tl .1-$1,.")'-_ ,o7 -.

\; l . | ' '1.i "r t ,t\ / , - / A^.

i -T.t,ij'.., iJ'1 :-*,1'1. ')i7 - .

\ t { . | ' '1 . i . - ' : t , tt,: "'i....1 "=i' X...

''-;,-l?

. t-.\,-,

Ci,.l=,Li\ , . I [1 ie" . \ \ r .f \ "o'r

l'' i' ')l :\ ! '.

#--,1r r \

t ' l i ' , ,k ''ti, r.,r '=bl!"'\: ' Tf "'11--t'":'' , , ' ' El.R'

-' "'\ ' 12

| ,4.'e\ '., .. "' 13

T',,U*., ''is$ -. .

ta. . t t . .

' | ) t18 17 16 lb 14 Tl/r-or -r

12

Pan I; Notch€d belt m€chanism - Components oyerview

q Do not kinko Nobhrd bslt toirung - Figo Rcmwlng, In bfling €.d tln6lonlng * Chaptef

la-12 mo Ran6w

{7 - PutLyq Nob locadon whrn Insbl ngq Rdmvfu and tffng - Chapteq Notcf,l€d balt llnorlng snd fitng, bndonlng

ll -t0 m i rr.tum (C0.)q Ranoro Lubri€b bctbn idngc Tlghbnlng c.n b. dono in $va..l lbgaae Ih6 dghhn[€ sngb rry ba rfidurld with e ptot|cbr, br axrmpb mearudrg bot ..nooso-

ll - Poly-V !.lto lLrk dirtc0on d rctruon bion rmovingo Raman hg .nd imttlllng

- 91.1st1.,e Poly-V ball roldng -- Anchorq Vahlclcs lltbd tfffi aia oondi0onlt'lg ftGaUng) havr an €dduomlldlcr oflcr

m- otchad laft gu||{ - lou|r patt

2l - Engha moundng

211- t0 mo Rcnax

2t - 2t t{m

,!4.ldL wh..l

X€ll6o 2 ar!6 2

Part II; Cylinder block - Components overview

I . Englno blocko Ahminium cylinder block -

Components oveNie\ /

q Piston and conrod -Components overvie'!v

2 .50 Nmq Tjghtening order: First

tighten the upper right-hand bolt, then the lowerrighthand one and fnallylhe lett-hand bolts ( viewedin direction of t.avel)

3 - Oll filbfo Loosen at the hexagonal,

using the universal oilfilterwrgnch or the rotstion tool-u-40078-

o Tighten the filter by handa ObseNe the Instrallation

in8tructions printed on theflter

4 - mE: 20 Nm + rl turn (90.)

5 - Comp.ct bnckoto For altemator, heating

compressor gnd Poly-Vbelt tensiongr

o Removing and installingcompac{ brackot inv€hiclos fitted with airconditioning /heating

' Rep Or 87

I

s//

fTiSTTu I

Eel"i6o I oa6 2

Part ll; Gylinder block - Components overview

fl rvot"Clutch rcDa,'s - ReD Gr30.

6-13NmLoos€n and tighEn tho boits on the side otthe flywheet uslng the spanner -U-4O05iA-

7 - Oil .umpo Rcmoving End installingo Fit with a si l icon based sealant D 176 404 A2, ETKA (eleclron c pans catatoglrelo Cl6an sealing Eurface beigrq installing

I - Oll pulgo bolt, 30 Nmo In engines where the bolt and ring form a Bingle piece, replace the unit.

0 - Tohsioning elomento For Poly-V belto Only fof vehicles fitted with air condltioning (heating)o To reduce tension in th€ Poly-V b€lt, use a wrcnch on the tensbn rolter securing bott.

Pan II: Cylinder block - ComponenB overview

o Removing and installing Poly-V belt a"-:.i...

Nqichod bolt .outlng

A - NqMed belt sec.ndary b€nchB - Principat notched belt:

U€J'16.12 aft 2

Removing and installing poly-V belt

Removing and installing poly-V belt

il"""[;;"out" o"""nbcd rctqr! to vohict!. flttod wtti rir condtflonor

Romovlr|g

- Ma.k direction of rctation ot poly-V belt.- uae

-a _sptnner on the securing bolt gwivel tensioningror|ea In otrection of arow

- Remove poly V{ett .Fttlnga-'rII J ,Yot!. 8€tolr .fitting-the

poty-V bett. ensure that att mechanicatdswmbttas [altematot aN ai conditbner (hedtit{,)corpresso/i t/arsferpa/mpl arc ficurely lnslatd.'

. ,Vl1en fitting the poly_V beft, ensun that it is fitted withme-@opct diection of tdation and that it is @rews€d.€o on the pulleys.

- FiB-t fit th€.Poly-V bett onto thc crankshafr pulloy and|aslly onto the ten8or roll6r. Sbrt engine snd check $at bqlt run! pDpe.jy.

'oly.V bllt routing

|elt routing with air condltioning (heating) compressor1-Pulley-alb.nator2 - Ai. conditoning compressor (heating)3 - Crankehaft/puley4 - Tenslon roll€r

Ieli6o I q?r6 I

rcFl

Checking distribution timing

Checking distribution timing- Remove engin€ proleclion together with air filter €nows_

- Removo uppor notched belt guard.

Place ihs crsnkshafr in cytinder 1 bp dead centre lhenotch on the pulley shoutd match the edge of the mark _

Th6 lockhg spaceg on the c€mshali sprockets shouldIne up w[h me spaces on the csmshafr hou6ng _arows-

! rvor"Ih6 md.ks 6E on o@osite sides ol the notchdd bett)tbct<ets. tum the dankshaft one mo(e tum

Ielido I olt6 I

€10-c077

Removing and installing, tensioning notched belt !.elLi6a I qll6 2

Removing and inslalling, tensioning notched belt

sAT 8010 T10016

T200188 r+30025E

Sp.cl.l toolr .nd worft.hop oqutpmont requl.ld

I

I

Removing and installing, tensioning notched belt 2cJ"i6a2 otw 2

a Toque wr€nch ,SAT BO10-. Counterhold -T10016-. Counteftold -T200188-. Support ,U-30025E,

Removing

Removing

- Romove engine protection together with air filter -armws-

- Remove upper notched belt guard.

Place the crankshafr in cylinder 1 top dead centr€. Thenotch on the pulley should match the edge of the mark -

- The locking spacas on the camshaft sprockets shouldline up with the spac$ on the camshaft ho$ing €nows-

I rv"t"lf tha ma*s are on oppoaite sides d the notched baftsptDckets, tum lho cmnkshaft ono morc tum.

lmmobilise both camghaft sprockets using tho counterhold -T10016-, as follows:

!sl,i6q I o?16 4

E10.Ct77

Remoyinglsl"i6q 2 oz6 4

- lnsert both tockjng pins th.ough the locking spaces ontne camshaft sprockets. as far as the end point on thespaces on the camshaft housing.

S rvor"T-he .two tocking..pins arc conectty fifled il the tinat pafts _D_ae tn lino wilh lin6 -A-

- Insort support -B- as fEras possibte in th6Intakec€rmshaff spocket -c-

T-o remove the notched belt separate the engrne consote aslollowsl

Conneci the support -U-3OO2SE- as shown In theo|agram.

Remova the upp€r securing bolt ofthe lower notched beltguaro bcated below the @nsole

Release the @olant resg.voir and leave to one sroe.

Slightly protension th€ engin€ and remove th€ botts _A-secunng the engine consol€ to the rylinder neaornountrng and the bolts -8- secunng lhe enqine consolero m6 Dodywork, and remove th6 console

Remove the bolts -A- fixtng the console to the cylindernead and separate.

Removing

Remove the right front wheet.

Remove thc lower engine proteclion , Rep c, SCrehove the front right-hand wheel housing guard . D.j. t at)

y:I D 9 R of.the poty-V bett before removrng and thendEmount as icllows:

Use_a-spanner on the securing bolt swivel tensioningror|er ln otrecflon of errow

Remove poty V-belt .

Loosen the bott fixing the pulley and the wheet ot thenotched b€tt. Securc pu €y wtth retaining toot_T2OOi0B_

Remove pulley. Screw back the bolt with two washers tonoE notched b€ll sprocket in olace

In vehicles fitted with airclnditioning (heating), removethe tenlion rolter for the poty_V belt.-

Install tower notched belt guard.

Mark the toohed belt D.O.R.

emoving principat notched belt

Rele€,s€lhe principat_notched bett tension o er, byloosen|ng bott -1- and release the notched belt by iuming

Xei.i6a 3 tr26 4

v 3.r ?86

Removing

the teBion roller antictocloise -snow_.- Remove ngtched bett

Remove the branch dedved ftom notched bert.

Eel"i6o 4 on6 4

R6l€as€ the ten8ion roller from th€ branch derived fromgle notched b€lt -.1 - and retease the notjchod bett byrgtating lhe lansion roller clockwi€e.

Remove tension ro er of the de.ived branch of thenotched belt

Remove notched bslt.

Fitting and tensioning

lroa9

Icl,i6c I qno J

Fitting and tensioning

. The notched belt sprooket for the crankshaft is fred to the crankshafrwith a bolt and two washers.

. The camshafrs shoutd be tocked using the counteftold _T1OOj6_ In theexrsflng lockrng spaces in th6 camshafl housing. and 6ecur6d topGvent tuming.

- Place the crankshafl m cytinder .l top dead centre. Thenotched tooth should tine up rvith the mark on the oilpumD.

@ rva"Do not confu'a the marks on the seat rctaineloil pump. lhenotched tooth should tina up with tho na* codetj witt; 4V.

- Fit the notched bett of the derivGd branch clockwise, firstabove the intake camghafl sprocket and then above th€€xhaust camshafr sprocket. The slack section of thenotched bett shoutd hang b€low tf reusing a notched beltensure to reft following the original direction of rotation.

Fit th€ notched belt tgnsion ro er ofthe dgrlved branch, asfollowsl

Tum the t6n6bn roller of the dedved branch of thenotched b€lt using the int€dor hexagon -t- clockwiselowaro6 the marker windou/ €row_ (the tenslon roller isslack)

Pregs upwards the low6r part of the denved brsnch olthe notched b€lt with the tension roller and screw in lhesecunng bolt of the tension rolter.

Tighte-n.the roller s€cu.ing bott by hand. The projeclingpart of the bas€ ptate should frt in the cytincter neaodrill€d soace -2-_

- N6xt, teGion the notchod trelt, by tulning the tensonlotter anti-ctockwise, using the interior hexagon in pos _1-, untilthe marker arm -2- coincides with th; protudingpan on the markerwindow -anow-_

- Tightgn the t€osion roller nut

fhe camihdfts should be tocked using lhe countoftold -.10016-. until the principat notchod bett i6 fitted.

- Fit the principal notched belt anti-clockwise, stading withthe water pump, the tcnsioh roller, the crankshafr, theidler roller and lhe intake camshaft sprocket. lf reuging a

Fitting and tensioning

notched beltensure to rellt bllowing the original di.eclionof rotation.

lfthe tension roller was dismounted earlier, install as follows:

Tum lho t€nsion roller of th€ princioal notched b6tt to thepogition shovirn -Enow-, using the interior hexagon,turning anti-clockwlse.

Fit the tension roller and tighten the boit by hand, bolt -2-of lhe seal retainer should fit inside lhe g.oove on thesupport plate -1- of th6 tension rcller.

lf reusing a tension roll€r, relBase the securing bolt.

Turning the tension roller clockwise, tsnsion the notchedbelt until the marker arm -3. lines uo wilh the notch onthe base plate -arrow-.

Tightgn tho lension rcller s€cr.ring bolt

Remove the counterhold -T10016- trom the csmshaftsprockets.

tre].i6a 2 az6 3

l-\ rt:n6El

Fitting and tensioning

- Rotate lhe crankshafr lwice in the DOR of the engineuntitthe Top Dead Centre ofcylinder j |s reached.- Next recieck the notched belt adjustrnefi and th6

Posrtbn of the tension mllerslf necossery, repeat the tensioning of the notched belts.lnstallation.is canied out in the reveFe order to removat,ooservtng the following:

- Re-install notched bett guard.

- Re-install crankghaft pulley obseNlng the blowing:. Replace the bolt holding the crankshafr pultey/sprocket.. V\h€n fiting th€ pulloy check the fxing with respect tothe notched bett wh€ot_. Tighten

-the new greased cent"al bolt to a tightening

torque: 90 Nm + 1. tum (9f).

- Installing cllindor hesd console

- Fit tho enginc assembty suppoft, ongine eqe :...

--1llj ,Yor.lhe_assembly mounting sgcuri4g borfs sr€ st/ofD|, Oons ardnust D6

'!,DIACoCI.- h8tgllcoolanl €xpanSion tank.

- In6blling Poty-V belt . .

! rvoo)n fltting^the dbbed bett, make sue that it is @ne(xtyoczleo on the pu ew. Fit lho fiont right-hgnd wh6€t housing guard . R.p

Gr 66

' Installthe lowerenglne prctection . Rep cr 50_

' Fit the right font wh€€t.

Ee?'i6a 3 qrd 3

Checking notch€d belt ,elsion roller

Checking notched belt tension rollerChacking pdnclpal not*rd balt bnsion roller _, ChapterChccking bnsbn ro sr ol fie d6.iv€d brandt of ths notch€d bolt.- CheDter

t€tr16q I (r'16 1

9AT&10

Irtrttfi:______q " ,, ^-

fitlttiE -q , ,. N"

|@=ad

T200rtA

,Dacltl toob and wo rllop.qulpmant nqulnd' Toque f,4snch -SAT gOtO-

counbrnob -T200188-Support -U-30029E-

t--

Checking principal notched belt tension roller

Checking principal notched belt tension ro er

- Remove engine protec{ion together with air filter -arows-

- Remove upper notched belt guard.

To remove the notched belt separate the engine console aEfollows:

Connect the support "U-30025E- as shown in theo|a9ram.

R€move the upper securing bolt of the tower notched bettguard located below the consols.

Sllghtly pretension the enging and remove the bolts -A-s€curing tho €n9in6 console to the cytinder headmounting and the bolts -B- s€curing the engino consoleto the bodywork, and remove the conaole.

letri6o I on6 3

t-i

Checking principal notched belt tension roller

Remove the bolts -A- fixing the consote tic the cylinderhead and separate.

Remove the right front wheel.

Remove the lowgrengine pfotection , Rep Gf 50.

remor,/e lhe front righlhEnd whe€l housing guard . o. I

Mark the direction of rotation of the poly-V bett. Use aspanner on the bolt securing lhe tension roller and tuftthe roller clockwis€.

Remove poly V.belt .

LoG€n th€ boft fixrng the pu ey and the wh66t ofthenotched belt. secure pu 6y with retaining toot-T2oo.!68-

Remove pulley. Screw bgck the bolt with lwo wash6rs tohold notched b€tt sprocket in place.

In vehicles fitted with air conditioning (heafing). removethe t€nsron rctter br the poly-V belt.

Installtower notched bett guard.

Rotat6 the cranksh€fr twice in the DOR of the onoinountil the Top Dead Centre of cytinder 1 is reached.

Memorise th6 position of the t€nsion rcller marker arm _arrow-. Press the notched bett hard with the thumb. The

Ie?"i6q 2 qz6 3

=1---:--;t:j

-:Nr.\\

Checking principal notched belt tension roller

marker am ahould mov€.

- Sbp pre$ing the noEhed belt.

- Tum the crankshafr two comoleb tums in the di.ection ofraialion of the engine.

- Check the position of the indicato'r arm. Th€ indicatorarm Should haw retumed to ib original position.

lf he indicator 9rm does not retum to the odginal poeition:

- R6placs th€ tensign roller

lf the tension rollctr i3 corect, check tho teNlon |oller of thederiv€d branch of the notchgd b€lt

!el,i6o 3 o116 3

Checking tension roller of the derived bmnch of the notched belt,

Checking tension roller of the derived branch of thenotched belt.

- Memoris€ the position of the tensaon rcller marker am -1-. Press the notched belt hard with the thumb-anow-.The marker arm should move.

- Stop prsssing the notchod b€lt-

- Turn the crankshafi two complgte tums in the dir€ction otrotation of the engin€.

- Check the position of the indicabr am. The indicatoram should have retumed to its original position-

lfthe indicator arm does not return to the odginal position:

- Replac€ the ignsion rollef.

lf both t€nEion roller8 are conect, cany out the installation inthe r€verae oder to €moval, observing the following:

- R€-jnstall notched b€lt guard.

- Re-irctall fiankghafr pulley observing the bllowingl

. Replace the bolt holding the c|ankshsfi pullEy/sprocket.

. Vlhen fitting the pulloy check the fixing with resp6ct toth€ notched belt whe€|.

. Tlghten the new grgased s€curing bolt

- Installing cylinder head consol€

- Fit the engine a6E€mbly guppo.t, engine sid6

UU [vo,tThe assemdy mounting secuing bolts ars stra6 bolts andmust ba replacad,

- Install coolant oxpsnsion tank.

- Installing PoV-V belt

--1LlJ t{oloOn fitting the dbbed belt, mako sutg that it is conectlylocated on the pulleys.

- Fit the front right-hand wheelhousing guard RepGr 66

- Installthe loworengine p.oteclion ' Rep cr 50.

- Fitthcrightftontwheel.

Eel.i6s 1 on6 I

€ylinder block, sealing flange md engine flyrvheel: removing and fiuing

Cylinder block, sealing flange and engineflywheel: removing and fiftingo Aluminlum cylndaf bhd( - Cdnponantr ol,ofll6r - chapter. Crloklhei o[ !rel, pu[ty !ita: |lpkcrnrllt - chaptef. Ramoring and inltrnhg flywl|e€l * chapterI Ddvc pLb: l! novw and lmbllhg - chapte.. Saafing lbrgo lbr c'rnktlle'l fiM|€d dda: rtpla€lng - chapter. Cnntahgft d[r|.r|lbn8 - Chapter

>€ll6a I ar!6 I

Aluminium cylinder block - Components overvrew !e),i6o I on6 2

Aluminium cylinder block - Components overview

I Caufion

The c'ankaho{t musa not bo rcmoved. Just loosening tlt€ maln beadng caps wlll cause ddormalon of thecy ncter block bearlng ped€stals, fhls detorrnatton wltl ctuse a reducdon ol tha b0arlng clo'''',nce. Evan ll thab.adng ahdla trc ngt

'9plaeed bearlng damago coutd occur due to a dfiferent beadng cto',|€nca.

ff ths beating cap bdla arc loosgn€d, the cyltndq block must be ,sptace.t comptete wlth tha ctunkshaft

n.asurlng aha fiatn beedng cl9€''nce ls not pGllblo vlth nofinal wo*shop equtpment

[]u,vo.€Clutch Epairs ' R(tD Gt 34.

4 " l0Nm

2 - Oll Intake pipe€ Clean filter if soiled

3 - Alumlnlum cyllndor block

,[ - Knock aonror I GOl.

5"20Nmo Tightening torque afEcls

th€ functionlng of theknock sensor | .G61-

I-80Nm+tt turn (90.)

o R€new

7 - Flywhely drlve plrtetr Removing and insblling

flyvrheelo Driv6 plate: removing and

inslalling

8. t2 Nmo Renew

I " Scallng tl.ngg wlth lendgrwhool .nd rlng lorlo Only replace the unit

complote with the sealingring and gender wheel

o Sealing iange forcrankshaft , iywhe€l side:replacing

l0 . Ga8k9to Renew

I l -Oi lpumpo Replace completelye \ryhen fitting, rcmember the crankshafr traction elemento Should fit into ihe adjustrnent slegveso Removing and installing

12,=.,:t I

- / ' . - i " : ) ( ' .v /'-- .-./ ., .t'i ( ' : il l *

..t1 !,, '

t ' , ) t - ' - ' ; , '

iir;i:-\ ir i.i r";l:li\ ';: Iil _.1,r l:i' t{:5 Vo.j- l. ly.j), i li

cf lt i

I

?

I..)

6

10

13

12

ri11

I

10

I 7fF13{44, I

Aluminium cylinder block - Components oren rew

12 - Oil seelo Renew

t3 - Traciion elorngnto Oilwell before fitting the oil pump

le).i6c 2 ord 2

Crankshaft oil seal, pulJey side: replacement

Crankshaft oil seal, pulley side: replacement

Sptcl.l toglt and worl(.hop aqulpmcnt raqul|td

. Torque uEnch -SAT 80 10-

. Counterhald.T200'188"

. Guide ele€ve -T2008'lB-

. Extractor "T20143-

Romovlng

- Removing principal notched b€lt ' chaFter.

- Removo t|e notched b€lt{,r€nk8hafi cogrigel ,llei-rl

- Insort the extractor -T20143- and extract the seal -1-.

Flttlng

- Lightly lubricate lhe se€ling lip ot the oil 6eal.

fe?'i6o I q?t6 2

s T 8010

gennF=;-::aJ1j ".**

T200618

t15-10010

Cranksha-ft oilseal. pulley side: replacement

Slld€ oil seal ovEr 6daot6r -T2008182-.Plac€ Es€ombly onto crank8hafr joumal.

U8o th€ 6depbr .T2008 1 Bi/1 . and pr€8s the guld€sl€eve.8sal unit until fie s€sl frt8 svenly, using lhe olds€curing bolt to do 90.

Removo ths adapbr -T20081BE-.

Fit he wh€sl ior th€ nqtah6d belt on thc cr€nkchafr,immoblllsing it ullng the counbrhold -T2001 88-.

Fitling princip€l nobhed b€lt Chartcr.

l*Lilrl2 snt 2

Removing and installing flywhe.el

Removing and installing flywheel

Spgchl toolr md rcrl(rhop equipm.nt roqulrsd

. Torou€ w.ench -SAT 80lG

Iei,i6o I ord 2

sAT 8010

[".CCC{.H= j, 2c,c4Nn

5 t5 nr

l- ',rocri6o I

T20176

. Counterhold -T20176-Ramovlng

. G€aabox aemoved.

- Mark th6 nywheel wllh tesp€ct to the €ngln€.

- Fit counter-hold -T20176- in the ctlinder hole block andalign ilywhe€I.

- unbolt fwhccl.

Ftttlng

lrctallation ls carrled out in the rsve€E ord€r to lomoval,ob6erying the following:

- Inv€rt the po8ition of the counterhold -T20170. toimmobilbe thc qMle€lwhen tight€ning ths bolt!

- Us6 new boK's and tighten to pre€cribed torque :-r".

Removing and installing flp{rcel !e),lic 2 om6 2

f-

Drive plate: removirg and installing

Drive plate: removing and installing

Spochl toob rnd rorklhop equlpm|nt rrqdrud

. countEftold -T2008t-

. Depth geugB

Rcmovlng

- Atbch th€ counterhold -T20064- b the divs olate.

- Looscn th! bolts holding the drive pl€te.

Fltgng

- Flx the drive phb uslng lhe llat w€8her wilh rgcsls€s -1-

- In86rt new boltB €- and lighttn b a torque of 30 Nm.

Eel"i6q I crd 2

TAD64

I woczsr5 I

Drive plate: rernoving and installing

Check dimension €- in 3 points and calcutate theavenge.

Specificstlon: '19.7... 21.3 mm.

,Vo!e

le).i6a 2 oro 2

{ /3 measured acloss tDo hole ol the dive date to the borodsuiace of the cylinder btock

lf th6 specifications ere not mgt:

Remov€ the drive plate again and ua€ tho compenaationwasher -2-. Tighten the bolts again -3- to a torque of 30

Tighlen the bolb -3- to a torqu€ of 60 Nm and r€tighten90' (l/a tum) (th€ retightening may be mad6 in stage6).

Seding flange for craukshaft, flywlreel side: replacing

Sealing f,ange for cr.nkshaft, flywheel sde: ,eplacing

lpacl.l ioob |nd wo*thop |quhrn t rtqulnd, C€otlr 0{ld6 -Ti@l7-' Count€rhou -T20i 76-

Tolquo wrnch €AT 80tO-Tolqu. wllncrr €Al eOlOA4C-Thrlo hlx.Omal bolb M6 x 35 mmThbkn.se gaugcDial caliesr

t€li6o 1 ar6 I

sAT 8010 sAT 80l0r2,fc

60...900 Nmntmrn=--_.:q

20...100 Nmtrnrr--q

s..-zs Nm

fm176

. LrS.tma

Removing the sealing flange with the sender wheel ftom the crankshaft

Removing the sealing flange with the sender wheel fromthe crankshaft

,Vo,eTo show the wo& sequence morc dearly, tho sequence is descdbed far arcmovecl enqne.

- Remove the flWheel or the drive plate

!e?,iDo 1 qn6 2

- Position crankshaft at TDC cylinder. 1:

The notched tooth ofthe notched belt wh6elshould iine upwith th€ mark on the oil oumD -arow..

fl mr.Do not cantuso the ma*s on the seal rctainer/oil DunD. Thenotched tooth should line up with the ma* cded with 4V.

- Remove oilsumo

Rgmove cnging spgad sond€r -arow-.

Un6c.ew the attachmGnt bolts trom the sealing flange

Scrsw three bolts M6 x 35 mm into the threaded spacesof the aealing flang€-erows-.

Screw down the bolb, altematety (max. l/2 tu.n (180")per screw), on the s€aling ffange and removo it ftom thecrankshaft with thg s€nder wheel.

Removing the sealing flange with the sender wheel Aom the cranksh!ft *)'inn2 arb2

f--

nsert pressing the sealing flange wirh the sender wheel onto the crankshaft

nsert pressing the sealing flange with the sender wheel)nto the crankshaft

floto

leli6c I ar6 I

, ProgFssir€ use of e new generation ol &aling f,angcs with PTFE seal(fetton). The &ating lange with olastb waslrer @ntlnuos to boavailable as a sparc peft

I When litting a new seating frange, only ue frE same type of f,ange 8sprcviously frtted.

I The sealina f,anae with he PTFE seal is designed wllh a pressu.a nngon the @aiing tip. Ihis prgssurt ,itg frrr,ts the lunctton of an asstrmdyslesve and aannot be rcno,ld befo.g lltting.

I Onc€ assemt g4 do not sepercted the sealing flange and the sendarwheel ot nodw the rosltion.

, The wat sufa@ of thg seatlng llange with elastic washer of the igndelwheet with ref{€,clto the c'r.nkshalt has an elastomoic law Thistayer should alwals be kept frge of M and g|€asp

. Tha sender wheot frnds its pgsition autonatk]€ y whan fifted tg theposltbn pin of the c€ntrc guide -710017'

. The scalhg iangp and 6P s€.al nakd up ona inscparcble camponcntand cen only ba rcplac€d along with tha sndet wtteel.

. The posltkm dthe cente gui e -71N17' wlth tewcttoths cnnkshafi is dotemined by a guidd pin in68fted in athreadod g4,aee in tl'€ c'8nkehoft.

A - H€xagonal boltB - Attschment gurface

C - lnst€llation bellD - Allsn keyE - Guide pinF - Po8iton pin

lrit&E'l

A - Fitting the s€aiing flange with sender wheel on the cantre guideTlool7

A - Fitting the sealing flange with sender wheel on thecentre guide -T10017-

I€r'i6o I on6 3

- Tighbn lhe hexagonal nut -A- tc jugt befofe the hreadedspindlo attachment surfac€ -B-.

- Fix the c€ntr€ guido -T10017- holding it in plac€ in ab€nch vica, b ths thFadsd Epindlo surfacs -B-.

- Pr633 down on lhe insEllstion b€ll {-. so thst it resb onttlc hlxagonal bolt -A-€rtow-.

lro6rTha interiot pad of the ftting devio€ and the tnstalatfui bemwt be st the Earno l?€bht,

i1c:1r

- Unsc{s\f the attachment clip -A- frcm he ns.r s6.lingflange.

UU woleDo not Bitow the eondet wh€€/ from the s€alhtg f,arye o.chcnge its positbn.

Removing and installing, t€nsioning notched belt 2e)"i6a2 ori 2

r Torque wronch "SAT 8010-. Counterhotd -T10016-. Counterhold-T2001A8-. Support -U-30025E-

A - Fitting the sealing flange with sender wheel on tie centre guideTl00l T t€),i6o 2 ord 3

lhe attachm€nt hole -B- on the s€nderwheet-C- mustcornctde witn the malk -A- on the seeling llange

- Secure the sealing iange by th6 hont on a flat, cteanSUnace

Press lhe sander wheel (s6aling lip pregsure ring next tor, r.f E seal) -A- rn the directjon of the arrow dow;wardsunu rt rest6 0n the flal sudsce.

|e upper edge of the sender wh€et and the front edge ofe gealing 1lange must coincide -aarows-.

A - litting the sealing flange with sender wheel on the centre guideTl0017 Iel.i60 3 (r?16 3

- 9l?i,.",9"Fl:lt!: seatins fanse on the cenrre suide -,i,1,"!,ij;;I",li$ir" *sition pin -A- sirs in the hot; _B_ of

woit=nsure the s'aling flanga tiea fldt on the assemDty toot.

Wlen tight€ning th€ three knurted botts-A_ on rne surraceor th_e assembly device, pregs ttre senaer wtreet iseitinilp pressure ring next to PTFE seat) _B_, so that thepos|r|on prn can nol come out of the sonder wheel hol€.

| ,v"r.1sut6 that tha.sendet wheel rcmains securcd in the fiftingtv,c.e M6n frtting the seating f,ang'.

lJ - frt the centre guideTl00l T with the sealing llange on the cmnkshaft flange:

B_-fit the centre,guide _Ti0017_ with the sealing flangeon the crankshaft ftange:Prereq!lsiles

. The crankshafr ffange must be cjean ( of oil and grease).

. The engine shoutd be in TDC cytinder I-

,iHl"": s:#j*"nar bort -A- to the end of the

- f::_q:!t?gd "pindte

or the assembry device _inu?gffliTt;t",f"trfiy;nuntirrthe_hexaso;ar nur _A_ is in

- l^olllt]rg f9t eart_of the insta ation be towards theseanng surface ofthe oil sumD.

*J[rXiT]lJ:*'* usins the Arren borts -A- to the

tel,i60 I qn6 2

1f rvor"

lnl!!.Alt", bat" -e-

"oorr. stums inb the ctanr'shaft

;"ffJ;lgiff'nil::35 -A- on the ensine brock to

B -.F-it the cenfe guideTlo0l T with the sealing flange on the cmnkshaft flanee: >'rj'i6a2 M 2

--- -- la

r-I

u - rjolt the centre guideTl00lZ to the crar*shaft flanee

f,;!3't ttt"

""nt." guide -T10017- to the crankshaft

!el.i6o I cz6 I

- Using your h€nd slide the insb ation be -A- in theorec'ton of the aror /_until the sender wheel (seatiig tippressure nng next_to PTFE seal) _B_ res{s upon thecfanKshan flang6_C_.

D,rror'!!:.9!:*?9!t

-D-.of .the assenbty clovice is nseftedtri:f,,!,'u;,il";:ff.tr1x:l,H,"n#i:!,J:i;n:- Mainta_in the insia ation bellin this posit/on and tight€ntne lwo Alten bolb of the assembly device by hanir.- Tighten by,iand the hexagonal bolt -E_ on rhe threededsptno|e until it @mes into contiact with he inlta ad;G

D - Press the sender \r{reel with lhe c.enlre guideTtool T onto the oratksbaft flange; E€Xl5a I 0r!6 I

D -. Press lhe sender wheet with the cenbo guide _Tiooi7_onto ihe crankshaft flange:- TlghEn tn6 h€r€gonal nut ol hs aElambly dcvice wit l

Sf#ffilBlStff F'fr;no oc roiruc wancii'

Imo.l-'11!!! 2t Cq ?ufd U ,f.asF'd tf,tt6f,n cyttn&t bt.xj< aM8darng flanga at|l8,r tbh&/ni,g hox'o€tr- nuib 35 Nn.

sAT 8010/24CTt1111z lffi'71

f--

E - Check the fitting position oftlrc sender wheel on the clankshaft.

E - Ctectftthe fitting position of the sender wheel on the

- Unscrew |he hexagonal bolt -A- to the end of thetnGaded soindle.

- Remove screws M6 x 35 mm _B_ tom the cylinder block.- Urscrew the three knurt€d bolts _C_ from the sealingnange.

- Move-the instaltation be _D. of the a$€mbly deviceDacK _as tar as the hexagonal nut _A_ (only foi sealingnange wth etaslic washerl

Ihe,sender rrhe€t is in the cor.ect position on ne crankshafrnejr_tjt9 diolancg _-a-. bgrween the crankshafrltenge -A-ani-ne senderwh6€l-B- is 0.5 mrh

Iel"i6o I oz6 2

! rvor"9!-y:l:.?h q ryse yilh lraE seat, conptetetyunsqew..the centrc guide _T10011_ and rchove thesea ng np prcsaurc fing.

l?H.il:lti /.!istan9E -a-. the cnnkshaft f,anse issnown wtnout the contre gui.h _T1(n17- bdted down.

Fit adial cstiper against the cr8nkshafi llanqe -A-(marker surfsc€)

t - check the fitting position ofthe sender whe€l on the crankshaft.

- U_sing a thickness gauge, measure _A_ the orst€nce _a-Dervi,een the dialcaliper and the sender wheel.

fdistance -€- is too small:

- Press the sender wheel again

f distance -a- is attained:. Remove the installation sleeve.

Bolt the new bolts securing the sealing fisnge |n diagonalpatrs.

Install engine speed sender -arrow_.Fit the oil sump

Fit the anterm€diate plate.

Fit the flywhe€t orthe drive ptale

t€i"i60 2 0r.-o 2

t - Rechtying the position ofthe sender wheel

F - Rectifying the position of the sender s/heel- Mov-e-the inst ation bell _A_ by hand towaros the sealingnange -E-.

- *.xlvJ-t!g ? b"tF M6 x 3s €_ on the ensrn€ btock togutoe me seating flange _B_.

- Iighten by.h,end the hexagonat boR -D_ on the thEad€dspmo|e untit it cprnes into contact with the inEbllation bell

- I9!Fj !" lg"".SolShur of the sss€mbry devic€ with5X+"#i3lXH:+;mt"flot,!- ant ttre toirue w[ncri -

. C_hactlhe ftting position of the s€nde. whegt on th9qankghan on@ m(Ve . r i ,, r.i distgnco €- i8 still too small:

T-igl|ten tt_e-h€ragonal bolt of the ftttng devrce ro aloque of 45 Nm.

C_hccl .the frtting polition ot thc send.r wheet on thacr8nxshsn once mOrc L h .nl,.r.

Id,i6o I ord I

i

j sAT8010

sAT801@4CT10o17lffil

-

)I

Lrfikshalt dinEnsions:€1,{60 I or!6 I

Crankshaft dimensions

nonrng dtlrnalon|nmm Coo|pd bxrlm

O on loqmrb-

Earlc dlmarub|t

1" Gc0flod

4,t2247,80{,0374,02247,55.0,Gt?

2'rlcdll€d 4,t247,30o,0tt7

3'rcdfred 4,M247,05{,037

r--I

Piston and conrod - Components overview

Piston and conrod - Components overview

@ rooBeforc catrying out assembty wo*, oir shourd be epptied to the suwotl and stide su,far*s.a Piston and cylinder measurcments

Xel,i6o I on6 4

6

ImiEea't

I - Saf.ty rlng

2 - Plrton spdng pino lf dificult to move, heat

piston to 60 .C

o Removing and insta ingwth the tappet -T20019-

3 . Pktono Testingo Mark insta ation position

and respective cylindertr The anow on th6 pigtcn

h€ad should point bwardsthe pull€y

o hstall using piston ringInsE atpn sleeve

4 - Compro|llon .lngtq Oisplace cutouts 12Ooa Remove and insbtl

compresaion riogs usingpBton flng ptieF

o The labelling ,TOp' mustfacE lowalds piston crown

o Piston ring ends:checkctearance

o Checking piston ring sideclearence

3 - Oll rcr.pgr rlng!q Caaefully remov€ and

install by hand the oilscraper rings made up of 3pans

o The labelling "TOp' mustface towards paston crown

o Pistgn dng ends: check clearanceo Checking piston ring side dea€nce

6 - Conrodo Renew as set only.o Mark cytinder assignment -A_o Fitting position: The marks -B_ should point in the direction of the pu evo Piston axialguided

7 - Conrod bearing cap€o Rods div'rded by fracturing 'cracking" can onry be fitted h one position and onry wth the corresponding conrod

rrslon and conrod - Components overview

8 - Conrod bo& flghten to 20 Nm +1/4 turn (gO .) tuihoro Renewo Oilthreads and contact surface.o To measure Gdial ptay, tighten to 20 Nm, without reiightening

I - Engine btockq Interior cylinder diameter: checkingo Piston and cylinder measurements

l0 - H.lt bgartngo Do hot interchango used bearing shelso Centrally align bearing she s on jnsedaono Check the radialptay using a plastigago:New:0.020...0.061 mmt /ear timit 0.091 mmvvh6n measuring the radjal play, do not rotatje the crankshaft

Ie)"i6o 2 an6 4

,ilton rlng onds: chock clqarance

lpoclal toob .nd wo.tahop oqulpmanf Fqutrad

' Gauge

. lns€rt-ring gt rig.ht angles from above into lower cylinderopenrng ftom_of approx. t 5 mm fom the towei 9;g;;;tne cytmder. For insealion, theae must be no s€gm;nts on

It is nol poisibte to giv6 !n i.dic€lion ofth€ r€ar tinil

|gcklng piston rlng sids cloan nceoci.l toob and worklhop equlpmont rgqulrodGauge

st clean piston ring housing groove.

rhlon rlngllmcnslon! in nm

Now W.ar llmn

compression rings 0,20...0,50 1,0, comprgssion ringsI scraper ing

0,40.. Q,70 1,00,25...0,50

Piston and cofiod - Crmpot€nts overview

rbton: chGklng

p.cial tool! and wo.tlhop oqulpmant f.qultldOute. micrometer 75...100 mm

l9i"-lf -1".:!p...r 1o mm rrom the lowe. edge,psrpendicutarto thg shsfi ofthe spring pin.

terance with respect to max. nominal measurement O.O4m,

Omlnal meagurement I i In,

bdor cylindor dlamgtor: checklng

r€cl.l tool! .nd wod€hop oqulpmrnt rrqulrod

Intemal dial gauge SO...1OO mm

Measure borcs al three points in both direq|ona: acrcssmc engmc -A- and in linc with c€nklhai _B-.

l€rance with Gsp6ct to max. nominal rneagurement O.O8

minal measurem€nt . r'r..:r r: l

!e1.i6q 3 aL6 4

Fllton rlngOlmgnrlon! In mm

Now Worr llmlt

1. comprgssion rlngs 0,04...0,08 0,15z. comprcsBion rings 0,02...0,06 0,15ort $.eprr dng nol inaaSrralble

Pltstot and coErod - Componsnts ovgrview

!mory:r]rg, rylytwr b,rE nust. lot b dorq whan 0pc),tttrdr.D,ock ir ,t (!d tD t'f,,6tr/l.1'lfiiaid l-m172_,;- -nco?ttct t|rcarenlg'|tt r|q/d 0t

' Da postDb.

Eel,i6c 4 o16 4

II

l,t$on alld cylirder m€asulenents>6ll5a I 0r!6 I

Piston and cylirder n|eesul€rnents

Removing and installiag cylindcr h€ad

Removing and installing cylinder headChocking compllg€ions

- Chaotef

! r"r. U-},ry! tntt"flW an axchatlf|' ct indct haad, an UE @n f!c, s{rrfE€sDe|yr€en tho sttfpott otenen/E- tu er rw/n,i nnge'! na caniiira oeo$ad batol€ htsta tN he cf,,mshalt hous,ng.. fhe ptaddc p&:keq pie(rs tor p,&div olcn vatws mud rd beEmow<t un l hmt odar€/ty tF/6re ftt V-tb cytkthr hcftrj,

-'--. A{br Edadng AE cyt rder r'E,sd., aI @olant nug- b *,aufi... Ol th€ &Wft and dW s;/bc€E &/.o$ @trying out |{,!|,ntrify wotk. tunovlng md insfi, iN AD h&,t6 matwd eN l,r,o ,rhrt s. Lnape4 tqetua ry*n _ @mpanenb cn,'otif,/w '

a Cyllndlr haad - compon$t ovlrvlofl , Chapter. C€ridrsft houllng:ranovlng and ining r Chapterr Removing and Inltrllhg cyllndaf hed , Chaptera ComprBJon: vadic€dm

- chapter

:€1,{6a I 0r!6 I

II

Cylinder head - component overview

Cylinder head - component overviewI - Notchod belt guard . upper

pan

2 - Principet notched belt:o Mark D.O.R. beicre

removingo Check for wearo Oo not kinko Notched belt routing

o Removing, installing andtensioning

3 - Socondary br.nch notchgdbolto Mark D.O.R. before

removingo Check for weafa Do not kinko Removing, insta ing and

ren6Dnmg

4 - 10 Nm + tl turn (gO.)

o Renewo Tighten from centre

outwards

5 . lgnltlon c.btg. suppo.t-gutd.

o Only engine cod6 lettersAUB

o Engine code lotteIs BBy,BBZ, BKY with cabtesupport for ignilion coits inrod fom

a Tighten the camshafrhousing to a lorque of 5NM

6 . Flexlble connoction tubeo Only engine code tetters BBy, BBZ, BKy

7- l0Nm

E . Non-Eturn valveo Only engine code letters BBy, BBZ, BKy

I - To lir cleanera Only engine code letters gBy, BBZ, BKy

{0 - Camlh.It houstngo Removing and insta inga Remove rcmnants otold sealanto Beicre ftting appty -D 188 003 Aj- , ETKA leieclron c paa(s catatoquej

X6),i5o I 0n6 3

rylnder head - compoDent ovewiew

q V\ihen installing fit ver&lally ftom aDove onto studs and dowel Dinsll - Support

12 - Plns

13 - Rolbr tockor ..m!o Check that th9 rclter beadngs tum smoothtva Oil sliding surfaceo Use s€curing dip to ctip onto support elgmgnt when ingtallino

t4 - Suppor$ng olomcrfo Do not mix thsm upo Wth hydraulic valvs clearan@ comp€ns€ton.q Oilsliding surface

l5 . Cyll||drr hr|d botto Ren6wo Follo\,v insbllation instuc{igns and sequence when lo€€ning and tghtenlng , chaoter

16 - Cyfindrr h..d g$kotq Ron€wq Metat gask€tE Rengw coolant afier €placing cylindgr h€ad gask€t

t?. Cylnd h..do Removing and in3lalling , ch:pro,o Check frcr dsfo.mation , Fqo R€n€w coolrnt sfre. ropl€cing aylindcr head gaskgt

16 . Tondon ro[o. of th. d|'lv.d bnnch o, th. notch.d brl.q T68ting , Dhapterq T€n€ion the nobhed bslt. , Chaprer

19 - 20 Im

:m - R.|r notchld brlt gurd

2l - Llltlng .yo

tllndrr held dlioml0on; varlllcdlonanmurn gllor,tEble debrmafion: O.O5 mm

>€li6o 2 0,t6 3

Cllinder head - comporrcn overviewl€li6q 3 a,!6 3

R:dfi

II

Lamsnafi housing:removing and fi fting

Camshaft housing:removing and fitting

Q rvore, t:!:.?!!,:y..th" omshafts arc hous,eo n a c.asrng. Beroreo$mounting tha casing first renow the principal ,ia.nui i.tt. r ne can\shafr housing sealing sur.face must nol bo t?wort<ed.. Valve gear - ConponenE owview , a.r.t:,,,1Specl.l toolr an.t wo*ahop aqulprnt tlquFqd. To.que wrench -SAT 8010_. Two stude (M 6 x 70). D 186 003 A.t Seatant

8*8itor -T1 0094- (only engino code tetters BBy, BBz,

sAT 8010

' - - '

- . ' , ,

, . r (eN'n

>€l.i5q I an6 I

lwoor.jFl

Removing

Removing

- Firsl see if the vehicle has a coded radio. tf so, refer to the anti-thefrcode.

- Wth the ignition switched ofr, disconnect battery earth strap.

- First removg principal notched bett

Engine code AUB

- Remove the spark plugs together wjth the ignilion cabte guide.

- Remove the 4-pin connector from the lgnition transformer _N152_.

- Disconnect connector terminal from Hall Sender -G4O-.- Undo securing bolt -anow- ftom the cable guide support.Engino codo tottsrs BBy, BBZ, BKy

- Remove the 4-pin connectors from the ignitionhansicmers_

- Removing ignition coils. To do so, use the extractor -T10094-

- Remove the air duc{ from the camshafr housina.

- undo securing bott -arrow- from the cablo guido support.;ontlnu€d tor all vghlclor

Undo the securing bolt of the rear notched belt guard. inthe region ofthe right ring tor the toad hoo(

Remove the bolts fxing the coolant pipe to the camshafrnoustng,

Loosen the camshafr housing bolts, from outslde toInstoe. o|a90na y.

Carefully lift the camshafr housing off.

Ie2"i6o I azr6 1

I rttrngXd,i8q I ond 2

Fitting

Prcrrquisite6

. The pistons must not be positioned at TDC.

. The.camshafls shoutd be locked using the counterhotd -T10016_ in theextstlng tocking spaces in the c€mshai housrng. and secured topreventturnino_

- ::T::.,,::"^t::ll:Tllnb on cyrinder head and camshaft housms witha commercially available flat sciaDer

- Prevent dirt €nd sealant remnants from enienng cylinder head.- Clean contact surfuces, which should be ftee of oil and grease.- Apply-a thtn even coat of sealant onto the clean camshaltnousmgJealing surhc4. _See shaded area on

@ rv"oT-he sealant.must not be apptied too thickly omor,viro9xclss sea/arf could ertet the oil channeis ano cause,amage b the engino.

Ensure all rolle'-r rocker fingers contact the valve ends _1_

!lllnT;|":f ""0*o "," their respective support

B,olt tw! studs (M6 x 70) on the cytinder head beicrelnrng the camshafr housino

Caretully fit the camshaft housing vertically onto thecyflnoet head sluds and pins _arrows_

lsj9i Ty caTsl?ft lousins secunng rrotls (eventyrom Insde to outside diagonally).

Take care not to tilt the cemshafl housing

F rttlng

S rvott

nsra ng cahshaft housino

continue insblhtion iclloriing reverse order lor removing.

Eelltn2 q.6 2

i

I

Removing and installing cylincler head

Removing and installing cylinder head

pocld toob rnd wortriop.qutpm.nt l|qut|tdS€t €AT 1m6Z-Torque wEnch €AT gOlO-Counbrhold -T1O0t4-Tlay -f2U73-Pliers -T20029- or counbrhotd -T20174-Support -U-30025E-O 1 88 CO3 Al S€atant

ter"i6a I a?r6 I

sAT 8010

T10014

8L 12L

60...300 Nmfi]l-nrrr.--____q

20...100 Nmnn'D--=--..r-?

s...25 Nm

720029

Lr5-lmrS

1a0173

Rernoving

Removing

Prcrequisite.

. Engine at tepid tempe€ture at most.

. The pislons must not be positioned at TDC.

- Firsl see if the vehicle has a coded radio. lf so, ref6r to the antltheftcode

- Wth lhe ignition switched of, disconnect battery earth strap.

- Remove camshafr housing,

- l:l1)f T,ll1.q"r fingers togsther with support et€monts and tayasroe on clean surfece

- Engure that the roller rockef fingeE ancl the support elements are notmtxeo up.

- Remove battery and battery rctainer -arrows_.

- Enpty coolaht

- Loosen hose clips and pull coolant hoses ofi thernermosktt cover

- Rgmove the dip stick guide pipe

- Remove the fuel supply hose in the fuel ran.

Xe),i6o I oro 3

Fuel ayttam ls unator ptosauttlt Weaa safoty gloveaano grasso. to awid lnlury .nd cont ca wtflr-rkln.Eeforc openlng the sys'i,tm ptaca a ctoth afound ahoconnec{on. .fhe/r neteata proasurc by carsruttypultlng fuel hos€ lrom connac{o'..

- Loosen or separate the bllowing components:

' the hos€ from the intEke manifold lo the actNe carbonter

, lhe loxa-pressurc hose to the brake so.vo from the inl6tmanifold.the 2-pin

-connector of the Knock sensor | €61- (rearsection ofcylinder block) and the 4_pin connector of thepressuae 8ender in the intiake manifold, t€low the intakemanrcE, ront nght sectionthe conneclor of the engine spe€d sender below thedipstick guide pipe support. and remove tne connectorrom [s position on the BuDDortthe connectors ofthe coolant tempeEturc sender, otlpressure sw[cn and exhaust gases recirculation valvethe. connectors ot th€ injeciors and the throtfle controlunI

ngln9 codo letteE BBy, BBZ, BKy

the-connector of th€ heated low p€ssure valve of the oildeflectcr.the hose trom the intake manibld to the acdve carbonfilter

Removing

Continuod for all vehlctes

- Partially .emovs the elechic fitings and pu to one side.- Remove front exhaust pipe ftom exhaust manafold .

- Und,o the sTuring bolt of the rear notched belt guard, inne regon of tho right ring icr the load hook. -

- Fit the support--U-30o25E- and rais€ engine stighflyusmg spindte-A-.

@ rvor.Aoth rings for the.toad hook aE frfted in tho cy'inder head;ror^mrs/ea-son ,l is ,oc€qsary to fix an addihonat suppott ion@E€pt he engine at the cylinder block

As sho,nn -in diagram-screw the counterhotd _T1OO14_rnr.o me thr9aded hole above the cootEnt pump in thecynnder block Tightening torque: 20 Nm.

Lifr engrne stigh y using s€cond spindte _B- until spindle _A- iS r6liev€d

Remove spjndle -A-.Remove_secu.nng clamp of coolant pip€ to coolant pumprrom nermostatt cov€r

Loosen cylinder h€ad bolts in the sequence indicatedand remove using a M12 spanner ftom the kit _SAT1006t2-

Caretully remove cytinder head.

\'t ien separating the cylihder head, ensure lhat there areno connectorgsupporls still a(ached. and if necessaryo|sconnect them.

Is),ibo 2 on6 3

Rcmovingt€r,l6a 3 0{6 3

I xrd@ I

Fittiry

Fitting

@ rvot..

Y!!:p,y:r: y. ,:w cytndet head gaskot from its packing untilmmedratety beforc ils installation.. Handle new gasket extrcmety carqfu|y. tf damaged, leaks may result.-

:1"_":^:-"9i! gl9th'n cytinders so that no dirt or partictes can ger inoerween ryttnder wall and oiston

- Carefully clean rylhder head and cylinder btock sealing surfaces.Ensure no bng grooves or scratches are produced (if ur-singsandpaper. I must be at least jOO grain)

- Carefully remove any abrasive metal particles and then remove thecloths

- Position crankshafl at mC cylinder. 1:

The notched tooth otthe notched bett wheotshoutd line upwr$ the maft on the oil gumo _anDw_

@ rvor"y.lpr,p!ryy !. !l1rk" on the seat rcteinedoir pump. Thenorcned both shoutd tine up with tho na* codod with 4V.

- Turn crankEhafr back stigh y.

- Fjt the new cylinde. head gasket so that the lettering(spares number) can be aeed

- Fit the cylinder head obseNing th6 centring pins of thecytrnder block.

- hsert new cylinder head bolts and tighten by hand.

tei"i6q I qn6 I

Tighten cylinde. head bolts using wrench Ml2 ftom kit -SAT 10062- following the sequdnc€ indicateoTighten alt botts to 30 Nm.Then tighten atl bolts 1/a tum (90 .) turth€r using a rigidwren6h.Finally re-tighten all bolb 1/.( turn (90 .) further using arigid wrench.

Install support etements in cytinder head and titaespective roller rocker fnger onto respective valve stemeno and support elements.

;ontinue installation following rcveBe order for removing.Fit camshan housing

Fill cooling system

1,,

I,, l l'(r,

..4..''|;

I

il . -I

{Ej

Compression: verifi cation

Comprcssion: verifi cation

pachl ioolr d werl(.hop aqulpm.nt EqrlndTofquo sr€nch €AT AOIO.Extrector -T10094- (onty €ngln6 codo latters BBy, BBZ, BKy )Wtsnah "T20175-Cofip.e!3ion b€br -VAG 176$ oFVAG 1381_V€hiclc Diagnosl!, Trsting and Inbrmsdon S.ystom _VAS OO51_

tr|lqublb

Uin€ oilbmprratur. murt br at lc€lt 30 .C

:€li6o I 0r!6 I

sAT 80!0

60...300 Nm**D-----q

2O... t00 Nm*'---"ta

5...25 Nm

fm175

vAs 5051

Lrtt(nrt

r

r e$ sequence

Test sequence

- Remove engine prctection together with air flter _arrcws_

Engine code At B

- Remove the spark plugs together with the enlton cablegu|oe.

- Remove the 4-pin connector from the lontt|onransrcrrner -N152_arlow:nglno codo tettoE BBy, ABZ, BKy

Remove the 4-pin connectors from lhe On|tronransbrmers -arrows_

f;go;nO ignition

"oit". To do so, use the extraclo. -

Remove the air duct frcm the camshafr housing.,nlinucd for all vohlcloc

Remove all glow plugs using w.ench -T2O17S-.

t€1.i60 I ott6 2

tl4 a6t*,

^\" \

r^\l fi 6\r

) r - ) ) ' \

J)) 'J

Test sequqc.e

'f,xltu2od2

- Ro|rtolre tura -2S frlm ttlc fi!. box

! l",r

fffirg ,t/$. ?C rr{inrrpis dr. veg, qepry io 0r,

Alk snod|ar rnrchanlc b dap|ts! scccLrabr b $!maxlmum, !o th€t th€ throtte b btefiy op6n.

;lskA8rHf* * comprlsioo bbr _vAG 1381-

! r"rt9t!9t€nt qgsnit gpo,rdtp it sfrw6o,,8 W i,t*t&,rjo0 now b ua &A uni.

- Op€.ab ltrtur unfl batff !iou,! no tuihlr ptllEur!nq€!ta.

Conprlsdon vduq:

. thw: 10..0.15 bsrr Wbar llmlt 7 berI Tolrr.bL dtfbrlnc! betrrun a[ cytinda 3 be,

- Sghbn

!p|rk plug! with $rft ptw rplnnrr -T2O1ZS_ to

bninu! inlbtbilon folo'vho rlrraru ordcr lbr tlmoving.

- lnbrrog€b rnd arac lbui mdrory ot anglna cofltrol unit

Servicing valve gear

Servicing valve geara Valve gear - Cornponents overview !-.. :;.,,.a Rewo*ingvalveseats . i_1..,,,:.... Renewing camshafi oilseals (]..rj,i_r. Checking valve guides , ,, r-,r.,. Replacing valve shat s€als.

Iei,tdq I on6 I

Valve gear - Components overview

Valve gear - Components overviewI - 20 Nm + t/. turn (90 ")

o Renewo Use locking spanner _

T100i6- to toosen8nd tighten

2 - Camsh.igoa.o Note the position when

ftting the toothed bett

3 - Oil eoalo Onty reptace with camshafr

ftt€do Lighfly lubricate the sealina

tip of the oitsealq Renew

4 - Socondary b.anch notch.dbolta Mark D.O_R. before

removingo Check icr wearo Do not kinko Removing, installing and

lenS|ontng

5 - Camlh.ft houllngo Removing and jngtalling

o Remove remnants of oldsealant

o Beforc fitting apply -D 188003 A1- . Er^A(eleclron c paris catalog!el

q V\Aen insta ing fit vertica yrom above onto studs anddowel pins

6 - t0 Nm + r/. tum (90.)

o Renewo lghten frcm centre oulwards

7 - Covo/support for tgnttion tEnatormer -N152_8. l0Im

9 - Rollor Eckor tingoro Check ro er bearingo Oilsliding surfaceo use securing clip to clip onto support element when installing

l0 - Somicones

lel"i6o I our6 5

2 5

I12 3

13

12--

24I

23 22

n

of Nl som-l

-d'-i

Valve gear - Cornponmts overview

It . Plug

t2-20Nm

t3 - Llttlng oye

14. Prrtaurr rrt lnlng v.lve,6 Nmo Cle€n the th€ad and fit with .D 104 102 41- - ETKA (etectronic catatogue of pa[s]o Do not ovg' lighten; the valv€ could s€ize

15 - Suppo lng ot.monto Check the oatinjection holeo Wh hyd|aulic vdw clgaranca comp€Gation.q Do not mix them upo Bebrs ingblling check camshafr axial clearsnce , Frqq Oil sliding surEca

l8 " Vrlyo plrto tprlng

lt - Vrlv! rprlryq R€moving and Installing

. Digrnounted cllind€r hEad ahaprer, vatue ghaft seals: replacing

. In8tallgd cylinder he€d . ChalrF,r, VslvE Bhafi ssals: replacinglE - Valvo |trm |..1

q Rsn€lv ' Ch?pLer

19 . Vrlv. Ooldoo Tegting Ch.ptef

20 . Oll ptt tutt awlich -Ft- 0.J - O.? b.r, 25 Nmo T9$lng Chaplel

o h ca8€ ot lEakage, cut out and r€plac€ s€aling ring2l - Vllvor

o Not to be reworked; ont grinding-in p€rmtesibleq Valv€dlm€neions Frq

22 - cfllnd.r ho.do Roworking valv€ se€b Ctraprorq Rewerklng cylinder head seating surface , Frg

23- l tNm

2a . T.nrlon rclhf of tha drrly.d branch of th. notclrd batt,o T6gling ,Chaptei

o Notch€d bslt, ftting, tEnsioning , Chaptcr.

25 . sc|l boft,.6 t{mc Fitwilh -D 154 102 A1-

- ETKA (etectronic parts catatogue)

o Do not sc|!w too faro Marimum dopth of enfance b€low support surface of cemshafr housing: 2mm

26 - Ca'r|rhrfito Check axial dearance ,Frg

o Oil bebre ffling (atso tie bearing of the axiat bush)

tel,i6o 2 qn6 5

iiI

Valvg gear - ComponeDts overview

o ldentifcatiofi of the camshafrs, distribution timingo Replace the sealrings behind the assemblytr Renewing camshafr oilseals

27 ' O.ringo Renewo Oil bebre ftting

Camshatt lprockots whh thG countorhold -Tl00l6.llmmoblllrs

- Inse( the locking pins in the locking holes on thecamshafi sprockets and in the holes on the camshafrnousng.

[!J iro.eThe two locking pins are cniectly fitted if tha frnal patts -Oarc in line wM line -A-.

- Insert support -B- as far as possible in the intakecamshaft gprocket 4-.

- Once both sprockeb are locked, the camshafr sprocketsmay be loos€ned or tightened.

Xel.i6q 3 crll6 5

Rowo.king cyllndor haad laallng auaface

. Cylinder head reworking dim€nsioni a = minimum 108.25mm

Chocking camlhaft axial play

Speclal tooL and workshop gquipmenl roquir.d

. Support -T20020-

. Dialgauge

Measure when the camshaft housing is removed and thecover is fitted.

. Wear limit max. 0.40 mm

t€?'i6o 4 on6 5Valve gear - Components overview

|dontmc|tbn ot tho csm.hrftt, dbtrlbutlon tlmlng

22l3aa

Valva dlmdralona

LtlJ rbt"Valves are not b be rcvrod<ed. Ot y gnndiwln is parmitted.

Englno codor AUB, BBZ BBY, BKY

ldgntlficatlon bctrf,ccn tho camprlr!

cyllnd.r I .nd 2 cyllndor 'l .nd 2

htak9 c€m -E- "03€AF '030Ac'Exhaust cam rA- "0364G' "03€M'

Valve gcar - Componcnrs ovewiew f€Ii6a 5 ar!6 5

Dim. lnH v.hr. Outbt vilvr

Oa mm 29,5 20,0ob mm 5,973 5,953

mm r00,9 100,5

o 45 ,t5

Calculate the max, permissible reworking dimension

- Me8suae distance betw€en end of valve stem and uppereoge ot cytindea head.

- Calculate maximum permicsible reworking dirnensionrom measured distance and minimum diiension.Minlmum measurements:

. Inlet vdw 7.6 mrh

. Exhausl valve 7.6 mm

M€sguret distance minus minimum dim€nsion = max.poam|sstble machining dimension.

Erempl.i

DistancE m€asuredMinimum distanc€

I€?.i60 1 07Io I

Calculate the max. permissible reworking dimension- lrcert valve and press firmly against valve seat.

S rvor"l:#uru;I:.is to ba Ehewed as paft of a repair, use a new valw for the

8,07,6

mmmtn

= Max. permi$ibte rEworking dim. 0,4 mm

, ]*,Ijj;ff:liiiiPrl.*.{ns drn.nlron i! .rro{,n on i[u,rlltiom for

'!l,o ine varvo

K€working inlet valve s€at

Reryorking inlgt velv6 aaat

.928.7 mmE Moc prn||blhta ruwortino dhlrnlha -. 1.5. . . 1.8 mm. towcr rdga ot crlld.r hr&. 4E . vril! $€t lnola

:33:[#;ff"?'#ffi"Cdo{Un! r|0. p.||n.|bb iafirth, dtnarr.ton - , Chapt€r

Eal{6a I ars6 I

f--I

KeworKng exhaust valvg seat

Rewoddng exhaust yalve reat

f€1,i6a t an6 I

r -?-t -

' O2S.O 6m= M!x. parmbdbb r!*lrktng dlnl.ndoo _. appEx. 1.9 mm. to*!f adg! o, cylindlr hra(, 4b . vah,o taat anob- 30 . hlghar sngb d' comcflon- ou - tflraf engb of corudlon

Cabuhthe m& painLabL |tslatt|3 *finrloat -, cnapler

exvwrng carnsnalt oil seals

Renewing camshaft oil seals

rchl toob rnd wo*rhop aqutpn nt nqutrldTorqur wEnch \gqT SOIO-Counbfiotd -TZOOIgB-Guld€ slrsvc -T2009,1 B-Eldracbr -120143-

:€r!i6o I 0r!6 I

o €r^7"Y

@%6%.

f-

KemovtngXel.i6q I qn6 I

Removing

- Fi6tremovethetwonotched betts . (.r,rr, , : ,

- Turn crankshafr back slighfly.

Q rvor'

'#igffi##f::d\i,r/!J".l,iiff ui,iir,#,"0*"- Rejnov-s camsh€ft sprockets. To toosen bons, hold thecansnafr sprockets usjng the counterhou _T,lOO16_

In6e.t the ext actor -T20143- and extracl the seat.

FttlngEel,i6q. I ad I

Fitting

- Lightly tubricate the seating lip of the oit soat.

- P^osition.oil seatin adapler _T2OO81B/5_ ano p|aceassemDly onto camshafr joumal.

- Y:.1!"-1ipi"J !oo81B/1- and press rhe guide::?"r?rfl ,iil, j: g: .aximum, usins the sprocket

- Remove the adaptcr -T2OO8 i B/S-.

- Fit camshafr sprcckets.

I rvor"Note tl€ position ot the q@ctG?j6 with respoct to the pins inne cad,sratls.

- Lock the l€spoctivE 6prock€t with the counremotd _I ruu ro- ano tgnten lhe new bolts to 9 torque of 20 Nm.uonthue tightening boli V, turn (gO")

- Fitting notched bett ..j;, ,i

lontinue installation bllowing.evErse ordsr br romoving.

Checking valve guides

Checking valve guidesSpoclal toolg lnd wor*lhop .qoipmant rgquked. Support -T20020-r Dialgauge

Tolt sequonco

Ed,i6c 1 orc I

T20020

I w00-2300 |

- Ins9n a new valv6 into 9uid6. The gnd ofthe valve stemmusr o€,tush with the €dge of the guide. Due to thedrgnt ofiBtence in st6m dimgNions. en3ure that only an|nrEr vatue ia uB€d In th€ intst guide and an €xhsust JaN€|n Ing exnaust guid€.

- Debrmine amount of Eidolr,ays plgy.

I lry'ea.lirnitt 0.8 mm

I the rock is exc€ssivel

- Replaca the cylindEr head.

I

Replacing va.lve sbaft seals.

Replacing valve shaft seals.

pachl ioob md wodchop.qulpn nt |tqulr.dTorque wbnch -SAT gOlO-Messuing bot -T20033.Pr€8sure toot -120034C-Installstion bot -T2m39-Exhactcr -T2 0058A.V\,tsnch -T201 75-

t€l"i6a I on6 I

nnKlIl:-E"*_

lz(re4c

Eq|qu"\ ,22

e\ig-65,* e, ' ,

f f i lHlu -\*!,6l

R4

rI

Kemo!1ng (wlth cylinder head in plac€)

Removing (with cytinder head in ptace)- First remove principat notched beft , Cf:r!!e,- Remove camshafi housing, ,ltirrpl:r.

;":H[f,"5r ffi g:ff T,s;:Hi#;:iir#i:Tr:i"ino *,- Remove spa* plugs with spaft plug spanner _T20175-.- Set piston of the r€spedive cylindef to .bonom d6ad centrE,.- Fit the adaptof -T2OOg4p7-.- Screw.the measudng tool _T2OO33- into the spark plug

- gonnecl the msasudng toot -T2OO33_ to a compressed

"t[l]'!]o* rt'nit" 6 bar )' and rernove the vatve

Pull ofi valve gtEm 6eals with extraclor _T2OO58A_.

Iei,l|q I o116 I

Removing (wirh cylinder head removed;

Remoying (with cylinder head removed)- Atbdl the counbrhotd -T20034p_ onto a workbench.

- Remove valve springs with the pressure tool _T2OOg4tj-eno the adaptor _T20034p2_.

- Pull ofi valve gtem s€als with extractcr -T2OOS8A_.

XeliSo I o16 I

FittingE€1{6o 1 0116 I

Fitfng

- T^o arcid dlmsga ot r€lv6 Eab, pbca tna phldc daay! {_ovr. ygtvsdam (this lharrc i! Induded wi0r'the roarci.

- Flt fir mw vatvr Ebfn tG€l €qio thc inlidtrlon bol -T2003$.- Oll.rrsi,e lbm laql laafing llp end stit! tha ret c.tlftflv

1!H3r;:] ontc 0tc vdv€ gukla uling thc kltbfi€tion bd|

- Fit c.ol!f|' t houalng - Chapter

- Flt and lnrbn notchld b.lt - Chapter,Cootlnu. lmtdbtbn blowlne rlvqla odar 6r runovlng.

II

Lubrication syst€m componetrts: temoving ard fitting

Lubrication system components: lemovingand titting

Er,f,tdc I 0,!6 I

!

frcoff bea quanlltle's d nt6/'/ drri&rs or partitar €re lound ln tllp a'r'8lnad wr'€/-t @nrg tha

',ut'f,.,lae oflpalsrgps |7| n{ te cbrned

eraw at'd tlp oI ll16rJ€/!.rf,d tu otdprb pt"vcnt fitt',er .tfil€oewnnng btarftta oI bwl mu€' M ba alow the M ( np/tk - N<d dnqe lo tll€c!t'/Dtb @n&tot1 . W rdd< nwls - Fa.

Engh. o{ lUru k b rd lDrdllatlom - chapterLubiaanon !y!bm - Cornooorr|t! ov!|vbry - ChapterRc|novlru and hltdlng annp + ChapterRmovlne and hltrlflng oil FJrfp - ChapterH6try tholtrt (o||rrl€i€tf amp b[.lhrr) 7T:dr.cldng+ ChapterOll t[rcarl! and oll prt!trIr! ryldr fl-: draohne * Chapter

bngine oil filling levels and specificarions

Engine oil fill ing levels and specificationsOil cepacity

w'th oil filtef 3_2 ltr.

Engine oil gpecificadons

use engine oilto VW standard 5OO OO, 5Ol Ol or S02 00.Only in speclal cases: Multi-gEde orts conesponotng to Apl_SF or SGspectncatons.

Xel,i6o I oz16 I

Lubrication system - Components overvtew

Lubrication system - Components overview1 - Oil prsllure switch -Fl _.

trom 0.3 ... 0,7 bar. 25 N;o Testingo ln caseofleakage, cut out

ano reptace sealing dng

2 - Connectoro Only engine code tetteG

BBY, BBZ, BKY

3 -10 Nm

/a - Oll deflgctoro Only engine code letters

AU8

5 - To.lr f,ltoto Only engine code letters

AUB

6-l0Nm

7.P|| lgo Replace gesket if it shows

signs of damage

8 . Oll dlpsflckB Oil levetmust not b6 above

m8x. mark on dipstick!o Marks

I - Fllllng funnolo Remove in case ofoll

evacuation throughabsorption

l0 - Guldo ptpo

ll - Prlnclp.l notchod bolt:tr Mark D.O.R. before removingI Check for wearo Do not kinko Notched belt routingo Romoving, installing and tensioning

t2 - ldle. rollo. tor p.inctpal notchod bolt

13 - Oll filtoro Loosen at the hexagonal, using the unjversal oll filt€r wrench or th€ aotation tool-U-40078-o Tighten by hando Observe the jnstallation instructions prjnted on the flter

14 - Oil pumpo Reptace comptetelyo \/vhen fitting, reriembea the crankshafr traction element

Iel.i6o I oz16 3

33

ril ll r

323313029

12345 7 I I 10 11

r4 1513

6

' l20 19 1E 17 16

i-NTi {rbtl

lnE{

I t :

22321 3

Lubfication system - Componenb ovenlew

o Should fit into the adjuaknent st€eveso Removing and instalting . Cndt:e.

l5 -12 Nma Renew

16 - Cr.nk ha|l toothod bdt wh.olo Observe position when fting the toohed belt , Chapter

l7 - Oll ..alo Rend/v , Chapter

l8 - c!.kcto Renewo Should ft inb the ad.iugfnent sle€ves

19-2t Nn

20 - c!!k!ta R€n€w

2l - Suctlon ltnro Clsan filter if sollod

22 . Tan.lon rcllaro Te6ting , ()haftc'q Nobhed bstt, fitflng, t€nsioning , Charrter

23 - Oll t.v.Uolt trmporatuo land.r G2EE_o Dgpsndlng on v€r€ion

24 " Odnga Rgnow

23 - Oll .umpo Removing and insb lng , Chaple.o Fitwih a silicon based s€alant D 176 404 42, ETKA (eteckonrc parls catatogue)E Cl€an s€allng gu.bc€ bsbr€ installing

26 - Oll pu|!. bott, 30 t{mq In snganeg whsr€ ths bolt and dng torm a singl6 pl6cr, feplacs ths unlt.

?-13Nmo Loos€n and tght€n ths botb on the Bide of tle ftywh€et using thc spanne. -U4OO51A-

28-atNm

28 - Tr.cllon aLmcDlo Oilwe beb.e fitting the oil pump

30 - Odngq Renew

tl - Ho. ng .haod.r (cnok hrfr ruDp b|r.thar) +{79-o Only engtne code tetters BBy, BBZ, BKyo Testing , Chapter

!2 - O{lngo Replace if damaggd

'€L16{I2 snn 3

I

Lubricatio! syslem _ CompoD€Db overview

3i! -To Int .m tbldo Ont €ngine cod! t€frqtr BBy, BBZ, BKy

hrtlnf! on o|l dtp.tht

1 - Max. maft2 - Min. maft

" - 35. *_!P:t yepy ddg€ or pdnrld at! end lmxrEfi: do not add oll

b - |f th6 lcvll b wlthin th€ finbd al!a, ott mey b€ addodc - Zom b€hrln min. r|8tt and qppar od!6 of pdnbdrll€: add at molt 0.5 ttr otott

E€fl.i,tio 3 0!6 3

r-I

Removing and installing sump

Removing and installing sumpSpcclrl tools d workshop oqulpmgnt i€qutlrd. Torque rrrench €AT 6010-

r V'r,/t€nch-U-400S1A-r Hand drillwith ptestic brushr Flat scrspEr

' Probctive glasEes, Silicon based s€atantD 116 404 A2 , ETKA (eteclron cparts catalogue)

t movlng

R6mov9 the lowsrenging protsction , Rep cr 50Drain engine oil.

Remove the ftont exhaust tube ftlm the exhaustmanfold L ] rrrr , ,

Unscrew the bolts fixing sump b geerbox t.r. .Romove bolts fixing oil sump with liquid seal . tlr..,Rqmove oil sump. lt may be n€ceasary to reEaa€ sumpDy tapping lightly with a rubb€r h€ad hammer.Remove s€atant feaidue on cylinder block wrth a flafscmper

sAT 8010

@0f|*.r , , 2c, iaxm

&CC|H.;;.5 25 ttF

Eei,l6q I qno 3

Removing and installing sumpEe),i6o 2 ord 3

- Rehove the s€alant residues at the oil sump usrng aro€ing brush. e.9. a hand dri machine with ptasticDrusn (wear paotective goggles)

" Clean contact surbces, which shoutd be free of oil andgrcase.

rlltlng

if rorObseve use+y date of seatant.The,ol sump must be insta ed withh S minutos aflalaPPtYhg the silbone seatent

I? !:!p !.h:! y,rs q" oit sump, thrcaded pins M6 nayDe tnsertect in two points in the cylindet bto;k ftanoe.

Cutoftube nozzle at upper marklng (nozzE approx. 3mm).

Apply_ the silicone-base s€alant to the clean suriace of

il"?3".lr1lih?**ts as shown. searins compound

2...3 mm thickpass next to the bolt hotes, through the inner side -

I rvooe-soatng compound bead must not be thicker, otheflvA,e=:::u-e -y?!ng

corypoun.t coutd enter the sump andtcK he ott sudtion pipe strainer.

Fitlhe oit sump immediatety tightening tighfly a oftheanachment bolts

Tighten the bolts on the sump.

Tighten the bolts fixing the sump to the gearbox

.\smol'ug and rnstalling sump!€).i6a 3 on6 J

- Put the ffont exhaust tube on the exhaust manifold

[f ror"

t3'ii":,i3!:f ilf i:i"!,#;y:,2"#:fl :!,Uy:;|::;

Rernoving and installing oil pump

Removing and installing oil pumpSpqcial tools and wortshop equlpment ruquir€d. Iorque wrench -SAT SOIO-

. Guidesleev€.T200818-

. Flat rasp

Rrmovlng

- Removing principal notch€d belt ir ,r; -., Notchedbelt removing and fitting, tensioning

- Fix the notchsd beltrrankshafr sprockgt to thec.ankshafr, -1- using the irrm€r securing bolt_2_.

. Position crankghafr at TDC cylinder. 1:lle notched_ tooth of the notch€d belt wheet should tine up,m the m€i( on the oil oumD -erow_

! ,vor")o.not cor1ft1se the mafts on the aeat rgtainor/oil pump. TheoEhed tooth should tine up with the na* caded witi 4V.

Xe].i5c I orc 3

T2008lBFla

*\a

A{A"^.^w(h-<"\y [ /A 1\/_ ts*(br*"

-.\s,./FrvoGrsfl

sAT 8010

ACUCH*r.:

;t 60..30O NF

L -u, :+--, 2c roc N,n

[CClj+=";.5 25 Nr

Removing and installing oil pump

- Turn the crankshafr or the notched belt sprocketanticlockwise for three teeth trom TDC: The thrid tooth -arrcw- to the right of the notched tooth -A- should line upwith the TDC ma* on the oil pump housing.

@ ru"r"This adjustment establishes the assembly po$ition of thec.anl/ohaft in otder to hou* the oil pump. One of thecrankshaft cam tods is up.

- Remove the principal notched belttongion roller

- Remove oilsump

- Remove €)draction hose

- Remove th€ notched belt cogwheel from the crankshan

- Remove oil pump.

- Remove gasket.

- Using a nat scrapea, remove sealant rcsidue trom thecylinder block.

- Clean contact surfaces, which should b€ fr€e of oil andgrease.

Fittlng

Prs,oqul.lte

One of the cam lods -anow-is in the crankshaft in the uppersecton.

- Fit the new gasket on the guide pin.

- Oilthe crankshafr cam rods.

Eel"i6s 2 qa6 3

Removing and insalling oil pump tsl,i6o 3 on6 3

T200818/2

t- E.r-!or-l

Line up arrow -A- ofthe interior rotor ofthe oilpump withthe assembly position mark -B- on the cover ofthe oilpump housing.

Lightly oilthe sealing lip of the oil pump s€a..

Place the adaptor -T20081B/2- over tho oil pump sealand carotully guide the pump onto the crankshaft camrods.

lfgiven, line up the interior rotor, slightly offsetting withrespect to th€ drive rod in the crankshaft.

Next, caretully ft the oil pump on the guide pins.

Fix the oil pump tightly with new bolts

Remove the adaptor -T2008182-.

Fit extraction hose

Fit the oil sump

Fit notched belt sprocket and tension roller ;Notched belt Fitting and tensioning

fteatmg fteostat (crankshaft sump breather)N79: checkins

ln"::[fl Jn*""t (crankshaft sump breather) -N7e-:

@ rvort.

!!:!?ati!S Rheostat (can/('haft sump Drcdther ) -N7s- has at momaempenture a resistanaa of 3. . .l A

' !tr:,Y# *Z#{:s;e:rstance is at Non temperatue. the vehide

Tort aaqugnca

- Remgve the double @nnectoa-Arrow- ano measurc thereststance belween the pins of the heating resEtance.. Specification: 3... 7 elf the specification is not obtained:

- Reptac€ the oil deflector with heating resBtance.f the specified value i9 achieved:

- Checking po^/er suppty

:hocklng yolt g. ruppty

Remove th€ dol|ble connector -arow_ and, with thergrtlon,connected, mEasure the voltage oithE re;;vedconneclor b€lwe€n pina .1 + 2lSpecifi cation: min. 1 t.5V

th€ specification ls not obtainEd:Check lhe cablsB with the aid of the electric ci.cuib: i " f i :T , : " ; l ' " ' . "

oao"\ b 'a.r ' orr)Lr,o. .q

Xd,i6q I on6 I

\\''li\-.-,ff

JL \

@t]l't=l

\\'='!i\=,f f -JL\

P{f'A-

vx pressure and oil pressure switchFl: checkins

Oil pressure and oil pressure switch _F1_: checking

rocl.l tool. rnd wo.trhop equlpmont r.qulrgdOil pressure teste. -VAG 1 342_Voltage tester -VAG 10278_Measuring tool e6t -VAG 15g4C_

] rvor"t;tffig opeetpn ol and @ryicing visuat and aca/slic o,l prEssuretgcntl vunent flavl dtagran)s Eleclncatfaujt hndng and.Ftttinq

tt ttoquence

R_em-ove oil prcsswe switch _F 1_ and screw Into oilpressure testef -VAG 1 342-

i:::-,""J,iETifi "'Tn;yfl".,"1i#"'311"*'"0*

Xel.i6o I o16 2

v.A.c 1527 B

,*.

v.a.G 1504 C

Oil gessure and oil pressure swilchFl: checkins

- Connect brcwn wire I of tesbr to e€dh (_).

- C_o"nnec{ voltage bster -VAG .t 5278_ with suxiligrycabEs trom the measudng toot set -VAG 1 594C_ 'toposnve of battery (+) and to oit pressure switch. Th€LEU mu$ not t6ht.

- lf the LED tighb up, replace oit pFssure s^,itch _F1_.lfthe LED doEs not tight up:

- 9jld.9lgrl9 an9 sto{/ty increase engine Epe€o. the LEDsnourolgnl.up beileen 0.3 ...0.7 bar ifnot r€plac€ oilpr€ggurE switcll.

- !:]:::: :pf€ "p€..d turth€r. Bring up to 2ooo rpm and€|se$e oitiemp€ratu.€ to g0 "c, the oilpressuri shouldb€ 2.0 bar at l€ast.

Al highgr-engin6 spe€ds thg oil pl€agurc mu$ nor exc€edr,u oar. |r n€c€$ary, feplEce the oil pump with the retie,

r ' .A.n ,L - i 1 l

2*],i5s.2 arb 2

I

ti

Kemoving aod installing pans ofcooling sysrem>€l"i6o I oro I

|r$"t;ttn and installing parts of cooling

@ rvoo. lhe @lingPystem is under pressu,i9 when the engine is wdtm.,rgretbrp, ttlsprossu/a must de a,ducxld befga ,w;;4;..-"', hose ctunneclions aE

-secuBd with spdng_type ctips. Atways u8spnng dips when peioming npai..!,:

, ,::Fjlp:p.,:ryVe9d,ps, ,r rs eddsaDro ro t/so ptierc _r2oo2s orE@ntpn toot -T2O1fd-' Utthe-n insteling, rc,'rte @lant holr,s without tension and not toudtinoomet @mponents (note ma*ing on @otant con;r;di;;;;;;;;;;):.""

Bodywoft cooling gystem, - Componsnts o\€rview . r)lrnr rl,iEngine cooling sysbm, - Components ovs tew . lh r.r lCoolant hoso conn€ciion diagrEm , (j ,;,4cD|ainlng offand filling coolant . athanrl]rRsmoving and in8talling G|diabr . itir;!,,ijRemoving and insblling coolant pump . .,,ra1,r,_Radieb. fan -W- and Rirht redi.tor fan _VAS_: dleaktng , ch.ptelEngine aooling sy8bm: chgcking br leaks . r ljn.il.l

wffi{Lwtr#'ffitiiy;ih::{h ".,,*

'ffiffiwwiwEnaufa aarrflctdrt ctearanca lor att movtng or hot compoaco'..

rrodywo* cooling system, _ Componenb ovenrew_ .l€l,i6a I ozro 2

Bodywork cooling system, _ Components overview_ .I - Radiator

o Removing and instalinq. t r : : . ,nn

o Retew c@lant af,erreptacrng cylinder head9asket

2 - O-rtngo Renew

3 - Uppor cool.nt hotoo is fxed to the radiatcr with

a ctampo Check that it is s€ated

Securelyo Coolant hose @nneclion

diagGm a , ,i,:

4 . Alr duct

5- l0Nm

6 -Aux rry |hna In vghicles with optionsl

equpment

7 - Sacudng c po Check that it is s€ated

s€curely

8 - Suppono For electric fan

g - Conneclor

l0 - R.dhtor ftn

ll - Towa.d! thgno.tat cove,o Coolant hose conneclion

diagram rtl .rt,t,.,j

12 - Exprmton tlnk

" SH:y^tdl$:l3t sv:th€Tr,cl'eck with the cootant sv6tem te6ter -sAr 1274-.ada$ot -vAc 1274ts- e d

13 - Plugo PT?gure.relief valve in filler cap: check with coolant systgm tester _SAT 1274€no adaptjer -VAG 127419_

l,t - Slpporto To connect to ian brminel

15 - Lowor coolant horcE is fxed to the radiator with a ctamoa Check that it is seated Gecur€lyo Coolant hose connection diagiam alf:rL:i,j

!

'| 2

I

tFTf-osrs'-l

Dr.,syworK coormg systet4 - componenrs overview- .

ta - R|dhr ||o th4|o.uttch +t!_, !r mo Fgr ole(tic fano Switchtng bflDo.atuns:

: ]:sF€d cngagd, s2...97 r, dbdsasld: s4...91 .C

. 2r lpaod.ng!g€d: 99..0. iOS .C, or.nlngod: 91..0.96 ftt - auppoft

o For rrdirbrq No6 lnltr auon porltong Nob tha f|!|! ar! vltbua r€ lons

I t - l0Nm

I*Litu2ot62

Engme-srde cooling system, - componenrs overnew

Engine-side cooling system, - Components overviewThe.moltat .ide

I - Connoction hole

2 - Short thir.dod boft, 9 Nm3 - O.rlng

o Renew

4 - Cooknt thormostrto Checking working: H€at

ne nermosiat in waterThe end of thethermoelement shouldbegin to open at (apDrox_84 .C) and finish ei '(app.ox. 98 .C).

5 - To hort grchrngo.o Coolant hose @nneclion

diagram . . . r . , . .

6 . From 9xpgn.ton tanko Ciolant hos€ connection

oEgaam . , . . | 1

7 " Thomort t hou.lng

8 - From hrat oxchrng.ro Coolant hos€ @nnection

diagram ,, ,, t,

I . Coot.nt ptpaq Coolant hose connection

olagram , .,;,,

l0 - Rlng g..keto Renew

1l . Coolgnt pump houalnq lncyllnd.r block

12 - Socu.tng clpo Check that it js seabd s€cu€ly

t3 - 10 Nrn

t,t - ptug

o Betore rcmovhg, casually r€duc€ cootng sysE m pressure15 - Coolant tahpaEturr tondar.GB2_

o Wth Cootant temperature sender €2-o Beigre removing, casually reduce coonng system pr€6sureo Resistanc€ values for @olant tempeEture gender €62_ I l

6 . S€curing cllpo Check that jt is seated s€curely

7-Bol tGNm

t€rli6o I 0116 3

6 7 8 3 910 11

I314t5 13 12 3

Engine-side cooling system- - Components overview

'18 - Support

l9 - To radl.tor, uppor prrt

q Coolant hose connection diagram i'.: i ii,

m - F om ndhto., lowo. p.rtcl i-r'r l

o coolant hose conn€ction diagram . i-ir:it)lr)'

Coolant pump llde

I - P.lnclprl notchcd bolt:o Mark D.O.R. before

lerYrovingo Check br wearo Do not kinko Notched belt routing

o Rgmoving, installing andtensioning ' 1ri i,rIr ' '

2 - Front ot cgolant pumpo Check br €ase of

movem9nto Completely replace in cas€

of fault or lgakag€q Romoving and installing

, i , i , r t ) i i l

3. t0 Nm

4 - Rolr notchad brlt gurrd

3 - Notchod belt gurrd - upporp8n

6 - Notchgd bolt guard - lomrp.n

7 - Pulleyo Not€ location whon

installingo Removing and fitting

' Cr,!Drer; Notched belt:removing and frtting,tensioning

o Removing and inshllingPolY-V belt a:i:rirl"

8-90Nm+r[rum(90"]

o Renewo Lubricate before fittingo Tightening can be done in severalstageso The angle of €-tightening may be measured with a protractor, for example measuring toot -T20030-

9-10Nm

Eel.i6o 2 az6 3

2 3 4 5

TNr$orsl 1

/-6

h,-4-3

i i i - \* *l 41t/\

ql . l .c , E(i -,.{gt,{

!,rz

hr", l i )i i j't$lffI i I 'vrt l

t2 11 10913

Engine-side cooling system, - Componenis overview

'10 " 50 Nm

It - Support wlth idter rocker,r2

- 20 Nm

13 - Crankshafr toothod belt who.lo Observe position when fittang the toothed belt

t€).i60 3 0116 3

Coolant hose cormection diagram

Coolant hose connection diagramI - Erp.mlon trnk

2 - Cool.nt dgld tubao Fixed on he camshafr

howing

3 - Hxtlng h.rt archrngor

,t - ATF r.dldorq Only icr vehicle6 with

autodlatE gggrbox

5 - Lowcr coolant l|oe.

8 - Rrdlrtor

7 . Uppor coohnt ho..

8 " Thrmodrt houtlng

I - Coolrnt rlgld tubc

l0 . Cyllndcr Uock h.rd

ll . F ant ot coohnt pump

12 . hirk! mrnliold

Ee.1"i6a I aro I

10 9 87 6

firre.68-'l

Draining otrand filling coolant

Draining off and filling coolant

Sprchl bob md uod('hop aqulp|||.ot [qulrrd

. Measuring bol -T10007-

. Tray -T2017$

. counbrtpld -T20174-

. Adapbr -VAG 127418-

. ChaEcr -VAS 809&

Xellio I o16 I

T10(x}7

v.A.G 1274tA

lLrTl@

T20173

f-

Draining otr

Draining ofi

- Op€n f€ cap of the cootsnt o@oeion tenk.

- Removo lttr loft. c|lgin€ ptotldion - Rep. cr5o.

Esllda I an6 I

- Bl€€d coolant titough drainags lcrai, €now- ot radiato(.

I l"o.@serw drwosat €gu,ador|8t

I

f>- / )

<--/l

r--I

Fill ing

Fil l ing

Xe),i6c I oro 4

p roo. Ohly use antifrceae additivo G 12 according to specifrcanon TL VW

774 F. ldentification: purDle colour.. Tho puryle @lourod G 12 (according to specification TL VW 774 F)

nay be mixed with the eaiier Bd-caloured G 12 antifteoze additie. G 12 is hever to be mixed wM other antitreeze additives.. fffluid in expansion tank is btortth, c 12 has been mixed with d

diffarent type of c@tant. ln this cas' dlt the @olant shoutd bercpaceal.

. The G 12 dnd the anti fteeze with the indication "ac@rding to TL VW774 F' avoid damage due to c{/nosion, l6ezing ot tine daimentation.I.ney atso ncrcdse the boiting tempeftture ot [re liquid corrant. Forthts reaaon, the cooling systefi must always hsve tho pr€scr'b€dmixfuft of antiheeze and antitust

. Es@cially in c1cunties with topical ctimates, antifreeze hehs togudnntea tetiability ot running wheh tha engine is subnitt;d to hiahsrross, t arks to fte ,{rher boiting point that it Drovides.

. Antifteezd pjotecdon must be gud'e,nteod to aryrcL _2SoC (inciuntries with arctic dimates, to apprcx. iS .C)

. The coolant concentfttion must not bo lgducad by adding water ln hotseasons o. in courtrres with hot climabs. Ihe peicentqie of antitreezeadditiw must be at least 40%.

. f, for rcasons of ctimate, greater antifieeze prctection is needed, the -.t1z- percenngp can be incl9asad, but onty up to 60% (antifrcazeprctection to -40 oC). ff the ntio is grcav the cding and antiteazeptolocton capacia is /.gctuco(l.

. The measudng lool -710(nl- is tpcdnnendad fot detemining tpcu iont anti-hgeze density.

. Old c@lant is not to be rc-used fo outing /F/placement of ndiator, haatexchanger, cylindq head or cytinder head gasket.

Recommond.d mlxturg nllo.:

An0+.o?oprotoctlon unill

Antlltr.r.par9cnt go

G 12 Note Ou.ntlv ofwttel

-25 "C-35 .C

40%50%

2.25 |2.8 | 2.Al

Cool.nt quantity mry vsry d.p.ndtng on lh. vonicb 6qu,pn.nl

Clo3e the drainage bolt for the cooling tiquid -anow-.

Filling Xetr"ido 2 ozro 4

- Installthe lorverengine protection Reri Gr 5il

lf the charger -VAS 6096. l! not us.d

Fill with coolant up to -max- malk on expansion tank.

Close expansion tank.

Start engine and keep engine speed at approx. 2,000rpm br 3 minutes-

Run engine until radiator fan cuts in.

Switch offengine.

Check coolant lev€land top up if necessary.

Vtlhen the engine is hot, the coolant level should be at -max-.l,lihen the engine is cold, the level should be between -mln- anq -max-.

I. DANGERI

Hot st€9,m or hot c@lant can oscape whan the cap onlhe expansion tank ls opqrad. Covar ahe cap wlth acloth, and opon lt carelu y.

Filling

lf the charger -VAS 6096- ls qssd

- Fill coolant reseNoir -VAS 6096/ 1,with at least 8 Ipaemixed coolant oI the recommended mixture ratio

- Fit adapter for cooling system tester -VAG 127418ao lhecoolant exparcion tank.

- Fit charyer -VAS 6096- onto adaptor -VAG 1 27,y8-.

- Introduce air discharge hos6 -1- in a small recipient -2-.\ hen llashing off a small quantity of coolant is cardedaway, which i8 to b€ collecbd.

- Connect both valvea -A- and -B- (levef arm transveGe todireclion of flow).

- Connect hose -3- to compressed air.

. 6... 10 bar oressure.

- Open valvs -B- (l€ver arm pointing in direction of fiow).

The suction jet pump creates a vacuum in the coolingsystem.

. The display instrument needle must move to the gregnarea.

- Also briefly open valve -A- (turn lever in direction of 0ovi,)90 that the charger -VAS 609& hos6 can fill with coolant.

- Close the valve again -A-.

- Leave valve -B- ooen fur futher 2 minutes.

. The suction jet pump crcates fudher vacuum in thecooling system.

. The display instrument n€edle must remain in the greenafea.

- Close valve -8-.

. The display ingtrument needle must remain in the gre€narea so that the vacuum in the cooling system isauffcient to continue with the refilling.

lf the needle is belo\ / the green area, .epeat the procedure.

lf the v€cuum d.ops the cooling system is l6aking.

- Pullout p€ssure hose-

letri6a 3 on6 4

V.A.G127418

Fill ing 2efui6a 4 osi 4

- Open valve -A-.

The vacuum in the cooling system makes that coolant issucked gut of th6 coolant res€rvoi. -VAS 6096/1 - and fhecooling system is filled.

- Check coolant level and fill coolant uD to -max.- maft.

- Clo6e expansion hnk-

- Start 6ngine and keep enginE sp€ed at approx. 2,000lpm for 3 mlnutgg.

- Run engine until radiator fan cuts in.

- Switch off engine.

- Check coolant level and tcp up if nec$sary.

. Vlrten ths €nglne b hot, the coolant lgvel should be at -max-.

. V\rhen the €ngine is qold, ths level should be betu€9n -rntn- ano -max-,

/I\, DANGERItlot af€am u hot o'dtna cm otcaF whm tha cap onthe oxparclu bnk E gf€r?€d, Covor the crp utt',i actoth, and op€/' L ca.f/tu y,

Removing and installing radiator

Removing and installing radiator

X€l.i6o I 0?16 2

sAT 8010 T10007

T20070 T20173

T20174

Fsloooil

Spocial toola and wo.ftlhop equipmeni requiEd

Removing and installing mdiator

. Torque wrench -SAT 8010-

. M€asuringtool-T10007-

. Pliers -T20029- or countertold -T20174-

. Centre guide -T20070-

. Tray -T20173-

RofioYing

llj lvobTo carry oul this wotk it is nocossary fo discgnrect battety eafth stftp. Tolhis ond, il is necessary to check whether the whicle has a c.dd Edio. ff

2el.i.6a2 an62

so, rcfer to the dn$-thefl agding.

- Wth tho ignition swilched off. diEconnecl bsttery eaflh gtrap.

- EmPtY coolant r:h rr;r 'r.

- Pull coolsnt hos€s off radiator.

- Pullconngctora off lhermo.swiich and radiatorfen.

- PlEco lhe lock caader date into 36Mce po€ilion RepGr 50

Vthlclo! wlth alr condltlonlngrhdtlng

A CeualonAlr condt lonln lh.atlng coot n clrluft muat not baopanad

fo evahl dafirra b,ha condanaar and ralrlgcl.plp6/.leevat, &,ke caft hot ag bqrd, twkt orlbrtch ahaplp$lalaova axc.d,ttvaly,

- Unbolt r€laining clamp(s) for coolant tub€8.

- Unacrew ths condongof from ib atiachm€nt to the radiatorand seculE it to th6 brak6 lock canier.

Contlnu.d tor.ll v.hlcl.o:

- Remove radiator ducting end oloctrcfan!

- unscrew radiator tolb and tEk€ oul radiator end f6n.

Flttlng

Installation ls cafiied out in lhg revolro od6r to removal,ob8erving the follo\ding:

- Fillcooling Eystem i'r' :r: .

Removing and installing coolant pump Isl.i6q I on6 2

Removing and installing coolant pump

sAT 8010

60...300 Nm

20.. .100 Nm

5.. .25 Nm

T10007

T20173 T20174

fL1s1 oooel

Sp€cial toob and woaklhop equipm.nt r€qulrud

Removing and installing coolant punp

floto

a Torque wronch -sAT 8010-. Measuringtool-T10007-. Plie|s -T20029- or counterhold -T20174-. Tray -T20173-

Is1"i6q 2 on6 2

a The intagrated coolant pump seal must not be sepanted fmm tho

. Damaged or leaking coolant pumps must be completely rcplactd withseal

a Bolote rcmoving coolanl pump, cover toothec! belt with a cloth to ptolectagdinst cooldnt.

Removing

- Empty coolant '

- Removing principel notchod b€lt

- Remove idl€r pulley €-. To do so, uscrew bolt -5- on idlerpuney.

- Unscrew boll8 -1- and .4- and remov€ lhg rear notched beltgu€rd -2- together rvith the coolant pump -3-.

Flttlng

Inslallation is carded out in th€ revorso order to .omovel.observing the iollowing:

- Fit lhe coolant pump -3- in ihe cylindor block with the rearnotched belt guard and tighton securing bolts .4-

Fil the s€curing bolt -1-

Fil the idler pulley -& and tighten the securing bolt -5-

Notch€d bell, Fitiing, ien6ioning

Installing Poly-V bell '

Fill cooling system

w,-^I trt-

4

5

trob \l*J:o ' . f ,

Radiator fanVT and fught radiator faDV35: checking

Radiator fan -V7- and Right radiator fan -V35-:checking

Spoclal toob and wo.kshop equipment requirod

. Measudng toolset -VAG 1594C-.I Cunent flow diagrams, electrical fault finding and fitting

locations.

Test asqulttmsntg

. Basic fuses should presenl no problems.

. Radiator hn thermo-switch -Fl8-. OK.

Te3t agquanco

- Pull3 pin connector off radiator fan thermo switch -F18--

- Bridge contacl -1- and contact -2-of connector withcables of measuring tool set -VAG 1594C-. The Radiatorfan -W€nd the Right hand radiator fan -V35- shouldgtart at sDeed 1.

- Switch on ignition.

- Bridge contacl -'! - and contacl -3-of connector withcables of measuring tool set -VAG 1 594C-.

The Radiator fan -V7-and the Right h6nd radiator fan -V35-should sbrt at speed 2.

lffan 1st or2nd speeds do not run:

- Use cuffent flow diagram to locate and eliminate open

le),i6o I qr6 2

v A.G 1594 C

Radistor fanvT end Right radiaor faV35: checkirs

cilqlit in wiring , Cunent flow diagrams, Etectricat faultlrnding and Fitting locations.

lf no wiring lbutt ir d€i6cbd:

- Roplaco hc Rediabr ten -W- or theRlgtrt+rnd rEdiatorfan -\135-.

rrAtu2afr2

I Er9{05a I

f-I

EnAine cooling system: checkiDg for le€ks

Engine cooling system: checking for leaks

f€Nta I on6 2

v,Ac tr?a/!

u,A!ttnlt

Spachl ioob and xodahop .quborr quh.d

. Cooling lylicm bsbr .sAT '1274-

. Ad€Dior -VAG 12ZU&

. Adeoior -VAG 127U$

T6t nqulrmnta

. Englnr at opffating tmp.rstuE

T..t trq||.nca

2\ orrceattoatun qrplc€pfrtr,{t |,'f.vl'r'r atu qn drW$lo''',,* tt op.{'rd.covJi'! clpvt't, ctdr,.ldqt Lcad.rtty.

r-

Engine cooling system: checking for leaks

- Open cap on coolant expansion tank.

- Insert the coolant system tesbr -SAT 1274- wjth the adapter -VAG 127418- into tho expansion tank.

- Use hand pump on tester -SAT 1274- to create a paessure of appror.1.0 bar.

lf tho pressure drops:

- Locai,e the leak and rectify the fault.

Zx)"tba 2 on6 2

Testing pressue relief valve in frller cap

Testing pressure relief valve in fi l ler cap

- Insert the coolant system tester -SAT 1274- with the adapter -VAG 1 27419- into the cap.

- Operate hand vacuum pump of the cootant tester -sAT 1274-.

. Vvlen pressure exceeds 1.4... 1.6 bar, the pressure release valveshould oDen.

Ee),i6a I oz16 I

Kemovmg aod installing parts offuel supply system

|;S$'"n and installins parts of fuer suppry

!,v"*. The @n€cflorc bt dD extbte tulr's eorPs o.scrpw d|!'g

B &atnct usit'g eping W. Alwefs optrrcc clarnO-tmo criq wttt ry,drr-t/)o d&c-.. I na ug d damp q sr,rew tyrp dips is nu pem[6fbf..' E[T# N:y;p;

*r", tt ie advtsabb to us dte9 _noo2u q,

!!Y-!:!Zllc ot ,.ny, the punp ot the tuet dt'.'tbut,t, aE tudwwy Ey$€n nud ba bbd _ ihapterI F:eHil:?nd tu.tittorwth compon€nb - conpononb ov€rvt€f,,.

: *Y.ryq* *.n wortdng o.r tultsuppty rylbm .. chapter) Kut€€ lbr cl€Enlinoga - ChaDler) Rsmovlng snd Insblling fucld€liwry unlt _ Chapter, R€moving end Insblling i|ctdrtiwry Bend€r - Chaprer' Rrflpvlng end instalting li|ct bnk * Chapter, Fuel{lltlr trtnrwing

- ChapterFusl dellr€ry Ey!i!m; bl9€ding

- ChapterOpcfedon ot cEshfiJ.l shut-olf

- ChapterFu.l pump and fuct Eylbm: cNrocUng _, Cnapter

E€ll6o I 0r!6 I

f-

luet tank and fuel filter with components _ Components overview.

Fuel tank and fuet filter with components - Components overview.I - Socudng cup

2 - Plug

3 - GGkoto Replacs if damaged

4-1,6 m

6 - Flllor crp s.to Wlh dusiguarda Removing and ftting

, Rep Gr 55

6 - G.|vtty vrlv.o For Enoval, rsmove th9

tu61 tank cep . Itent undome secu.ing tab and pushthe inlet valve out,upwards.

o Ch€ck valve cgntinulty

. Perpendicular valve: open

. 45o vslve: clos€d

7 - Errth connoctono Ch€ck t|at it is sgsbd

8€Wr€ly

8 . Vmt plpoo Bgtwe€n gc1ive cErbon

flbr , ltenr and vgnt pipe

o Chock that it is s€atedg€culgly

I - Actlva crrbon fitrr ry.tamtr Location: in rlght rear

whoEl houslngq Aclivg c€rbon filter syst€m - Components overvlew . Chapr,j

l0-10Nm

ll - Vent ptpeo Hous€d h lhe fuElbnko Ch6ck that it is s€ated securEly

12 -23 Nm

13-Fuol t nkq Removing end installing . Chaptero lf $€ tuel tank has been r6ptaced, the tuel 6uppv sysbm must be bled, Chaprer

14 - Socudng rtrspq Note the difbfent measuremenb

15 - V.nt plpo

l€l"ida I oTro 3

I2s45678

9

10

1l

13

l2

I N200506 |

30En

276252423222120t,?";.r.

. ' ' ' - . \

18 17

16 t5

' i l t . , ' , '1r \ ' ' /14 12

I

Fuel tank and fuel filter \ir'ith components _ Components overview. !€l"i6o 2 o,Tr5 3

a Forthesolenoid valve .t forths.tr check that it is seated *"rr",, '*"t

**n oeposil system (puls6d) -N8o-, in the .ngine compartment

16 - S€cudng cfipo Check lhat it is seated securely

t7 - Fuot flltarq Ren€w , Chapter

t8 - Fuet r{pply llnotr blacko To th6 fuel diskibutor in he inbke manifotdq Check that it i8 a€atisd sscurely

19 . c|skoto Replace if darnagEd

20 . O.dngo REngw

2l - Fu.l p.qrurs ttgulrtoa:o T€ting , Chept.,r

22"5Nnq For fuelfilte. securing fange

23 - Rlng gnk.to R€plac! ifwomo itoieten vt ith tuet for installation

24 - Fuol grugg !!nd!re Rsmoving and Ingtalling , Crj.,rtt.rr

26 - Fuot do vrry untto Removing and installing r | .l ,...o Fusl pumpandfu6lsysbm:ch€cking, Lt,r! i. lo Nolo ftting position on fu€ltank , t rqa Clean the strainer ifdirty

28 . Rotum ptpoo Blueo Botwe€n th€ tu91 pump unjt and the fu61 filt€ro Check that it is seated securely

27 - Supply ptpco Elacko B€tween the fuel pump unit and the tuet filt€ro Check that it is seat€d secur€ty

2E - Conmcdon nut, 81, Nrra Removing and insb ing with the robtion ioot _U-4OO5SA_

29-t0Nm

t0 - Vgnt valvgo Testing F ..E To rernove pull tocking latch tighffy io inside and pull vatve out

Fuel tank and fuel filter with components , Componenls overview.

Fltting posltion of tuol d.llygry ||nlt f,ange

The mad(s on the fuet tank and the fange must coincide:

. Blue or blue marked r€tum pipe -1_ to @nnec$on wthdentifcation R

. Elack supply pipe .2- to connec{ion with identifcation V

@ rvortAf,er insldlling tuet detivory unit ftange. choci that thesuwty rctum an t braather pipes arc sti ctipped onto the

Vont vrlvg: chocklng

a Lever in rest position: closeda Lev€r prcgaed in the dlrection of the anow: openr-t[!J 'vo,eBeforo installing vent vatve rcnove tuel tank cap.

!el.l6o 3 our6 3

lt"ro6l

Darery precautions &.hen working on fuel supply system

3iii|ot"""ut'"ns when workins on fuer suppry

>€1.i60 I 0116 I

WARNING

:i;L'!x:f;{:J,:ffi:l,y##!::#;w#tr;"!!::W.ny rcCah work, especia y tn the engtne"*"n, *,

"*rtion a the tott6wing iue-i;e cnnpea

wffi#Fffi {,#rfr!!ii#wtp,.^Enaufo auffic/,nt ctoa.ance lor a movlng or not co.|'pgnen5.

lryhen.dlsconn*dng baatary, obrerve,afealt moaru rs , Rep.

ffi :,fi rd'ffi Tffi 5l'ff"t?i,fl "il:i*Tf;;gs"lf",[0,,"$f IP".to:.l-:q,l]l,rp r n ptace an €xtraction hos€ ctose ro the openinornln6-ru4 tank to extErcl escsping fu91 fum6s anA

"*n"r, on

"i1.,-"r"t"exuaclrcn system. lf no exhaust €xtraction sy6te, is "ua "Of", "]"-O]"ftan (a.s long as motor is not in Eir flow) with ; dispfa""."ni g[#i-'"'than 15 mqh can be used.

Prevent 3kin contacl wjth tuell Us€ fuel resistant gbvesl

f9l-T! .Eranlq_remove tuse no. 41 from tuse hotderoeroE opening tho fuel syslom aa the fuel pump can Deadrvated by lhe daive/g door contact switcir.

Kules lor cleaDlinessf€i,{6a t ard I

Rulos for cleanliness

ffi,fi?'i3flrffffffiHlupprv and hi''di'r !v8br','s

: IT[:y.y: 1 unbns.and diaconr sr!a! bafor! dirco

'rcrns.. rlacalqnovcd plrtr on s claon lurtlca and cowr Oo na urc nuiy'. Co€rorcaro u y do|r any .)foa€d psn! f hc rlpalr b not b b€rnaoc |mmcdlalst.' ffiffi"mffi,mrylffi,m,lH,sm*. tt?|cn thr"aydrm ia op.n: Do not rc.k wltt cofitpr!!$d etr Ar frr |!poaEtDb, do not mov! thr t €ilcL.

Removing and installiq fuel deliv€ry unit

Removing and installing fuel delivery unitSpgcld toob and wortrhop .qulpmant r!qu||!d. Tuming bot -U-4OOsSA_

r Torque wrgnch -sAT

80 i O_

Xel,i6o I an6 I

u.4{r055A

l-wd6-l

sAT 8010

'x rj 60...3ooN|n

@ot"l-.--?.r. 2o rm Nm

I5 ?5 Nn

Ed,i6q I a,ro I

Removing

- First see it the vehicte has a coded radio. tf so, refer to the anti_theft@oe.

- Nob safety precautions beforo starting work- Wth the ignition switched off, disconnect battery earth strap.- Move rear seat brward.

- Remove cover from fuel delivery uhit under rear seat.

Fuel system ia under pr"ssurel Wear aalory qovesard grrsses toauokt inl.try.and conbct wi{r shin. Belorc oioning tne &sten' '-

ptace. a.clodr -a,oun.t flre conn*tton. l:hen ier*"; p;;i;;icarcfu y pullng fwl hose frcm connactton.

- 9,"I:og. *"l9agt fengo n_, return pip€s (btue) -2_suppry prpes (btack) -3-, press buttons on tu;t ho;ecoupttngs to do this.

Plsition rotation toot -U-4OO5SA_ on couplng nut andunscrew llang€.

Pull fueldelivery unil and sealout ofthe opening in tueltl|nk_

E.ru Noteq.e.tu-el delivory unit is to be Enewect then drain the otd1r Debre d,sposal.

and

FittingEd,i6o I oro I

Fifting

- The inslallation of the tuel deliv€ry unit is canied out in the reverseoroer.

fl rvor"On frtting dE finl delivety unit, ched< flrat the fuet tevd sendor is not

Coat f,ange Odng with tuet when frfring.Check that the fuel hoses sit frtmtv.NoP instaladon position of tuet deliwry unit f,angc. Mad<on ndnge must altgn wilh na* on fuel tank €rows-.Yt:! lnstall.itv tuet detjwry unit. &eck ft|at the wppty.tetum and b@ather pl,€s aE sti ctip@d onto tuat t;nk.Aflar redacing the tuel deuvery unit, the system shouldto blod C l\tLn\

iI

t(emovlng and installing fuel delivery sender

Remoying and installing tuel delivery senderRomovlng

- R€move fuel deliv€ry lnit , Chapier.

- Release pips connec{or lugs -3_ and -4_ and pull ofi.- Ln tehlning tabs -1- and -2_ u/ifi a screwdnver andoEconned fuel geug6 gender dowrwarua _aalow-_F|t{ng

ln3tallition .ls cani€d out in the tBv6r9e ord€r ro .smovat,oDservhg the bllowing:

- hsort_fusl lgv€t gend€r in tho guid€6 on the fuel d€livsryu ano push up unul it sngageg.

- lrctall fucl dslivsry unlt , ath;rplef.

Xd,i6a I cnd I

!

i

l€mol'rng and installing fuel tank

Removing and installing fuel tankgpscl.l toob md uo.t top oqulpm.nt ,tqut|td. Torqus wrench -SAT SOj O_

, Hydraulic lsck -SAT t04O_

X€li6a I o,& I

sAT8010

60...3@Nm

@0|.€4, 20 loor,i,n

666H:r;5 25 Nh

sAT 1040

Removing

Removing

- Note safety precautions before starting work- First see if the vehicte has a coded radio. tf so, reier to the snli-theft

- Wth the ignition switched ofi disconhect battery earth strap.- Remove.cover from fuel tank filler neck and unscrcw the cap fom the

- Drain fuel tank, clean fuel llller and surrounohg area.- Move rear seat fo|ward.

- Romove cover from fuel d€ljvery unit under rear seat.- Renove connector from fange _1_.

- Remove active carbon filter

- Remove guards undemeath fuel tank.

- RemoveJrom body all fixings foft aear part ot exhaustsystem Then lower lhe exhaust system a litfle, hsnging tttrom the body with wre.

- Remove rearaxle . Rep (jr .4:).

Ed,i6o I oz6 I

Pull off6upply hos€ -.t- and vgnt pipe -2_, prcss buttonson nose couptings to do this.

Fuel system ia und& pr8{,aur€t Weer selsty gtovos.nd- gressen ao evold inlury .nd con''lca wtih-sktn.?,efttrs opontng Uta ayg'3,m place a ctot ercund the,onnoqron, .fhen tr/ease pfo'sufe by cardu yourttng fuet hoaa r,om camnec{on- '

j::f:.fiftXHn "tos rrom tuer tank with hvdrauric

Removing tuet tank.

f ittmg:s1,i6u I qr!6 I

Fitting

ln,8g|llr i! cariqt out in tha tlvlrle ordcr b rqnoviC, oos$ring thcrol(wtng:

. &lEtirrfld nd hoor! ar3 b bc toltattad tdnk+ee.

. Slcurs tto€ls wfu| lpriry"dlp3.

. Donc{-contlla thc tud Cpr! wfitt $oae o, tha l!tum pha or thcDlltlnaf oDat.. Flt alsr ardc - Rep_ cr.42

!mr. A{tcr.ln(afl*Io fual gauga e,rdtlt, cltr,dtot wtor pt'{,c eo ffi clpg *, *'ff

ire.awU' r*n na,

{yw*yd aofi",tr,nc a,rtuc s*rysyen$oudro

II

tuet ttlter: renewing

Fuel filter: renewing

Xel,i6a I ozo I

Kemovlng

Rernoying

- Srperab .[ hoaaa -t- ton tie furl ,tt!r

- Ronol,c tha !.q/dng chflp bolt {- lhom thc t|cl nfiar- Rdnovrfurt tthr.

X€l,I6o I 0r!6 I

trt t tngXd"i6o I o,Io I

Fitting

- [ifl'f,X9"

t *"'"0 out in the reverse order to romovat, observrng the

The tightening torque for the securing ctip is 5 Nm.

@ rvortAfrar rcplacing (tfring) the fuet tilter, the fuet suppty systom should be Aed

Iuel qellveDt sygtem: ble€ding

Fuel dellvery systam: bloeding

X€1,{6o t a&6 3

sAT 13.8&3 v.A.c 131820

tacLl ioob ||rd roriJro9 lqd9|||.| fi|UttrdA&pbr hed €AT 1349r$g-Adaptor -VAO t3l8n&Rrnob @ntd -VAG 1946/3A"

n ltqulnn .

Futaa rr! OK.Bltb|y vofblr, ,t i.5 V mhimum.Furl FllrF lltry OK.

tt taquanca

Ror|q/! cd|cr lfom futc hotdlrP![ ol,t n !a no. 41 lhom t|! fula cani€r.

lltr€t oertvery system: bleedingXel.i6q 2 qrd 3

*"*##"Tfl?i3Tl-""S911flffi ,51,il;#i

. R€mov€ engine protection together with ar. fitter _a(ows-

i=

i

H5:1:lffJtxl.*" tne breodins v€rve cover from the

/i'. DANGERT

' WJ ! # E :il!:&;!H ;fr#H: ;i t:t"i i." !ii!!,iif f! I#H Iil i !,i!!{; H, *

Fitladapter -VAG i 3.18t2G1- onto adapter _VAG

luel delivery syslem: bleeding

3il#i"i':;9":L ""dockwise' untir the ""rve is

l|3,1[X'g,THfff95J"-:* 1 3 1 0,,0- to the tuel

C-onn€ct,hose b adapter -VAG j 3j6l2o_'_ ano nsertno3e ond in a containgr to collect the fuel, see fgure.Tm_th€-shut-off tap of the adapior -VAG I 3 t Eno_tu ycrocKtyts€

Op€rate.r€mote conbol -VAG 1 348/3A- unttt tuet itowgreg ol air bubbleB from bleed valveTum the cut-off tap anti{lockwigE. until the vatv6 iscompbtety oD9n6d.

I{"_qg ho:g,oj !!g "gepte. _vAG .t31820_.1_ and thenme€laptgr -VAG i 31E/20_ ofi the fu61 di6Mbutor blred€r

Fit engino protecflon togBther with air flterTske rerot€ controt-VAG 134g/3A- ofiwith adaptorcsblor-SAT 1348/3-3- and ins€d tus€ no. 41 In the fuse

.A.c 13,8/2: t_7

\,t . !\ . a: '. 31,8

I€1"i6a 3 qno 3

vpcrEuon ot cfash/fiEl shut-oft€lf6a I ar!6 t

Operation of crash/fuet shut{fi

ffiffi##ffi#FffiffiffiHHS'"At $r r!l||. tkno, hb !y&m Bovldaa bctb, Ardhg pcrli rr'|c.,

trffiffi frffi *,1"r3"*#.i*'* br 2 $condr inl^hcn oprning tha tual lyrbm:Oblan/. labty p|rcau0oo!

- Chapter.

- Chcd(_h. Ftl.t pump ]!hy.Jtt_ _ Vehrcb diagnosis. testing andInrormation system VAS sOSj

tuel punp and fuel system: checkinsXel.i6o I o16 3

Fuel pump and fuel system: checking

v.A.G 1594 C

.citl toolr .nd rc.tlhop €qutphont rrqutr.d

v.A.c 134U3A V.A.G 15278

v.A.G 171 5

12G10015

!

Fuel putrD aad firel syst€Dr: checking

. Ad.dor bld €At ,t348/:tj-

. Tuming tool -t La0OSSA-

. Rcn|olr contot -VAc t3i{&g A-r Volbgo blbr -VAG i527&. Mr.ludng bol lct -VAG 159'iC-r Munm.br -vAG 1?i5-

' Toqua w.toch €AT SOIO-, Prlrtun brbr.VAG 131&' Ad.pbr -VAG 13ttut-

Ad.pbr -VAG 13i6/$Adrpbr -VAO l3t8/1i-Adeiof -VAG 1316/17-Adlptor -VAG l3tE23.Maa!|rrlng conhncrCumnt lb!, dh!.rnr, alrctic.t tult fittdtng .nd frft|g loc.tbnt

-t [qul naota

B.tilry wlblc, ,t I .5 V mlntrum.Fs.r no. 41 , OK.A[ cooqrTtcr drcf|c!, fr. rxmpta: liOhb, h.aild rurwnoqw. lho{ld ba oftIn whii.t wlth air condlirnk! (hratino], thi! mu.t bao|3@nnactr|o.

E€l"i6a 2 ar6 3

t t-t!

@:€:.r ; - - . .

vt6i l f i

I tz0{02 |

r--I

Fuel punp and firl systcm: ch€cking

,{ob

f,rliflrdloig on c|!dt ,trl dtdf - chapteL

E€rJ6c 3 0116 3

t,Vob

Operation and voltage supply: checking

Operation and voltage suppty: checkrng

D"*T.o peiotm these lasks, th.e baftery earth stap must be ren ovec!. To this end,t E necessary to check whelher lhe vehicle has a coded ftdio. lf so, rcfer lothe enti.,thaft cding.

- l\rove reEr goal forward.

- Remove cover fiom fu€l delivery unit und6r rear s€at.

- Sx,itch_on-ignition. Fuel pump mu3t run audjbty (if repeating the test, a owat leagt 10 3€cond3 to pa33).

lf lhe fuol pump doe8 not run:

- Switch ofi ignition.

- Remove covcl ftorn fuse hold6r.

- Pull oul fuse no. 41 ftom thc fule cenior.

- Connect emote controt -VAG .t 346/34- with adaptGr cabte -SAT'| 348/3-3- to cont ct 4t to tuet pump and battory'positive (+).

- OperEt thc acmota controt -VAG i348/3A-.

Fuel pump runs:

- Check activallon ofthe Fuol pump rclay -J17- . vehrc e0,rgnoss leslrng a'rd rnformarron sysrenr VAS 5051.

Fual pump do68 not run:

- Pull4-pin conn.ctor -1- ofifucltank iange-2-.

- Connact multimgler -VAG 1715- with auxiliary csbl6 t om lhomeasuring tool sct -VAG 1594C- b .xterior conlacts ofconnector,

- OpcrEie the remole control-VAG ll4O/3A-

r Sp€cifed valuei approximetcly lhe baflery voltage.

f the specifcation b nol obtained:

- Find where ceble is brokan . CLrrlent llow draorams Etecrfical'd I t , lo .q a,d - , r i lg o.ano-s, end el imineto-fauh,

f the sp€cified value is achieved (voltage suppty OK):

- Posilion rotalion tool -U-4OOss/q- on coupting nul and unaqswfange.

- Check that the eleclricalwires between ffenge and fuet pump ereconnec{ed.

t no open circuit can be found:. Replace fueldelivery unit ' t i : , , .

Xel"i5q I clto I

Uheckrng delivery mte

Checking delivery rate

lost requirsmonts

. Voltage supply for the tuet pump, OK

. l"_!:-t_e]1""ry Fte is measured at 3 bar, thereto,e, beforemeasunng th€.delivery rate it rs necessary to check the fuel systempressure ancl the retaining pressure

Toat rgquonco

- Remove cover from fuse holder.

- Pullout fuse no. 41 fiom the fuse carief- C-onn€ctJemote @nkd _VAG .1348/34- wlh adaptercabE -SAT j 348/3-3- to contact 41 to fuel pump andban€ry positive (+).

ld,iid I a,rd 3

Delach fuetretum pipe -1-, pr6$ing in the coupting keys

WARNINGFud syttam b unalor prarrurcl tloar sateay gtova,.nc. g€saea to awld tnlurynd cont ct urihlkln.,e'ont oFotryl tha aystam ptace a ctoth around thoaonaecuon, .fhan 'g,/lraae piersurg by carfrrrty,unhg fuat hqle ,aom connectton.

Connect adapter -VAG .131g/17_ fo pressure lester andpEc€ adapt€a end in a moasuring conlains.OpeEte the rcmote controt -VAG 1 3ut8l3A- tor sseconds, tjo fi the tuet ftter

Emply measuring container

The^qua-ntity ol tuet detivered by the tuet pump rsoopenoent upon bafiery voltage. Thercfore uemu&rneter -VAG 1715_ should be connected to lhe twoouler pns.on the fuel pump, using themegsuring iool sot-vA\r rcv4u_ (ll|e pump switch remains conneaed).Operate the remote control -VAG 1 348i 3A_ igr 30seconos, and mea$re fuel pump voltage.

Compare the quantity of tuet delivered witfi specific€tion.

I

Checking delivery rate

-"- Minimum delivery cnf/30 seconds

-'.-Voltage in fuel pump with engine ofiand the pumpworking (approx. 2 votts tess than the baflery vottagei.Readout example:

During the test, the tuel pump is measured at 10.5 volis.Wlh this voltage the pump should prcduce a mtntmumdelivery rate of540 c.c./30 s.

lf the minimum detivery rate is not attained:

- Check the tuet pipes to the ftter for possible restriclions(kinks) or blockages.

lftuelpipes are OK:

- Check delivery range before fitter.

Xd"i6c 2 o16 3

Fud sy5Jtem Is unater pr4asurol Woar galoty glovesand gtaases a0 avoial Intury anal contact wtth skln-Bdorc o@ning ths sys.F/m ptace a ctoth.rgund ahoconnecUon, lrran ,l oale pEssuro by cara,futtypultlng fuel hoae from connectton. -

- Pull supply hose -1- off intet to fuel filter, press buttonson hose couplings to do this.

- Connect fuel supply pipe to p.essure lester -VAG 13.18_,usrng adapter -VAG 131 8/1 7-

- Connect adaptor -VAG 131E/1.1-and -VAG t3.t6/1_topressurc tester and place edaptor end in a [€asuring

- Open cut{fi tap on p.ecaure gauge -VAG 13.18_. Thebver then points in the throughfow direction _A_.

- Operate.remote control-VAG 1348/3A-, and slowty closeshut{fftap, unhlprcssu16 gauge -VAG 1318_ showsapprox 3 bar. Frcm this point on do not nove position ofcut-of tap.

- Empty measuring container.

- The quantity of tuet deliver€d by the tuet pump isoepenoent upon battery voltage. Therobre themulttmeter -VAG 1715- shoutd be connected to the twoouter pins on the fuel pump, using themeasunng tool set-VAG 1594C- (the pump switch remains connecled).

- Operate the .emote conkol -VAG 1348/34- for 30s€@nds and measuls fuel pump voltage.

Repeat delivery rate check

'the minimum delivery rate is now atiainod:

Replace tuel filter.

'the minimum delivery rate is again not atbtned:

Remove the tueldelivery unit and check the st€inerflterfor soiling

v.A.G 1318 v.A.G 1318/11

v.A.G 131v.A.G 1318/17

Checking delivery rate

Only when up b now no tault has be€n detected:

- Replace tueldelivery unit .Chi:pter.

f the delivery ratg has beer attained but neverthgtess yoususpect a tuel supply system fautt (e.g. intermitbnt iaitilra ofruer suppty system):

- Check the cur€nt draw of the tuel pump as follovi,s:- Reconnect stt disconngcled fuel pipes.

- Using the cun€nt pinca6. conned the Multimebr _VAGlL]c-.9 91te.or.rte _sleply cabtes of rhe tuet pump(gxrerEr contaclg of the l?ang€ connector).

- Stad engine and run et idling spe€d.

- MeasuG lhe curEnt consumption of thE fu€l pumD.. Sp€cification: E amD mgx.

@ rvor.ff there .is a temptury tuet system tauft, the check can atsoo.-cAnpd out duing a test dtw. with the hdp ot a s@ndo€ato/l-

It the curqnt d€w is exc€€ded:

- Replac€ fusld€liv6ry unit . . i ,,1rr.,,.

Eel,i6o 3 oz16 3

Checking fuel system pressure regulator and residua.l pressure Xe),i6o I o16 2

residual

v.A.G 1318/17v.A.G 1318

v.A.G 131tU!)

Checking fuel system pressure regulator andpressure

Teat requlroments

. Voltage supply for the tuel pump, OK

logt soquenco

- Uncouple supply hose -anow- and collect leaking tuelwith a cloth.

- Insert the pressure tester -VAG 1318- on the suppty hoseusing adapter -VAG I 3'l 8/9- and adapter -VAG 1 318/1 7-,as shown in the illustraton.

- Open cut-ofi tap on pressure geuge -VAG 1318-. Thelever then points in the throughfiow direction -A-.

- Start engino and run at idling speed.

- Measure the fuelprcgsur6.

. Specification: approx. 3 bar.

lf the specific€tion is not obteined:

- Switch offengine.

- Chsck fuelpump non-return valve

- Venfy the fuel pressure aegulator

lfthe specified value is achieved:

- Switch ofiengine.

- Che6k hoses for l6aks and holding pressure, to do thisobserve the fall in pressure in the pressure gauge -VAG1318-. After 10 minutes the pressure should not dropbelow 2.0 bar.

lf the pressore drops belor/ 2 bar:

- Slart engine and run at idling speed until a pressure hasbuilt up ot approx. 3 bar, slop the engine and ctose shut-ofi valve -anow- in the pressure gauge -VAG .131&.

- ObseNe prcssure drop on prGsure gauge -VAG 1318-.

I WARNINoFud systam ls under presgurel Wear salety gtoyosand glastq b avotd tnlury and conbct wtth skln.Eetora oDE,nlng tl'€ syt'F,n ptac. a ctoth arcun t theconnactlon, fhen ralgaso pr9gsuro by carctu ypullng fuol hose ftom conn*tlon.

Checking fuel system pr€ssrrre regulator and residual pressure

After 10 minubs tie prBsure shouH not drop belo$, 2.0oar,

lf the gBssure drcp6 again:

- Chsck pip€ connec-tons, O-fings on tuel dlsftibutor andinjeclors br leaks.

- Ch€ck lhEt t|e press{lr€ bstar -VAG 13'18- and adaptersaro hgnnoticqlly s€aled.

ffi r"oNors nnoving p,Drsue gauge -VAG 131&, Naca a dotharcund the c!,nnedbns to bo loosened.

It th€ pr€saur€ do€a not drop:

- Chrck fuclpump non-Etum valvs 'chapter.

- V6dry th€ fu€l plBEEurB tBgulabr , chapter

LELIia2 ord 2

t

Fuel pressure regulator: checking

Fuel pressure regulator: checking

Check condltlons:

. Check fuel pump non-retum valve is O.K.

Toat aequerce

- Remove cover from fuse holder.

- Pull out fuse no. 41 from the fuse carrier

- Connect remote control -VAG 1348/3A- with set ofcables from measuring tool set -VAG 1 594C- to contact41 to tuel pump and battery positive (+).

.. I waRlvrrvcFud ayafurr ls undor prosaurol Woar sahty gloyesand gla.a$ to ayold lnJury and con.'ca wl h skln.Bofor. opq ng ths tystem place a cloah argund thoconnectton.

':hqt rclaate $oasura by carcfu y

pulthg luel ho^to tom conn€c$on.

- Pull ofi supply hose -1- ofioutlet to tuel filbr, prgssbuttons on hose couplings to do this.

- Connect the pGssure gauge -VAG 1318- to the tuel filterwith the help of the adaptor -VAG ,|3i823- end -VAG1318/17-.

- Close prBssure gauge cut-ofr tap (levsr at right angle todirection of flow -B-.

- Operate the remote conkol -VAG 1348/3A- tor about 10secondg, to fill th€ fuel filter and cr€at€ a pGssure ofaoDrcx. 3 bar.

- Obs€rve pr€ssure drop on pre$ure gauge. After 10minutes the oresaure should not droo below 2.5 bar.

lf the pressure drops again:

- Check that there are no leaks in the pipe connections.

lf no leaks are obseNed in the pipes:

- Renew fuel pressure regulator

Xel.i6q I on6 I

v.A.G 1318

v.A.G 131Ur7

Testing check valve offuel pump Ee)"i6c I oro I

Testing check valve of fuel pump

Telt soquonco

- Remove cover ftom fuse holder.

- Pull out fus€ no. 41 from the fuse carrier

- Connecf remote @nkol-VAG l34g/3A- with adaptercable

-SAT 'l 3481/3-3- b conbct 41 to fuel pump and

battery positive (+).

I WARNINGFuel syatom Is under preg,surut Wear salety grovesan.t gtassat ao avod hjury anct conhct wtah akln-Bato'€ o!nlng tha sygaem ptdce a ctoth atgund dreconnecfion. Tho, /gr€ase prslsrrrq by carutu ypulttng fuel hoso from connacrlon-

Pull off supply hose I - from tuel filter, pr6ss buttons onhose couplings to do thiE.

Connect lh€ pressure 9au9€ -VAG 1316- to the fuet fittervrith the h€tp of the adsptor -vAG 13.18/17_

Connect adaptor -VAG 1318/11- and -VAG 13i8/1_ topres3ur6 tester -VAG 131& and place adaptor end in €measunng contjainer.

Close cut-off tap of the pres6u.e gauge -VAG 1318-(|ever at nght engle to direction offiow_B-).

O!-erate remote @ntrol at shorl intervals untrr a pressureof 3 bar has bujlt up.

,i weawaIt ng€.r of spr.y wh.n oponlng the shut-df tap, halctconblner ovaf the praaure gauge lrce connec on.

. If pressure builds up loo high. lower excess pressur€ bycaretully opening the shut-off tap.

. Observe pressure drop on pressure gauge -VAG 131 g_.After 10 minutes th€ pressure shoutd noadroD betow 2.sbar.

'the pressure droDs further

' Check that th6re are no leaks in the pipe connecrons.

'no leaks are observ€d in the pip€s:

Replace tuel delivery unit

v.A.G 1318 v.A.G 1318/11

v.A.G 1318/17v.A.G 131Ul

Electronic power control (EPC)

Electronic power control (EpC). Operation. Electronic power @nbol (EpC) - ComponenB oveav|ew

Xd,i6o I 0n6 I

Operation

Operation

In the EPC, the throttl€ is not opeEt€d by a control cable ftom theaccelerator. There is no mechanical link between the acceleEtor and t|ethrottle valve.

The accelerator position i9 transmitted to the engine contlol unit by meansof two accelerator position sendsrs (variabl€ resishnces; positjoned in ahousing), connecied to the acc,elerator.

The position of thg accelerator (decided by the driver) is one of the meininput paaameteas to the ongine conlrol unit.

The th.otug is opsrabd over $e complete revolution and lo€d range by aneleclric motor (throttle positioner) in the lhrottle control part.

The throttle valve pogitloner actugt9s the throttlo valve eccording to thecommands it fEcsivcs f1)m the Engins control unit.

Vvith the €ngine ofiand th€ ignition connected, th€ sngin€ @ntrol unitopsratos the throttle positlonsr according to ihe data provided by theacc€lerEtor position 3€nder For sxample, when the accsler€tor i8 prcs8€ddo\rn halt way, th€ throttl€ v9lv9 poEilion€r opens the throtlle valve by 9nsquivalgnt amount, i.e. about halt wgy.

Vvhen the ongino i9 running (End und€.load), the €ngine contEl unit c€nopen and clos€ ths thottlq valve indopsndently of th€ acc€lorator pGition99nO6rS_

Fo. example, h€ ihrottle vslvo mighi al.Bady b€ fully open even thoughthe accolcrator i9 only prg$cd do\m haff way. The advanlag€ of thb ishat lossE8 through botten€cb c€ussd by f|e thottle arg avoidEd.

Afr€r evalugting thg to.que rgquiromenb of varioug aompon6nE (e.9. airconditioning (he6ting), automatlc gearbox, ABS/ESP ), the €ngine contrclunit calculabs lhe optimal th.attle vatue opening angle for the r6Bpectivesihraton.

Thi8 alEo give! va3tly improwd consumption and exhaust emb8ion levsls9t cgrtain load conditiong.

It is incg.roct to b€ll9ve that th6 'E-Ges' is compdsod of ono or twocomponents only. The EPC is I system, whiah b compris€d of allcomoonsntg which haw an Iniugnca. control or monitor th6 poBition ot theth.otd€, s.g. ths accelgrstor p€dsl posnion sender, the throttl€ valvecontrol unit, thg EPC wsming lamp, thg enging conlrol unit...

>s?'i8o I on6 I

Elcctrronic po\rM coltol (EPC) - Compon€nts overvicw

Electonic pow€r control (EpC) - ComponenE overuiewI . &pporl

e Rfi|olring and i0ng- Reo. Gr46

2 - CoonacbrE Blr|( 6+ln

I . Acc.lr{or Fdal Da|ttootrx'.r €t$ ridrcc.L?ator padd loallloo..|xt r -2 €ltac \rlhai r!flrovlng, tllmv!

locn wdl Drobcflorl rndDadalduabr,

q Tedlng -

V€hictediagnosis, t€3ting andinicrmation swlem VAS5051

{ . t0 n

I€.1,{6a t as6 I

r-

Aative aarbon filter system

Active carbon filter systema ODerationo Active ca6on filter system - Componenb overyiew. Checking fueltank breather

Ee]"i6c I q?ro I

Operation

Operation

Depending upon the air pressuG and ambient temperatJre, fuelvapourwill form above the level of fuel in the tiank.

The active c€Ibon filter systern prevents these HC emissions escaping tothe atmosphere.

Fuel vapours pass through a gravity valve (which clos€3 at an angle ol45") located at the highest point in the tank 8nd through a vent valve into theactive carbon filter in limited quantities.

The acliv€ carbon absorbs these vapours likE a sponge.

Wren the car is being driven and the lambda control is aclive (enginewarm), the active carbon filter solenoid valv6 1 (pub€d) -N80-, (al8oknown as regeneEtion valve), is actjvated by the engine contol unitdepgnding upon load and €ngine speed. The opening period depends onthe input signals.

Intiake manifold vacuum draws fre3h airthrough th€ vent opening on th€undErside of the aclive c€rbon filt€r during ths puqing prccedure(regenerating th€ active carbon). The tuelvapour8 8torsd in thE aclivec€rbon 6nd feah ah are tEd to combustion in m€tered quantiti*.

The prEaauE tEbntion valv€ pr€v€nts tuel vapoura trom bsing dr€wn fromlhe tiank wh€n th6 sol€noid valve 1 tg. the Ectiv6 carbon filter (pub€d) -N80- iE open and intake manibld vacuum is pr€8€nt. lt th6r6bre ensuresthat the gvacuation of the aclive ca6on flter has prio.ity.

The Solenoid valv€ 1 fo. the aclive carbon filter (pulsed) -N80- is clos€dwlthout power eupply (for s)€mple the.e is a bnak in the power supply).The aclive carbon flter will not b6 purgod.

I rvoo. the cgnnediona fot tho texribre fubes arE socured using spritu type

dips ot screw dips.. Fuel hoses in the ongine conpattmant must W be secu€d with

spdng tW clips.. Fot ftfting spdng-lype c,ips, it is advisab/e tcusop eB -T20029- ol

rctmtion tool -T20174-.

ObservE g€bty pBcautions

Follow rules for cleanliness . , :. , .'.

t€1,i6d I 0Jr6 I

Active carbon filt€r system - Components overview !d.i6o I czro I

Active carbon filter

t " Vent pipo

system - Components overview

o From thesolenoid valve 1for the active carbon filter(pulsed) -N80- (in theengine compartment)

o Check that it is seatedseclllely

2.10 Nm

3 - Throfrlo vllvg modulo -1338-

o lf the throtde valve controlpart is replaced, the n€wcontrol part must beadapted to the enginecontrolunit ;Functions and compnents:adapting.

o h vehicles fdted with anautomatic gearbox, it isalso necE3sary to adaptthe geabox control unit

. ; Functions 8ndcomponents: adapting

o Testing

,l - Solonold v.lvo I tor rctlvaerbon filter (pul8.d) -NElr.o In engln€ compaftnEnt,

nghto Valve cloged with ignition

switched ofio When the engine iE warm

the valve will b€ activatedfrom th6 engine control unit(pulsed)

5 - Connoctoro black,2 pin

I - Actlvo carbon itrr ry.tom

2

_..-3

Hf,. . y.. .o

5-A. . . - - ' t1-

4 -'-

Tsjj-oosu I

o Location: in right rear wh€el housingo Filled by lhe gravity valve . and the vent vakeq To remove:Remove rear rightwh€€lRemove the rear right wheei housing proteqtion

Remove pipes andRemove bolt and detach tank by bottom part

7 - Vont plpe rvnft pro€sufo rttrntlon v.lvoo From the gravity vatue on the tuel19nko Check that it is seated s€curely

Checking fuel tank breather

Checking fuel tank breathel

Eet',ilo I ord 2

sal lflart EAT ITEO

v.A"c lst

Sprcld ioob md work hop rqutpm t ltqulrad

. Adapbr€AT 136U1., tland pump .SAT 1390-, Vacuum tg3t6r -VAG

.t 368-

I.!t raqulDmant

r lgnilion OFF

frlt aaquanca

- Remo\rE frgm the SolcnoH vslve 1 fti h€ activs c€.bonflt6. (puls€d) -N80-2- ltle v6nt ho€. -1- fiom the activgca6on flter.

- Conn€ct to hose -1- the hand pump -sAT 1360/1- andth-e va@um bat6r -sAT | 390- wing the adaptor -VAG1388-, a8 shown in illustreton.

Checking fuet tank breather

- S€t vacuum t€sbr to -AlB- position.

- Op€.ate hand pump .sAT l3gGseveral times. Vacuummust not build up.

lfa vecuum bulld8 up:

- Check breather connection -3- located on botom of€ctive carbon filter.4- igr soiling; d€en if neceEsary.

lfa vacuum does not build up:

- Temporgrily 8sal breather conneclion -3- and op€.atevacuum pump again !€v€ral limes. A vacuum must buildup.

(Ih€ vacuum cloautB valv€ ot h€ aclivg carbon filts shouldclGe).

lfa vacuum do€s not build up:

- Rensw sc{ivs c€fton filt€r.

1368

Y2

Erooro:-l

'f,Lif,a2 ari 2

Servicing injection system

Servicing injection system. Ci€ncralno@ on Inj€cdon - Chaptera lnj€cdon ryetrm - Componanb owrvlaw - chapter. Inlccdon tylbm - Componcnb ovc l€w

- Chapter

. Intakg maniiold - Componcnt! o/rrylg^, - Chapter

. Fucl Rsllwilh Inl€do€- Comlon€nts o,srvie$, - chapter

. Englnc glad wllh alr n|t!r - Componcnb ovgrvbw ' chaptera Saiety pr€cautlo0E

- chaptef. RulrE for clr€nllncS! J chapter. Trchnlcaldata , chaoter

t€r,i6a I 0r!6 I

f-

General notes on injection

General notes on injection

. The control unit ior lhe tuel injection and ignition sysiem is equippedwith self{iagnosis. Beiore carrying out repairs and fault finding, theiBult memory mu6t be intenogated li\3rl -r. Also, the lo'r, pressurehos€s and conneclions must b€ checked 0nfilhated air).

. The fuel hos€s in the engine comparfnent musl be immobilis€d usingspdng-type qlips. The use of lcrcw of clamp-type clips is notpermiss€ble-

. Beiore disconnec{ing and feconnecling th€ batbry, sl.vitch off theignition. lf this precaution is not taken, the engine control unit may beoamageo.

. For the perbct tunclioning of Eleclrical componenb, a midmumvoltagg gf 11.5 V is n€cessary.

. Do not uso gilicone s€alants. ParticlEs of silacgne dt-awn into the enginewill not b9 bumt in th9 gngine and damage the Lambds prob€s.

. lf the gngine sbrt8, runs br I thort period and then stop8, afrgr iaultfinding, repairs or @mponent iestg, then lhe fault may lie with theimmobilher blocking th€ €ngin€ control unit. Thg fault memory must beinterrogat€d and, it n€c,9ssary the conbol unit matchedFunctions and compon€nt8: adapting

. Cartain t€st8 may l€ad tc a fault being detected by the control unit andsbrgd. Thgr€bre, the tault memory mugt be inte.rogat€d and d€lgted ifn€csasary, afr6r all teEt8 and rspaic have be€n completBd I ' .

. Vehlclog with an airbag ars frtted with s crash tuel shut-otf. Thissyslam reducas tir€ d8k ola vehiclg bumlng in the event ofa crash inthet t|€ tuel pump is swibhed ofi by the tu€lpump r€lay. At the samotime, bctter engine Strarting b schleved. when the door i8 op€n€d, thefuel pump is activatod br 2 B€conds In order to brlild up preSsurs in thetu€l Eystem.

t€?'i6q 1 qn6 I

lnjection system - Components oveNiew .

Injection system - Components overview .

I . Solenold vrlva I ior acuvoc..ior flt r (pul8.d) .N80-

o Activg carbon filter sysbm- Components ov€rview

2 - 3.pln connactolo For engine speed sender -

G28-

3 . Intako mrnliold prrrruroaond.r-GZl- and dr lntakct mp.nturt ..ndar G72-l l : , ' ,

,l - Intrkr mrnliold

5 - Inl.cto6 N30 .., N33o cylinder injec{or 1 -N30-q Cylindor injector 2 -N31-o Cylinder inj€clor 3 -N32-o Cylindor inj€c1or 4 -N33-O i ! ,

I - Knock !.nror | -O6l-o As8€mbly point Cylinder

block, intake sid€o Test ing 1 r i : r ' r , ' l

o Connec{or contact gregold{lated

7 . Englna conbol unltA i . ' r l

I - Thlotlo vrlv. modul. .J338-O i i , , ' r '

o lf the throttle valv6 controlpart is repl€c€d, the n€wconfol part must beadapted to the gnginecontrolunit i i ir ' ' ir '"r 'Funclions and compnenb:adapfng.

o In veh{cle8 fltted wilh an automatic gearbox, it is also n€c€ssary lo adapt th€ gearbox control unitFunctions and componenb: adapting

o Tgstlng . i'i rrLr,i

9 . Englng lp€od $ndor -G28-o Assembly point Cylindor block, intake sideq Testing (:f ?l lr ' i

10 - lgnldon trangtormer +{152-o Wth markings for fte ignidon cables:

. A = cylindef 1

!e)"i6q 1 orlo 2

./ ,2

/ ' t \| \-.1...-- -"' ,// z' i \

/ - l ( ( t ' " . . . ' , i , , )\r: /l + Z,r\ )5 ;,.,i 'u i i i \ . ,7' ls ] i I \ . ' - . . /\ i \ , /

\ " - - l

\-.__._.,' \..__-./ TsJ4-0333l

Injection systen - Compongnts overviaw . >.8\itu2 wd 2

. B = cylinder 2

. C = cylinderS

. D = cylinder 4o ' l tem

I I - Connoctoro For Lambda probe €3$.and Heabr br tambda orobe -219.o 6 pinso Gold plgbd contacts

12 - Erhrutt ga. l|cl]suLdon vrlva .l{18- and podandomatgr for axhrult na ]lchruhdon .G212-E ' ltemq It rgplac€d, adapt the control unit to the exhaust gas recirculation vafue , charrlet Functions and @mponenb:adapting

tA . Coolant tamf|Oratuta a.ndar G62-a Beforg rcmoving, possibly Educ€ cooling sygtcm pregsurro R€i8trance valuss fo. aoolant t6mper9tuB sender €82- , F q

t/t - Hdl .ond.r €aO"o Testing chi)ptr.lo , I0r ! i

15 . Lrmbdr prob. €:tt-, l0 l{mo Location: in sxhault manlblda Rsmove and in8lall with wsnch -U.40080.E Onlygrea86$r€adwlth 'G052i i2A3,,ETKA(eeclronrcpartscataogue).The.G052, l12A3,mustnot

rsach th9 probs body groovsgo In c€9€ of l€ak999, cut oui snd rsplac€ s€aling ring

16 - hmbd. pl!b! dt r c.trMlc conv.rtlr €t3O-, !0 ma Location: in princlpal elslytic convortsrq only grqasc fir€€d with 'G 052 112 A3" ' ETKA (erectronrc parts cataiogue). The .G os2 i 12 A3' must not.€ech ths pDbe body grogvesq Rsmove and insbll wih wr€nch -U-400E0-E In carc of l6aks99, cut out and replac€ s€eling ring

Injection syslem - ComponenLs overview t€),i6o I on6 3

Iniection system - Components overview

I - Plugo Replace gasket if it shows

signs of damage.

2 - Englno gurd whh elrfllte.o Air filter: removing and

fttingq Componenb oveNiew

3 . Condultr guldo

o Clipped ove. tuel rail

4.10 Nm

5 - Blocd valvoo Fueldelivery sysleml

ble€ding

6 - Fugl irll wlth InlqctoEtr Components oveNiew

7-20Nm

8 - ot iho braka loavo

I - Connoctoao Black, 0 contactso For Throttle valve module -

J338-o Connector contracb arg

gold-plated

l0 - lt como! trom Solonoldvalva I tor actlvo ctitonflltrr (pulr.d) -N80-o

ll - Intlk9 mrnltoldo Components overview

12 - Gaakoto Renew

13-l0Nm

lil - lt corte! trom Exh.ult gra6! rocirculatlon valvs -Nt8-o lfs|e controlunitig replaced, adapt the exhaust gas r€circulation valve-N18- ', ::Functionsand

components: adapting

'l 5 - Lambda prgbg aftor c.tatdlc convo,tor €l 30-, 50 Nmo Location: in principal cal,alytic convertero Only grease thr€ad wilh 'G 052 112 A3' , ETKA ie eclron c parts caia ogue). The 'G 052 112 43' must not

reach the probe body grooves

o Redrove and installwith wrendr -U-40080-o In case of leak€ge, cut out and replace sealing ring

29

2A27

2

3

2423

4

5

67

89

10

11

4:;- --tz-.,.-.,

\

-Y -- 13

t4

-FJ.4r18t

lnjection sysiem - CompoDents overview Eel,{ta2 Mn 3

16 - Connoctoro ForLambda p.obe after cablytic converter €1 30- and Heater ior lambda prob€ 1 , after cahlytic converter -229-o Located in a box on th6 floor of the vehicle, covsr with protoclive plate-

o 4 DrnSo Gold conneclor contacl 3

lt . Lambd. prob. G39-, 5{, NmE Location; in €xhawt manibldo Remove and install with wrench -U-40080-o Only greas€ hrsad with'G 052 112A3',ETKA(eectronicpartscatalogue).The"G052'112A3'rnustnot

reach the prcbe body grooveso In case of leakage, clrt out and r€plece sealing ring

tE - Connacloro For Lambda prob€ €39-and Heater ior lambda prob€ -Z19-o 6 -oin l l t ' r i

o Gold Dlated contacls

l9 - Enllna.p!od !.ndor €28.o Fittlng location lir','o T$ting al i ' 'o gEfors rsmoving, remove intake manitold ', ,1

2t -5Nm2l . O.rlng

o Ronew

22 . Clloa Chgck that ii i8 s€at€d 8€cut€ly

2:l - Conn ctoro For Coolant temperahrre 8€nd9r -G62-o 2-pin, gold coloured

2,1- Coollnt tampc.atur! randar €62-o Bsiors removlng, possibly r€duc€ cooling systEm pG38ur€q Registanca v.lues fur coolant tempsrature sgnder 462- | r

23 - Plugo Bgbre rgmoving, possibly reduce cooling 8y8tem plgssure

26 - O-rlngo REnew

27-10Nm

28 " Thormoctrt hourlng

29 - Supply hor.o Black, with white marko lmmobilis€ wilh spring clipsa Check ihat it is seated secur€lyo F t tu"l flbt '

'" '"'30 - Conncctor

Injection system - Compon€Dts ovsrview f€ 6a3or63

o Fof q€lnr conbol unito Only dhconnrd or conn€d wilh lgnlto.r !fl,ibhad oft

3l . Enlln codrol mltOn npLcamni, tha coartol unit rrult ba mfrfFd b tha oLci,onlc lmrpblltscr j Chaptet Functoru andco[pon6t!: adlptng

12.3upFftq For anghc confol unlt

!t - 2 l{il

r

Intake manifold - Comoonents overview

Intake manifold - Components overview

1 . Throttle valvs modulo .J33E"tr lf the throttle valve control

part is replaced, the newcontrol part must beadapted to the engineCOntrOlunit I r,:: r. i. ' ;Functiong and compnents:adapting.

o In vehicles fitted with anaubmatic gearbor, it isalso necegsary to adaptthe geabox control unit

. .,.,,,,. ,,; Functions andcomponents: adeptin9

o Tesling ', . ' i ,r,

2.10 Nm

3 . Grlkctq Not the instrallalion positiono Renew

4 - Intrrmodlato flrngo

llj ^ro6eln engines Mh @dos AUB,BBZthe intermediate f,ange iEen integral peft d the intakemanifold

5 . O-.lngo Replace if damaged

8.20Nm

t . Gr.ketq Renew

I - Gulde phto Note installation po3itionq Replace ifdamaged

I . O.rlngo Replace if damaged

l0 .3 Nm

Eel.t6o I o116 I

I I . lnLko m.nifold Orliurr .cndor .G7l . wllh 9ir Intakg tomperature tandor Gl2-o Resistanca values of th€ htake air t€moerature sender €42- I l

12 - Inirka manlfoldo Injection system - Componenb oveNiew (l'_.i'l.r

3

5

6

l-N24n46€ I

Fuel Rail with injectors- Components overview

Fuel Rail with injectors- Components overviewI - Supply ho..

o Black, with whits ma*o lmmobilie€ with spring dipso Ch€ck that it ie sested

g€CUrgtyq From tu6lfilter , lem

2-10Nm

3 - Furl l|llo Jet proJeclion lr€99 and

seal: Checking . a h.rnrero Removing snd insblling

, Chapter

a - BLcd vrlv.o Fuel dclivsry sygt€m:

bleeding , Chapter

t . Socurlng cllpo Ensur! s6at€d conrcfly at

lnj€c,tor and fuel rEilo ReplEce if dernagod

0 - O.rlngo Ran€wo Bebrs insblltng mobt€n

with clc€n engine oll

7 . InlactoE N30 .., Ntto Cylinder Injeclor 1 .N30-o Cylindsr inisctor 2 -N3.t-o Cylindsr Inj€ctor g -N32-o Cyllnd6r injsctor 4 -N33-o Rcd8bnc€ 12...17 O.

!el,i6o I oro I

5/

4

5

6

7

6

fN2l;4671

tngrne guard with air filter - Componen6 o\ervrew

Engine guard with air filter _ Components overviewI - Airclear6r uppcr part

2 . Ring garketo Not the installation positiono Replace ifdamaged

3 - Flltor cerbtdggo Removing and insta ing

4 - Air clcaner lower pa,t

5 . Rubbor support

S-3Nmo Obs€rve not€s on

insta ation

7 . Rlng gslketo Not the inEta ation positiono Replac€ if damaged

8 - htske ho6g wlth contrct i.pa Checking iniake air

preneating

I . Cover

aatatlnco valuc! for Cootant tgmperatur9 londor.c62"16 olagram is divided into two temperaturc rang€srA - frcm 0...50 "CB - from 50..0.105 "C

(amples:

fT..c;";Xpno" n

"no -reaponds to a resisrance of

!91" i"# onn"

" "nO "oresponds to a resistance of

T-, 6

3

2 6

f NZ4r 46tl

Xd.i8a I oni 2

tngme guard with air filter - Conponenrs overvrew

lnld.nc. v.tu.! ot thr Intrko .tr bmpor.tu'! !.ndo,

lhe diag.am iE divided into two temperature rangs8:A - from 0...50 .CB - f.om S0..O.1OS.C

:x9mp|€3l

!{c;";1ono" n

"nc *nesponds to a rBsisrancs or

80oC b i ange B and cor$ponds to a rosistanca of

It),i6a2 an6 2

aaoo

.00

to0

!00

t@

aoo

a@

2!O

1!t

ko9

a

z

100

too,fr

!00

lao

a!o

lott

imo

100

rxwr caxmcge: rgmoval and ass€mbly

Filter cartridge: removal and assemblvRt rovlng

- Remove engine prot€ction Iogether yi,ith air filbr €nows_

- Separate exhaust breather pipe from engine_- 5,'il)?'i"i:'s ffi'fi y#ff;ff xg";' "'*". u'"'"n,Fittlng

- $3ilT;-jff :#lit;i ffiT;""#;'" **,*! ror"'W####ffi",

{#_"wnaximum rcvolutions ot {rltcwdiwt, 2OOnn.naximun tightaning toeue 3 Nm.

X€l,i6q I 0n6 I

Safety precautions

.4rcry preqtutrons

./l'. cautlon

Xe),i6a I quro 3

,11,1:l::lllty,,:" g leEons and/or damage to rhe tuet injeclion andrgnruon syst6m, the foltowing must be noteol

trttrJjT,i"sl,F$$"*{i',"*Yi#ii13""r1""i :ff""i"!'#ilffi the ienition cabres with the

au?"""il,it'l"j1T;J:?,["J,f*Fgff fl ]ffi 'si"T.,

w# :,{!ffi.i: ffi f,i#l i!:i,! i ;: {"

W!#i#"iiW###;#i,ffi7:Y#:#*'"*rance ror att movtt E or hot

)t€ th6 following if testeB and measuaing insrum€nts haveoe used du.ing e rosd t€st: -

Tg^sters and measuring insLumgnis must atways b6fi"#r^i"i"9iff". *"t and operated by a 2nd person

e$ and measudng instrum€nts are operatod ftom hoht$engers seat and the vehicle is invdlved in sn accident,'#ffHg!1Ji,lili,ffit courd be seriousr', injured

X*;ngn'n" '" to o" ,urned at starter speed wirhout

R€move engine protjeclion togethgr with air filter .arrows-

lhe cod. AUB

Sal'ety precautions

- Remove the 4+in connector from the lgnitiontGnsformer -N1 52--arrow--

Englno codo lotel! BBY, BAZ, BKY

- Remove the 4-pin connectors -aftowg- fiom th6 ignitiontransformeB.

Conlinuod for all vohlcle.

Ee?rido 2 oz6 3

^-

- Remove fuse 25 hom the tuse box.

Safety precautionsXd,i6o 3 oro 3

S rvo'-Removinginlectots.

tusa 25 interrupts the wttage suppty to the

Kutes tor cleanlin€ssX€t tda I ors6 I

Rules for cleanlinessFor uo.t on the fust supw 3y!tgm, the bltofling.s rut€8, nuet be

. mt*"?:"

,t unton! end tha adient *.as befor€. Placo rqno\r€d parb on . dean surfaca and co\,!r_ Us€ lint fe6 clolhslt

orlT#l|ff.ti"' *l oprn componcib ir r'pai. cannot be oaniJ

'3ilY.lgm#ffiTml:ff ',,",.$flr#f"ff f"s,iff$",,' x"ifiilH',iL,ffli11fl,,trft"g1trffitr#,$"."n o.

r

r sluDcal qata

Xel.i6c I qr!6 I

Technical data

ldling spe€d chsckldling 1/min

r ETKA (etectronic parts catatogue)

hom sppfox. S7O0 fom approx. 6600

Engln€ contol unitSp€r€pen no.:

, i,{ot aditr.i.bt

SpecOlimiblion

f-

Checking components

Checking components. Throttle valve conkol unit -J338-t verifcation . i ' : ' ,. Injectors N30... N33: verification. Jet projection imsge and sealr checking. Checking intake air preheating. Engine speed sender -C2E-: verification

l^e).i6o I olo I

Thrcttle valve control unitJ338: verification

Throttle valve control unit J338-: verification

Sp!3hl toob rnd workrhop cqutpm.nt |tqutrud

I Hsnd h€ld multimeter.VAG 15268. or muttir€t€r -VAG 17iS-. Msasuring tools€t 'VAG 1594C.. Tester -VAG 1598/31-. Current llow diagram8, €l€clrical fault fnding and fitting locations

S rott. lf lhe throtda vatue @n|ol patt is replacad, the new @1W paft must

bo sdapted to the eryino @rttgl unit . a hdplec Functions aN@Wnents: adspting.

. ln vehid.s frfied with an automatic geafto& it is also rocossary toddapt the gaaftOx @nfuOl unit . Ct 1p'pr Funlti'tls anct @mponenb:a.taptirg.

Talt |tqulltmenb

!s?'i6a I qE6 3

v.A.G 1526 E v.A.G 1504 C

v.a.G 1598 |r

1?o:19Q1

r ororue vatve coot ol turitj33g: verificarron

. Thfottle neither damaged nor dirty.

. Coolant ternperature, gO "C minimum.lort rcquonco

- Remove engine probction together with a,r ftte.

Xeli6c 2 oa6 3

-arows.

Pull 6-pin connecior off throtte valve conlro, unit €r.gw_.Meesurg th+e throtfle valve driv€ r€3ist6nc€ between

Specification: .1.0... S,O ehe specification is not obt€ined:Replace the throtfle valve control unit -J338-.

he specified value i6 achi€vedlChect,vottag€ suppty of thrctfle vatve control unit andwlnng lo conhol unit r h L

rere are no faults in the voltage supply or wiring:Replace the engine controt unit ..r ,jr i, .

llrottle valve control unitJ33g: verificafion Ic,)'l6c 3 ar6 3

6.. i '

r

vnEr&llB volErge supply and wiring to control unit

Checking voltage supply and wiring toTg3t ,squi|bmont8

. Battety vott€ge at teast ''1.5 V.Tgsl sgquence

- Pull 6-pin connector off throt{e valve @nrot unit _arow-.

9:.11:5lJ!1l3ld_ !9ld 'urtimeter _vAG 15268_ or

IiIiHS,l -Yi9-l il9; to.pins 2 + 6 of ihe connector br

Switch on ignition.

Specjfication | 4.5 V minimum.Switch off igni on.

3i,ilt,lH#,,jffi,:: ro measure vorraee to conrad 2Switch on ignition.

Specificalion: 4.5 V minimum.

Switch ofi ignition.

le specification is not obbinedi

v(,nnecr Egrer _VAG i 598/31- tro conkot unit cablend|ress! wlnout @nnee{ing enginG control un|t,

!e).i6q I ond 3

control unit

\ necKtng vottrage supply and wiring to control unit

fl,e;!f :?fl,s.fi Bffir6 tesrer -vAG

llSltlol8lly.check wiros for shods ro one another, rio vehtcle earth or roDanery posttive.

Specification: . O

l wiring fautt is detectedl

check engine control unit voltage supply . veh cte dragnosrs leslrng

!

Iel,l6o 2 czto 3

5

JTi,r.t-lConnecllon Fcrnete roc*er vAG ridii

1

2:

i117

uI 118

9lwrae resistanc€: Max. 1.5 O

Checking voltage supply and wiring to control unit

an0 rntorrfatcn systenr VAS 505j.

le?,idc 3 oro 3

Injectors N30 ... N33: verification

V.A.G 1526 B V.A.G 1527 B

v.A.G 1594 C v.A.G 1598t31

v.A.G t7r5

124-10002

InjectoN N30 ... N33: verification

SpocLl tool. .nd wo*ahop.qulpm.nt Fqulrod

le),i6a t oro 2

Injectors N30... N33: verification

. Hand hetd multim6ter _VAG 15268- or huttimeto. _VAG .t 715F

. Voltage tester .VAG 15278-

. Measuring tootset -vAG 1594c-r Tesier -VAG 1598/31-. Currenl flow diagramg, electrical fault fino|ng and fittihg locataons

>E)\i6(I2 Mb 2

vuwlrry gtrelglsmg

Renove angina prctrdton b$tiar wtth 8ir fitt!| -smtv!.

ngln. aod. AUB

lffig:-f&ffi r.m hc renitrondn. co(h h|b|| BBy, BBZ, Bl(Y

l€lf6o I a,i6 4

Checking energisingTad ||qulran|n|lr. Fule no.29, OX.'

"1?fi.iiggg;ptrnt (s6rrtox brrr hou!rn!)

. Ea.lh connrcdon in phoum crEmbar OK. B8tbry voltogc, 11.5 V n{nlmurn' 5,Yn'ff"m,fnH,?f;X}iffT,"?X"llii"*.,' flihflfi',#*;ffS(trc*' v€hicre diasnosis,r Fuotpump llby OKfrat raquanca

#ff#--HHH##Hr-_IB+#

=FF

i= '!!+t==-==-*-==

,____--======::Ii%

Checking energising

- Remove the 4-pin connectors from the ignitiontransfrcrmers -anows--

Conflnugd ior all vohiclo3

- Pull terminal connectors €nows- off injectorg.

Connect voltage tester -VAG 1 5278- with auxiliarycables hom the measuing toolset -VAG 1594C-

le).i6o 2 trr6 4

Checking energising

between cylinder 1 @nnector pins.

- Activate starier motor and check the voltage supply tocyl. 1 injector. The LED should llght up.

- Repeat check at the injec{or connectors for Cyls. 2 ... 4.

- Switch off ignition.

lfthe LED does not light up on any cylinder

- Connect diode t6st lamp io Cyl. 1conn€dor, contact 1and earth. The LED must light.

- Repeat check at the injector connectors br Cyls. 2 ... 4.

lfthe LED does not light up:

- Switch off ignition.

- Check wir€ betw€en 2-pin conn€clor contact 1 and tuelpump relay -J17-br open circuit uEing curr€nt lloworaglam.

. Wre resisiance: MEx. 1.5 n

lf the LED do€s not light up on ons or sEveral cylindersl

- Conneqt tester -VAG '159881- to control unit cableharness, without @nnectin! engine conlrol unit.

- Check wiring between test box and 2 pin injestorconnectoG (to @ntrol unit) for open circuit according to

Iel.i6o 3 o16 4

Checking energising t*),ita 4 an6 4

curent flow diSgtam.

- Addltlonally check wir$ ior Ehort !o ono anothsr.

. Specilication: - O.

- Check wiring bqtwrsn conn€clor cgntiqb 1 gf Injsclo.s br opgn ai.c1|itio one enothgr,

I Wl9 regbtance: Max. 1.5 O

Connactlon F.m.L rockrr VAG ltg8,3t

Injoclor 1, conbcl2 96Injector 2, contacl 2Injeclor 3, contaci 2 68Injeclor 4, conbqt 2 to

Wt9 r$isbnc€: Max. 1.5 O

lnj€ctor rcsistence: che€king

Injector resistence; checking

T6!t loquanco

- Check tesi6tance ot injectors betwgen contacb.

. Sp€cification: 14... 17 O

[.jll tvo.oThe reeidance value ls valkt for awrcx. 20 "C. Resistanaevalue incrcas€,s with highar tedparatures approx. 4 ... I A.

lf lho spscificaton ie not obtainodl

- Renew d€f€ctive inj€ctor .lfc'll.

Ingbllaton of thg Inj€c{ors is cafli€d out in th€ reverse ord6rto rgmoval, obs€rvlng the blkrring:

. Ren€w O-ring8 on all Injector8 and lightly moigten wificle€n Englng oil.

. hssrl injeclora veffc€lv and in the conect po8itlon inbthe tuel rail and t€cure wih retaining clips.

. Fit tuel rall ta the cllindsr head wlih all f|e inledolscon€c{y pleccd and bolt unlformly.

Eel"iic I s?ro I

Jet projection image and seal: checking

sAT 8010 v.A.G 1594 C

v.A.G 1630

\W

124- 10003

Jet projection image and seal: checking t€)"iio I oro 3

Spoclal toola and workahop equipmant roquiied

Jet projection image and seal: checking

Pull2-pin connecior off coolanl tempoEturo sender -G€2-

Connectthe digital potentiomoter -VAG 1630- to pins 1 + 2of connector, uring auxilaary cables from measuring lools€t-VAG 1594C-, Bnd adjusl the side connected to 15 kO.

Unclip the wiring harness for the injectors from intakemanifold and thormoglat housing.

Remove fuel tailcomplete rvith all injectoB from cylinderhead (fuel hoses romain connecled)

Xe?'i6o 2 on6 3

. Torqle wrench -SAT 8010-

. Measuring tool set -VAG 1594C-

. Digital potentiometer -VAG 1630-a Measuring conlainer

Teat lcquircments

. The fuel pressure must be in order, checking

Toat aoquonco

- Remove engin€ protgction together with air filter -arows-.

Jet projecrion imagc and seal: checking

- Hold a Bmall contrainer under the injector to be chocked andpull connocloE ofi all oth€r injectors.

- Havo 2nd pgroon opeaate starter. Injector musl sprey inpuls6s.

- Ropsat check wiih other injeclor3 ensuring that the injeclorio be chock6d is the only onc @nn6ct€d.

- Th€n check injectorg for loaks. No mora than 2 dropdminmay leak out.

lf lhe fuel los3 is grestgr:

- Srvitch off ignition.

- R6new defeclivo inlector

In8tallation ot the injec,torg i! carri€d out in the revers€ order toremoval, obsorving the tollowing:

. R6n6w O-rings on all Injectors and lightly moisten wilhcl€an ongino oil.

a Inserl injoctors venic€lly and in the conect poailion into thefuel rail and securo with retaining clips.

. Fit fuel rail to th6 cylinder head with all the injoclorscarrec{ly placed and bolt uniformly.

Xe),i6o 3 o16 3

V.A,G

Checking intake air preheating

Checking intake air preheating

Spdclal toob and worl(lhop €qulpmrnt lrqulttd

. Chilling spray (commercially available)

To.t lgqognce

- Remove air intake hose trom air flter.

- Check confol flap pogition I -.

. Above +23 oC fiag must clgse wa.m air cgnnection

. B€low +10 rc fraD oDens wam ak @nnection

B "ottThe wvrking of thg heat defiBnt .2- may easily be checkedapplying a conwnttumal codant spfty.

Is?.{60 1 cz6 I

Engine speed senderc2S: verifi cation Xel.i6a I s?ro 3

Engine speed sender €28-: verificationThe engine sp€ed 86nde. €28-is a sp€od and rgfsrsnce mark s€nd€r. lf th€.e i9 no 6p€€d signal, ths gnging will not stari. lfthe gpe€d 8lgn6l failg whsn the engins i8 running, th€ engine stall8.

v.A.G r 5:It 3 v.ac I se4 c

v.A.G r5eull

I !?qq!-s'r

Sp.cblloob rnd rcrl(thop rqulp|n.nt r.qulEd

. Hand h6ld mullimetsr -VAG 15288- or multlrnobr -VAG 1715-

. Measudng tool sat -VAG 1594C-

. Tester -VAG l599/31-

. Cu.lent llow diagremg, ebctrical ftult indlng and ftting locationr

Ioat r!qul|t|mr$!

. Battery vohage, 11.5 V minimum

Ttat $quanct

- R€rnove engine prol€clion bgethor with air filter -anows-

u-

Engine speed serderc28: verification

Disconnect the 3-pin connector to the engine spe€dsender -6rrow- (in the intake manifold, to the dght).

- Connect hand held multimeter -VAG 15268- ormulhmeter -VAG 171s-to measure voltage using aux.cableg from measu ng tool set -VAG 15g4o-to contacts1 (positive) and 3 (earth) on engine speed s€nder@nnector.

- Switch on ignition.

. Specification: 4.5 V minimum.

- Switch offignition.

lf no voltage is present:

Connect tester -VAG 1598/3'l- to conhol unit cablehamess, without connecting engine control unit-

Xe),i6o 2 ozro 3

Engine speed sendefi 28: verification

Check the cables betwe€n the tggt box and the 3-pinconneclor plab br an opEn circult frcllovi/ing the currentcircuits diagram.

t€i'i6(r 3 ono 3

- Additionally check wires for short to one another.

. Soecification: -

O

lf no fault is bund in wiring €nd there is vott€ge between contacts '1+3:

- Rqplac€ the engine speed send€r -G28. . ll.,r'r.

lf no tault is found in wiring and there is no voltage between coniacts 1+3i

- Replace the engine conholunit

Conngctlon Fomdo lock t VAG l508r3l

1 872

3 10E

lryire rEsistancei Max. 1.5 O

Engine contml unit

Engine control unit. Engine conlrol unit Roplacement cl.-Dl.f. Adapting tunctions and @mponents ilr;ri.]i.;fI Intenogaling and erasing ehgin€ cohtrol unit fault menlary ' .i :pic

le),i6c I oro I

- Switch ofr ignition.

- Release conneclors for control unit and pull off-

Engine control unit: Replaaemerf

Engine control unit: Replacement

Removlng

- First pint out or memorise the control unit identification and also theprevious conhol uflil @ding . .. .rr t r.

t€1,[60 I on6 I

l-to3s'l

- Separate the bracket lugs -anow A. and remove th6engine control unit fiom the Engine fonvards €r.ow 8-.

Fltting

- Place the new control unit into the retaining frame.

- In8t€llcontrol unitconn€cto. and lock.

- Check th€ previous ooding and adjust the n€w controlunit VehLcle d agnosrs leslngand nforl1ratron systernVAS 505 T,

- Finally, inte.rogate thg fault memory of the new engine@ntrol unit and eras€ the iault memory it nocessary.

- Take vehicle for a le3t drive.

- IntenogatB the new control unit fault memory again.

Adaptiry functions and components

Adapting functions and components

Spsclal toob md work*op aquiprnant requirld

. Central diagnosis -VAS 505'l-

r. .4i:; : lr: I

lE;ir36-']

vAs 5051/5A

w00-r0104

t6l.l3o I on6 2

. 3m. cable -VAS 5051/5A- or 5m. cable -VAS 5051/64-

Wolk laqutnca

- Conn€ct the central diagnGis -VAS 505't - with lhe 3m.cable -VAS 5051/54. or 5m. cable -VAS 50516A-.

- Select tunclion "guided fault finding' in the vehiclediagn$is testing and infcrmation syEtem -VAS 5051/-

Onc€ allcontrol units have b6en interDgat€d:

- Pre$'Go to' key.

- Select'Function/component s€lec{ion'.

- "Selec{ engine'.

- Select'Engin€ cod€'.

' Select'01 - Systems c€pable of self{iagnosis".

- Select 'Engine management.

Adapting finctions and c.omponents

Selecl 'Funcdons'.

Sslsct 'Functon or componanf.

EeLltu 2 attd 2

lntenogating and erasing engine control unit fault memory

Interrogating and erasing engine control unit fault

Eel"i6q I crrt6 2

memorySpschl logh .nd wodGhop equlpmont

'oqullod. Cenkal diagnosis -VAS 505'l-

. 3m. cable -VAS 5051,/54- or 5m. cable -VAS 5051/64.

Woat laquencc

' r . 'A:.1 : i 1r: I

tffit

vAs 5051/5A

w0-10194

- ConnEctthe centraldiagnGb -VAS 5051- wilh the 3m.cable.VAS 5051/6A- or 5m. cable -VAS 5051/6A-.

- Start engine and run at idling speed.

Only when engino do6s not start:

- Switch on ignition.

- Brigiy presg th€ key "vehicle self diagnGis".

lnterrogatiDg and erasiog engine contlol unit fault memory

lndlc€ffofl or - VAS 5051 -:

- S€l6ct v6hicls systcm '01 - Engln€ €leclronhs' ln menu -

- Wbit until th" bllowine b dllplaysd.

lndlcation on - VAS 5051 .:

- Selrct tunctlon '02 - Iniarogaig i.ult memory'.

- lf no hult is 3torsd in englno contol unlt '0 fault(s)debcted' i8 dlrplaysd.

- lf iaultS havc b€qn rucoded in the englng control unit,thls is disphy€d on the sqren.

- Prs8s tho E key.

- S€l€cl functon '05 - Erase fault m!rDry'.

- Pr€€s tuncdon 'oGEnd outsuf.

2eLl6{,2 onn 2

Y'6 t ' l tu l l -

ffi

nrs

I

{ l i * l n ls l l -

I

R€noving and installing pads ofexharst system

Removing and installing parts of exhaustsystem

t€fi6a I qn6 I

t

! ,vro.A{ts lnr,€Mtloo wot < dt lto orAard lral€rfr, .Sdd eb nw& btEhn hal lrfor€ ,ll no lCrairs eN that thcta b stiIf/rot *!€//€]tloilfto.n tha W. lt t'€,c,l!c/',f, lo,tr,', (htM aN dMb darrF anddlgn dlencFir aN axhaugf pllp s th,/ aikffi oblr"rca ler'€ln|€lnrd to tha NWot < aN tha Eup@/ls an avaly Mled.Feproca serf.lock lg ru6.

Edraud mrnfibld, ltani axhn t pFa wlh cetrlyfic @rwrlbr $!d!cc.a|ori!!: Componat! onarrlOr, .- ChapterSlllncar wl0l Nr!.mlcn dcntdtr - Congomntr olqMcw - chapter

Exhaust manifold, fiont exhaust pip€ with catalytic conveder and accesso.igs: Components ove... l€l,160 I o1t6 2

Exhaust manifold, frontComponents overview

t - Wam alr coll€ctor date

2.10 Nm

exhaust pipe with catalytic converter and accessories:

o Follow the corecttightening order I -.

3 - ,10 Nm

4 - Supportq S€cured to cylinder block

5 - Exh.urt mlnllold wlth bulltin prs{atalytlc convlrtgr

6 - Grtkoto Renew

7 - Lock nut, 25 Nmo Renew

I - l,.rmbdr probo €39-, 50 Nmo Location: in exhaust

manifcldo Rgmove and install with

wrench -U-40080-o Only gr€a99 thread wilh "G

052 J12 A3' ' ETKA(eleclronic partscatalogue). The 'G 052112 A3" mugt not.egch thgprobe body grooveo

a In ca86 ofleakage, aut outand replace s€sling dng

t - Conn.ctoto For Lambda prob€ -Gsg-

and Heaterbrlsmbdaprobe -Z l9-

o 6{ in l ,

o Gold plated contacts

10 - Connsctole ForLambdaprobeafrcrcatalyticmnv.6r-G130-andH6aterforlambdaprobe1,aftercstalyticconvener-z29-o Located in a box on the fioor of the vehicl€, cover with protective plate.

o 4 prns

o Gold connectof contact 3

ll . Ltlr|bdi .frot c.talytlc convg.tor Gt3lt- 50 Nmq Location: in principai catalytic convertero Only grqgs€ thread with "G 052 112 43" - ETKA leleckon c parts catalogLre). The 'G 052 112 43' must not

reach the prob€ body groovesq Flemove and install with wrench -U-40080-E In case of leakage, cut out and replace se€ling ring

" ,z- \ . . ' ' -7lN.--" - 8

/ 1j." *1 ,-11011

--12r,13

18

' .atar)F('

: l

14

I N26-048ii I

' ' t ' .- -

Exha$t mardfold, front exbaust piF with catalytic conveftr atld ac€€ssories: Componenls ovc.., h lfu2 odt6 2

l2-Doutachmp

13.To lnt 'mrd||t.

lllrnc.r

la -21 m

13 - Fioit axhturt hrba u h catdytc coiyada.q Not! p€rt number + ETKA (elect.onic parls catalogue)

ll .s.curlo! rlngo Roplaca if demagcd

l7 -40 Nnq Rene

lE - Grrtdq Rqn6w

tlghtanlnl aaqo c. wrnn d. colLcbr dab to arh|rdmanllold

1 - Trghbn bolt -1- b hc bNuo of l0 Nm.2 - Iighbn bolt -2- b ttr6 brquo of l0 Nm.3 - Ilohbn bolt -3. b 0ro b|qu€ ol l0 Nm.

1

tffil

r-

Silenc,er with susoension glements - ComDonents overview Xe)"i6o I oro 2

Silencer with suspension elements - Components overviewI - Front llloncaa ' Note

a Fit without tErclon

2 - 25 l{m

3 - irounilngo Be 8ur€ tc fit in conect

poaltiono Replac€ if dar€gEd

,t . Cuidno locrtlon , Noteo Markad by lmpEssions on

connec'ting pipe

5 . Rs|l rlloncr ' Notea Fit wihout tsnsion

3{ 3I

1) A! ll|nd|'d, lh. ilnt .nd €ar dlancao .|! | .lnglr cornponcnl. Wnan tlpaldng. lhaLonl rnd |!ar llloncarr a|t auppliad individualt wli a doubL cLmp for c.iirctlng!ot.lh.r Cd ln. co.Dcllon lub. p.D.r$ioi.r ln lhc cunhg bc{ion, 'tenr! wlh lh!pli.r! -U-4O079 F!

goprn0no polnt on .xh.utt plpc

- Cut the sxhaust pip€ p€rp€ndiqrlady in th€ cuttlnglocation,shown by th€ aroyt, -2.; u8€ the -U-40075-.

- V\trgn installing double r€pair damp-4. placa botweensids rnaftings anor/s-l - and .3..

. Tightening tcrqu€: 25 Nm

Silencer with susDemion elemen& - ComDonents overview f*Ltu2a162

4r=L: - : \ i @,rf

>\:,i7^ \I (b.rR

Exhaust gas r€circulalion system

Exhaust gas recirculation system

t€,'l6q I o?t6 I

ffi ro.

a

me eqtrp @nt/ol unt E |r$onsDb tu actrvatirg the oxhaust gaat&tvllatloo Efrfon vla tha exhaur{ gas Bdranhbn valw .tt1&,Tho exhauff gas tdtculaion vefue +'11& wfrh @tD dtao€d dunwrcnsan"c ttat vatous croas radlmd Wnhgg are N$M at d lenntplunger Blts.mmks b &Wd a('dvatlon, th€ valva nry b€ novB<t b tny ,ogil*m,V|ll€never exlnur' W t"{lJ/r{latk},t vdw ls rdad, 8dapt tt|6oteit'€ drtd unit b tlrd exhau{, 988 Edrwlatbt whtc - chapteqFur/kms nd cpr,n'pt'pr'']b edcpltng.

ExhtuEt 948 .EdGul€{on rylbm - Componotr owrvlcw - chapter

Exhaust gas recirculation system - Components overview Eel.t6q I 0116 I

Exhaust gas recirculation system - Componentsovervlew

I rvor.. This owNbw ol the conponents ls tot all engines, the pafticular leatuos ot

each notor will be atealt with latar. In engineswilh co<les BKY and BBZ, the intermcdiato flango ,,

" isanlntegrAl paft of the in.tako manifold

. In aogines wilh codes BBY manulactued ftom 05n003lho intotmealiatoflange tt rlt is an integlsl pdn o, the intake hantfold

. Whout exhaust gas rcclculalion for engines wllh codo BKY, manulaclufta!hon 0t2@5

1"10} lm

2 - Throid. v!lv. modul. -1338.

o lf the thlottle valve controlpartisroplacad, the nerf control paft mustb. sdapiod to the engine conlrolunit :. .ri '. ; Function3 andcompnents: aaleptng.

o In vahicl$ ffll6d with an automaticg6irbox, il is also nec6aary toadept lhe ggarbor control unil' , ,; Functiotu endcomponcnb: Edepling

o Tclting , ,,

3. Gr'k to Not th. installation posltlono Rencw

a - Ol tfia Solonold vrlve 'l for actlvec.rbon filt r (pul!.d'.110.

5 . Ad.pto.o Bawtcen thc Solcnoid valva I for

active celbon till.r (pulrod) -N8Gand the cylinder hcad

0'20Nfi

7- 10 Nm

I "10Im

I ' Conn.Gdng plpc

l0 - Flltor

ll . Erhruat g|l |rclrcul.llon v.lvg .I40.and Pot nfofirt r to. exh.ualga. raclrculafon .G212-

o lf replacod, adapt tho confol unil to the exhauat gas recirculation valve rf !,,, i; Funclionb and componenb: adapting

12 -O" ngo Replace il damaged

13 - lnto|moallate iango

?F - - -1

13

12

3

11

3

f( .

*

6

Ignition system: repairing

lgnition system: repairing. lgnltion rydom gcneral Inlbflraibn + Chaptera lgnltbn lyligm . Co|nponrnb oyrM6r, - Chapter. S€fty prgcau0ons

- Chapter

. Sp€ft plug irlt dats - Chapter

. Hall Eandd .G40,: dEcldng - Chapter

. lgn on trandbfirr +{152-: draddng - Chapterr lgnltton coils wi0t ou$d strgc!" N70, N127, N291 y N292 -:t/c'lllcetlrn

- Chaoter. lGod( lanBor l€61-: vodficatbfl - Chapter

t€l,t5a I a!!6 I

Ignition system general information

lgnition system general information

. Only the components which specifically relate to the ignition systemare dEalt with here. The other compon€nts may be found in thehjeciion system' Ohapier

. The conbol unit fur the fuol iniection and ignition sFtem is equippedwith self{iagnosis. Before carrying out Epairs and faultfinding, thefault memory musi be intenpgated . chirpt;i AlEo, the lryi, pregsurehoses and connections must be checked {infltrated aid.

. B€b.q disconngc'ting snd .gconnecting the battery, gwitch ofi theignition. lf thig prec€ution is not taken, lhe engine confol unit may b€oamageo.

. For the perfect funclionlng of €lectrical components, a minimumvohage of 11.5 V i8 nece3sary.

. lf th€ sngine sbrts, run8 iof a short period and then stops, afrer faultfinding, repairs or component tests, then th€ fault may lie with theimmobilizer blocking the engin€ control unit. The fault memory mwt beintenogated gnd, if necegsary lhe control unit matched ' ahn,:1lc|Functions and component8: adapting

. Ce.tgin tegb may lead to a fault bslng det€cted by the control unit andstored. TherEfor€, the fault msmory must be intenogated End delet€d ifnec63sary, afrer allb$5 and rrpairs havg been complet€d ' (--fntr,,'

. Vehicl€8 with an airbag are 1itt9d with a crash fusl 8hut-ofi. Thlssystsm reduqeg ho .isk ot I v€hiclg bumlng in the event of a cragh inthat the tuel pump i8 switched ofby the tuEl pump relay. At the Eametime, bctts. sngins starting i8 achi€v€d. Vvl€n the door is op6ned, th€tuel pumD 18 aclivated tor 2 Ee@nds in ordg. to build u! Dro$ure ln thefuel systsm.

Xel,iSo I oro I

Ignition system - Components oyerview

lgnition system - Components overviewEngln. code lsttcta BBY, BBiZ, BKY 'Anchor

Engh. code AUB

I - lgnltlor c.blcs lMth 8uppre8sion

connector and 6paft plug@nnoq@r

q Rssbtence 4.8...7.2 kO

2 .lgnltlon tr|nltormor .Ntt2-o Fitting localion li.'r,a \Mth mafting8 frc. lhe

ignitlon qabl€8:

. A = cylinder 'l

. B = cylinder2

. C = syllnder 3

. D = cylinder4

3 - Connrcioro Black, 4 contncba Fof ignition tran8lormor -

N'152-

a. t0 Nm

6 - Conncctoro Black, 2 contacbo For knock s9neo. | €61-o Conn€c1or contacl3 are

gold+lated

I " Knocl tomor | .CGl-o Fitting location lt.:f.q Tcating . Clrnrrteo Connectoa @ntacts aro

gold+lated

7 .20 Nmo Tightening torque afiacts th€ funclloning ofthg knock s€nsor I G61-

8 - Conroctolo Black, 3 contactgo For Hallsender -G40-

I - Hall !€nd.r .G40.

o Fitting location ' ltenl

o Testing . alrapicr

l0 . G.lngo Replace if dameg€d

ll . lgnltlon c.ble. .upport{uldo

4

10

l-NaB{161 I

XeliSa I aro 3

Ignition system - Compon€nts oveNiew >€Liiio 2 0'16 3

12 - Sp.rk plug, 30 Nmo Remove and install $/ith wrench -T20175-o Elecirode typ€ and s€pa.ation . alhirft.r, lest data, spark plugs

Englne cods lott r! BBY, BBZ, BKY

I - Conngctoto Black,4 contacts

2 - bnruon coll 3 wlth outputttago.N29l-o Remov€ with extraclor -

T100s4-q lgnition coil I wjth outsut

stage -N70-o lgnilion coil2 with outplt

stiage -N127-o lgnidon coil4 with output

Etage -N292-3. Connoctol

o 8lack, 2 contacbo For knock sen6or | €61-o Gold plated contacts

,l - Knock lonaoi | .GGl .o Fittlng location i-,, .o T$tlng { lrr.rtL,'ro Connector contacb aro

gold-plsted

5.20}{mo TighEning torque atfecb

lhe tunctionlng of theknock s€n6or | 461 -

I - Connrctoto Black, 3 conlactso For Hallsender -G40-

7 - H.ll rondgr -G40-o Fining location r,'i'lo Test ing ( . l i . r | r" l

0 - O-rlngs Replace if damaged

9-r0r{m10 - Sp.tk plug, 3,0 Nm

o Remove and install with wrench -T20175-o Electro<re typ€ and separalion Chir.r,:'., Tegt data, spatk plug6

{l - Cablo guldo

o Tighten the c€m$hafr housing to a torque of 5 Nm

2

I J:-ol,-iJ, Itt{JU

34

"0ll

13

12

' I

Y

T:

fNr&ors4 I

lgnition system - Compononts ove iew

12 - E.nt cabl.o Tighten or loosen only when the ignition is oIt

13-10Nmo Tighten or loos€n orly when the ignition b of

Iel.i6o 3 arc 3

Safety pr€cautions

Safety precautions

To prevent injuries to persons and/or damage to the fuel injection and€nition system, the icllowing must be noted

. For safety rcasons the fuse No. 41 rnust be removedfrom the fuse holder before opening the fuel system,otheMise the tuel pump can be activated by the doorcontact switch.

. Do not touch or r€move the ignition cablss with theengine running or idling.

. Always g^,itch ofi the ignition beiore disconnecting orreconnecting injection or ignition system wiring or testerc:rbles.

Note the following if testerg and meaEuring instruments haveto b€ usgd during a road te6tl

a Testers and measuring instsuments must always bes€cu€d to the rear seat end opgrated by € 2nd p€rsonfrom this location.

lf test and rneasuring instruments are operated fiom frontpas€engeCs seat and the vehjcle is involved in an Eccident,the person siftlng in this seat could be seriously injuredwhen the airbsg is triggered.

. lf the engine is to be tumed at starter spe6d withoutstraning:

- Remove engine protection together with air filter -arrows-

Engln€ codo AUB

lel"iSo I oz16 3

.'t'. WARNING

Fud syrsten ls under pg9,sura! W.ar ialeay gloy€€ ard grr9ses Eoayold InlW and conbct wrtl skln. Beforc gpaning the gys'F,mplaco a clolh around tha connectlon, fhan reloase preasurc bycar*utly pultlog fttel hoae trom connectiot .

;'l'., cautlanWhen dolnE aay rgpalr wo*, earyla y ln tho e,nglnecamp.fttrrant, pey atundon b tho tollowlng duo baho cromped condldona:

Att condul.' (fot axample for tuel, hydraultcs, catbgn, f€r, quld c@ler and coollng ag.na, b/','ke ltuld, loy.,tesau.l) tnd,ha desffc cable, mwt be placed lnauch t way ahat thay rcaum tg ahelr orlglnal poaltton,

Enaurc sutftcLnt cleannce lor tll mavlng q hotcomoonenta,

Safery precautions Iel,i6o 2 o,116 3

- Remove the 4-pin connector from the lgnitiontransformer -N 1 52-araow-.

Engine cod.l.ttoE BBY, BBZ, BKY

- Remove the 4'pin conn€ctors -anows- from the ignitionha nsiormerg.

Conlinuod for all vohlcle.

- Remove fuse 25 from the fuse box

Safety precautions Eel"i6o. 3 o16 3

@ rvor.Removinginjectors.

fuse 25 intetrupts the vdtage supply to the

Spark plug test data

Spark plug test data

Ed,ibc I oro I

Engin. codol6tt rr

AUB BBYwIh rutomrtlc

gsarbox

BBY BBZ BKY

lgnition ordgr 1-34-2 '1-34-2 1-34-2 1-34-2 1-34-2Partsrcf€renco

f l . te

Manutactrt€r'scode

101,000,033 M

BKUR 6 ET.1O

101 000 062 AB

PZFR 5 D-11

101,000,033 M

BKUR 6 ET.1O

'101,000,033 M

BKUR 6 ET.1O

101,000,033 AA

BKUR 6 ET.lO

Electrgde9€paaaton

0,9. . . 1.1 rnm 1,0. . . 1.1 mm 0,9.. , 1.1 mm 0,9... 1.1 rnm 0,9. . . 1.1 mm

Tighteningtorque

30 Nm 30 Nm 30 Nm 30 Nm 30 Nm

Parts€f€rence

Manufacturs/Bcode

Electrodg8sparation

10'1 000 041 Ac

14 FGH 7DTURX

101 000 041 Ac

14 FGH 7 DTURX

101 000 04r Ac

14 FGH 7 DTURX

101 000 041 Ac

14 FGH 7 DTURX

0,9.. . 1.1 mm 0,9 ... 1.' l mm 0,9.. . 1.1 mm 0,9.. . 1.1 mm

Tlghteningto|!u€

30 Nm 30 Nm 30 Nm 30 Nm

Partsrebr€n0g

M9n uigciursfscode

101,s05,803 B

14F-7HUR2

El€cfode8€pgretion

Tightoningto.qu9

0,8. . .0.0 mm

30 Nm

t UFlo-drt. 3p.clllc.tbnr .nd !p.rl plug changr lnla 6b , Book ret, For updrt d Prtu llbianor a6. , ETKA (ere.(on c parts caralogue)

Hall senderG40: verifi cation

Hall sender -G40-: verification

Spaclrl tool! .nd wo*ahop rqulpm.nt raqulrad

. Hand hcld multim€ter.VAG 15268- or multim€tlr.VAG 1715.

. Mea8uring bol s6t -VAG 1594C-

. T6et€r .vAG 1598/31-

. Cun€nt iow dlagram!, €l€ctric€l fault finding lnd fitting loc€tions

Tatt raqulrtmanta

. Battery \roltagc, tt least 1 '1.5 V.

Ta|t.rquanc.

- Remove €ngine probclion bggth€r with air filter €now8-

>€1.{6o I 0?16 3

v.a.c 1526 B v.a.G 15ea c

v.a.G 1$461

l!P:!9Q I

Hall senderc40: vedfi cation

Extraot the 3-pin connector from the Hall s€nder -G40-

- Connect multimet€r to measure voltage at contacts 1(positive) and 3 (eadh) of Hall sender -G40-, using theauxaliary cables of the meagurement tool 6et -VAG1594C-.

- Switch on ignition.

. Specifcation: 4.5 V minimum.

- Switch off ignition.

lf no voltage is present:

Connect tester -VAG 1598/31- to control unit cableharness, without @nnecting engine control unit.

Xe).i6q 2 o'16 3

Hall senderc40: vedfi cation

Check for interruptlons of the cables bgt!,veen the testbox ad th€ triple conneclor, following the eleclric clrcuho|agram.

- Additionally check wires for short to on€ another.

. Specifcationr - O

lf no wiring fault b detected and voltage was pr$€nt bet\,.,een contacts I+3:

_ Reotace the Hall sender -c40. . rerl

lf no fault is icund in wiring and there is no volbge between contacts 1+3:

- Replace the engine control lnit . -i ,1r1,: .

tel,i60 3 on6 3

l- Ar4oors I

Connectlon Fomrl. rock.t VAG 160813l

'| 98

86

108

Wre .$istanc€i Max. 1.5 O

Ienition transformerNl52: verificatiol

lgnition transtormer -N152-: verification

Only engin! code l.tt ra AUB

Isli6o I on6 6

V.A.G 1526 B V.A.G I527 B

v.A.G 1594 C v.A.G 1598/31

v.A.G 1715

ffiL24-10002

Sp.cl.l tool! rnd wgrk hop equlpmont ruqul.ld

. Hand held multimotor -VAG 15268- or mullimeter -VAG 171t

. Voltage tester -VAG 15278-

. Moa6urin0 lool set -VAG 1594C-

. Tester -VAG 1598/31-

. Cunenl flow diagramg, electrical fault finding and frtting locations

Ignition transformerN I 52: vedfication Ie)"i5o 2 on6 6

l\?Bffil

Tert roqullomontg

. Allfusos mu6t be OK.

. Battery vollag6, 1'1.5 V minimum

. Halls€nder -G40-, co.roci check

. Engine speed sender -G28-, conect; ch€ck

Tolt aaqucnco

- Remove lhe 4-pin connector from tho lgnition transfomer -N 1 52--arlow-.

Ch.cklng volt|g..upply

Wth the hgnd held multimetcr -VAG '15268- and theauxiliary cables ofthe m€asurement toolset -VAG 1594C-,measuro tho pow6r supply in the removed connoctorb€tween :

Connactlon Conn€ction

2 4

Switch on ignition. Specification: 1'1.5 V minimum.

Isnition hansformerNl 52: verifi cation Ee),iia 3 aro 6

- Switch off ignition.

lf ho voltage ia present:

- Check, using circuit diagram, for breaks in lhe c€ble circuit

- Check wiro botween 4-pin @nnector, contact 4, and earlh to. gpencircuit according to current flow diagram.

a Wre resistanc6: Max. 1.5 Q

lf the power supply b found to be conec{, chock aclivalion /. :: | -,:.

4.pln connaotoG conhct

r€layholder plate

Wirg regiStancs: max. 1.5 O

- Chqck br oD€n cirruit b€tween:

4.pin connoctor, contact Connoctlon

4 earth

Wre rgsi6tancs: max. '1,5 O

!' DANGERI

Durlng the noxt fcst, nolther ahe Unlfron tansfonner connec&tt norhe test cabtaa ahould ba touched-

lsnition tmnsfomerNl52: verification

Activ.tion: checking

- Remove engine proteclion together w h arr filler -arows-.

- Pull terminal conn€ctors -afiows- off inj€ctors.

!el,i6o 4 on6 6

- Connecl the voltage t69ter -VAG 15278- using auxiliaryc€blea measurcment tool 6et -VAG 1594C-, to pin6 I + 4(ignition output 1) and contacts 3 + 4 (ignition output 2) of€moveo connector,

- Operate starler and check the ignition signal frcm enginecontrolunit. LED lamp must tlash.

- Switch off ignition.

lf the LED flickers and there is voltage between cont€cts 2 +4

- Replace the ignition tran6former -N 152-

lf the LED lamp does notfiash:

- Checking wiring

i i

E1Lr.C077

tgnition transformerN I 52: verifi cation

lrvlrlng : chocklng

I€Ii60 5 0116 6

Connect l6sle. -VAG 159E/31- lo control unit csbleherness, without connec'ting ongino conhol unit.

Check the cablos botwean the lest box and lh6 4-Dinconnector plate for an open circuit bllowing the cun€ntchcuils diaOram.

Connection Fom.le.ockot VAG I 598131

102

- Addilionally check wiles fgr ghort to one another.

a Specificatioo: - O

lf no wi.ing fault b detgc{sd €nd voltagg wag pr€rsnt bolween contac8 2+4.

- R6placa the ongin€ control unil , chapter.

Ignition aansformerNl 52: verificalion tslida 6 0716 6

| \aol31 I

Sacondary Fabtanoe: chack

- Ch6ck secondary r6si8tenc6 in taminal 4 b€tw€6n:

lf the spocitication i! not obtainod:

- Roplsce lh.lgnilion trangtomer -N152- ' tem.

W|9 resiatance: Max. 1.5 O

cfl. c]1.1 4

2Soocificstion: 4.0...6.0 kO (to 2(P C

lgnition coils with output stages- N70, N127, N29l y N292 -: verification

lgnition coils with output stages- N70, N127, N291 yN292 -: verification

Only engino code lett 13 BBY, Bttiz, BKY

Ee),i6q I olro 5

V.A.G 1526 B V.A.G 1527 B

v.A.G 1594 v.A.G 1598/31

v.A.G 1715

ffi12410002

Ignition coils with ourput stages- N 70. N I 27. N29l ) N 292 -: verilication

Sp€clal took rnd wo.kahop aquipmont roquiFd

. Hand held multimeter -VAG 15268- or muftimeter -VAG | 715-

. Voltage tester -VAG 15278-

. M6a6uring tool sel 'VAG 1594C-

. Te6t6r -VAG 1598/31-

. Cunent tlow diegrems, olectric€l tault finding and fitting locaiions

Ta3t r€o uitcrnanta

. The tuE6s must be OK.

. Hall sender -G,{0-. conocl, check ^r , .l '

. Engine speed sender €28., coned, check ' ':

Tt€t atquanca

LU no..lgnition coils and thair rcspectivo outpul stegos arc one unit.

- Remove th6 ignition coil conngctor to b€ tert€d.

Ch.cklng volt.g..upply

- Wth the hand held multim6l,ar -VAG '15268- and th.auxiliary c€bl$ of the m€a3urement tool sst -VAG 1594C-,m€aauro tho po\/v6r aupply in the romoved conoeclorD6lwe9n :

Eei.i6o 2 o16 5

- Switch off ignition.

lf no voltago ia prea€nll

- Check, using cirouit di6gram, for breaks in the cabl6 circuitbetween:

Codnectlon Connactlon

1 3

2 3

Switch on ignition- Spgcificdtion: 11.5 V minimum.

Ignitior aoils rvith output stages- N70, N127, N291 y N292 -: verification !€l.ido 3 0?16 5

4.pln cormacior, conbct

relayholder plat6

Wlre reliatanc€: max. 1,5 f)

- Ch6ck br op6n ciaclit b€tw€€nl

+pln connactor, conLct Connacdon

egnn

2 e€rth

Wre resiEtance: max. 1,5 O

lf th6 power Eupply is found to b€ cor.ect, check aclivation ' Anchor.

Acdvador: chacklng

- Pull out fuse no- 25 from thc fuae carigr.t'E t[_1U rro.rtufioving tusa No. 25 intetrupE the voftege swply to tho

Ignition coils with ouput srages- N70, N127, N29l y N292 -: verification

injectors.

>eli60 4 on6 5

- Using auxiliary cables flom Moasurcment tool set -VAG1 594C-, connoct the voltage t$ter -VAG 1 5278- to the 4-pin + engine earth ol the connector r€mov€d from cylinder

- Operatg sta er and check the ignition Bign9l from 6nginscont.olunit. LED lamp mustflaeh.

- Ropeat tast on connec{ora of cyl 2 to 4.

- Switch off ignition.

lf the LED llght flEshes and the power aupply is correct:

- Repleco lh6 coftesponding agnition coils wilh outsut sttg6

lf the LEO lamo do€8 not fla3h:

- Checking wiring

Wlrlng i ch.cklng

- Connec,t the t68tar -vAG 1598/31- lo the co.trol unit cablehsm6ss. Wllhout connocting lhe 6ngin6 cont|ol unrt.

Check the cables between the tesl box and the 4-pinconnector for an op€n circuit following the curenl circuitsdlagram.

Ignition coils with output stages- N70, N127, N29l y N292 -: verification Xe.?'i6tr 5 oz6 5

Cyllnd.rrcontrct F.,r.l. rock.t vAG 1t906{

Cylindor I, cont ci 4 102

Cylindqr 2, coniact 4 103

Cyllnd.f 3, conlec't 4 9il

Cylirdcr 4, contacl 4 95

Wiro r.sidanc.r M.x. 1.5 O

- Allo ch6ck cabl€8 for thorl circullr brtwen lhcm.

I Splcficttlon: - O

lf no fault i9 tound In wldng and th€tq l! vgltrgc botweon contacla 1 +3 and2+3:

- R6plEc6 th€ ongino conttolunit 'chapter

Knock sensor IG6 I : vedfication

Knock sensor I -G61-: verification

Spochl toob |nd we*.hop rqulprn.nt 'tqulltd

. Test€r -VAG '159E/3t-

. Hand held multirneter -VAG 16268- or multim€ter -VAG 1715-

. Measuring bol 8et -VAG 1594C-

. Cun€nt fiow diagrsms, eleclrical fault fnding and ftting localions

[[ rvot. lt is extpndy impottant to k6€.p to the tiJhtening toque of 20 Nm to

ensuro ttre ,@ocr( sg,rao/a -G61- peiotm pefiedly.

. Only gold{lated @ntacts may be us€'d when setubing the knacksensor 1 -G61.@nrcctot @ntada.

Toat |tq||l|tmgnta

. Knock sensor 1 461- fault recognis€d by selfdhgnosis ' chapter.

t€r,i6o I on6 3

v.A.G 1526 B v.A.G 'r 504 C

v.A.G r5$r:tl

r.qq.!!o8 l

Te6t sequgnce

- Remove fiom the Knock sensor I G61-arrow- the 2-pin@nneqor.

Connect tester -VAG 1598V31- to control unit cableh€mess, without conn€ciing engine control unit.

Knock sensor lG61: verification

Check wiring bgtween te8t box and the injeclor 2-pinconnectors irr open circuit using cunent flow diagram:

Xe)"iic 2 aro 3

llz.ii;l

Knock sensor IG61 : voification

- Addfiooslly d|rd( wlGa br lhort to on€ and|€r,

. Sprdicatlon: -

O

lf no wi.ing feult le da{adad:

- Loolg|l knod( trNor | €81- and f8hbn agin b 20 Nm,

- Tak6 vahicb br ! blt driv€.

Obl€|va lh! n€calary !€bV pr€caulibm wh!fl carrylng out ! rod tert- ' Chapter.

- Dudng ho roed Eat tho iollotrlng oporeting conditions must bo fulfrll€di

. Ths oool8ri bmDcrafirl! ahoukl bc sbot a 80 qC.

. Vthcn lha Wnp€r|tu|! b rt€chad, opacting condi0on! - ldhg, Padthmffie, Full throt0a .nd Ovrnun mud br sltrln.d larlrd tlrE!.

. At tul| thtour, llw mult lxcrad 3500 rpm.

- Inimogab th6 contol unit lbult m€mory agein -

chapter,

lflhc fault oonlnu€r:

- Rcolsca ltrod( lanlor | 461- -

ltem.

Xe,X,i6a 3 a't6 3

Connac'lho Fnmb rcc||tVAG lSe0rill

1 106

99

Wr! ru€iStBnce: Msx. 1.5 O

t--