Engine Cusb Cuta Cusa Repair Manual Eng

Service
Workshop Manual
Fabia III 2015 ➤
Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine
Engine ID
CUS CUT CUS
B A A
Edition 05.2019
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Fabia III 2015 ➤ , Rapid NH 2013 ➤
1.4/55; 66; 77 kW TDI CR Engine - Edition 05.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Denomination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Safety precautions for working on vehicles with start-stop system . . . . . . . . . . . . . . . . . . 4
2.3 Safety precautions during road tests in which testing and measuring equipment is used . . 4
2.4 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Safety precautions when working on the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Rules of cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Foreign bodies in the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Cable routing and securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 Assembly of radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Disconnecting engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Attach engine attached to engine and gearbox mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2 Removing and installing engine mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.3 Removing and installing gearbox mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.4 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.5 Support the engine in its installed position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3 Engine trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.1 Removing and installing engine trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.1 Assembly overview - V-ribbed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2 Summary of components - sealing flange on the belt pulley side . . . . . . . . . . . . . . . . . . . . 30
1.3 Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.4 Removing and installing tensioning element for V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . 33
1.5 Removing and installing bracket for auxiliary units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.6 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.7 Removing and installing belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.8 Replacing crankshaft sealing ring on the belt pulley side . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.9 Removing and installing the sealing flange on the belt pulley side . . . . . . . . . . . . . . . . . . 40
2 Cylinder block on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.1 Summary of components - cylinder block on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . 43
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.1 Summary of components - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.3 Replace the needle bearing in the crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.4 Measuring axial play of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Contents i
4.1 Assembly overview - piston and conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

4.2 Removing and installing the piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.3 Measure piston projection in TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.4 Check piston and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.5 Separating new connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.1 Summary of components - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.2 Assembly overview - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.4 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.5 Removing and installing gasket rings for injection units . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.6 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.7 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.1 Summary of components - toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.2 Summary of components - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.3 Removing and installing toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.4 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.5 Remove the toothed belt from the camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3.2 Removing and installing gasket ring for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.3 Checking hydraulic balancing elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.4 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.1 inspecting valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.2 Testing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.1 Assembly overview - pan/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.2 Removing and installing the bottom part of the oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.3 Removing and installing top part of the oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.5 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 117
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3.1 Summary of components - oil filter housing/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . 120
3.2 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.3 Testing oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.4 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.5 Removing and installing valve for oil pressure control N428 . . . . . . . . . . . . . . . . . . . . . . . . 126
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1 Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.2 Check cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.3 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.4 Flushing the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.5 Flushing cooling system, quick start guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.1 Summary of components - coolant pump/thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
ii Contents
2.2 Summary of components - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

2.3 Summary of components - coolant temperature transmitter . . . . . . . . . . . . . . . . . . . . . . . . 160
2.4 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2.6 Removing and installing coolant regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.7 Testing the coolant regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
2.8 Removing and installing coolant valve for cylinder head N489 . . . . . . . . . . . . . . . . . . . . . . 166
2.9 Removing and installing coolant temperature transmitter G62 . . . . . . . . . . . . . . . . . . . . . . 166
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.1 Summary of components - coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4 Coolers, radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4.2 Summary of components - fan shroud and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
4.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
4.4 Removing and installing fan shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
4.5 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1 Exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.1 Summary of components - exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.2 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.3 Replacing exhaust gas turbocharger pressure box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2 Charge-air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
2.1 Summary of components - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
2.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
2.3 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
2.4 Removing and installing charge air temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . 200
2.5 Checking the charge-air system for leak-tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.6 Leak testing the charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1.1 Schematic overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1.2 Installation location overview - fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
1.3 Filling/bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
1.4 Check the fuel system for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
2.1 Connection diagram - Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
2.2 Inspect the vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
3 Injection units / high pressure accumulators (fuel distributors) . . . . . . . . . . . . . . . . . . . . . . 215
3.1 Summary of components - injection units (injectors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3.2 Summary of components - High pressure reservoir (fuel distributor) . . . . . . . . . . . . . . . . . . 217
3.3 Check injection unit return quantity with engine running . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3.4 Checking the injection units in open state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
3.5 Removing and installing the injection units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3.6 Removing and installing high pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
3.7 Removing and installing high pressure reservoir (fuel distributor) . . . . . . . . . . . . . . . . . . . . 227
4 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
4.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
4.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
5 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
5.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
5.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
5.3 Removing and installing the throttle valve control unit J338 . . . . . . . . . . . . . . . . . . . . . . . . 238
Contents iii
6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

6.1 Removing and installing the fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . 240
6.2 Check fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
6.3 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
6.4 Removing and installing air flow mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
6.5 Removing and installing differential pressure transmitter G505 . . . . . . . . . . . . . . . . . . . . 245
6.6 Removing and installing fuel temperature transmitter G81 . . . . . . . . . . . . . . . . . . . . . . . . 247
6.7 Removing and installing pressure sensor for exhaust gas 1 G450 . . . . . . . . . . . . . . . . . . 247
7 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
7.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
7.2 Removing and installing engine control unit J623 with protective housing . . . . . . . . . . . . 249
8 High pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
8.1 Summary of components - high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
8.2 Removing and installing the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
9 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
9.1 Summary of components - lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
9.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

1 Exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
1.2 Separating exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
1.3 Removing and installing pre-exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
1.4 Removing and installing middle silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
1.5 Removing and installing rear silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
1.6 Align exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
1.7 Inspecting the exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
1.8 Installation position of clamping sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
2 Cleansing exhaust emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
2.1 Summary of components - exhaust gas cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
2.2 Removing and installing exhaust gas cleaning module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
2.3 Removing and installing the exhaust flap control unit J883 . . . . . . . . . . . . . . . . . . . . . . . . 279
3 Exhaust temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
3.1 Summary of components - exhaust temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . 281
3.2 Removing and installing exhaust gas temperature sender . . . . . . . . . . . . . . . . . . . . . . . . 282
4 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
4.1 Summary of components - Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
4.2 Removing and installing radiator for exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . 288
4.3 Test air-tightness of the radiator for exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . 291
4.4 Removing and installing exhaust gas recirculation valve 2 GX6 . . . . . . . . . . . . . . . . . . . . 291
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
1.1 Summary of components - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
1.2 Removing and installing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
1.3 Removing and installing automatic glow period control unit J179 . . . . . . . . . . . . . . . . . . . . 297
1.4 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
1.5 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
1.6 Removing and installing the engine speed transmitter G28 . . . . . . . . . . . . . . . . . . . . . . . . 298
iv Contents
00 – Technical data
1 Denomination
(SRL001380; Edition 05.2019)
1.1 Engine number, engine data

♦ The engine number (“engine identification characters” and
“serial number”) is located at the front at the engine/gearbox
joint -arrow-.
♦ In addition, a sticker with the “engine identification characters”
and “serial number” is attached to the timing belt guard.
♦ Starting with the letter “C”, new four digit engine codes have
been introduced.
♦ The first 3 digits of the engine identification characters refer to
the displacement and the mechanical construction of the en‐
gine. They are type-punched on the cylinder block including
the serial number.
♦ The fourth digit refers to the output and torque of the engine.
It depends upon the engine control unit.
♦ The engine identification characters are indicated on the ve‐
hicle data sticker.
♦ ⇒ Maintenance ; Booklet Fabia III
♦ ⇒ Maintenance ; Booklet Rapid NH
Engine codes CUTA CUSA CUSB

Manufactured
Fabia III 08.2014 ► 07.18 11.2015 ► 07.18 08.2014 ► 07.18
Rapid NH 05.2015 ► 07.18
Emission EU6 EU6 EU6
standards con‐
forming to
Displacement cm3 1422 1422 1422
Output kW at rpm 77/3500 - 3750 55/3000 - 3750 66/3000 - 3250
Torque Nm at rpm 250/1750 … 2500 210/1500 - 2000 230/1750 … 2500
Bore ∅ mm 79.5 79.5 79.5
Stroke mm 95.5 95.5 95.5
Compression 16.2:1 16.2:1 16.2:1
ratio
Firing order 1-3-2 1-3-2 1-3-2
Exhaust gas recirculation yes yes yes
Exhaust temperature regula‐ yes yes yes
tion
Balancing shafts yes yes yes
Exhaust gas turbocharger yes yes yes
Charge air cooler yes yes yes
Lambda control yes yes yes
Particle filter with catalyser yes yes yes
Number of cylinders/valves per 3/4 3/4 3/4
cylinder
Volkswagen Technical Site: https://vwts.ru
1. Denomination 1
2 Safety instructions
⇒ “2.1 Safety precautions when working on fuel supply system”,
page 2
⇒ “2.2 Safety precautions for working on vehicles with start-stop
system”, page 4
⇒ “2.3 Safety precautions during road tests in which testing and
measuring equipment is used”, page 4
⇒ “2.4 Safety precautions when working on cooling system”, page
5
⇒ “2.5 Safety precautions when working on the exhaust system”,
page 5
2.1 Safety precautions when working on

fuel supply system
NOTICE
When undertaking all installation work, particularly in the engine
compartment because of its cramped construction, please ob‐
serve the following:
♦ Route all the various lines (e.g. for fuel, hydraulics, activated
charcoal filter system, coolant and refrigerant, brake fluid
and vacuum) and electrical wiring in their original positions.
♦ Ensure that there is adequate free access to all moving or
hot components.
CAUTION
♦ Fuel feed line is pressurised.
♦ The fuel or the fuel lines in the fuel system can become very
hot (risk of scalding)!
♦ Allow the fuel to cool before opening the lines.
♦ Wear safety goggles and safety clothing, in order to avoid
injuries and skin contact with fuel.
♦ Place cleaning cloths around the connection point before
detaching hose connections. Reduce pressure by carefully
removing the hose.
CAUTION
For reasons of safety, the power supply to the fuel pump must
be interrupted before the fuel system is opened. The fuel pump
would otherwise be activated when the driver's door is opened.
One of the following options must be used to interrupt the cur‐
rent supply:
♦ Disconnect battery
or
♦ Take out fuse for fuel pump control unit - J538-
or
♦ Pull connector off fuel delivery unit flange.
2 Rep. gr.00 - Technical data

Carry out the following measures before starting work on the fuel
system:
♦ The extraction hose of an exhaust extraction system which is
switched on, must be positioned close to the assembly open‐
ing of the fuel tank in order to extract the released fuel vapours,
even before the work is commenced. If no exhaust extraction
system is available, a radial fan (motor not in air flow of fan)
with a delivery volume of more than 15 m3/h must be used.
♦ Prevent skin contact with fuel!
♦ Wear fuel-resistant gloves!
NOTICE
♦ Do not remove fuel hoses from the fuel filter.
♦ Do not lever the connection fittings.
♦ This leads to leaks and damage to the fuel filter top part.
♦ Ensure that no diesel fuel gets onto other components in the
engine compartment. If this happens, clean immediately!
NOTICE
♦ Because of insufficient lubrication by diesel fuel, misfuelling
can cause irreversible damage to high pressure compo‐
nents, particularly the high pressure pump!
♦ Damage can be expected in the form of scoring and particle
erosion.
♦ Thus, free metal particles contaminate the fuel system as
well as the injection system, whereby further damage can be
expected especially to the fuel pressure regulating valve and
in the injection units.
Check the filling level of the fuel tank:

♦ The fuel tank must be empty for weight reasons when remov‐
ing it. If necessary, extract fuel from the fuel tank.
♦ The extraction hose of an exhaust extraction system which is
switched on, must be positioned close to the assembly open‐
ing of the fuel tank in order to extract the released fuel vapours,
even before the work is commenced.
♦ Prevent skin contact with fuel!
♦ Wear fuel-resistant gloves!
When removing and installing the fuel tank, observe the following:
CAUTION
Risk of accident due to the fuel tank weight!
The fuel tank must be empty for removal.
Observe the following points to prevent injury to persons and/or

damage to the injection and preheating system:
♦ People, who have a heart pacemaker implant, should not bend
over the engine compartment when the engine is running, as
the injection units generate an output high voltage pulse.
♦ No fuel lines must be opened when the engine is running.
2. Safety instructions 3
♦ Disconnect and connect wires of the preheating and injection

system as well as measuring device wires when the ignition is
switched off.
♦ Do not carry out engine wash unless the ignition is switched
off.
♦ Before disconnecting the battery determine the code of the
radio fitted with anti-theft coding.
♦ Always switch off the ignition before disconnecting and re-
connecting the battery. Otherwise the engine control unit may
be damaged.
♦ Some additional work must be carried out after connecting the
battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Connecting
and disconnecting battery .
NOTICE
In order to avoid the high pressure pump to run dry and to ach‐
ieve a quick engine start after parts are replaced, the following
points must be observed.
♦ If parts of the fuel system have been removed or replaced,
to bleed the fuel system it is necessary to perform the fuel
system filling/bleeding process
⇒ “1.3 Filling/bleeding the fuel system”, page 211 .
♦ If the fuel pump, fuel line or fuel filter have been removed or
replaced, the fuel system filling/bleeding process must be
performed
♦ If the high pressure pump is removed or replaced, the initial
fuel filling of the high pressure pump must be carried out
before the first engine start
♦ If the high pressure system was opened, it must be checked
for tightness
⇒ “1.4 Check the fuel system for tightness”, page 212 .
2.2 Safety precautions for working on vehi‐

cles with start-stop system
When working on vehicles with start/stop system, please observe
the following:
CAUTION
There is risk of injury from automatic engine starting on vehicles
with start/stop system!
♦ In vehicles with an activated start-stop system (indicated by
a message in the dash panel insert), the engine can start
automatically if necessary.
♦ It is therefore necessary to ensure that the start-stop system
is deactivated when carrying out work on the vehicle (switch
ignition off, if required switch ignition on again).
2.3 Safety precautions during road tests in

which testing and measuring equipment
is used
If the test and measuring devices are operated from the passen‐
ger seat, the passenger could be injured by the release of the
passenger airbag in the event of an accident.

CAUTION
There is a risk of accident from deflection and insufficient se‐
curing of testers and measuring instruments!
There is also a hazard from the release of the passenger airbag
in the event of an accident!
• Using testers and measuring instruments during driving op‐
eration causes distraction.
• Increased risk of injury from unsecured testers and meas‐
uring instruments must be prevented.
♦ Testers and measuring instruments must always be secured
on the rear seat using a seat belt and by a 2nd person on
the rear seat.
2.4 Safety precautions when working on

cooling system
CAUTION
Hot steam may escape when the expansion reservoir is
opened.
♦ Wear safety goggles and safety clothing to avoid eye injuries
and scalding.
♦ Cover cap with cloth and open carefully.
2.5 Safety precautions when working on the

exhaust system
Danger of poisoning by chemical substances.
Exhaust gas temperature sensors can contain chemical substan‐
ces. Risk of injury to the respiratory tract and poisoning.
– The exhaust gas temperature encoder must not be cut or
opened.
Risk of injury due to hot condensate and particles in the exhaust
system.
– The exhaust system may contain hot condensate or particles.
Risk of injury to the eyes, skin and the respiratory tract as well
as danger of poisoning.
CAUTION
♦ Wear protective gloves and safety goggles when discon‐
necting the exhaust system!
♦ When disconnecting, use a suction device or provide ade‐
quate ventilation.
Risk of damaging the decoupling element.

– Do not twist decoupling element more than 10°.
– Do not load decoupling element with tensile stress.
– Do not damage wire mesh on decoupling element.
2. Safety instructions 5
3 Repair instructions
⇒ “3.1 Rules of cleanliness”, page 6
⇒ “3.2 Foreign bodies in the engine”, page 6
⇒ “3.3 Contact corrosion”, page 6
⇒ “3.4 Cable routing and securing”, page 6
⇒ “3.5 Assembly of radiators and condensers”, page 7
3.1 Rules of cleanliness

Carefully observe the following “rules” for cleanliness when work‐
ing on the fuel supply/injection system:
♦ Thoroughly clean the connection points and their surroundings
before releasing.
♦ Place removed parts on a clean surface and cover. Use lint-
free cloths.
♦ Carefully cover or close open components if the repair is not
completed immediately.
♦ Only install clean parts: remove spare parts from their wrap‐
ping immediately before fitting. Do not use any parts which
have been stored unwrapped (e.g. in tool boxes etc.).
♦ When the system is opened: do no use compressed air. Do
not move the vehicle.
♦ Ensure that no fuel runs onto the fuel hoses. If happens, clean
the hoses immediately.
♦ Protect electrical plug connections from dirt and moisture and
only connect them when dry.
3.2 Foreign bodies in the engine

To prevent the penetration of foreign bodies, open channels of
the inlet connection and exhaust tract must be sealed with suita‐
ble plugs during assembly works on the engine, for example from
the screw plug set for engine - VAS 6122- .
3.3 Contact corrosion

The use of unsuitable connection elements (screws, nuts, wash‐
ers, etc.) can cause contact corrosion.
This is why only connection elements with a special surface coat‐
ings are fitted.
Therefore, the rubber or plastic parts and the adhesives are made
from electrically non-conductive materials.
If there is a question mark about the suitability of parts, generally
use new parts ⇒ ETKA - Electronic Catalogue of Original Parts .
3.4 Cable routing and securing

♦ To ensure the original installation position, lines such as fuel,
hydraulics, vacuum, activated charcoal filter system lines or
electric cables must be marked before removal. Make photos
or sketches where necessary.
♦ Sufficient clearance from all moving or hot components must
be ensured in the engine compartment due to its cramped
construction. This prevents damage to lines.

3.5 Assembly of radiators and condensers

The radiator, condenser and charge air cooler may have minor
indentations on the fins, even if assembled correctly. This does
not constitute damage. Radiators, condensers and charge air
coolers must not be replaced because of these indentations.
3. Repair instructions 7
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 8
⇒ “1.2 Disconnecting engine and gearbox”, page 14
⇒ “1.3 Attach engine attached to engine and gearbox mount”,
page 16
⇒ “1.4 Installing engine”, page 17
1.1 Removing engine

Special tools and workshop equipment required
♦ Engine mount - T10536-
♦ Engine/gearbox jack , e.g. -V.A.G 1383 A-
♦ Hose binding claw - VAS 6362-
♦ Screw plug set for engine - VAS 6122-
NOTICE
When installing a complete new engine and after fitting the high
pressure lines, it is absolutely necessary to tighten the clamping
claws of the injection units to the specified tightening torque
⇒ “3.1 Summary of components - injection units (injectors)”,
page 215 . In order to align the injection units when fitting the
high pressure lines, the clamping claws are only tightened
"hand-tight" after delivery. If you do not do so, the engine may
be damaged.
– Remove engine cover

⇒ “3.1 Removing and installing engine trim panel”,
page 27 .
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery tray .
– Remove air filter housing
⇒ “4.2 Removing and installing air filter housing”, page 231 .
– Release cover -1- and take off.
8 Rep. gr.10 - Removing and installing engine

– Unscrew screws -1- and remove air inlet -2-.

– Remove shift mechanism from the gearbox ⇒ Rep. gr. 34 ;
Shift mechanism; removing and installing shift mechanism .
Vehicles fitted with a manual gearbox
– Remove clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch slave
cylinder; Removing and installing clutch slave cylinder .
– Unlock and disconnect connectors -1-, -2- and -3-.

Vehicles with automatic gearbox
NOTICE
Risk of damaging the slave cylinder.
After removing the slave cylinder with connected tube-hose line,
no longer press the clutch pedal.
– Touch a conductive component with the hands (without

gloves) to discharge static electricity.
– Remove the cap of the connector -1- on the double clutch

gearbox mechatronics - J743- and pull up the latches
-arrow-.
– Unscrew the nuts -2- and -3- and remove bracket of the cable
guide.
Continued for all vehicles
– Release the line and vacuum hoses -arrow- and remove hoses
-1-.
Note
Label the connectors on the solenoid valves. There is a risk of

mix-ups.
– Release and pull off connectors -2- and -3- and unlatch brack‐
et -4- and place it on the engine with the solenoid valves.
– Disconnect vacuum line of the brake booster.
– Remove engine control unit - J623- from the holder
⇒ “7 Engine control unit”, page 249 .
1. Removing and installing engine 9

– Release and pull off connector -1- for the engine control unit -
J623- and pull off connector -4-.
– Slacken the wiring loom for engine control unit and place on
the engine.
– Drain coolant ⇒ “1.3 Draining and filling coolant”, page 131 .
– Loosen hose clamps -1- to -4-, remove coolant hoses.

– Loosen clamp -5- and place coolant hoses to one side.
– Detach quick couplings -1- to -4- and disconnect fuel hoses

and place on the engine.
– Release and pull off connector -2- and unscrew screws -1-.
Pull off coolant expansion tank -3- and place on the engine.

– Release nuts -1- and remove earth cable -2-.
– Pull connector off exhaust gas temperature transmitter 1 -

G235- and lambda probe 1 in front of the catalytic converter -
GX10- -arrow-.
– Pull off cap -2- of line 30/B+ -1-.

– Unscrew nut and remove line 30/B+ -1-.
– Disconnect plug connections -3-.
– Loosen hose clamp -1- and disconnect coolant hoses.

– Remove the front left and right wheelhouse liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheelhouse liner; remov‐
ing and installing front wheelhouse liner .

– Unscrews screws -1- for electrical coolant pumps and release

and pull off connectors -4- and -6-.
– Loosen retaining clips -2- and remove cover for noise insula‐
tion -3-.
– Remove pre-exhaust pipe
⇒ “1.3 Removing and installing pre-exhaust pipe”,
page 266 .
– Remove the assembly carrier ⇒ Chassis, axles, steering; Rep.
gr. 40 ; Assembly carrier; Removing and installing assembly
carrier without steering gear .
– Unscrew drive shaft left and right from the gearbox ⇒ Chassis,
axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐
stalling the drive shaft and strap it up towards the rear.
– Release retaining clips -1- and -2-, release hose clamp -3- and
disconnect coolant hoses.
– Unscrew nuts -1- and remove cover -2-.
– Pull off connector -1- and undo line of lambda probe.

– Remove V-ribbed belt
⇒ “1.3 Removing and installing V-ribbed belt”, page 31 .
CAUTION
Risk of injury through refrigerant!
♦ Do not open the refrigerant circuit of the air conditioning
system.

– Release and pull off connector -3- for throttle valve control unit.
– Unscrew screws -2- and -4-, remove air conditioner compres‐
sor with connected coolant hoses from bracket and strap up
to the right.
Note
When attaching the engine mount, take note of the gap at the bolt
-T10536/3- . The gap must point towards the oil pan. If necessary,
loosen and turn the bolt.
– Fit the engine mount - T10536- as shown and secure with

screw -T10536/5- and nut -T10536/4- .
– Insert the engine/gearbox jack - V.A.G 1383 A- into the engine
mount - T10536- and raise the engine/gearbox unit slightly.
Note
Use the double ladder to release the screws for the assembly
bracket.
– Completely unscrew engine mount screws -3- for engine

mounting -2-.
– Completely unscrew screws -1- for gearbox mount -4-.
CAUTION
Risk of damaging vacuum lines or electric cables and the en‐
gine compartment!
♦ Check that all vacuum lines and electric cables between en‐
gine, gearbox and body have been loosened.
♦ Guide the engine/gearbox unit out of the engine compart‐
ment carefully when lowering.
– Carefully lower the engine with gearbox.

1.2 Disconnecting engine and gearbox

⇒ “1.2.1 Disconnect the engine from the gearbox - vehicles with
manual gearbox ”, page 14
⇒ “1.2.2 Disconnect the engine from the gearbox - vehicles with
automatic gearbox”, page 15
1.2.1 Disconnect the engine from the gearbox

- vehicles with manual gearbox
♦ Workshop crane , e.g. -VAS 6100-
♦ Shackle - 10-222 A/12-
Work procedure
• Engine/gearbox unit removed and attached to engine mount -
T10536- .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
– Release screws -arrows- and remove gearbox support brack‐
et.
– Attach the gearbox with the clevis - 10-222 A/12- to the work‐
shop crane - VAS 6100- .

– Unscrew the connecting screws -1-, -2-, -5-, -6-, -7-, -8- con‐
necting the gearbox/engine.
– Remove the gearbox from the engine, taking care with the in‐
termediate plate.
1.2.2 Disconnect the engine from the gearbox

- vehicles with automatic gearbox
• Engine/gearbox unit removed and attached to engine mount -
T10536- .
– Disconnect coolant hoses from gearbox oil cooler and loosen
hose clamps.
– Move the engine/gearbox unit with engine/gearbox jack -
V.A.G 1383 A- to a work bench and lower the until in such a
way that the gearbox is positioned on the support.
– Expose electrical cables on the bracket -arrow- and place
plug-in connection -1- on the bracket.
– Unscrew screws -1- and -2- and starter from the gearbox.

– Unscrew the connecting screws -1-, -3-, -5-, -6-, -7-, -8-, -9-,
-10- connecting the gearbox/engine.
Note
Screw -3- is only accessible after removing the starter.
– Remove the gearbox from the engine.
1.3 Attach engine attached to engine and

gearbox mount
♦ Workshop crane - VAS 6100-
♦ Engine and gearbox mount - VAS 6095-
♦ Lifting device - MP9-201 (2024A)-
Work procedure
• Separate engine from gearbox.
CAUTION
Use securing pins on the hooks and rig pins to prevent release!
– Hook lifting device - MP9-201 (2024 A)- to engine and to the

workshop crane - VAS 6100- .
Note
For coordination with the unit centre of gravity, the perforated rails
of the lifting hook must be placed as shown.
CAUTION
There is a risk of accident from loose parts of the lifting device!
♦ The suspension hooks and locking pins on the lifting device
must be secured with plug-in locks -arrows-.
– Remove the engine with the workshop crane - VAS 6100- from
the engine and gearbox jack - V.A.G 1383 A- .

– Screw on engine with the gearbox side to the engine and

gearbox jack - VAS 6095- as shown.
1.4 Installing engine
Note
♦ Tightening torques apply only for lightly greased, oiled,

phosphatized or blackened nuts and screws.
♦ Other lubricants such as engine and gearbox oil are allowed.
However, do not use lubricants containing graphite.
♦ Do not use degreased parts.
Work procedure
Note
♦ Screws which have been tightened firmly to a torquing angle

must be replaced.
♦ Replace self-locking nuts and screws as well as sealing rings,
gaskets and O-rings.
♦ Hose connections and air guide pipes and hoses must be free
of oil and grease before being installed.
♦ Secure all hose connection with spring-type clips that comply
with the series design ⇒ ETKA - Electronic Catalogue of Orig‐
inal Parts .
♦ Fit all cable straps on again in the same place when installing.
– Install intermediate plate

⇒ “2.1 Summary of components - cylinder block on gearbox
side”, page 43 .

– If there are no dowel sleeves -A- are available in the cylinder

block for centering the engine and gearbox, insert dowel
sleeves.
Note
A vehicle with manual gearbox is shown as an example.

– If a needle bearing is installed in the crankshaft, remove the
needle bearing
⇒ “3.3 Replace the needle bearing in the crankshaft”,
page 54 .
– If the clutch release bearing is worn, replace the clutch release
bearing ⇒ Rep. gr. 30 ; Clutch mechanism .
– Lightly grease the gearing of the gearbox drive shaft using lu‐
bricating grease for spline ⇒ ETKA - Electronic Catalogue of
Original Parts .
– Check the centering of the clutch disc.
– If no needle bearing is installed in the crankshaft, install needle
bearing
⇒ “3.3 Replace the needle bearing in the crankshaft”,
page 54 .
– Secure gearbox to engine.
– Install gearbox support bracket.
– Lift engine/gearbox unit with the engine mount - T10536- .
– Insert engine/gearbox assembly in the body.
– Initially insert screws -3- for engine mount by hand as far as

the stop.

– Initially insert screws -arrows- for gearbox mount -1- by hand

as far as the stop.
– Remove engine mount - T10536- from engine.
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐
moving and installing starter .
– Install pre-exhaust pipe
page 266 .
– Install lefty and right drive shaft ⇒ Rep. gr. 40 ; Drive shaft;
Removing and installing drive shaft .
– Install assembly carrier ⇒ Rep. gr. 40 ; Assembly carrier; Re‐
moving and installing assembly carrier without steering gear .
– Install AC compressor ⇒ Heating, Air Conditioning; Rep. gr.
87 ; AC compressor; Removing and installing AC compressor .
– Install the V-ribbed belt
– Tighten engine and gearbox mount
⇒ “2.1 Assembly overview - assembly mountings”,
page 21 .
– Install engine control unit
⇒ “7 Engine control unit”, page 249 .
– Remove clutch slave cylinder: ⇒ Rep. gr. 30 ; Clutch slave
cylinder; Removing and installing clutch slave cylinder .
– Install shift mechanism on gearbox ⇒ Rep. gr. 34 ; Shift
mechanism; Removing and installing shift mechanism .
– Electrical connections and proper routing ⇒ Electrical System;
Rep. gr. 97 ; Relay carrier, fuse holder, E-boxes; Removing
and installing E-box .
– Checking the oil level:
NOTICE
Risk of damaging control units as a result of overvoltage.
♦ Do not use charger for jump starting!
– Venting air from the fuel system

– Top up coolant ⇒ page 132 .
– Install the front left and right wheelhouse liner ⇒ Exterior body
work ; Rep. gr. 66 ; Wheelhouse liner; Removing and installing
the front wheelhouse liner .

Note
♦ After installing new parts (engine/partial engine, cylinder head,

camshaft housing or exhaust gas turbocharger), the oil pres‐
sure control must be limited to the high pressure level for
approx. 1000 km. This takes into account the higher friction
when running in new components and ensures optimum evac‐
uation of particles from running-in wear.
♦ The function to increase oil pressure does not always have to
be available on the engine control unit. In this case, the oil
pressure is not increased.
– Connect diagnostic unit ⇒ Vehicle diagnostic tester.

– Switch on the ignition and select:
♦ 01 - Adaption
♦ Oil pressure for engine run-in
Tightening torques - summaries of components
NOTICE
♦ When installing a complete new engine and after fitting the
high pressure lines, it is absolutely necessary to tighten the
clamping claws of the injection units to the specified tight‐
ening torque
page 215 .
♦ In order to align the injection units when fitting the high pres‐
sure lines, the clamping claws are only tightened "hand-
tight" after delivery. If you do not do so, the engine may be
damaged.
Component Nm
Screws/nuts M6 10
M7 15
M8 20
M10 40
M12 65
Note
Replace bolts / nuts that are tightened at an angle of rotation, as

well as replacement components after removal.
♦ Assembly bracket
⇒ “2.1 Assembly overview - assembly mountings”,
page 21 .
♦ Attach gearbox to engine ⇒ Rep. gr. 34 ; Removing and in‐
stalling gearbox .

2 Assembly bracket
⇒ “2.1 Assembly overview - assembly mountings”, page 21
⇒ “2.2 Removing and installing engine mount”, page 22
⇒ “2.3 Removing and installing gearbox mount”, page 23
⇒ “2.4 Removing and installing pendulum support”, page 24
⇒ “2.5 Support the engine in its installed position”, page 25
2.1 Assembly overview - assembly mountings
1 - Screw
❑ Gearbox mount
❑ Replace after disas‐
sembly
❑ 40 Nm + 90°.
2 - Screw
❑ Gearbox mount to body
sembly
❑ 50 Nm + 90°.
3 - Gearbox mount
❑ Removing and installing
⇒ “2.3 Removing and in‐
stalling gearbox mount”,
page 23
4 - Gearbox bracket
5 - Screw
❑ Gearbox bracket
❑ ⇒ Gearbox; Rep. gr.
34 ; Assembly bracket
6 - Screw
❑ for pendulum support to
assembly carrier
sembly
❑ 30 Nm + 90°.
7 - Screw
❑ for pendulum support
sembly
❑ 40 Nm + 90°.
8 - Pendulum support
❑ Removing and installing ⇒ “2.4 Removing and installing pendulum support”, page 24
9 - Engine mounting
❑ Removing and installing ⇒ “2.2 Removing and installing engine mount”, page 22
10 - Screw
❑ for engine mounting
❑ Replace after disassembly
❑ 20 Nm + 90°.
2. Assembly bracket 21
11 - Double screw
❑ 30 Nm + 90°.
12 - Screw
❑ 30 Nm + 90°.
2.2 Removing and installing engine mount

Removing
⇒ “3.1 Removing and installing engine trim panel”,
page 27 .
– Disconnect quick couplings -1- and lay fuel hoses on the en‐
gine.
Remove the coolant expansion tank -3- and pull up laterally.
– Support the engine and gearbox in installed position
⇒ “2.5 Support the engine in its installed position”,
page 25 .
– Uniformly pre-tension the engine/gearbox unit with spindles,
but do not raise.
– Release nuts -1- and remove earth cable -2-.

– Unscrew screws -3- and -1- and remove engine mounting

-2- towards the top.
Installing
The installation occurs in reverse order. However, pay attention
to the following:
Note

2.3 Removing and installing gearbox mount

Removing
– Support the engine and gearbox in installed position
⇒ “2.5 Support the engine in its installed position”,
page 25 .
– Unscrew screws -1-, -2- and -3- for gearbox mount.

– Remove gearbox mount -4-.
Installing
to the following:
Note
Replace screws which have been tightened firmly to a torque an‐

gle.
– Fix the gearbox mount to the longitudinal beam.
NOTICE
There is a risk of damaging the thread in the gearbox support
by tightening the bolts obliquely!
♦ Before the screws are turned, the gearbox supports and
supporting arm must be absolutely parallel to each other. If
necessary, push up gearbox using a hydraulic trolley jack.
♦ Do not remove support bracket until the bolts securing the
assembly mounting have been tightened to specified torque.
– Raise the gearbox with the hook - 10-222A/32- so that the

gearbox support bracket is resting on the supporting arm of
the gearbox mount.
– Remove supporting device - MP9-200 (10-222A)- .
Note

♦ Battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing
and installing battery
2.4 Removing and installing pendulum sup‐

port
Removing
– Remove the noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Summary of components -
noise insulation .

– Unscrew screws -1- and -2- and remove the pendulum sup‐
port.
Installing
to the following:
Note

gle.
Note

♦ Noise insulation ⇒ General body repairs, exterior ; Rep. gr.

66 ; Noise insulation; Summary of components- noise insula‐
tion .
2.5 Support the engine in its installed posi‐

tion
♦ Supporting device - MP9-200 (10-222A)-
♦ Adapter - T10540-
♦ Hook - MP9-200/10 (10-222A/10)-
♦ Hook - 10-222A/32-
♦ Shackle - 10-222A/12-
♦ Adapter - MP9-200/18 (10-222A/18)-
– If present, release connector -3- and pull off.
– Press release buttons on the hose -1- for crankcase ventilation
and remove from cylinder head.
– Fit supporting device - MP9-200 (10-222A)- .
1 - MP9-200 (10-222A)
2 - MP9–200/10
3 - MP9–200/18 (10-222A/18)
4 - 10-222A/32
5 - T10540/1
6 - T10540/2
7 - 10–222A/12
Arrow - hexagon bolt

– Secure the support bracket - MP9–200 (10 - 222 A)- on both
sides to the lid hinges with the tensioning strap - T10038- .
– Uniformly pre-tension the engine/gearbox unit with both spin‐
dles, but do not raise.

3 Engine trim panel

⇒ “3.1 Removing and installing engine trim panel”, page 27
3.1 Removing and installing engine trim

panel
Removing
– Carefully pull the engine cover off the rubber bolts one after
another -arrows-. Do not pull engine cover off in jerks or on
one side.
Installing
– To avoid damage, do not strike the engine cover with the fist
or a tool.
– Position the engine cover paying attention to the oil fill sup‐
ports and dipstick.
– Press the engine cover into the rubber bolts at the top, first on
the left, then on the right.
3. Engine trim panel 27

13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Assembly overview - V-ribbed belt drive”, page 28
⇒ “1.2 Summary of components - sealing flange on the belt pulley
side”, page 30
⇒ “1.3 Removing and installing V-ribbed belt”, page 31
⇒ “1.4 Removing and installing tensioning element for V-ribbed
belt”, page 33
⇒ “1.5 Removing and installing bracket for auxiliary units”,
page 34
⇒ “1.6 Removing and installing engine support”, page 35
⇒ “1.7 Removing and installing belt pulley”, page 37
⇒ “1.8 Replacing crankshaft sealing ring on the belt pulley side”,
page 37
⇒ “1.9 Removing and installing the sealing flange on the belt pul‐
ley side”, page 40
1.1 Assembly overview - V-ribbed belt drive
28 Rep. gr.13 - Crankshaft group

1 - V-ribbed belt
❑ check for wear
❑ before removing, mark
out the rotation direction
with chalk or felt pen
(risk of damage through
reversing the rotation di‐
rection of an already
used belt).
❑ do not kink
❑ Routing of the ribbed V-
belt ⇒ page 32
stalling V-ribbed belt”,
page 31
❑ Pay attention to the cor‐
rect position of the V-rib‐
bed belt in the belt pulley
when installing it
2 - Screw
sembly
❑ 10 Nm + 90°.
3 - V-ribbed belt pulley
stalling belt pulley”,
page 37
4 - Mounting bracket
❑ for generator
❑ installed on crankcase
⇒ “1.5.2 Removing and
installing bracket for alternator”, page 35
5 - Screw
❑ 20 Nm + 180°.
6 - AC generator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator .
7 - Screw
❑ Tightening torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator .
8 - AC compressor
❑ Do not open refrigerant circuit
❑ installing and removing ⇒ Heating, Air Conditioning; Rep. gr. 87 ; AC compressor; installing and re‐
moving AC compressor
9 - Screw
❑ Tightening torque ⇒ Heating, Air Conditioning; Rep. gr. 87 ; AC compressor; installing and removing
AC compressor
10 - Tensioner for V-ribbed belt
❑ before installing, check whether both dowel sleeves for centering the tensioning element at the cylinder
block are present
⇒ “1.4 Removing and installing tensioning element for V-ribbed belt”, page 33
1. Cylinder block (pulley end) 29

11 - Screw
❑ 20 Nm + 90°.
1.2 Summary of components - sealing flange on the belt pulley side
1 - Screw
❑ Tightening torque Pos.
-1-
⇒ Item 1 (page 82)
2 - Crankshaft toothed belt
sprocket
❑ there must not be any oil
present on the contact
surface between the
pulley and the crank‐
shaft
❑ can be installed only in
one position
3 - Sealing ring
❑ for crankshaft on the
belt pulley side
❑ Replace sealing ring
⇒ “1.8 Replacing crank‐
shaft sealing ring on the
belt pulley side”,
page 37
4 - Screw
❑ Tightening torque and
tightening order
⇒ Fig. ““Sealing flange
on the belt pulley side -
tightening torque and
tightening order”“ , page
31
5 - Fit pin
❑ Different versions ⇒ ET‐
KA - Electronic Cata‐
logue of Original Parts
6 - Fit pin
KA - Electronic Catalogue of Original Parts
7 - Sealing flange on the belt pulley side
⇒ “1.9 Removing and installing the sealing flange on the belt pulley side”, page 40

Sealing flange on the belt pulley side - tightening torque and tight‐
ening order
– Tighten screws in steps in the given sequence:
Level screws Tightening torque
1. -1- to -10- Tighten by hand as far as the stop
2. -1- to -6- crosswise in steps up to 13 Nm
3. -7- to -10- 13 Nm
1.3 Removing and installing V-ribbed belt

⇒ “1.3.1 Removing and installing V-ribbed belt - Vehicles without
air conditioning”, page 31
⇒ “1.3.2 Removing and installing V-ribbed belt - Vehicles with air
conditioning”, page 31
1.3.1 Removing and installing V-ribbed belt -

Vehicles without air conditioning
Note
The repair kit includes the V-ribbed belt, the assembly tool -
T10367- and an illustrated work procedure ⇒ ETKA - Electronic
Catalogue of Original Parts .
Removing
noise insulation .
– Remove the front right wheelhouse liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheelhouse liner; Removing and
installing the front wheelhouse liner .
– Cut through V-ribbed belt.
Installing
Assembly is carried out in the reverse order. When installing, ob‐
– The following work procedure is described in the illustrated
work procedure from the repair kit.
– Start engine and check ribbed V-belt run.
1.3.2 Removing and installing V-ribbed belt -

Vehicles with air conditioning
♦ Locking pin - T10060 A-

Removing
noise insulation .
NOTICE
Risk of damage by reversing the direction of rotation of a V-
ribbed belt that has already been used.
♦ Mark the direction of rotation with chalk or a felt-tip pen be‐
fore removing the V-ribbed belt so that it can be reinstalled
again.
– Swivel tensioning device in -direction of arrow- to slacken the

V-ribbed belt.
– Secure tensioning device with locking pin - T10060 A- .
– Remove the V-ribbed belt.
Installing
to the following:
– Lay the V-ribbed belt in stages, as shown:

1- V-ribbed belt pulley
2- Tensioning pulley for V-ribbed belt
3- Belt pulley for generator
4- Belt pulley for AC compressor
– Turn the tensioning element in the -direction of the arrow- and

pull out the locking pin - T10060 A- .
– Check that the V-ribbed belt is positioned correctly.
– Start engine and check the that the V-ribbed belt is running
correctly.

1.4 Removing and installing tensioning ele‐

ment for V-ribbed belt
Removing
– Remove alternator ⇒ Electrical system ; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
– Unscrew screw -2-, loosen screws -4-.
– Remove the air conditioner compressor from the engine.
– Unscrew screw -2- and remove tensioning roller -1-.

Installing
to the following:
Note
♦ Insert the dowel sleeves for centering the tensioning element

for V-ribbed belt ⇒ ETKA - Electronic Catalogue of Original
Parts .
♦ Replace screws which have been tightened firmly to a torque
angle.
– Tighten air conditioner compressor.

Note

♦ V-ribbed belt drive


1.5 Removing and installing bracket for aux‐

iliary units
⇒ “1.5.1 Removing and installing bracket for high pressure pump”,
page 34
⇒ “1.5.2 Removing and installing bracket for alternator”,
page 35
1.5.1 Removing and installing bracket for high

pressure pump
Removing
⇒ “3.1 Removing and installing engine trim panel”, page 27 .
– Remove the toothed belt from the camshaft
⇒ “2.4 Removing and installing toothed belt”, page 85 .
– Remove high pressure pump
⇒ “8.2 Removing and installing the high pressure pump”, page
254 .
– Unscrew pin screw -1- and screw -3- for the fuel return-flow
line -2-.
– Unscrew screws -1- and remove bracket for high pressure

pump -2-.
Installing
to the following:
– Install high pressure pump
254 .
– Install the toothed belt
Note

♦ Cylinder head
⇒ “1.1 Summary of components - cylinder head”, page 63

1.5.2 Removing and installing bracket for al‐

ternator
Removing
– Remove the bracket for high pressure pump
⇒ “1.5.1 Removing and installing bracket for high pressure
pump”, page 34
– Remove alternator ⇒ Electrical system ; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
– Unscrew screw -2- and remove bracket for alternator -1-.
Installing
to the following:
– Install the bracket for high pressure pump
⇒ “1.5.1 Removing and installing bracket for high pressure
pump”, page 34 .
– Install high pressure pump
254 .
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;
Removing and installing alternator .
Note


1.6 Removing and installing engine support

Removing
– Remove top toothed belt guard
⇒ “2.3.1 Removing and installing top toothed belt guard”, page
83 .
– Remove bottom toothed belt guard
⇒ “2.3.2 Removing and installing bottom toothed belt guard”,
page 84 .
– Remove engine mounts
⇒ “2.2 Removing and installing engine mount”, page 22 .
– Raise (lower) engine/gearbox unit with the spindle uniformly
so that the screws for the engine support bracket are acces‐
sible.

– Unscrew and remove nuts -1- and remove refrigerant lines

-2- from the double screws.
– Release screws -A- by one turn and unscrew screws -B-.

– Unscrew screws -2-, -4- and -5- and remove engine support
bracket -3- upwards.
Installing
to the following:
– Insert engine support bracket -3- and first tighten screws -2-,
-4-, -5- by hand, then tighten to specified torque.
– Tighten the screws -A- and -B-.
– Install engine mount
⇒ “2.2 Removing and installing engine mount”, page 22 .
– Install bottom toothed belt guard
page 84
– Install top toothed belt guard
83 .
Note

gle.
Engine support bracket - tightening torque and tightening order

Level screws Tightening torque/torque angle
1. -2-, -4-, -5- 7 Nm
2. -2-, -4-, -5- 50 Nm
3. -2-, -4-, -5- Turn 180° further

1.7 Removing and installing belt pulley

Removing
noise insulation .
– Remove V-ribbed belt ⇒ page 31 .
– Release the holding clamps -1- and push the refrigerant line
-2- to one side.
– Hold the screw for crankshaft sprocket with the socket insert
and release the screws -arrow- for the belt pulley.
– Unscrew screws and remove belt pulley.
Installing
to the following:
Note
Assembly of the belt pulley is only possible in one position.
– Install vibration damper and tighten the new screws ⇒ ETKA

- Electronic Catalogue of Original Parts .
Note


1.8 Replacing crankshaft sealing ring on the

belt pulley side
♦ Counterholder - T30004 (3415)-
♦ Extractor - T10443-
♦ Guide bushing - T10117- or -T10117A- with screw - T10117/3-

Work procedure
83 .
page 84 .
⇒ “2.5 Remove the toothed belt from the camshaft”,
page 93 .
– Crankshaft arrester - T10490- for crankshaft.
NOTICE
Risk of damage to valves and piston crowns!
♦ The crankshaft must not be turned any further when the
toothed belt has been removed and the camshafts are
mounted.
Risk of damage to the toothed belt!
♦ Do not over-tension or kink the toothed belt.
– Unscrew screw -1- for crankshaft-toothed belt sprocket with

the counterholder - T30004 (3415)- .
– Unscrew screws and remove crankshaft-belt pulley.
NOTICE
If it is turned back too much, the inner pressure plate loosens -
T10443- from the pressure screw.
The pressure plate must then be pressed onto the pressure
screw once again.
– Carefully turn back set screw -arrow- of the extractor - T10443-

until a slight resistance is noticeable.

– Place extractor - T10443- straight, as shown in the illustration,

and lock by tightening the set screw -2-.
– Screw in the pressure screw -1- until the gasket ring is pulled
out.
– Clean the contact and sealing surfaces.
Note
The sealing lip of the gasket ring must not be oiled or greased
additionally.
– Position the guide sleeve - T10117/1- on the crankshaft.

– Carefully slide the new gasket ring for crankshaft -1- over the
guide bushing onto the camshaft.
• The labelled side of the gasket points outwards.
• The guide sleeve - T10117/1- remains fitted on the crankshaft
while the gasket is being pressed in.
– Place guide sleeve - T10117- with screw - T10117/3- onto the

crankshaft.
– Press in gasket ring -1- to stop.
– Position toothed belt pulley on the crankshaft.

• The contact surface between the V-ribbed belt pulley and the
toothed belt pulley must be free of oil and grease.
• The surface -arrow- on the toothed belt pulley must be placed
in contact with the crankshaft journal, as shown in the figure.
NOTICE
mounted.

– Tighten screw -1- for crankshaft-toothed belt sprocket with the

counterholder - T30004 (3415)- .
– Lock the crankshaft toothed belt sprocket using the crankshaft

arrester - T10490- .
• The studs of the crankshaft arrester - T10490- must reach into
the threaded bores of the toothed belt pulley.
• The rig pin of the crankshaft arrester - T10490- must reach into
the bores at the sealing flange.
– install (set the timing) ⇒ page 88 .
Note

♦ Toothed belt
⇒ “2.2 Summary of components - toothed belt”, page 82
1.9 Removing and installing the sealing

flange on the belt pulley side
♦ Counterholder - T30004 (3415)-
♦ Assembly tool - T10053-
♦ Cleaning and degreasing agent , e.g. -D 009 401 04-
♦ Silicone sealant ⇒ ETKA - Electronic catalogue of original
parts
Removing
– Remove toothed belt

– Unscrew screw for crankshaft-toothed belt sprocket with the

counterholder - T30004 (3415)- .
– Remove crankshaft toothed belt sprocket.
– Remove sump top part
⇒ “1.3 Removing and installing top part of the oil sump”, page
111 .
– Unscrew the remaining screws and release the sealing flange
from the bonding.
– Carefully drive out the sealing ring from the removed sealing
flange.
Installing
– Remove residual sealant on the cylinder head and sump top
part using a chemical sealant remover.
– Clean sealing surfaces, they must be free of oil and grease.
– Fit the assembly tool - T10053/1- onto the crankshaft journal.
Note
Pay attention to the use by date on sealant.
NOTICE
Risk of blockage of the lubrication system through excess seal‐
ant!
♦ The sealant bead must not be thicker than specified.
• Thickness of sealant beads: 2-3 mm.

– Apply sealant bead -2- to the clean sealing surface as shown.

– Apply a thin coat of sealant to the lower sealing surface -1- on
the sealing flange.
Note
The sealing flange must be installed within 5 minutes after apply‐

ing the sealant.
Install sealing flange with built-in sealing ring

– Insert the new sealing flange using the assembly tool -
T10053/1- .
– Remove assembly tool - T10053/1- and tighten screws for
sealing flange by hand as far as the stop.
– Tighten screws for sealing flange crosswise. Tightening torque
and tightening order
⇒ Fig. ““Sealing flange on the belt pulley side - tightening tor‐
que and tightening order”“ , page 31 .
Install sealing flange without installed sealing ring
– Push sealing flange onto the dowel pins on the cylinder block.
– Tighten screws for sealing flange crosswise. Tightening torque
and tightening order
⇒ Fig. ““Sealing flange on the belt pulley side - tightening tor‐
que and tightening order”“ , page 31 .
– Installing seal
⇒ “1.8 Replacing crankshaft sealing ring on the belt pulley
side”, page 37 .
Continued
– Install sump top part
111 .
Further installation occurs in reverse order. However, pay atten‐
tion to the following:
Note

♦ Sealing flange
⇒ “1.2 Summary of components - sealing flange on the belt
pulley side”, page 30

2 Cylinder block on gearbox side

⇒ “2.1 Summary of components - cylinder block on gearbox side”,
page 43
⇒ “2.2 Removing and installing flywheel”, page 44
⇒ “2.3 Removing and installing sealing flange on gearbox side”,
page 45
2.1 Summary of components - cylinder block on gearbox side
1 - Screw
sembly
❑ 60 Nm + 90°.
2 - Flywheel
stalling flywheel”,
page 44
❑ Pre-tension gearing in
the flywheel
stalling flywheel”,
page 44
❑ Can only be installed in
one position
3 - Engine speed transmitter -
G28-
❑ Summary of compo‐
nents
⇒ “1.1 Summary of com‐
ponents - Glow plug
system”, page 294
4 - Screw
❑ Tightening torque
ponents - Glow plug
system”, page 294
5 - Intermediate plate
❑ must be positioned on
dowel sleeves
❑ do not damage/bend
during assembly work
6 - Fitting sleeve
❑ 2 units
7 - Sealing flange on the gearbox side
❑ with integrated sealing ring
❑ Removing and installing ⇒ “2.3 Removing and installing sealing flange on gearbox side”, page 45
8 - Screw
❑ Tightening torque and tightening order
⇒ Fig. ““Sealing flange on the gearbox side - tightening torque and tightening order”“ , page 44
2. Cylinder block on gearbox side 43

Sealing flange on the gearbox side - tightening torque and tight‐

ening order
2. -1- to -6- crosswise in steps up to 13 Nm
2.2 Removing and installing flywheel

⇒ “2.2.1 Pre-tension gearing in the flywheel - vehicles with auto‐
matic gearbox”, page 44
⇒ “2.2.2 Removing and installing flywheel”, page 44
2.2.1 Pre-tension gearing in the flywheel - ve‐

hicles with automatic gearbox
Note
In vehicles with automatic gearbox, the gearing of the gearbox in

the flywheel must be pre-tensioned and secured. Pre-tensioning
is initiated when the engine is started for the first time and it se‐
cures the gearing between flywheel and gearbox.
– Insert screwdriver into the recess and turn by 90° in direction

of arrow -A- so that the locking clutch -1- is exposed above the
recess.
– Press in the locking clutch with a tool in direction of arrow
-B- and loosen the screwdriver.
– Repeat the procedure for the other locking clutch.
The gearing in the flywheel is now pre-tensioned and ready for
installation.
2.2.2 Removing and installing flywheel

♦ Flywheel lock - MP1-223 (3067)-
Removing
• Gearbox removed
– Remove the clutch ⇒ Rep. gr. 30 ; Clutch mechanism .

For all vehicles

– Insert counterholder - MP1-223 (3067)- into the bore on the
cylinder block Pos. -B-.
– Loosen and remove all flywheel bolts.
Installing
to the following:
NOTICE
In vehicles with automatic gearbox, the gearing of the gearbox
in the flywheel must be pre-tensioned and secured.
Pre-tensioning is initiated when the engine is started for the first
time and it secures the gearing between flywheel and gearbox
⇒ “2.2.1 Pre-tension gearing in the flywheel - vehicles with au‐
tomatic gearbox”, page 44 .
Note
Assembly of flywheel is only possible in one position.
– Insert counterholder - MP1-223 (3067)- into the bore on the

cylinder block Pos. -A-.
Note

♦ Cylinder block
side”, page 43
2.3 Removing and installing sealing flange

on gearbox side
♦ Tool insert SW 24 - V.A.G 1332/11-
♦ Depth gauges , e.g. -VAS 6082-
♦ 3x screw M6x35
♦ 2x screw M7x35
Press out sealing flange with rotor
• Gearbox removed.
– Remove the flywheel
⇒ “2.2 Removing and installing flywheel”, page 44 .
Note
For clearer illustration, the following work sequences are shown

on the removed engine.

– Remove intermediate plate -1- from the dowel sleeves arrows

-A-.
– Move intermediate plate -1- upwards.
– At the same time, pull the retaining lug arrow -B- of the inter‐
mediate plate -1- out of the recess behind the sealing flange.
– Turn the crankshaft at the screw for toothed belt pulley until
the crankshaft is positioned on “TDC” as shown in the illustra‐
tion.
– Removing the oil pan
111 .
– Remove engine speed transmitter - G28-
⇒ “1.6 Removing and installing the engine speed transmitter
G28 ”, page 298 .
– Unscrew screws -arrows- on sealing flange -1-.
– Sealing flange and rotor are pressed together with 3 M6x35

mm screws from the crankshaft.
– Alternating, screw in three screws -arrows- (max. 1/2 turn
(180°) per screw) into the threaded holes of the sealing flange
-1- and remove the sealing flange together with the rotor -2-
from the crankshaft -3-.
– Remove sealing flange -1- with rotor -2-.

Sealing flange with rotor
Note
♦ The sealing flange with PTFE sealing ring is provided with

sealing lip supporting ring -2-. This support ring serves as a
fitting sleeve and must not be removed prior to installation.
♦ Do not separate or turn the sealing flange and rotor -1- after
removing them from the spare part package.
♦ The rotor -1- is brought to its installation position on the as‐
sembly tool - T10134- by a locating pin ⇒ page 47 .
♦ Sealing flange and sealing ring form one unit and must only
be renewed together with the transmitter wheel.
♦ The assembly tool - T10134- is brought to its installation po‐
sition to the crankshaft by a guide pin, which is inserted into a
hole in the crankshaft ⇒ page 47 .
Assembly tool - T10134-

A - Clamping surface
B - Nut
C - Assembly housing
D-
Locating pin
E - Allan screws (2 pieces)
F - Guide pin for petrol engines (red knob)
G-
Guide pin for diesel engines (black knob)
H - Knurled screws (3 pieces)
I - Inner part
Mount sealing flange with rotor on assembly tool - T10134-

– Untwist nut -B- until just before it touches the clamping surface
-A- of the threaded spindle.

– Clamp assembly tool - T10134- on clamping surface -A- of the

threaded spindle in a vice -1-.
– Press assembly housing -C- downwards until it lies on hexa‐
gon nut -B-.
– Screw nut onto threaded spindle until inner part of assembly
tool and assembly housing are at same height.
– Remove the securing clip -arrow- from the new sealing flange
-1-.
Note
Do not remove the rotor from the sealing flange or turn it.
• The locating hole -A- on the rotor -C- must be flush with the
marking -B- on the sealing flange.
– Place sealing flange with front side facing down on a clean

level surface.
– Press down sealing lip supporting ring -1- in
-direction of arrow-, until it rests on the level surface.

• The upper edge of the sealing lip supporting ring -1- and front
edge of the sealing flange -2- must align -arrows-.
– Lay the sealing flange -1- with the front side on the assembly
tool - T10134- so that the positioning pin -D- engages into the
hole -3- of the rotor -2-.
• Sealing flange must lie straight on the assembly tool.
• Only 2 of the 3 knurled screws -H- can be screwed in at a time!
– Press on the sealing flange -1- and sealing lip supporting ring
-2- by tightening the 2 knurled screws -H- onto the surface of
the assembly tool - T10134- .
Note
This prevents locating pin from slipping out of sender wheel hole.
– When installing the sealing flange, ensure that the sender

wheel remains fixed in the assembly device.
Attach the assembly tool - T10134- with the sealing flange -1- to
the crankshaft flange:
• The crankshaft flange must be free of grease and oil.
• The engine is at “TDC”.
– Screw nut -B- on until it reaches end of threaded spindle.
– Press the threaded spindle of the assembly tool - T10134- in
-direction of arrow- until the nut -B- rests against the assembly
cup -C-.
– Align flat side of assembly housing to the cylinder block sealing
surface on the oil sump side.

– Secure the assembly tool - T10134- and the sealing flange

-1- with Allan screws -E- to the crankshaft flange -2-.
Note
Screw in Allan screws -E- into the crankshaft flange by approx.

five thread turns.
– Slide the guide pin for diesel engines (black knob) -G- into the
crankshaft flange.
– Screw in two M6x35 mm screws -2- by about 3 turns for sealing

flange guide -1- into the cylinder block.
Secure assembly tool - T10134- to crankshaft flange

– Push the assembly cup -C- by hand in the
-direction of the arrow- until the sealing lip supporting ring -1-
rests on the crankshaft flange -2-.
– Check whether the guide pin for diesel engines (black knob)
-G- is correctly seated in the hole on the crankshaft. This gives
the rotor its final installation position.
Note
The guide bolt for petrol engines (red knob) must not be fitted into
the threaded hole of the crankshaft.
– Tighten the two hexagon socket head bolts of the assembly

tool hand-tight.
– Screw nut -B- onto threaded spindle by hand until it lies against
assembly housing -C-.
Press rotor onto the crankshaft flange using the assembly tool -
T10134- :
– Tighten nut -B- of the assembly tool - T10134- to 35 Nm.
• After nut is tightened to 35 Nm, a small air gap must still be
present between cylinder block and sealing flange -1-.

Checking transmitter wheel installation position on crankshaft

– Screw nut -B- on until it reaches end of threaded spindle.
– Unscrew both bolts -2- from the cylinder block.
– Pull the guide bolt for diesel engines (black knob) -G- out of
the crankshaft flange.
– Remove knurled screws -H- from the sealing flange -1-.
– Unscrew the Allan screws -E- from the crankshaft flange.
– Remove assembly tool - T10134- .
– Remove sealing lip support ring.
– Mount depth gauge - VAS 6082- onto the crankshaft flange

-2-.
– Measure distance -a- between crankshaft flange -2- and rotor

-1-.
• Set value: dimension -a- = 0.5 mm
If dimension »a« is too small:
– Press down rotor ⇒ page 51 .
If dimension »a« is achieved:
– Complete the remaining installation ⇒ page 52 .
Re-pressing transmitter wheel

– Secure the assembly tool - T10134- and with Allan screws
-E- to the crankshaft flange.
Make sure the positioning pin of the assembly tool - T10134- en‐
gages in the bore of the rotor.
– Tighten the two Allan screws -E- hand-tight.
– Press the assembly tool - T10134- against the sealing flange
-1- by hand.
– Screw nut -B- onto threaded spindle by hand until it lies against
the assembly housing - T10134- .
– Slide the guide pin for diesel engines (black knob) -G- into the
crankshaft flange.
– Screw the knurled screws -H- into the flange -1-.
– Screw 2 screws M6x35 -2- to guide the sealing flange into the
cylinder block.


– Check the fitting position of the rotor on the crankshaft again
⇒ page 51 .
If the dimension »a« is too small again:
– Check the fitting position of the rotor on the crankshaft again
⇒ page 51 .
Installing
Installation is carried out in the reverse order. When installing,
observe the following:
– Tighten screws for sealing flange crosswise.
– Installing the oil pan
111 .
– Install intermediate plate
side”, page 43 .
– Install the flywheel
Note

♦ Sealing flange on the gearbox side

side”, page 43 .
♦ Engine speed sender - G28-
⇒ “1.1 Summary of components - Glow plug system”,
page 294 .

3 Crankshaft
⇒ “3.1 Summary of components - crankshaft”, page 53
⇒ “3.2 Crankshaft dimensions”, page 54
⇒ “3.3 Replace the needle bearing in the crankshaft”, page 54
⇒ “3.4 Measuring axial play of crankshaft”, page 55
3.1 Summary of components - crankshaft
1 - Drive wheel
❑ for balancing shaft
❑ is not as spare part
2 - Crankshaft
❑ Measure axial play
⇒ “3.4 Measuring axial
play of crankshaft”,
page 55
❑ Checking axial clear‐
ance with Plastigage:
❑ Axial clearance: new
part: 0.03-0.08 mm;
wear limit: 0.17 mm
❑ do not rotate crankshaft
when checking radial
clearance
❑ Crankshaft dimensions
⇒ “3.2 Crankshaft di‐
mensions”, page 54
❑ A needle bearing is in‐
stalled in vehicles with
automatic gearbox
3 - Bearing shell
❑ in bearing cap
❑ without lubricating
groove
❑ Replace used
4 - Bearing caps
❑ Bearing cap 1: belt pul‐
ley side
❑ retaining lugs of the
bearing shells of the cyl‐
inder block/bearing cap
must be on top of one
another
5 - Screw
❑ 50 Nm + 90°.
6 - Bearing shell
❑ in cylinder block
❑ with lubricating groove
❑ Replace used
7 - Thrust washers
❑ for bearing 3
3. Crankshaft 53
❑ only in cylinder block
❑ moisten with oil
8 - Cylinder block
3.2 Crankshaft dimensions

Grinding di‐ Crankshaft bearing Rod bearing journal-∅
mension journal-∅ mm
mm
Basic dimen‐ 54.00 -0.022 47.80 -0.022
sion -0.042 -0.042
3.3 Replace the needle bearing in the crank‐

shaft
♦ Interior extractor 16-18 mm , e.g. -Kukko 21/2- or -VAS 251
635-
♦ Countersupport , e.g. -Kukko 22/1- or -VAS 251 621-
♦ Centering mandrel -T30029 (3176)-
Note
Only on vehicles fitted with automatic gearbox.
Condition:
• If the engine and transmission were separated, always replace
the needle bearing -arrow-.
• The leading edges of the internal extractor must not have bro‐
ken out.
Removing
– Attach interior extractor to the needle bearing edge -arrow-.

– Pull out the needle bearing -1- with internal extractor -A- e.g.
-Kukko 21/2- or -VAS 251 635- and countersupport -B-, e.g. -
Kukko 22/1- or -VAS 251 621- from the crankshaft -2-.
Installing
Note
The marked side of the needle bearing should be legible when in

its installed condition.
– Clean the bearing in the crankshaft and apply a thin coat of

lubricating grease.

– Drive the needle bearing with the centring mandrel - T30029

(3176)- into the crankshaft.
Assembly depth: dimension -a- = 0 mm.
Note
If the needle bearing is driven into too deep it will need replacing
as it is damaged when pulling it out.
3.4 Measuring axial play of crankshaft

♦ Universal dial gauge bracket - MP3-447 (VW 387)-
♦ Dial gauge e.g. -VAS 6079-
Work procedure
– Screw on the dial gauge with universal dial gauge bracket -
MP3-447 (VW 387)- to the cylinder block and set against the
wall of the crankshaft.
– Push off the crankshaft off the dial gauge and set the dial
gauge to “0”.
– Press the crankshaft by hand against the dial gauge and read
off the value.
Axial clearance:
• New part: 0.07-0.17 mm
• Wear limit: 0,37 mm
3. Crankshaft 55
4 Pistons and conrods

⇒ “4.1 Assembly overview - piston and conrod”, page 56
⇒ “4.2 Removing and installing the piston”, page 58
⇒ “4.3 Measure piston projection in TDC”, page 59
⇒ “4.4 Check piston and cylinder bore”, page 60
⇒ “4.5 Separating new connecting rod”, page 62
4.1 Assembly overview - piston and conrod
1 - Conrod bolt
sembly
❑ Oil threads and contact
surface
❑ 30 Nm + 90°.
2 - Connecting rod bearing cap
❑ Check fitting position
❑ as a result of the con‐
necting rods separated
in the cracking process,
the cover fits only in one
position and only to the
relevant connecting rod
❑ Mark assignment to cyl‐
inder
3 - Bottom bearing shell
❑ Fitting position
⇒ Fig. ““Bearing shell in‐
stallation position”“ ,
page 57
❑ Replace used
❑ check for firm seating
4 - Top bearing shell
❑ Fitting position
⇒ Fig. ““Bearing shell in‐
stallation position”“ ,
page 57
❑ Replace used
5 - Connecting rod
❑ with a split bearing cap
❑ Renew as set only.
❑ Mark assignment to cylinder
❑ separate new conrod ⇒ “4.5 Separating new connecting rod”, page 62
❑ Axial play wear limit: 0.37 mm
6 - Piston pin
❑ Removing and installing ⇒ “4.2 Removing and installing the piston”, page 58
7 - Circlip
❑ 2 units

8 - Piston
❑ with combustion chamber
❑ replace the piston if there is any sign of crack formation
❑ Mark the installation position and the assignment to cylinder ⇒ page 57
❑ Removing and installing ⇒ “4.2 Removing and installing the piston”, page 58
❑ Check piston and cylinder bore ⇒ “4.4 Check piston and cylinder bore”, page 60
❑ Measure projection in TDC ⇒ “4.3 Measure piston projection in TDC”, page 59
9 - Oil scraper ring
❑ Check ring gap ⇒ Fig. ““Checking piston ring gap”“ , page 61
❑ Check end clearance ⇒ Fig. ““Checking ring-to-groove clearance”“ , page 62
❑ use piston ring pliers for removing and installing
❑ Label “TOP” or manufacturer's mark must point upwards towards the piston crown
❑ Install edge offset by 120° to piston ring
10 - Compression rings
❑ Check ring gap ⇒ Fig. ““Checking piston ring gap”“ , page 61
❑ Check end clearance ⇒ Fig. ““Checking ring-to-groove clearance”“ , page 62
❑ use piston ring pliers for removing and installing
❑ Label “TOP” or manufacturer's mark must point upwards towards the piston crown
❑ Offset gaps by 120°
Installation position and assignment of piston/cylinder
NOTICE
Risk of damaging the piston crown!
♦ For re-installation, mark the assignment in colour on the pis‐
ton crown of cylinders that have already been used.
• Arrow on piston crown faces towards the belt pulley side

-arrow-.
Bearing shell installation position

– Insert bearing shells in the connecting rod and in the connect‐
ing rod bearing cap centred.
• Dimension -a- = 2.5 mm.
4. Pistons and conrods 57

Oil spray nozzle and pressure relief valve (depending on design)

1 - Screw with pressure relief valve, 24 Nm
2 - Oil spray jet (piston cooling)
• Fitting position: align guide edge of the oil spray nozzle to the
cylinder block surface.
NOTICE
Risk of damaging the oil injection nozzles!
♦ Do not bend oil injection nozzles.
♦ Check oil injection nozzles after reinstalling the pistons.
♦ Replace the oil injection nozzles if they are bent.
4.2 Removing and installing the piston

♦ Mandrel - VW 222 A-
♦ Piston ring pliers
Removing
• Engine secured to engine and gearbox mount
⇒ “1.3 Attach engine attached to engine and gearbox mount”,
page 16 .
– Remove cylinder head
⇒ “1.3 Removing and installing cylinder head”, page 66 .
– Remove oil pump
⇒ “1.4 Removing and installing oil pump”, page 114 .
– For re-installation, mark assignment of the conrod bearing cap
to the cylinder and to the conrod.
– Remove conrod bearing cap.
– Pull out the piston with conrod upwards.
Note
If the piston pin is difficult to remove, heat piston to 60 °C.
– Remove the circlip from the bore of the piston pin.

– Remove piston pin with mandrel - VW 222 A- .
Installing
to the following:
Note

gle.
– Oil the contact surfaces of the bearing shells.

– Install piston with a commercially available piston ring ten‐
sioning strap.
Fitting position:

• Installation position and assignment of piston/cylinder

⇒ Fig. ““Installation position and assignment of piston/cylin‐
der”“ , page 57
• Bearing shell installation position
⇒ Fig. ““Bearing shell installation position”“ , page 57 .
– Install the conrod bearing cap according to marking.
– Install oil pump
⇒ “1.4 Removing and installing oil pump”, page 114 .
– Install cylinder head
Note

♦ Pistons and conrods

⇒ “4.1 Assembly overview - piston and conrod”, page 56
4.3 Measure piston projection in TDC

♦ Measuring bridge - MP3-404/7 (VW382/7)-
♦ Gauge block plate - MP3-405/17 (VW385/17)-
♦ Dial gauge - VAS 6079-
Test sequence
– gauge - VAS 6079- with measuring bridge - MP3-404/7
(VW382/7)- and end measuring plate - MP3-405/17
(VW385/17)- attach to cylinder block as shown in the picture
– Measure the supernatant on each piston at the two locations
indicated by -arrows-. Measure in the longitudinal direction of
the engine at the rear and at the front of the piston.
Note
♦ When fitting new pistons or a stripped engine, check the piston

projection in TDC on all pistons.
♦ If different values are measured during the projection meas‐
urement of the piston, the greatest dimension applies for the
seal assignment.
Depending on the piston projection fit the relevant cylinder head

seal in accordance with the table below.
Piston projection over Identification
cylinder block - top side Number of bores
mm
0.91 … 1.00 1
1.01 … 1.10 2
1.11 … 1.20 3

Identification of the cylinder head gasket

♦ -Arrow 1-: Part number
♦ -Arrow 2-: Bores
♦ -Arrow 3-: ignore
4.4 Check piston and cylinder bore

Inspecting piston

♦ External micrometer 75...100 mm
– Measure about 15 mm from the lower edge and offset 90° to
piston pin axis.
Deviations from specified dimension: max. 0.04 mm.
∅ piston
Basic dimension mm 79.45 1)
1)Dimensions without graphite coating (thickness 0.02 mm).
The graphite coating wears off.

Checking cylinder bores

♦ Internal precision measuring instrument 50…100 mm
– Measure at three points crosswise in a transverse direction
-A- and lengthwise -B-.
Deviations from specified dimension: max. 0.10 mm.
∅ cylinder bore
Basic dimension mm 79.53
Note
Do not measure the cylinder bore if the cylinder block is fixed to

the assembly stand with the engine mount, as this may result in
incorrect measurements.
Checking piston ring gap

♦ Feeler gauge
– Insert ring at right angles from above down into the lower cyl‐
inder opening, about 15 mm away from edge of cylinder.
Piston ring mm Gap clearance
New Wear limit
1st compression ring 0.30 … 0.40 0.55
2nd compression ring 0.20 - 0.45 0.95
Oil scraper ring 0.20 … 0.40 0.65

Checking ring-to-groove clearance

♦ Feeler gauge
– Clean the annular groove before inspecting.
Piston ring mm End clearance
New Wear limit
1st compression ring 0.06 … 0.09 0.08
2nd compression ring 0.05 - 0.08 0.08
Oil scraper ring 0.03 … 0.06 0.08
4.5 Separating new connecting rod

It can happen that on new conrods, the provided separation point
is not completely cracked. If the connecting rod bearing cap can‐
not be removed by hand, then proceed as follows:
– Mark the assignment of the connecting rod to the cylinder.
– Slightly -1- clamp the conrod in a vice with aluminium protec‐
tive jaws slightly, as shown in the figure.
Note
♦ Only tension the conrod slightly in order to avoid damage on

the conrod.
♦ The conrod is clamped below the broken line.
– Unscrew both screws -2- by approx. 5 turns.
– Using a plastic hammer, carefully knock against conrod bear‐

ing cap in -direction of arrow- until it is loose.

15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.2 Assembly overview - cylinder head cover”, page 65
⇒ “1.3 Removing and installing cylinder head”, page 66
⇒ “1.4 Removing and installing cylinder head cover”, page 73
⇒ “1.5 Removing and installing gasket rings for injection units”,
page 75
⇒ “1.6 Removing and installing camshaft housing”, page 76
⇒ “1.7 Checking compression”, page 79
1.1 Summary of components - cylinder head
1 - Cylinder block
2 - Dowel sleeves for centering
❑ for cylinder head
❑ replace after removing
the cylinder head
3 - Cylinder head gasket
❑ replace after removal
stalling cylinder head”,
page 66
❑ Identification of the cyl‐
inder head gasket
⇒ Fig. ““Identification of
the cylinder head gas‐
ket”“ , page 65
❑ Observe part number ⇒
ETKA - Electronic Cata‐
4 - Screw
sembly
❑ 20 Nm + 90°.
5 - Bracket for auxiliary units
❑ for high pressure pump
❑ with lifting eye for en‐
gine
installing bracket for
high pressure pump”,
page 34
6 - Screw
sembly
❑ 20 Nm + 90°.
7 - Cylinder head
❑ Removing and installing ⇒ “1.3 Removing and installing cylinder head”, page 66
1. Cylinder head 63
❑ Lay removed cylinder head on a foam pad only, otherwise the glow connectors may be damaged
❑ check for distortion ⇒ Fig. ““Checking cylinder head for distortion”“ , page 65
❑ must not be reworked
❑ before installing, check whether both dowel sleeves for centering the cylinder head at the cylinder block
are present
❑ with plug on gearbox side (15 Nm) ⇒ ETKA - Electronic Catalogue of Original Parts
8 - Screw
❑ Replace if damaged.
❑ 15 Nm
9 - Fit pin
❑ for camshaft housing
10 - Screw
❑ pay attention to order for slackening
⇒ Fig. ““Cylinder head - tightening torque and tightening order”“ , page 65
⇒ Fig. ““Cylinder head - tightening torque and tightening order”“ , page 65
11 - Sealing ring
❑ component part of position -12-
12 - Screw
❑ 15 Nm
❑ for charge air cooler
❑ with lifting eye for engine
14 - Screw
❑ 20 Nm
15 - O-ring
❑ Moisten with coolant
16 - Screw
❑ 20 Nm + 45°.
17 - Countersupport
18 - Coolant temperature transmitter - G62-
⇒ “2.9 Removing and installing coolant temperature transmitter G62 ”, page 166
19 - Screw
❑ 5 Nm
64 Rep. gr.15 - Cylinder head, valve gear

Checking cylinder head for distortion

– Check the cylinder head at several points for distortion using
the 500 mm knife-edge straightedge - VAS 6075- and feeler
gauge.
♦ Max. permissible distortion: 0.1 mm
Note
Cylinder heads for TDI engine must not be reworked.
Identification of the cylinder head gasket

Note
Differing thicknesses of cylinder head gaskets are inserted ac‐

cording to the piston projection. If only the gasket is replaced, it
must be replaced with a new gasket with the same marking.
Cylinder head - tightening torque and tightening order
Note

gle.
Level screws Tightening torque / torquing angle

1. -1- to -8- 30 Nm
2. -1- to -8- 90 Nm
3. -1- to -8- Turn 90° further
4. -1- to -8- Turn 90° further
1.2 Assembly overview - cylinder head cover
1. Cylinder head 65
1 - Seal
2 - Cylinder head cover
stalling cylinder head
cover”, page 73
3 - Differential pressure trans‐
mitter
❑ Pressure sensor 1 for
exhaust gas - G450-
❑ Differential pressure
transmitter - G505-
⇒ “6 Senders and sen‐
sors”, page 240
4 - Screw
❑ 8 Nm
5 - Hall sender G40
stalling Hall sender G40
”, page 298
6 - Screw
❑ 8 Nm
7 - Grommet
❑ in the cylinder head cov‐
er
8 - O-ring
9 - Coolant pipe
❑ Summary of components ⇒ “3.1 Summary of components - coolant pipe”, page 169
10 - Screw
❑ 8 Nm
11 - Hose
❑ for crankcase ventilation
12 - Screw cap
13 - Seal
❑ for cap
14 - Grommet
15 - Screw
❑ 8 Nm
16 - Vacuum line
1.3 Removing and installing cylinder head

♦ Tool - T10236-

♦ Sealant remover Gasket Stripper (stock code GST, stock item

No. R 34402), manufacturer Retech s.r.o.
♦ Protective goggles and gloves
Removing
– Remove the front wall ⇒ General body repairs, exterior; Rep.
gr. 50 ; Front wall; Summary of components - plenum chamber
cover .
– Release nuts -1- and screw -3- and remove bracket -2-.

– Release retaining clip -2- and remove air guide.
– Release clamp -2- and unscrew screws -4- and -5-.

– Remove air deflector with exhaust gas recirculation pipe -3-.
1. Cylinder head 67
– Unscrew screw -2- for oil pipe -1- and cut cable strap -3-.
NOTICE
Risk of oil contamination by coolant and dirt!
♦ You must close the opening for the oil pipe in the oil pan with
screw plugs after removing the oil pipe.
– Unscrew screw -1- and pull own oil pipe -2- to top.
– Remove camshaft housing
⇒ “1.6 Removing and installing camshaft housing”,
page 76 .
– Release retaining clips -1- and disconnect fuels hoses -2- and
-3- from the high pressure pump.
– Release screw -1-.

– Use the assembly tool - T10118- to release and pull off the
connector -1-.
– Disconnect connector Pos. -9- ⇒ Item 9 (page 233) and vac‐
uum line Pos. -10- ⇒ Item 10 (page 233) on the intake mani‐
fold.
– Remove exhaust gas cleaning module
⇒ “2.2 Removing and installing exhaust gas cleaning module”,
page 275 .
– Tie off heat shield collar and release and pull off connector
-1-.
– Remove radiator for exhaust gas recirculation -2- downwards.
– Unscrew screws -1-, -3-, -4- and -6-, -7-, -8-.

– Remove oil feed line -2- and oil return-flow line -5-.
– Unscrew the screws in the sequence -8- to -1- and carefully

remove the cylinder head.
1. Cylinder head 69
Installing
NOTICE
The use of inadmissible abrasives can result in consequential
damage, such as turbocharger damage, connecting rod bearing
damage, etc..
♦ Abrasives (sandpaper, grinding wheels, sanding pads,
sanding fleece, abrasive wool, etc.) cannot be used.
♦ The sealing surface (see photo) must not be raised.
♦ Dark discolouration (see photo) does not need to be re‐
moved.
♦ When removing the seal residue, make sure that no dis‐
solved seal residue enters the open channels from the en‐
gine.
♦ Ensure that adjacent workplaces are clean and that none of
the above mentioned abrasives are used.
– Remove any residual gas from the cylinder head and cylinder
block using a standard scraper with a blade. Sealing surfaces
must not be damaged!
– Remove any dissolved residue with a lint-free cloth.
• Sealing surfaces must not be damaged!
• There must not be any oil or coolant present in the blind holes
for the screws.
• Remove the new cylinder head gasket from its wrapping im‐
mediately before fitting.
• If a new cylinder head is installed, the contact surfaces be‐
tween roller cam follower and cam slide must be oiled.
• To prevent the silicon layer and the area of the bead from being
damaged, handle the gasket with the utmost care.
• To ensure that no valve is set during starting, turn the crank‐
shaft carefully by at least 2 turns.
• When the cylinder head or the cylinder head gasket is re‐
placed, all the coolant and engine oil must be replaced.
– Make sure that when cleaning the cylinder head and cylinder
block no foreign particles can get into the cylinder or into the
oil and coolant galleries.
– Carefully remove old sealant residue from the cylinder head
and cylinder block using a chemical sealant remover.
– Remove the crankshaft arrester - T10490- before fitting on the
cylinder head and turn back the crankshaft in the opposite di‐
rection of rotation of the engine until all the pistons are almost
evenly at “TDC”.
– If there are no dowel sleeves are available for centering the
cylinder block and cylinder head, insert dowel sleeves.

– Pay attention to the identification of the cylinder head gasket:

Note
♦ Install new cylinder head gasket with the same identification

arrow -2-.
♦ If parts of the crankshaft drive were replaced, then the new
cylinder head gasket must be redefined by measuring the pro‐
trusion of the piston in TDC.
– Fit cylinder head gasket onto the dowel sleeves -A- in cylinder
block with marking facing upwards.
Note
The assistance of a 2nd mechanic is required for fitting on the

cylinder head.
– Insert the cylinder head.

– Insert screws for cylinder head and tighten
⇒ Fig. ““Cylinder head - tightening torque and tightening or‐
der”“ , page 65 .
– Fit crankshaft arrester - T10490- .
1. Cylinder head 71
– Rotate the crankshaft in direction of rotation of engine until the

bolt -arrow- of the crankshaft arrester - T10490- engages in
the sealing flange.
– Install camshaft housing
⇒ “1.6 Removing and installing camshaft housing”,
page 76 .
– Install the bracket for charge air cooler
⇒ “2.2.2 Removing and installing bracket for charge air cooler”,
page 198 .
– Install charge air cooler
⇒ “2.2.1 Removing and installing charge air cooler”,
page 196 .
– Install the engine cover
– Change engine oil:
NOTICE
If a new cylinder head has been fitted, the cooling system must
be flushed and the coolant must be replaced to ensure optimum
protection of the surface
⇒ “1.4 Flushing the cooling system”, page 135 .
If the existing cylinder head is fitted:

– Replace coolant
⇒ “1.3 Draining and filling coolant”, page 131 .
Note


♦ 01 - Adaption

Note

♦ Cylinder head
♦ Exhaust gas turbocharger
⇒ “1.1 Summary of components - exhaust gas turbocharger”,
page 182
1.4 Removing and installing cylinder head

cover
Removing
83 .
– Remove the injection units
⇒ “3.5 Removing and installing the injection units”,
page 221 .
– Open heat protection sleeve. Release screw -1-.

– Unlock and pull off connectors -2- and -3- and remove differ‐
ential pressure transmitter from cylinder head.
1. Cylinder head 73
– Unlock and pull off connector -1- for hall sender - G40- and
remove vacuum line -2-.
– Unlock and pull off connector -2-.

– Unscrew screws -1- and remove cylinder head cover -2-.

Installing
to the following:
Note
♦ Renew O-ring.
♦ Replace gasket and screws for cylinder head cover if dam‐
aged or leaking.
– Install the injection units

page 221 .
– Install high pressure lines
⇒ “3.6 Removing and installing high pressure lines”,
page 224 .
– Install top toothed belt guard
83 .
– Connect vacuum hose
⇒ “2.1 Connection diagram - Vacuum system”, page 213 .
Note

♦ Cylinder head cover

⇒ “1.2 Assembly overview - cylinder head cover”, page 65 .
♦ Injection units
page 215
♦ Toothed belt guard
⇒ “2.1 Summary of components - toothed belt guard”,
page 81
1.5 Removing and installing gasket rings for

injection units
♦ Driver - 3390-
♦ Set of tools - T10133C-
Removing
– Remove injection unit concerned
page 215 .
1. Cylinder head 75
– Screw the gasket ring extractor - T40195- into the gasket ring
-1-.
– Fit extractor - T10133/3- with extractor - T10133/2- onto the
gasket ring extractor and pull carefully towards the top by tap‐
ping it.
Installing
– Press in the new gasket ring for the injection unit using the
driver - 3390- and a short extension -1- from the top up to the
stop.
1.6 Removing and installing camshaft hous‐

ing
♦ Silicone sealant ⇒ ETKA - Electronic Catalogue of Original
Parts
Removing
– Remove cylinder head cover
⇒ “1.4 Removing and installing cylinder head cover”,
page 73 .
page 93 .
– Remove high pressure reservoir
⇒ “3.7 Removing and installing high pressure reservoir (fuel
distributor)”, page 227 .
– Remove the bracket for charge air cooler
page 198 .

– Unscrew screws for camshaft housing in the sequence -12- to

-1-.
– Carefully release from the bonding and remove the camshaft
housing.
Installing
NOTICE
Risk of contamination of the lubrication system and bearing!
Cover opened engine parts.
CAUTION
Wear protective gloves and goggles when working with gasket
remover and degreasing agent!
– Remove residual sealant on the camshaft housing and on the

cylinder head using a chemical sealant remover.
– Clean sealing surfaces, they must be free of oil and grease.
Note
– Cut off nozzle tube at the front marking (∅ of nozzle approx.

1.5 mm).
NOTICE
Risk of contamination of the camshaft bearings through excess
sealant!
♦ Do not apply thicker sealant beads than indicated.
1. Cylinder head 77
– Apply sealant bead -1- onto the clean sealing surfaces of the
cylinder head as shown in the illustration.
• Thickness of sealant beads: 2 mm.
Note
♦ After applying the sealant, the camshaft housing must be in‐

stalled within 5 minutes.
♦ After installing the camshaft housing, allow the sealant to dry
for about 30 minutes.
– Carefully place the camshaft housing on the cylinder head,

pay attention to fit pins when doing so.
– Tighten camshaft housing screws
⇒ Fig. ““Camshaft housing - tightening torque and tightening
order”“ , page 97 .
– Install the bracket for charge air cooler
page 198 .
– Install high pressure reservoir
⇒ “3.7 Removing and installing high pressure reservoir (fuel
– Install camshaft sealing ring
⇒ “3.2 Removing and installing gasket ring for camshaft”, page
97 .
– Install cylinder head cover
page 73 .
NOTICE
Risk of damaging valves and piston crowns after work on the
valve gear!
♦ Because hydraulic compensation elements must be set, the
engine must not be started until approximately 30 minutes
after camshaft installation.
♦ To ensure that no valve is set during starting, turn the crank‐
shaft carefully by at least 2 turns.
Note

♦ Camshaft housing
⇒ Fig. ““Camshaft housing - tightening torque and tightening
order”“ , page 97
♦ Charge-air system
⇒ “2.1 Summary of components - charge air system”,
page 195

♦ High pressure reservoir

⇒ “3.2 Summary of components - High pressure reservoir (fuel
distributor)”, page 217
1.7 Checking compression
Note
♦ A rough test of the compression pressure can be carried out

in the targeted fault finding ⇒ Vehicle diagnostic tester.
♦ The following work sequence with the compression tester
gives more precise values.

♦ Flexible-head wrench SW 10 - 3220-
♦ Compression tester - V.A.G 1763-
♦ Adapter - V.A.G 1763/8-
• Engine oil temperature at least 80 °C.
• Battery voltage at least 12.5 V
Work procedure
– Pull the connector -1- off the fuel pressure regulating valve -
N276- on the fuel distributor.
– Start engine briefly in order to reduce the pressure in the fuel
distributor.
– Remove all glow plugs
⇒ “1.2 Removing and installing glow plugs”, page 295 .
1. Cylinder head 79
– Screw the adapter - V.A.G 1763/8- into the threaded hole of

the glow plug on the cylinder to be checked and connect the
compression tester - V.A.G 1763- .
Note
Use of the compression tester - V.A.G 1763- ⇒ Owner's Manual .
– Operate the starter with the assistance of a 2nd mechanic until

no further pressure rise is indicated by the compression tester
- V.A.G 1763- .
– Measure the compression pressure consecutively on all the
cylinders.
Compression read‐ Pressure
ings
Engine new 2.5-3.1 MPa (25-31 bar)
Wear limit 1.9 MPa (19 bar)
Max. permissible dif‐ 0.5 MPa (5 bar)
ference between the
cylinders
– Install glow plugs
– Querying and erasing event memory of engine control unit
⇒ Vehicle diagnostic tester.

2 Toothed belt drive

page 81
⇒ “2.3 Removing and installing toothed belt guard”, page 83
⇒ “2.4 Removing and installing toothed belt”, page 85
⇒ “2.5 Remove the toothed belt from the camshaft”, page 93
2.1 Summary of components - toothed belt guard
1 - Screw
❑ 5 Nm
2 - Pipes
❑ to differential pressure
transmitter - G505-
3 - Top toothed belt guard
installing top toothed
belt guard”, page 83
4 - Screw
❑ with collar
❑ inserted in the bottom
toothed belt guard such
that it cannot be lost
❑ 12 Nm
5 - Bottom toothed belt guard
installing bottom tooth‐
ed belt guard”,
page 84
6 - Screw
❑ with collar
❑ inserted in the bottom
toothed belt guard such
that it cannot be lost
❑ 12 Nm
7 - Rear toothed belt guard
8 - Screw
❑ 20 Nm
2. Toothed belt drive 81

2.2 Summary of components - toothed belt
1 - Screw
sembly
❑ Release and tighten us‐
ing counterholder -
T30004 (3415)-
❑ Do not additionally oil
threads and collar
❑ Further rotation can be
done across several
stages, e.g. 90° + 45°
❑ 180 Nm + 135°.
2 - Crankshaft toothed belt
sprocket
❑ there must not be any oil
present on the contact
surface between the
pulley and the crank‐
shaft
❑ can be installed only in
one position
3 - Nut
sembly
❑ 20 Nm + 45°.
4 - Tensioning pulley
5 - Pin screw
❑ 15 Nm
6 - Toothed belt
❑ mark the direction of ro‐
tation with chalk or a felt- Volkswagen Technical Site: https://vwts.ru
tip pen before removing
❑ check for wear
❑ removing ⇒ “2.4 Removing and installing toothed belt”, page 85
❑ install (set the timing) ⇒ page 88
7 - Screw
❑ to loosen and tighten, use counterholder - T10172- or -T10172A- with adapters -T10172/11-
❑ Do not additionally oil threads and collar
❑ 100 Nm
8 - Locating screw
❑ 9 Nm
9 - Camshaft toothed belt pulley
❑ There must not be any oil present on the contact surface between the toothed belt pulley and the camshaft
10 - Camshaft driver
❑ Removing and installing ⇒ “1.6 Removing and installing camshaft housing”, page 76
11 - High pressure pump
❑ Summary of components ⇒ “8.1 Summary of components - high pressure pump”, page 253

12 - Hub
❑ There must not be any oil present between the lock hub and the toothed belt pulley
13 - Guide pulley
14 - Screw
❑ 23 Nm
15 - Toothed belt pulley high pressure pump
❑ There must not be any oil present between the lock hub and the toothed belt pulley
16 - Nut
❑ Do not additionally oil threads and collar
❑ Tightening torque Pos. -2- ⇒ Item 2 (page 253)
17 - O-ring
18 - Screw
❑ Tightening torque Pos. -5- ⇒ Item 5 (page 157)
19 - Coolant pump
❑ Removing and installing ⇒ “2.5 Removing and installing coolant pump”, page 162
2.3 Removing and installing toothed belt

guard
⇒ “2.3.1 Removing and installing top toothed belt guard”,
page 83
⇒ “2.3.2 Removing and installing bottom toothed belt guard”, page
84
2.3.1 Removing and installing top toothed belt

guard
Removing
Note
Observe rules for cleanliness

⇒ “3.1 Rules of cleanliness”, page 6 .

– Loosen clamps -1- and disconnect coolant hose -2-.
– Loosen clamp -1-, disconnect fuel line and place to the side.
– Unscrew screws -1- and -2- and remove the top toothed belt
guard upwards.
Installing
to the following:
Note

♦ Toothed belt
2.3.2 Removing and installing bottom toothed

belt guard
Removing
– Remove belt pulleys
⇒ “1.7 Removing and installing belt pulley”, page 37 .

– Unscrew nuts -1- and push coolant pipe -2- to the side.
– Unscrew screws -arrows- and remove bottom toothed belt

guard -1-.
Installing
to the following:
– Install bottom toothed belt guard and tighten screws.
– Install belt pulley
Note

♦ Toothed belt
♦ Coolant pipes
⇒ “3.1 Summary of components - coolant pipe”, page 169
2.4 Removing and installing toothed belt

♦ Counterholder - T10051-
♦ Counterholder - T10172- with adapters -T10172/11- or -
T10172A-
♦ Offset screwdriver - T10264-
♦ Crankshaft arrester - T10490-

♦ Rig pin - T10492-

Removing
– Loosen clamps -arrow- and disconnect hoses of the lines for
differential pressure sender and place to the rear.
– Remove engine support
⇒ “1.6 Removing and installing engine support”, page 35 .
page 84 .
NOTICE
Risk of damage to the engine as a result of the toothed belt
pulley jumping.
♦ Only rotate the crankshaft in the direction of rotation of the
engine!
the camshaft toothed belt pulley is positioned on “TDC”.
– Lock hub of the camshaft using the rig pin - T10492- ; to do

so, insert the rig pin into fork -2- of the driver and into the bore
behind it -1- in the cylinder head.
– Loosen fixing screw -1- in the camshaft sprocket by half a turn
but do not release it.
– Lock hub of the high pressure pump using the rig pin -
T10492- ; to do so, insert the rig pin into fork -2- of the hub and
into the bore behind it -1- in the auxiliary units bracket.
NOTICE
Risk of engine damage!
♦ The rig pin - T10492- must not be used as a counterholder
for loosening the screw for the camshaft toothed belt pulley.
– Remove rig pin and partially undo the screws for the camshaft
sprocket. Before removing fully, peg back the rig pin.
– Loosen screw -1- for camshaft toothed belt pulley; to do so,

use counterholder - T10172- with adapters -T10172/11- .
– Remove the rig pin and partially unscrew the nuts -2- for the
high pressure pump toothed belt. Before removing fully, peg
back the rig pin.

– Loosen nut -arrow- for high pressure pump toothed belt pulley
by approximately 90°, use counterholder - T10051- to do so.

– Loosen nut -1- for tensioning pulley.

– Carefully turn eccentric of the tensioning pulley with offset
screwdriver - T10264- clockwise -arrow- until the tensioning
pulley can be interlocked with the rig tool - T10265- .

– Then turn the eccentric of the tensioning pulley with the offset
screwdriver - T10264- clockwise -arrow- up to the stop and
tighten nut -1- by hand.
NOTICE
Risk of damage through reversing the rotation direction of an
already used toothed belt!
♦ Mark the direction of rotation with chalk or a felt-tip pen for
the re-installation before removing the toothed belt pulley.
– First remove the toothed belt from the coolant pump and then
from the remaining toothed belt gears.
Installing (set the timing)
Note
The engine must be cold for performing installation work on the

toothed belt.
NOTICE
♦ When rotating the camshaft, the crankshaft must not be
positioned at “TDC” with any one piston.
Requirements:
• Tensioning pulley locked with rig tool - T10265- and fixed with
nut -1- up to right stop.
• The sheet peg -arrow- of the tensioning pulley must engage

in the cast iron recess of the cylinder head.

• The hub of the camshaft is locked with the rig pin - T10492- .
• Screw loosely inserted.
• It must still be possible to just turn the camshaft toothed belt
pulley, however it must not tilt.
• Fixing screw -1- of the driver loosened by one half turn, posi‐
tioned in the centre position in the elongated hole.
• Interlock crankshaft with crankshaft arrester - T10490- .
• Lock hub of high pressure pump with rig pin - T10492- .

• Nut loosely inserted.
• It must still be possible to just turn the toothed belt pulley of
the high pressure pump, however it must not tilt.
– Turn the camshaft toothed belt pulley and high pressure pump
toothed belt pulley in their elongated holes clockwise as far as
the stop.
– Fit the toothed belt in the following order:
1- Crankshaft toothed belt sprocket
2- Tensioning pulley
3- Camshaft toothed belt pulley
4- Toothed belt pulley high pressure pump
5- Coolant pump toothed belt pulley

– Loosen nut -1- for tensioning pulley and remove rig tool -
T10265- .
Note
♦ Sheet peg of the tensioning pulley must engage in the cast

iron recess of the cylinder head.
♦ Ignore -arrow-.
NOTICE
The locking screw must not rest at the bottom stop of the elon‐
gated hole after the camshaft sprocket is tightened!
– Check whether the locking screw -1- is located between the

centre elongated hole and the bottom stop -2-, where neces‐
sary correct the position of the camshaft sprocket by one tooth
in a clockwise direction and put the toothed belt back into po‐
sition.
– Turn the eccentric of the tensioning pulley carefully with the

offset screwdriver - T10264- clockwise -arrow- until the pointer
-2- is in the centre of the base plate in front of the gap.
• The nut -1- must not turn along.
– Hold tensioning pulley in this position and tighten nut.
– Position counterholder - T10172- with -T10172/11- adapters

at the camshaft toothed belt pulley, as shown in the illustration.
– Push the counterholder anticlockwise -arrow- and keep it pre‐
tensioned.
– In this position, tighten screw -1- for camshaft toothed belt
pulley and nut -2- for high pressure pump toothed belt pulley.
♦ Tightening torque: initially, 20 Nm
NOTICE
♦ The high pressure pump toothed belt pulley can only be
twisted to a limited extent.
♦ It is therefore crucial to check that the toothed belt gear does
not lie against the »stop« of the twisting range after tighten‐
ing.

– Make sure that the marking on the toothed belt gear is not flush
with the rig pin. You may need to correct the position of the
toothed belt gear of the high pressure pump by one tooth
clockwise and fit the toothed belt back into position.
– Remove the rig pin - T10492- and crankshaft arrester -
T10490- and test the timing ⇒ page 91 .
Test timing:
NOTICE
Risk of damage to the engine as a result of the toothed belt
pulley jumping.
engine!
– Turn the crankshaft at the screw for timing belt gear 2 turns in
the direction of running of the engine until the crankshaft is
positioned shortly before “TDC”.
– Position again the crankshaft arrester - T10490- on the crank‐

shaft timing belt sprocket.
– Turn the crankshaft in the direction of rotation of the engine
until the stud -arrow- of the crankshaft arrester engages during
this rotary movement in the sealing flange.
NOTICE
Adjustment error as a result of inaccurate “TDC” setting!
♦ If it has been rotated above “TDC”: Rotate crankshaft again
by 2 turns until it is again positioned shortly before “TDC”.
♦ Then lock the crankshaft from the direction of rotation using
the crankshaft arrester - T10490-
The hub of the camshaft must be locked with the rig pin - T10492- .
• The locking point of the hub of the high pressure pump is al‐
ways difficult to find again. A slight difference -arrow- does not
influence the engine running.

• The tensioning pulley pointer -2- must be positioned in the

centre between the pegs -1- and -3- of the base plate.
Note
A lateral offset of a maximum of 5 mm is permitted.
If the conditions are met, continue if timing is set correctly

⇒ page 92 .
If the conditions are not met, correct timing ⇒ page 92 .
Correct timing:
– If the hub of the camshaft cannot be locked, pull back the
crankshaft arrester - T10490- until the stud disconnects from
the bore.
– Turn the crankshaft slightly against the running direction of the
engine over the “TDC”.
A - Crankshaft arrester - T10490- stud is positioned to the left of

the bore:
until the stud -arrow- of the crankshaft arrester engages during
this rotary movement in the sealing flange.
– Tighten camshaft toothed belt pulley to 20 Nm.
B - Crankshaft arrester - T10490- stud is positioned to the right of
the bore:
– First turn the crankshaft slightly against the running direction
of the engine.
until the stud of the crankshaft arrester engages during this
rotary movement in the sealing flange.
– Tighten camshaft toothed belt pulley to 20 Nm.
Continued if the timing is correctly set or has been corrected:
– Remove rig pin - T10492- and crankshaft arrester - T10490- .
– Turn the crankshaft at the screw for timing belt gear 2 turns in
the direction of running of the engine until the crankshaft is
positioned shortly before “TDC”.
– Repeat timing test ⇒ page 91 .
NOTICE
♦ The locking pin - T10492- must not be used for loosening or
tightening the screw under any circumstances.

– If it is now possible to lock the camshaft hub, tighten toothed

belt pulley screw -1- to the end stop position using counter‐
holder - T10172- with adapters -T10172/11- .
– Tighten high pressure pump toothed belt pulley nut -2- to the
end stop position using counterholder - T10051- to do so.
Repeat timing test ⇒ page 91 .
Assembling
Note
Secure all hose connection with spring-type clips that comply with
the series design ⇒ ETKA - Electronic Catalogue of Original
Parts .
– Tighten fixing screw -1-.

Note

♦ Toothed belt
page 81
2.5 Remove the toothed belt from the cam‐

shaft
♦ Counterholder - T10172- with adapters -T10172/11- or -
T10172A-
♦ Offset screwdriver - T10264-
♦ Rig pin - T10492-
Removing
83 .


differential pressure sender and place to the rear.
– Remove vibration dampener
NOTICE
Risk of destruction as a result of the toothed belt pulley jumping!
engine!
the camshaft toothed belt pulley is positioned on “TDC”.
– Lock hub of the camshaft using the rig pin - T10492- ; to do

so, insert the rig pin into fork -2- of the driver and into the bore
behind it -arrow- in the cylinder head.
– Loosen fixing screw -1- in the camshaft sprocket by half a turn
but do not release it.
– Lock hub of the high pressure pump using the rig pin -
T10492- ; to do so, insert the rig pin into fork -2- of the hub and
into the bore behind it -1- in the auxiliary units bracket.
NOTICE
♦ The rig pin - T10492- must not be used as a counterholder
for loosening the screw for the camshaft toothed belt pulley.
– Remove rig pin - T10492- and loosen screw -1- for camshaft
toothed belt pulley; to do so, use counterholder - T10172- with
adapters -T10172/11- .

– Loosen nut -arrow- for high pressure pump toothed belt pulley
by approximately 90°, use counterholder - T10051- to do so.

– Loosen nut -1- for tensioning pulley.

– Carefully turn eccentric of the tensioning pulley with offset
screwdriver - T10264- clockwise -arrow- until the tensioning
pulley can be interlocked with the rig tool - T10265- .
– Then turn the eccentric of the tensioning pulley with the offset
screwdriver - T10264- clockwise -arrow- up to the stop and
tighten nut -1- by hand.
– Unscrew screw of the toothed belt pulley and remove the
toothed belt with the toothed belt pulley.
Install (set the timing) ⇒ page 88 .

3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 96
⇒ “3.2 Removing and installing gasket ring for camshaft”,
page 97
⇒ “3.3 Checking hydraulic balancing elements”, page 99
⇒ “3.4 Removing and installing valve stem seals”, page 99
3.1 Assembly overview - valve gear
1 - Screw cap
sembly
❑ Removing: In cases
where there is a built-in
camshaft housing, in‐
sert a punch at the side
of the cover and lever
out
❑ Installing: Drive in flush
without sealant with a
suitable thrust piece,
e.g. driver - 3390-
2 - Camshaft sealing ring
❑ replace after removal
stalling gasket ring for
camshaft”, page 97
3 - Camshaft housing
❑ with integrated cam‐
shaft
stalling camshaft hous‐
ing”, page 76
4 - Screw
❑ Sequence for loosening
stalling camshaft hous‐
ing”, page 76
tightening order
⇒ Fig. ““Camshaft hous‐
ing - tightening torque
and tightening order”“ ,
page 97
5 - Locking clip
❑ for hydraulic balancing element
6 - Hydraulic balancing element
❑ Check ⇒ “3.3 Checking hydraulic balancing elements”, page 99
❑ mark the fitting position for re-installation
❑ oil the contact surfaces before installing
7 - Fit pin
❑ for camshaft housing

8 - Cylinder head
❑ the valve seats must not be reworked because of the narrow tolerances
9 - Valve
❑ do not rework, only grinding in is permissible
❑ Check ⇒ “4.2 Testing valves”, page 106
❑ Valve dimensions ⇒ “4.3 Valve dimensions”, page 107
❑ inspecting valve guides ⇒ “4.1 inspecting valve guides”, page 106
10 - Valve stem gasket
❑ replace after removal ⇒ “3.4 Removing and installing valve stem seals”, page 99
11 - Valve spring
12 - Valve spring plate
13 - Valve collets
14 - Roller rocker finger
❑ Removing and installing ⇒ “1.6 Removing and installing camshaft housing”, page 76
❑ inspect roller bearings for smooth operation
❑ oil the contact surfaces before installing
Camshaft housing - tightening torque and tightening order

Level screws Tightening torque / torquing angle
• The camshaft housing must rest
on the cylinder head with its com‐
plete contact surface.
2. -1- and -2- 20 Nm

3. -3- to -12- 8 Nm
3.2 Removing and installing gasket ring for

camshaft
Work procedure
page 93 .
3. Valve gear 97
NOTICE
♦ If it is turned back too much, the inner pressure plate loosens
-T10443- from the pressure screw.
♦ The pressure plate must then be pressed onto the pressure
screw once again.
– Carefully turn back set screw -arrow- of the extractor -T10443-

until a slight resistances noticeable.
– Place extractor - T10443- straight, as shown in the illustration,

and lock by tightening the set screw -A-.
– Screw in the pressure screw -B- until the gasket ring is pulled
out.
– Clean the contact and sealing surfaces.
Note
The sealing lip of the gasket ring must not be oiled or greased
additionally.
– Fit the guide bushing -T10493/1- onto the camshaft, as shown

in the illustration.
– Carefully slide the shaft sealing ring -1- over the guide bushing
onto the camshaft.
Note
The guide bushing remains fitted on the camshaft as a stop while

the oil gasket is being pressed in.
– Press in the sealing ring with pressure bushing -T10493/2- and

screw -T10493/3- up to the stop.

3.3 Checking hydraulic balancing elements
Note
♦ The hydraulic balancing elements cannot be repaired.

♦ Irregular valve noises when starting engine are normal.

♦ Feeler gauge
Test sequence
– Start engine and allow to run until the radiator fan has cut in
once.
– Increase engine speed to about 2500 rpm for 2 minutes and
conduct a test drive if necessary.
– If the hydraulic balancing elements are still loud, determine
which is the faulty balancing element as follows:
– Remove cylinder head cover
page 73 .
– Rotate crankshaft on the toothed belt pulley screw until the
cam of the compensating element being checked is positioned
at the top.
– To determine the clearance between cam and roller rocker
finger, press the roller rocker finger down -arrow-.
– If a feeler gauge can be moved by 0.20 mm between the cam
and the roller rocker finger, change the hydraulic compensat‐
ing element
⇒ “1.6 Removing and installing camshaft housing”, page 76 .
Concluding measures
– Install cylinder head cover
page 73 .
3.4 Removing and installing valve stem

seals
⇒ “3.4.1 Removing and installing valve stem seals with cylinder
head installed”, page 99
⇒ “3.4.2 Removing and installing valve stem seals with cylinder
head removed”, page 102
3.4.1 Removing and installing valve stem

seals with cylinder head installed
♦ Valve stem seal extractor - MP 1-230 (3364)-
♦ valve stem seal insertion tool - MP 1-233 (3365)-
♦ Blank holder for valve spring - MP 1-229 (3362)-
♦ Disassembly and assembly device for valve collets - VAS
5161A- with doen - VAS 5161/3A-
3. Valve gear 99
Removing
– Remove all glow plugs
– Remove camshaft housing
– Assignment of the roller towing levers -1-, hydraulic compen‐
sating elements -4- and valves -3- for reintegration.
– Remove the roller rocker arms together with the hydraulic bal‐
ancing elements and lay aside on a clean surface.
– Bring piston of the relevant cylinder to “top dead centre”.
Note
♦ The top dead centre position can be determined by inserting

a suitable screwdriver into the bore for injector so that it touch‐
es the piston base.
♦ When rotating the engine, hold the loosened toothed belt tight‐
ly by hand so that it is not damaged.

– Place the downholder for valve spring - MP 1-229 (3362)- on

the cylinder head and screw on. Use the openings for the
camshaft housing screws.
Use the M6 screws with thread length 20 mm for screwing on.
Select screw connections in such a way that the downholder for
valve spring - MP 1-229 (3362)- is located above the respective
valve.
Note
Do not pay attention to hose VW653/3.
– Position the spindle shaft in the upper position of the side

brackets, as shown.
– Adjust the spindle shaft so that the spindle is perpendicular to
the valve spring.
• The Pressure piece - 3362/1- for the downholder for valve
spring - MP 1-229 (3362)- must be in line with the valve spring
plate.
• The side brackets for the downholder for valve spring - MP
1-229 (3362)- must rest on the cylinder head.
– Press the valve spring with pressure piece - 3362/1- .
– Turn the spindle until the valve cone pieces can be removed
with a magnet.
Ensure that the pressure piece - 3362/1- does not tilt on the cyl‐
inder head.
Note
Stuck valve cone pieces can be loosened with a plastic hammer

and with an impact mandrel - VAS 5161/3A- to solve. To do this,
the downholder for valve spring - MP 1-229 (3362)- must be ex‐
panded.
– After removing the valve cone pieces, measure the thread

length of the spindle and make a note of this for reinstallation.
– Pull off valve stem seal with the valve steam seal extractor -
MP 1-230 (3364)- .
Installing
NOTICE
Risk of damage to valve stem seals during installation!
3. Valve gear 101

– Fit the plastic bushing -A-, which is attached to the new valve
stem seals -B-, onto the valve stem.
– Lightly oil sealing lip of the valve stem seal.
– Slide the valve stem seal onto the plastic bushing.
– Carefully press the valve stem seal with the valve stem seal
insertion tool - 3365- onto the valve guide.
– Remove plastic sleeve -A-.
– Repeat the procedure for each valve.
note the following:
– Insert the valve spring and the valve spring retainer.
– Align the downholder for valve spring - MP 1-229 (3362)- with
the valve.
– Press the pressure piece - 3362/1- with the spindle to the pre‐
viously determined degree.
Note
Do not twist the spindle too much, otherwise the valve cone
pieces cannot be used correctly.
– Insert the valve cones.

– Loosen the pressure piece - 3362/1- by unscrewing the spin‐
dle in the upwards motion.
– Mount the rolling tower levers -1- together with the hydraulic
compensating element -4-.
Ensure that all the roller arms are correctly positioned on the valve
stem ends and are clipped in place on the relevant hydraulic bal‐
ancing elements.
– Install camshaft housing
– Install glow plugs
3.4.2 Removing and installing valve stem

seals with cylinder head removed
♦ Valve stem seal extractor - MP 1-230 (3364)-
♦ valve stem seal insertion tool - MP 1-233 (3365)-
♦ Engine and gearbox mount - VAS 6095-
♦ Blank holder for valve spring - MP 1-229 (3362)-
♦ Cylinder head tensioning device - VAS 6419-
♦ Impact mandrel - VAS 5161/3A-
Condition:
• Intake manifold removed
⇒ “5.1 Assembly overview - intake manifold”, page 233 .

• Exhaust manifold and exhaust gas turbocharger removed

page 182 .
Removing
– Assignment of the roller towing levers -1-, hydraulic compen‐
sating elements -4- and valves -3- for reintegration.
– Remove the roller rocker arms together with the hydraulic bal‐
ancing elements and lay aside on a clean surface.
– Insert the cylinder head tensioning device - VAS 6419- into the
engine and gearbox jack - VAS 6095- .
– Tension the cylinder head in the cylinder head tensioning de‐
vice, as shown in the illustration.
– Connect cylinder head tensioning device to compressed air.
– Push the air cushion with the lever -arrow- under the appro‐
priate combustion chamber.
– Allow just enough air to flow into the air bag so that it applied
to the valve disc.
3. Valve gear 103

– Place the downholder for valve spring - MP 1-229 (3362)- on

the cylinder head and screw on. Use the openings for the
camshaft housing screws.
Use the M6 screws with thread length 20 mm for screwing on.
Select screw connections in such a way that the downholder for
valve spring - MP 1-229 (3362)- is located above the respective
valve.
Note
Do not pay attention to hose VW653/3.
– Position the spindle shaft in the upper position of the side

brackets, as shown.
– Adjust the spindle shaft so that the spindle is perpendicular to
the valve spring.
• The Pressure piece - 3362/1- for the downholder for valve
spring - MP 1-229 (3362)- must be in line with the valve spring
plate.
• The side brackets for the downholder for valve spring - MP
1-229 (3362)- must rest on the cylinder head.
– Press the valve spring with pressure piece - 3362/1- .
– Turn the spindle until the valve cone pieces can be removed
with a magnet.
Ensure that the pressure piece - 3362/1- does not tilt on the cyl‐
inder head.
Note
Stuck valve cone pieces can be loosened with a plastic hammer

and with an impact mandrel - VAS 5161/3A- to solve. To do this,
the downholder for valve spring - MP 1-229 (3362)- must be ex‐
panded.
– After removing the valve cone pieces, measure the thread

length of the spindle and make a note of this for reinstallation.
– Pull off valve stem seal with the valve steam seal extractor -
MP 1-230 (3364)- .
Installing
NOTICE
Risk of damage to valve stem seals during installation!

– Fit the plastic bushing -A-, which is attached to the new valve
stem seals -B-, onto the valve stem.
– Lightly oil sealing lip of the valve stem seal.
– Slide the valve stem seal onto the plastic bushing.
– Carefully press the valve stem seal with the valve stem seal
insertion tool - 3365- onto the valve guide.
– Remove plastic sleeve -A-.
– Repeat the procedure for each valve.
note the following:
– Insert the valve spring and the valve spring retainer.
– Align the downholder for valve spring - MP 1-229 (3362)- with
the valve.
– Press the pressure piece - 3362/1- with the spindle to the pre‐
viously determined degree.
Note
Do not twist the spindle too much, otherwise the valve cone
pieces cannot be used correctly.
– Insert the valve cones.

– Loosen the pressure piece - 3362/1- by unscrewing the spin‐
dle in the upwards motion.
– Mount the rolling tower levers -1- together with the hydraulic
compensating element -4-.
Ensure that all the roller arms are correctly positioned on the valve
stem ends and are clipped in place on the relevant hydraulic bal‐
ancing elements.
– Install cylinder head
3. Valve gear 105

4 Inlet and exhaust valves

⇒ “4.1 inspecting valve guides”, page 106
⇒ “4.2 Testing valves”, page 106
⇒ “4.3 Valve dimensions”, page 107
4.1 inspecting valve guides

♦ Universal dial gauge bracket - MP 3-447 (VW 387)-
♦ Dial gauge
Test sequence
Note
♦ If the valve is to be renewed as part of a repair, use a new

valve for the measurement.
♦ On account of differing stem diameters, only use inlet valve in
inlet valve guide and exhaust valve in exhaust valve guide.
– Secure dial gauge to the cylinder head using the universal dial
gauge bracket - MP 3-447 (VW 387)- .
Note
If the valves are replaced when carrying out repair work, use new
valves for the measurement.
– Insert valve into valve guide. End of valve stem must be flush
with guide.
• Valve rock: maximum 1.0 mm
Note
If the wear limit is exceeded, repeat measurement with new

valves. If the wear limit is again exceeded, replace cylinder head.
The valve guides cannot be changed.
4.2 Testing valves

– Check valves on the shank and contact surface for scoring.
– If scoring is clearly visible, change valves.

4.3 Valve dimensions
Note
Inlet and exhaust valves must not be reworked. Only lapping-in

is permitted.
Dimension Inlet valve Exhaust valve

∅a mm 26.60 24.50
∅b mm 5.94 5.94
c mm 99.30 99.10
α ∠° 45 45
4. Inlet and exhaust valves 107

17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - pan/oil pump”, page 108
⇒ “1.2 Removing and installing the bottom part of the oil sump”,
page 110
⇒ “1.3 Removing and installing top part of the oil sump”,
page 111
⇒ “1.4 Removing and installing oil pump”, page 114
⇒ “1.5 Removing and installing oil level and oil temperature send‐
er G266 ”, page 117
1.1 Assembly overview - pan/oil pump

NOTICE
If considerable quantities of metal swarf as well as abrasion is
found in the engine oil when carrying out engine repairs, care‐
fully clean the oil galleries in order to avoid consequential dam‐
age and additionally replace the oil injection nozzles and the
engine oil cooler as well as the oil filter element.
♦ The oil level must not be above the max. marking - risk of
damage to catalytic converter!
108 Rep. gr.17 - Lubrication

1 - Nut
❑ 10 Nm
2 - Oil level and oil temperature
transmitter - G266-
stalling oil level and oil
temperature sender
G266 ”, page 117
3 - Oil drain plug
sembly
❑ 30 Nm
4 - Sealing ring
❑ component part of posi‐
tion -3-
5 - Bottom part of oil sump
stalling the bottom part
of the oil sump”,
page 110
6 - Seal
sembly
7 - Fit pin
8 - Top part of the oil sump
stalling top part of the oil
sump”, page 111
9 - Screw
❑ 8 Nm
10 - Oil suction pipe
11 - Sealing ring
12 - Screw
❑ 8 Nm
13 - Cover
14 - Oil pump
Note
An already used oil pump cannot be

reinstalled!
❑ with vacuum pump
❑ with balancing shaft module
❑ Removing and installing ⇒ “1.4 Removing and installing oil pump”, page 114
1. Sump, oil pump 109

15 - Fitting sleeve
16 - Cylinder block
17 - O-ring
❑ component part of position -18-
18 - Oil pressure control valve - N428-
⇒ “3.5 Removing and installing valve for oil pressure control N428 ”, page 126
19 - Screw
❑ 8 Nm
20 - Screw
❑ 8 Nm
21 - Oil pipe
22 - Seal
❑ Different versions ⇒ ETKA - Electronic Catalogue of Original Parts
23 - Screw
❑ 8 Nm
24 - O-ring
25 - Screw
❑ 16 Nm + 135°.
26 - Fit pin
27 - Screw
❑ 13 Nm
28 - Screw
❑ 10 Nm
29 - Sealing ring
1.2 Removing and installing the bottom part

of the oil sump
♦ Flexible-head wrench SW 10 - 3185-
Parts
Removing
noise insulation .

– Release connector -4- and pull off, loosen clips -5- and dis‐
connect electrical line.
– Unscrew screws -1-, loosen clips -2- and remove noise insu‐
lation -3- for oil pan.
– Drain engine oil:
– Release screws -2- and remove sump bottom part -1-.

Installing
Note
Replace gasket after disassembly.
Note

♦ Oil pan ⇒ “1.1 Assembly overview - pan/oil pump”, page 108
1.3 Removing and installing top part of the

oil sump
♦ Socket - T10058-
Parts
Removing
– Remove the flywheel

– Unscrew screw -2- for oil pipe -1- and cut cable strap -3- on
top and at bottom.
– Remove oil sump bottom part
page 110 .
For vehicles with air conditioning

to the right.

For all vehicles

– Unscrew screws -2- and remove cover -1-.
– Unscrew screws -2- and remove sump top part -1- from bond‐
ing. If necessary, undo the top part of the oil sump by applying
slight blows with a rubber-headed hammer.
Installing
CAUTION
Wear protective gloves and goggles when working with gasket
remover and degreasing agent!
– Remove residual sealant from the sealing surfaces on the cyl‐

inder block and on the oil pan with chemical sealant remover.
– Degrease the sealing surfaces.
Note
– Cut off nozzle tube at the front marking (∅ of nozzle approx.

2 ... 3 mm).
NOTICE
There is risk of blockage of the lubrication system through ex‐
cess sealant.
♦ Do not apply thicker sealant strips than indicated.
When the sealing flange on the belt pulley side was not replaced
Note
The bottom surface of the sealing flange on the belt pulley side
has a displacement of approx. 1 mm to the bottom cylinder block
surface after removing the old silicone seal, which must be com‐
pensated for by applying the required sealant on the correspond‐
ing area of the oil pan sealing surface.

– Apply sealant bead onto the clean sealing surfaces of the oil
sump, as shown in the illustration.
• Sump top part must be in contact with the intermediate plate
so that it is lined up with the gearbox flange.
– Position sump top part -1- and tighten screws -2-.
Note
♦ When installing the oil pan with the engine removed you must
ensure that the oil sump is flush with the cylinder block at the
flywheel side.
♦ Let sealing compound dry for approx. 30 minutes after instal‐
ling oil sump. Only then fill with engine oil.

– Install oil sump bottom part
page 110 .
– Fill with engine oil and check the oil level:
– Install the flywheel
Note

1.4 Removing and installing oil pump
Note
An already used oil pump cannot be reinstalled!


♦ Rig pin - 3359-
Removing
– Remove belt pulleys
– Remove sump top part
111 .
– Unscrew screws -2- and remove cover -1-.
– Secure drive wheel of the oil pump with rig pin - 3359- .

– Unscrew screws in the sequence -8- to -1- and remove oil

pump.
Installing
NOTICE
♦ During installation, the backlash between crankshaft sprock‐
et and drive wheel for the new oil pump must be set.
♦ The wheel for the new oil pump has a smooth paint covering
which wears off after a short running time, and thus auto‐
matically sets the backlash.

– Degrease crankshaft sprocket.
– Insert dowel sleeves -2- into the crankcase.
– Lock oil pump in the bore in the drive wheel -1- using the rig
pin - 3359- .

– Position oil pump -3- and initially screw in screws -2- and -4-
by hand as far as the stop.
– Insert balancing shaft module in -direction of arrow- and tight‐
en screws -2- and -4- hand-tight.
– Check that the marks on the gear wheels of the balancing shaft
-1- and the crankshaft -2- are opposite each other.
– Screw in the remaining screws and tighten by hand.
– Tighten the screws in the sequence -1- through -8-.

– Remove crankshaft arrester - T10490- and rig pin - 3359- .
– Install sump top part
111 .
– Install belt pulley
Note

1.5 Removing and installing oil level and oil

temperature sender - G266-
Removing
noise insulation .

– Release connector -4- and pull off, loosen clips -5- and dis‐
connect electrical line.
– Unscrew screws -1-, loosen clips -2- and remove noise insu‐
lation -3- for oil pan.
– Drain engine oil:

– Unscrew nuts -1- and remove oil level and oil temperature
transmitter - G266- -3-.
Installing
Note
Replace gasket ring -4- and nuts -1-.

Note


2 Engine oil cooler
Note
The engine oil cooler must not be disconnected from the oil filter
housing In the event of a defect, the engine oil cooler with the oil
filter housing must be replaced
⇒ “3.4 Removing and installing oil filter housing”, page 123 .
2. Engine oil cooler 119

3 Oil filter, oil pressure switch

⇒ “3.1 Summary of components - oil filter housing/oil pressure
switch”, page 120
⇒ “3.2 Removing and installing oil pressure switch F1 ”,
page 121
⇒ “3.3 Testing oil pressure”, page 122
⇒ “3.4 Removing and installing oil filter housing”, page 123
⇒ “3.5 Removing and installing valve for oil pressure control N428
”, page 126
3.1 Summary of components - oil filter housing/oil pressure switch
1 - Oil pressure switch - F1-

❑ Switching pressure:
0.03 - 0.06 MPa (0.3 -
0.6 bar)
❑ Check ⇒ Vehicle diag‐
nostic tester
stalling oil pressure
switch F1 ”, page 121
❑ 20 Nm
2 - O-ring
sembly
3 - Seal
sembly
4 - Oil filter housing with engine
oil cooler
❑ Oil filter housing and en‐
gine oil cooler must not
be disconnected
stalling oil filter hous‐
ing”, page 123
5 - Screw
❑ 20 Nm
6 - Locking clip
7 - Engine oil cooler
❑ Oil filter housing and en‐
gine oil cooler must not
be disconnected
8 - Oil filter
❑ pay attention to the notes ⇒ “1.1 Assembly overview - pan/oil pump”, page 108
❑ removing and installing:

9 - Seal
3.2 Removing and installing oil pressure

switch - F1-
Removing
3. Oil filter, oil pressure switch 121


– Release connector -1- and pull off and remove locking clips
-2-.
Note
Place a cloth below to absorb leaking engine oil.
– Screw out oil pressure switch - F1- -3-.

Installing
to the following:
Note
♦ Make sure the locking clips fit tightly!

♦ Renew O-ring.

Note

♦ Oil pressure switch

switch”, page 120
3.3 Testing oil pressure
Note
Because of the clutch guard speed, not all of the oil pressure
control steps can be set when the vehicle is stationary. For this
reason, the oil pressure must be tested with the vehicle diagnosis
tester.
– Connect vehicle diagnosis tester ⇒ Vehicle diagnostic tester.


♦ Testing oil pressure
3.4 Removing and installing oil filter housing

Removing
– Remove screws -1- and remove air inlet -2-.


Note
You must close the opening for the oil pipe in the oil pan with
screw plugs after removing. Otherwise, coolant would flow into
the oil.
– Unscrew screw -1- for oil pipe -2- on the oil pan.
– Cut cable strap -3- at top and bottom.

– Unscrew screw -2- for oil pipe and remove the oil pipe -1- to
the top.
– Unscrews screws -1- for electrical coolant pumps and release

and pull off connectors -4- and -6-.
– Loosen retaining clips -2- and remove cover for noise insula‐
tion -3-.

For vehicles with air conditioning

– Release and pull off connector -3- for throttle valve control unit.
to the right.
For all vehicles

– Release and pull off connector -1- on the oil pressure control
valve - N428- .
– Release and pull off connector -1-, unscrew nut -2- and cut
cable strap -3-.
– Release clamp -1- and disconnect coolant hose. Unscrew

screws -2- and remove coolant regulator housing -3-.
Note

– Release clip -1- and unscrew screws -2- to -6-.

– Remove oil filter housing downwards.
Installing
to the following:
Note
♦ Replace gasket and O-ring.

inal Parts .
– Install AC compressor
⇒ “1.1 Assembly overview - V-ribbed belt drive”, page 28 .
– Install the front right wheelhouse liner⇒ Exterior body work;
Rep. gr. 66 ; Wheelhouse liner; Removing and installing the
front wheelhouse liner .
Note


switch”, page 120
♦ Air filter housing
⇒ “4.1 Assembly overview - air filter housing”, page 230
3.5 Removing and installing valve for oil

pressure control - N428-
Removing
to the right.
Note

– Release and pull off connector -1-, unscrew screw -2- and re‐
move the valve for oil pressure control - N428- -3-.
Installing
to the following:
Note
Check O-ring for damage.

Note


switch”, page 120

19 – Cooling
1 Cooling system, coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 128
⇒ “1.2 Check cooling system for leaks”, page 129
⇒ “1.3 Draining and filling coolant”, page 131
⇒ “1.4 Flushing the cooling system”, page 135
⇒ “1.5 Flushing cooling system, quick start guide”, page 155
1.1 Connection diagram - coolant hoses
Note
♦ Blue = large coolant circuit.

♦ Red = small coolant circuit.
♦ Yellow = coolant circuit for charge air cooler.
♦ White = heating circuit.
♦ The arrows point in the coolant flow direction.
128 Rep. gr.19 - Cooling

1 - Coolant expansion tank

2 - Screw cap
❑ for coolant expansion
tank
❑ Check pressure relief
valve ⇒ page 131
3 - Heating backup pump -
V488-
stalling electric coolant
pump”, page 160
4 - Particle filter
5 - Non-return valve
❑ integrated in the coolant
hose
6 - Heat exchanger for heating
7 - Radiator for exhaust gas re‐
circulation
❑ Check for leaks
⇒ “4.3 Test air-tightness
of the radiator for ex‐
haust gas recirculation”,
page 291
8 - Exhaust gas turbocharger
❑ with connection fitting of
the coolant hose
10 - Choke
❑ integrated into the cool‐
ant hose, not visible
from the outside
❑ The fitting position is not defined, therefore the coolant hose must not be unclipped with the hose clamp
(Risk of damage!)
11 - Radiator for exhaust gas recirculation, high pressure
12 - Charge air cooler
13 - Coolant regulator
14 - Coolant radiator
15 - Radiator fan
16 - Charge air cooling circuit radiator
17 - Charge air cooler pump - V188-
❑ Removing and installing ⇒ “2.4 Removing and installing electric coolant pump”, page 160
18 - Engine oil cooler
19 - Coolant pump
20 - Cylinder head and cylinder block
1.2 Check cooling system for leaks

1. Cooling system, coolant 129

♦ Cooling system tester - V.A.G 1274 B-

♦ Adapter for cooling system tester - V.A.G 1274/8-
Test condition
• Engine must be warm.
Test sequence
CAUTION
Hot steam may escape when the expansion reservoir is
opened!
♦ Cover the cap with a cloth and open carefully.
– Open cap -arrow- for coolant expansion tank.

– Fit the cooling system testing device - V.A.G 1274 B- with

adapter -V.A.G 1274/8- onto the coolant expansion tank.
– Using the hand pump of the testing device generate a pressure
of approx. 0.15 MPa (1.5 bar).
CAUTION
Risk of scalding!
♦ Before the cooling system testing device -V.A.G 1274 B- is
separated from the connecting hose or the connecting piece
-V.A.G 1274 B/1- , the existing pressure must absolutely be
released.
♦ For this step, press the pressure relief valve on the cooling
system testing device -V.A.G 1274 B- and hold it pressed
until the pressure gauge indicates the value »0«.
• The pressure must not drop below 0.02 MPa (0.2 bar) after 10
minutes.
If the pressure falls below 0.02 MPa (0.2 bar):
– Search position of the leak and repair fault.
Note
♦ A fall in pressure of 0.02 MPa (0.2 bar) within 10 minutes is

caused by cooling of the coolant.
♦ The colder the engine, the lower the pressure loss.
Testing the pressure relief valve in the cap

– Screw the screw cap into the adapter for the cooling system
testing device -V.A.G 1274/9- .
– Connect the connecting piece -V.A.G 1274 B/1- to the adapter
for the cooling system testing device -V.A.G 1274/9- .
– Connect the connecting piece -V.A.G 1274 B/1- via the deliv‐
ered connecting hose to the cooling system testing device -
V.A.G 1274 B- .
– Build up overpressure using the hand pump on the tester.
Blue filler cap:
♦ The pressure relief valve should open at a pressure of 0.14 to
0.16 MPa (1.4 to 1.6 bar).
Black filler cap:
♦ The pressure relief valve should open at a pressure of 0.16 to
0.18 MPa (1.6 to 1.8 bar).
If the pressure relief valve opens too early or too late:
– Renew cap.
1.3 Draining and filling coolant

♦ Cooling system charge unit - VAS 6096-
♦ Catch pan , e.g. -VAS 6208-

♦ Refractometer
♦ Protective goggles
♦ Protective gloves
Note
♦ The drained coolant must not be re-used.

♦ Observe the disposal instructions.
Draining
CAUTION
Danger of scalding due to hot steam and hot coolant.
♦ When the engine is warm the cooling system is under pres‐
sure.
♦ Reduce pressure by covering the cap of the coolant expan‐
sion reservoir with a cloth and opening it carefully.

noise insulation .
– Place catch pan - VAS 6208- under the radiator.
– Release clamps -1- to -4-, disconnect coolant hoses and let

coolant drain.
Filling up
After replacing the components:
♦ Cylinder head
♦ Heat exchanger for heating
♦ Coolant radiator
♦ Charge air cooler
filling up is not sufficient. The cooling system must therefore be
flushed and the coolant must be replaced
NOTICE
Risk of engine damage if the cooling system is not filled/bled
adequately!
♦ You must bleed the cooling system with the ⇒ Vehicle diag‐
nostic tester after filling.

– Connect hoses -1- to -4-.

– Fill up the coolant reservoir -VAS 6096- with at least 8 litres of
pre-mixed coolant mixed to the correct ratio:
– 1Screw the adapter for cooling system testing device -

V.A.G 1274/8- to the coolant expansion tank -1-.
– Fit cooling system charge unit - VAS 6096- to the adapter -
V.A.G 1274/8- .
– Place the air hose -2- into a small container -3-.
Note
A small amount of coolant, which is entrained with the exhaust

air, must be collected.
– Close the valves -A- and -B-, while doing so turn the lever at
right angles to the direction of flow.
– Connect hose -4- to compressed air.
• Pressure: 0.6 - 1.0 MPa (6 - 10 bar)

– Open the valve -B-, while doing so turn the lever in the direction
of flow.
• Vacuum is generated in the cooling system by the suction
spray pump.
• The display instrument pointer must move into the green area.
– In addition, briefly open the valve -A- by turning the lever in the
direction of flow, so that the hose of the coolant expansion
bottle is -VAS 6096- filled with coolant.
– Close the valve -A- again.
– Leave the valve -B- open a further 2 minutes.
• A vacuum pump is created in the cooling system by the vac‐
uum pump; the display instrument pointer must remain in the
green area.
– Close the valve -B-.
• If the display instrument pointer remains in the green area the
vacuum in the cooling system is sufficient for subsequent fill‐
ing.
Note
♦ If the pointer is below the green area, repeat the process.

♦ If the vacuum drops, check the cooling system for leak points.
– Disconnect pneumatic hose.
– Open valve -A-.

• The vacuum pump in the cooling system draws the coolant out
of the coolant reservoir -VAS 6096- and fills the cooling sys‐
tem.
– Remove the cooling system charge unit - VAS 6096- from the
coolant expansion tank.

– Fill up coolant to “max” marking.
Note
Hose connections as well as charge air pipes and -hoses must

be free of oil and grease before being installed.
– Install the noise insulation ⇒ General body repairs, exterior;

noise insulation .
– For vehicles with auxiliary heating, switch it on for approxi‐
mately 30 seconds.
– Set temperature to “HI”.
– Switch off AC compressor. Press AC button to do so.
• The LED in the button must not illuminate.
♦ 0001 - Coolant circuit filling
– Follow the instructions of the vehicle diagnosis tester .
– After repair, check coolant level.
• If the engine is at operating temperature, the coolant level

must not be above the »welding seam« -arrow-.
• If the engine is cold, the coolant level must be approx. 5 mm
-arrow- above the “max” marking.
Note
The higher coolant level is necessary, as the coolant level may

still fall after bleeding.
1.4 Flushing the cooling system

The cooling system must be flushed after the following compo‐
nents are replaced:
♦ Cylinder head

♦ Charge air cooling circuit radiator

♦ Charge air cooler
When flushing, the coolant is replaced by the new coolant. This
ensure that the surfaces of the new components are properly
protected.
Note
♦ The cooling system is first flushed with approx. 12 litres of dis‐

tilled water. Distilled water is then replaced by coolant (mixing
ratio 50:50).
♦ The cooling system is vented with ⇒ Vehicle diagnostic tester
after the coolant has been changed.
♦ Do not re-use used coolant.

♦ Coolant flushing and charge unit - VAS 531 007-
♦ Test adapter - VAS 691 005/5-
♦ Ejector from the cooling system charge unit - VAS 6096-
♦ Refractometer
♦ Compressed air connection with pressure of 6-10 bar
Schematic overview of the coolant flushing and charge unit - VAS
531 007-

1 - Container with distilled wa‐

ter
❑ fill with at least 20 litres
of distilled water
2 - Coolant reservoir
❑ fill with at least 20 litres
of coolant
❑ Antifreeze protection up
to approx. -36 °C
3 - Empty container
❑ for used coolant
4 - Empty container
❑ for used coolant
5 - intake hose
❑ from connection 2 to in‐
spection glass
6 - Inspection glass
❑ discoloured inspection
glass must be cleaned
with nylon brush
7 - Vane pump
❑ Shutoff pressure: ap‐
prox. 0.15 MPa (1.5 bar)
8 - Valve block
❑ with pressure gauge
and shut-off taps
9 - Drain hose
❑ connected to the valve
block to eliminate pres‐
sure
10 - Flushing hose
❑ it is connected to the bleeder hose for the coolant expansion reservoir before flushing
❑ from connection 1 to inspection glass
❑ if not used, then close with plug
11 - Plug
12 - Hose clamps
❑ 4 units
13 - Adapter for cleaning
❑ Length: approx. 15 cm
❑ to clean the coolant flushing and charge unit for flushing
❑ connected between valve block and flushing hose, Pos. -10- ⇒ Item 10 (page 137)
14 - Adapter for extraction
❑ Length: approx. 100 cm
❑ connected to suction hose, Pos. -5-, to extract coolant ⇒ Item 5 (page 137)
Prepare coolant flushing and charge unit - VAS 531 007- :

– Fill container »1« with at least 20 litres of distilled water.
– Fill container »2« with at least 20 litres of coolant. Mixing ratio
50:50 approx. -36 °C.

– Empty containers »3« and »4«.

– Connect the battery charger.
– Remove valve block from the quick coupling on the trolley with
the device.
– Connect the coolant flushing and charge unit - VAS 531 007-
to battery.
Venting the coolant flushing and charge unit - VAS 531 007-
– Connect suction hose -A- to tank »1« with distilled water.
– Connect the discharge hose -arrow- to the quick coupling -B-

on the valve block.
– Close the shut-off taps -A- and -B-.
Note
Do not fit the valve block to the test adapter - VAS 691 005/5- yet.
The filler hose should be bled first.
– Switch on the pump -VAS 531 007- .

– Open the shut-off tap -A-.
– Briefly open the shut-off tap -B- to vent the filler hose.
– Close shut-off taps -A- and -B- again.
Connecting the coolant flushing and charge unit - VAS 531 007-

– Screw the test adapter -2- ( -VAS 691 005/5- ) onto the coolant
expansion reservoir -1-.
– Disconnect the discharge hose -arrow- from the quick coupling

-B- on the valve block.
– Fit the valve block -1- onto the test adapter -2-.
– Connect the ejector -2- from the -VAS 6096- to the quick cou‐
pling -B- on the valve block -1-.
Filling the cooling system with distilled water

– Guide the bleeder hose -8- for ejector into a container.

– Connect the vacuum hose -6- to the suction spray pump -7-.
– Open the shut-off tap -B- on the valve block -5-.
• Vacuum is generated in the cooling system by the suction
spray pump. The pressure indicator must fall to at least -0.085
MPa (-0.85 bar).
– Close shut-off tap -B-.
– Disconnect pressure hose -6-.
– Check the pressure gauge. The pressure indicator must re‐
main at - 0.07 MPa (-0.7 bar) as a minimum. The vacuum in
the cooling system is then sufficient for subsequent filling.
Note
♦ If the vacuum drops, check the cooling system for leak points.
♦ The generated vacuum depends on the pressure in the compressed air system.

• The pump -VAS 531 007- must be switched on.

– »Slowly« open the shut-off tap -A- to avoid coolant foaming.
• Vacuum in the cooling system causes the distilled water to be
drawn in and the cooling system is filled. The pump -VAS 531
007- also pumps distilled water into the coolant expansion
reservoir.
• After filling, the excess pressure in the coolant expansion res‐
ervoir must be released. To do so proceed in the following
manner:
– Close the shut-off tap -A- after filling.
– Disconnect the ejector -2- from the valve block -1-.
– Connect the discharge hose -arrow- to the quick coupling.

Open the shut-off tap -B- and leave open to dissipate the pres‐
sure in the cooling system.
Flushing the cooling system with distilled water

– Disconnect the bleeder hose -2- from the coolant expansion
reservoir -1-.

– Connect the bleeder hose -2- for the coolant expansion res‐
ervoir to the flushing hose -1-.
– Close the connection fitting on the coolant expansion reservoir
with a plug -3-. Secure the plug with hose clamp.
– Close shut-off tap -B-.
– Remove engine cover.
The cooling system is sub-divided into the following coolant cir‐
cuits:
♦ Cylinder block and cylinder head
♦ Charge air cooler and charge air cooling circuit radiator
Note
♦ The following work procedure involves flushing these 4 cool‐

ant circuits by alternately closing the bleeder hoses.
♦ This procedure must be performed twice with distilled water.
Then flush twice with coolant.
♦ The litre specifications are average values and may be differ‐
ent depending on equipment of the vehicle. The volume can
be read off the scale on the container.
♦ The change of colour at connection 1 on the inspection glass
is the relevant indicator for the flushing volume. The colours
only match between connection 1 and 2 on the inspection
glass on the second flush.
♦ If the colour in the inspection glass changes, further coolant
circuits are flushed.
1. Flushing the cylinder block and cylinder head with distilled wa‐
ter

A non-return valve -1- is installed in the bleeder hose of the charge

air cooler. The hose can therefore only be closed at the point
shown.
– Close the bleeder hoses with hose clamps at the points indi‐
cated.
– Open the shut-off tap -A- on the valve block. The engine now
pumps distilled water.
– Check the inspection glass: as soon as the coolant changes
colour, close the shut-off tap -A-.
• Required quantity of distilled water: approx. 2-3 litres
2. Flushing the heat exchanger for heating with distilled water

cated.
• Required quantity of distilled water: approx. 2 litres
3. Flush radiator with distilled water

cated.
4. Flushing the charge air cooler and charge air cooling circuit
radiator with distilled water

cated.

Repeat flushing steps 1-4 times, but always only pump approx. 1
litre of distilled water ⇒ page 142 . Then flush the cooling system
with coolant.
Flushing the cooling system with coolant
– Connect suction hose -A- to container -2- with distilled water.
1. Flushing the cylinder block and cylinder head with coolant
cated.
pumps coolant.

– Check the inspection glass: if you can see the coolant coming
out in the inspection glass, close the shut-off tap -A-.
• Required quantity of coolant: approx. 2-3 litres
2. Flushing the heat exchanger for heating with coolant
cated.
pumps coolant.
• Required quantity of coolant: approx. 2 litres
3. Flush the radiator with coolant

cated.
pumps coolant.
4. Flushing the charge air cooler and charge air cooling circuit
radiator with coolant

cated.
pumps coolant.
Repeat flushing steps 1-4 times, but always only pump approx. 1
litre of coolant ⇒ page 147 . The flushing procedure is then fin‐
ished.
– Switch off the pump after flushing.
– Remove all hose clamps.

Disconnect the coolant flushing and charge unit - VAS 531 007- :
– Open the shut-off tap -B- and leave open to dissipate the pres‐
sure in the cooling system.
– Remove the plug -3- from the coolant expansion reservoir and
re-connect the bleeder hose -2-.
– Close the flushing hose -1- with a plug.
– Remove the valve block -1- and the test adapter -2-.
– The coolant must be approx. at the »weld seam« -arrow-.

– If necessary, extract or fill coolant.
Extracting coolant

Note
Use the adapter for extraction, Pos. -14-, to extract coolant ⇒ Item 14 (page 137) .
– Disconnect the intake hose -5- from the container -2-.

– Connect the adapter for extraction -12- onto the quick coupling
of the intake hose -5-.
– Switch on the pump -7- and open the shut-off taps -A- and
-B- on the valve block -8-.
– Extract excess coolant with the adapter for extraction -12-.
– Close the shut-off taps on the valve block and switch off the
pump.
Bleeding the cooling system
– For vehicles with auxiliary heating, switch on the auxiliary
heating for approx. 30 seconds.
– Set temperature to “HI”.
– Switch off the AC compressor by pressing the AC button.
• The LED in the button must not illuminate.

– Connect vehicle diagnostic tester .

– Switch on the ignition and select the following options on the
vehicle diagnostic tester :
♦ 0001 - Coolant circuit filling
– Follow the instructions of the vehicle diagnosis tester .
– Allow engine to cool down.
– Check the coolant level and antifreeze:
• If the engine is at operating temperature, the coolant level

must be at the »weld seam« -arrow-.
• If the engine is cold, the coolant level must be approx. 5 mm
-arrow- above the max marking.
Note
The higher coolant level is necessary, as the coolant level may

still fall after bleeding.
Cleaning the coolant flushing and charge unit - VAS 531 007-

Note
♦ If the coolant stays in the inspection glass for a long time, it may discolour. The inspection glass must
therefore be flushed with distilled water after each flushing.
♦ If the inspection glass is discoloured, clear it with a nylon brush.
♦ Use the adapter for cleaning, Pos. -13-, to flush ⇒ Item 13 (page 137) .
– Connect intake hose -5- to container -1- for distilled water.

– Connect the flushing hose -9- to the adapter for cleaning
-10-. Connect the adapter for cleaning -10- to the quick cou‐
pling -B- on the valve block -8-.
– Open shut-off taps -A- and -B- of on the valve block -8-.
– Switch on the pump -7- and pump distilled water with the hoses
until the coolant is flushed off the inspection glass -6-.
– Switch off the pump and close the shut-off taps.
– Remove the adapter for cleaning and close the flushing hose
against with a plug.

1.5 Flushing cooling system, quick start

guide
Note
The Quick Start Guide lists the main steps in the workflow. These
can be printed and scraped during the workflow. A detailed work‐
flow is listed here
Step Activity Flushing volume

1 Draining coolant ---
2 Filling the cooling system with distilled water ---
3 Connect hose from coolant expansion tank on coolant flushing and filling device ---
4 Disconnect the ventilation hose for heat exchangers -1-, for charge-air cooler -3- 3 litres of distilled
and cooler -4-, flush cooling system water
5 Disconnect the ventilation hose for cylinder head -2-, for charge-air cooler -3- and 2 litres of distilled
cooler -4-, flush cooling system water
6 Disconnect the ventilation hose for heat exchangers -1-, for cylinder head -2- and 2 litres of distilled
intercooler -3-, flush cooling system water
7 Disconnect the ventilation hose for heat exchangers -1-, for cylinder head -2- and 2 litres of distilled
cooler -4-, flush cooling system water
Repeat steps 4, 5, 6 and 7, but always pump through 1 litre of distilled water always 1 litre of
distilled water
8 Disconnect the ventilation hose for heat exchangers -1-, for charge-air cooler -3- 3 litres of coolant
and cooler -4-, flush cooling system
9 Disconnect the ventilation hose for cylinder head -2-, for charge-air cooler -3- and 2 litres of coolant
cooler -4-, flush cooling system
10 Disconnect the ventilation hose for heat exchangers -1-, for cylinder head -2- and 2 litres of coolant
intercooler -3-, flush cooling system
11 Disconnect the ventilation hose for heat exchangers -1-, for cylinder head -2- and 2 litres of coolant
cooler -4-, flush cooling system
Repeat steps 8, 9, 10 and 11, but always pump only 1 litre of coolant always 1 litre of
coolant
12 Disconnect all closing pliers ---
13 Remove the coolant flushing and filling device and close the coolant expansion tank ---
14 Bleed cooling system with vehicle diagnostics tester ---
15 Inspecting antifreeze protection and coolant level ---
Locking points

1 - Vent hose for heat ex‐

changer for heating
2 - Vent hose for cylinder head
3 - Hoses for charge air cooler
4 - Vent hose for cooler for
coolant

2 Coolant pump, regulation of cooling

system
⇒ “2.1 Summary of components - coolant pump/thermostat”, page
157
⇒ “2.2 Summary of components - electric coolant pump”,
page 159
⇒ “2.3 Summary of components - coolant temperature transmit‐
ter”, page 160
⇒ “2.4 Removing and installing electric coolant pump”,
page 160
⇒ “2.5 Removing and installing coolant pump”, page 162
⇒ “2.6 Removing and installing coolant regulator”, page 164
⇒ “2.7 Testing the coolant regulator”, page 165
⇒ “2.8 Removing and installing coolant valve for cylinder head
N489 ”, page 166
⇒ “2.9 Removing and installing coolant temperature transmitter
G62 ”, page 166
2.1 Summary of components - coolant pump/thermostat
1 - Coolant pipe - front bottom

❑ ⇒ “3.1 Summary of com‐
ponents - coolant pipe”,
page 169
2 - O-ring
sembly
3 - O-ring
sembly
4 - Coolant pump
stalling coolant pump”,
page 162
5 - Screw
❑ 20 Nm
6 - O-rings
sembly
7 - Coolant valve for cylinder
head - N489-
stalling coolant valve for
cylinder head N489 ”,
page 166
2. Coolant pump, regulation of cooling system 157

8 - Screw
❑ 8 Nm
9 - O-ring
10 - Screw
❑ 20 Nm
11 - Coolant regulator housing
12 - Coolant regulator
❑ Removing and installing ⇒ “2.7 Testing the coolant regulator”, page 165
13 - O-ring
❑ check for damage
14 - Connection fitting
15 - Screw
❑ 8 Nm
16 - O-ring
17 - Retaining clip
18 - Screw
❑ 20 Nm

2.2 Summary of components - electric coolant pump
1 - Coolant hose
❑ Connection diagram
⇒ “1.1 Connection dia‐
gram - coolant hoses”,
page 128
2 - Fixing clamp
3 - Heating backup pump -
V488-
installing the heating
backup pump V488 ”,
page 160
4 - Fixing clamp
5 - Coolant hose
page 128
❑ Heating backup pump -
V488-
7 - Screw
❑ 8 Nm
8 - Grommet
9 - Screw
❑ 8 Nm
10 - Coolant hose
page 128
11 - Fixing clamp
12 - Coolant hose
❑ Connection diagram ⇒ “1.1 Connection diagram - coolant hoses”, page 128
13 - Fixing clamp
❑ Removing and installing ⇒ “2.4.2 Removing and installing charge air cooler pump V188 ”, page 161
15 - Screw
❑ 8 Nm
❑ Charge air cooler pump - V188-
17 - Grommet
18 - Screw
❑ 8 Nm

2.3 Summary of components - coolant temperature transmitter
1 - O-ring
sembly
2 - Coolant temperature trans‐
mitter - G62-
stalling coolant temper‐
ature transmitter G62 ”,
page 166
3 - Screw
❑ 8 Nm
2.4 Removing and installing electric coolant

pump
⇒ “2.4.1 Removing and installing the heating backup pump V488
”, page 160
⇒ “2.4.2 Removing and installing charge air cooler pump V188 ”,
page 161
2.4.1 Removing and installing the heating

backup pump - V488-
♦ Hose clamps up to ∅ 25 mm - MP7-602 (3094)-
Removing
noise insulation .


– Disconnect coolant hoses with hose clamps -MP7-602
(3094)- .
Note
Place a cloth below to absorb leaking coolant.
– Loosen clamps -1- and disconnect coolant hoses. Unlock and

pull off connector -3-.
– Unscrew screw -2- and remove the heating backup pump -
V488- -4-.
Installing
to the following:
Note
Parts .
– Check coolant level ⇒ page 132 .

Note

♦ Engine cover ⇒ General body repairs, exterior ; Rep. gr. 66 ;

Noise insulation; Summary of components- noise insulation .
2.4.2 Removing and installing charge air cool‐

er pump - V188-
Removing
noise insulation .
– Disconnect coolant hoses with hose clamps -MP7-602
(3094)- .

Note
Place a cloth below to absorb leaking coolant.
– Release and pull off connector -1-, loosen clamps -2- and dis‐
connect coolant hoses.
– Unscrew screw -3- and remove charge air cooler pump - V188-
-4-.
Installing
to the following:
Note
Parts .

Note

♦ Coolant pump
⇒ “2.2 Summary of components - electric coolant pump”, page
159
2.5 Removing and installing coolant pump

Removing

– Release and pull off connector -1- for coolant valve for cylinder
head - N489- with the assembly tool - T10118- .
⇒ “2.3 Removing and installing toothed belt guard”, page 83 .
page 93 .
NOTICE
mounted.
Risk of damage to the toothed belt!
♦ Do not over-tension or kink the toothed belt.

– Unscrew screws -1- and remove coolant pump -2-.

Installing
to the following:
Note
Replace O-rings after disassembly.
– Clean and smooth O-ring sealing surfaces.

– Moisten O-rings with coolant.
Note

♦ Coolant pump
⇒ “2.2 Summary of components - electric coolant pump”, page
159
2.6 Removing and installing coolant regula‐

tor
Removing


– Cut cable strap of the wiring loom on the oil pipe and push the
wiring loom to the side.
– Unscrew screws -1- and remove connection fitting -2-.

– Pull thermostat out of the coolant regulator housing.
Installing
to the following:
Note
Replace O-ring after disassembly.
– Clean and smooth O-ring sealing surfaces.

– Moisten O-ring with coolant.
– Insert coolant regulator -2- into the coolant regulator housing

-1-.
• The retaining lugs must engage in the guides -arrows-.
Note

♦ Coolant pump
⇒ “2.1 Summary of components - coolant pump/thermostat”,
page 157
2.7 Testing the coolant regulator

– Heat up the removed coolant regulator in a water bath.
Start of opening End of opening Opening stroke
87 ± 2 °C approximately 102 min. 9 mm
°C 1)
• 1) Cannot be tested.

2.8 Removing and installing coolant valve

for cylinder head - N489-
Removing
– Remove coolant pump
⇒ “2.5 Removing and installing coolant pump”, page 162 .
– Unscrew screw -1-, pull off coolant valve for cylinder head -
N489- -2-.
Installing
to the following:
Note
Replace O-rings after disassembly.
– Install coolant pump

⇒ “2.5 Removing and installing coolant pump”, page 162 .
Note

♦ Coolant pump
page 157
2.9 Removing and installing coolant temper‐

ature transmitter - G62-
Removing
• Engine cold.
– Briefly open the cap -arrow- for the coolant expansion reser‐
voir in order to remove the remaining pressure in the coolant
system.



– Use the assembly tool - T10118- to release and pull off the
connector -1- and unscrew screws -2-.
– Pull out coolant temperature sender - G62- to the front.
Note
Use a wire to pull out any O-ring or distance ring that has re‐
mained stuck inside the cylinder head.
Installing
to the following:
Note
♦ Replace O-rings.
♦ Replace distance ring if it is damaged.

Note

♦ Coolant temperature sensor

⇒ “2.3 Summary of components - coolant temperature trans‐
mitter”, page 160
⇒ “4.2 Removing and installing air filter housing”, page 231

3 Coolant pipes
⇒ “3.2 Removing and installing coolant pipes”, page 170
3.1 Summary of components - coolant pipe
Note
The arrows on the coolant pipes and the coolant hose ends must
stand opposite to each other.
1 - Coolant pipe - right

2 - Nut
❑ 8 Nm
3 - Nut
❑ 8 Nm
4 - Seal
sembly
5 - Coolant pipe - bottom right
6 - Screw
❑ 8 Nm
7 - Screw
❑ 8 Nm
8 - The coolant pipe at the rear
9 - Screw
❑ 8 Nm
10 - Screw
❑ 8 Nm
11 - Top coolant pipe
12 - Screw
❑ 8 Nm
13 - Front coolant pipe
14 - Nut
❑ 10 Nm
15 - Nut
❑ 10 Nm
3. Coolant pipes 169

3.2 Removing and installing coolant pipes

⇒ “3.2.1 Removing and installing the front bottom coolant pipe”,
page 170
⇒ “3.2.2 Removing and installing the right coolant pipe”,
page 171
3.2.1 Removing and installing the front bottom

coolant pipe
Removing
– Remove the throttle valve control unit - J338-
⇒ “5.3 Removing and installing the throttle valve control unit
J338 ”, page 238 .
– Unscrew screw -2- for oil pipe -1- and cut cable strap -3- on
top and at bottom.
– Unscrew screws -arrows- release clamp -3- and detach cool‐

ant hose.
– Release clamp -4- and detach coolant regulator housing -2-
from coolant pipe -1-.

– Release clamps -arrows- and detach coolant hoses from cool‐

ant pipe; disconnect plug from oil pressure switch - F1-
⇒ Item 6 (page 210) and unscrew screw -1-.
– Remove front bottom coolant pipes -2-.
Installing
to the following:
Note
♦ Replace O-rings.
♦ Secure all hose connections with hose clamps which comply
inal Parts .
– Install the throttle valve control unit - J338-

⇒ “5.3 Removing and installing the throttle valve control unit
J338 ”, page 238 .
Note


♦ Coolant pump
page 157
3.2.2 Removing and installing the right cool‐

ant pipe
Removing
3. Coolant pipes 171

– Release clamps -2-, push coolant hoses to the side and un‐
screw nuts -1-.
– Release clamps -arrows-, disconnect hoses and remove right
coolant pipes.
Installing
to the following:
Note
Secure all hose connections with hose clamps which comply with
Parts .

Note

♦ Coolant pipes
♦ Wheelhouse liner ⇒ General body repairs, exterior; Rep. gr.
66 ; Wheelhouse liner; removing and installing front wheel‐
house liner

4 Coolers, radiator, radiator fan

⇒ “4.1 Assembly overview - radiator/radiator fan”, page 173
⇒ “4.2 Summary of components - fan shroud and radiator fan”,
page 175
⇒ “4.3 Removing and installing radiator”, page 175
⇒ “4.4 Removing and installing fan shroud”, page 178
⇒ “4.5 Removing and installing radiator fan V7 ”, page 180
4.1 Assembly overview - radiator/radiator

fan
Note
The arrows on the coolant pipes and the coolant hose ends must
stand opposite to each other.
1 - Radiator mounting
❑ Radiator clips in bottom
front part of the vehicle
2 - Cooler for charge air circuit
stalling radiator”,
page 175
3 - Coolant temperature trans‐
mitter - G83-
❑ not fitted
❑ closed with plugs
4 - O-ring
5 - Screw
❑ 5 Nm
❑ 2 units
6 - Radiator mounting
❑ Top
7 - Radiator
stalling radiator”,
page 175
❑ After replacing, also re‐
place coolant
8 - Coolant hose
page 128
9 - expansion reservoir
❑ Check for leaks ⇒ “1.2 Check cooling system for leaks”, page 129
4. Coolers, radiator, radiator fan 173

10 - Screw cap
❑ Check for leaks ⇒ “1.2 Check cooling system for leaks”, page 129
11 - Screw
❑ 2 Nm
❑ 2 units
12 - Connector
13 - Fan shroud with radiator fan - V7-
❑ Summary of components ⇒ “4.2 Summary of components - fan shroud and radiator fan”, page 175
❑ Removing and installing ⇒ “4.4 Removing and installing fan shroud”, page 178
14 - Coolant hose
❑ Connection diagram ⇒ “1.1 Connection diagram - coolant hoses”, page 128
Connect coolant hose with quick coupling

– Remove old O-ring -2- in coolant hose -3-.
– Moisten new O-ring with coolant and insert into coolant hose.
– Press coolant hose onto connection -1- until there is an audible
click.
– Press coolant hose down again and check by pulling that the
quick coupling is fully engaged.

4.2 Summary of components - fan shroud and radiator fan
1 - Air deflector ring

2 - Radiator fan - V7-
⇒ “4.5 Removing and
installing radiator fan V7
”, page 180
3 - Fan shroud
stalling fan shroud”,
page 178
4 - Nut
❑ 8 Nm
❑ for connector
6 - Connector
❑ Radiator fan - V7-
7 - Expanding rivet
❑ for air guide ring
4.3 Removing and installing radiator
Note
The coolant radiator and charge air cooling circuit radiator are
removed together.

♦ Cooling system charge unit - VAS 6096-
♦ Catch pan , e.g. -VAS 6208-
♦ Refractometer

Note
♦ The radiator and the charge air cooler are separate parts.
♦ The radiator is fitted onto the charge air cooler.
⇒ “4 Coolers, radiator, radiator fan”, page 173
Removing
noise insulation .
– Remove screws -1- and remove air inlet -2-.

– Removing fan shroud
⇒ “4.4 Removing and installing fan shroud”, page 178 .
– Remove the front bumper ⇒ General body repairs, exterior;
Rep. gr. 63 ; Front bumper; removing and installing bumper .
For vehicles Fabia III
– Move lock carrier to service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Lock carrier; Move lock carrier to service
position .
– Release clamps -arrows-.

– Unscrew securing bolts -arrows-.

– Remove radiator from the lower bearings and carefully press
downwards.
Vehicles with air conditioning
CAUTION
Risk of injury through refrigerant!
♦ Do not open the refrigerant circuit of the air conditioning
system.
– Unscrew screws -arrows-.
NOTICE
Risk of damaging the condenser, the refrigerant lines and ho‐
ses!
♦ Do not over-tension or buckle refrigerant lines and hoses.
– Draw the condenser forwards and attach to the lock support.

– Remove the radiator together with the charge air cooler down
at the side.
NOTICE
To prevent damage to the charge air cooler, the separation of
the charge air cooler from the radiator must be carried out by 2
mechanics.
– Slide a wide cross-head screwdriver into the left lock of the

radiator for charge air cooler -1- at the front and rear.
– Open the locks by turning the screwdriver in direction of arrow
-A-.
– In this position, pull forward the charge air cooler -1- left in
direction of arrow -B- out of the radiator -2-.
– Slide the charge air cooler -1- off in direction of arrow -A-, at
the same time slide it in direction of arrow -B-, and unhook it
from the lock on the right -arrow- of the radiator -2-.
– Secure charge air cooler -1- against falling down.
– Remove radiator.
Installing
to the following:

– Insert the charge air cooler -2- into the right support.
– Lock the charge air cooler -2- to the supports of the radiator
-1-.
– Check for firm seating by pulling in the opposite direction.
Note
Replace O-rings.
– Install front bumper ⇒ General body repairs, exterior ; Rep.

gr. 63 ; Front bumper; Removing and installing bumper .
– Install fan shroud
NOTICE
If a new radiator has been fitted, the cooling system must be
flushed and the coolant must be replaced to ensure optimum
protection of the surface
If the existing radiator is fitted:

Note

♦ Radiator
4.4 Removing and installing fan shroud

CAUTION
There is risk of injury from radiator fans starting up automati‐
cally!
♦ Before carrying out work in the fan shroud area, disconnect
the electrical plug connections.
Removing


noise insulation .
– Disconnect plug connections -arrow-.

– Release hose lines on the fan shroud.
– Unlock the catches of the fan shroud with the radiator fan -
V7- , e.g. using a screwdriver.

– Unhook the top support -1-.

– Unhook the bottom support -2-.
– Slide out the fan shroud with radiator fan - V7- in
-direction of arrow- and remove from the bottom.
Installing
to the following:
– Insert fan shroud with radiator fan - V7- from below.
– Slide it onto all 4 supports on the radiator evenly from above.
• The fan shroud must audibly click into place.
– Check the catches are secure by pulling in the opposite direc‐
tion.
Note

♦ Fan shroud
page 175
4.5 Removing and installing radiator fan -

V7-
CAUTION
There is risk of injury from radiator fans starting up automati‐
cally!
♦ Before carrying out work in the fan shroud area, disconnect
the electrical plug connections.
Removing
Note
All cable straps should be fastened again in the same place when
installing.

noise insulation .
– Removing fan shroud
– Disconnect the plug connections for the radiator fan from the
holder.

– Press back the pins of the expanding rivets -arrow-.
– Carefully lift the fan ring on the rear side of the cover, e.g. using
a screwdriver.
– Remove fan ring.
– Release electrical line -1- from the cable guide.

– Unscrew nuts -arrows- and remove radiator fan - V7- .
Installing
to the following:
– Make sure the expanding rivets -arrow- fit tightly.

– Install fan shroud
Note

♦ Radiator
♦ Fan shroud
page 175

21 – Turbocharging/supercharging
1 Exhaust gas turbocharger
page 182
⇒ “1.2 Removing and installing exhaust gas turbocharger”,
page 183
⇒ “1.3 Replacing exhaust gas turbocharger pressure box”,
page 187
1.1 Summary of components - exhaust gas turbocharger
1 - Pulsation dampener
2 - Screw
❑ 8 Nm
3 - O-ring
sembly
stalling exhaust gas tur‐
bocharger”, page 183
5 - Exhaust gas temperature
transmitter 1 - G235-
nents
⇒ Item 1 (page 258)
6 - Seal
sembly
7 - Nut
sembly
tightening order
⇒ Fig. ““Exhaust gas tur‐
bocharger - tightening
torque and tightening
order”“ , page 183
8 - Seal
sembly
9 - Screw
❑ 14 Nm
10 - Oil return-flow line
11 - Seal
12 - Screw
❑ 8 Nm + 45°.
182 Rep. gr.21 - Turbocharging/supercharging

13 - Compression rings
14 - Hollow screw
❑ 27 Nm
15 - Oil feed line
16 - Screw
❑ 10 Nm
17 - Screw
❑ 10 Nm
18 - Heat shield
19 - Hollow screw
❑ 16 Nm
Exhaust gas turbocharger - tightening torque and tightening order

– Tighten screws in steps in the specified sequence:
Level Nut Tightening torque
1. -2- from inside to outside crosswise 11
Nm
Nm
Nm
• This action takes account of the
settling behaviour of the compo‐
nents.
1.2 Removing and installing exhaust gas

turbocharger
NOTICE
In case of mechanical damage to the exhaust gas turbocharger,
e.g. damage of the compressor wheel, it is not sufficient to only
replace the exhaust gas turbocharger.
In order to prevent consequential damage to the engine, per‐
form the following tasks:
♦ Clean all oil lines.
♦ Change engine oil and oil filter.
♦ Check air filter housing, air filter element and charge air
pipes as well as charge air hoses for soiling.
♦ Check all the air guides and the charge air cooler for foreign
bodies.
If foreign bodies are detected in the charge air system, the com‐
plete charge-air routing must be cleaned and if necessary the
charge air cooler must also be replaced.

1. Exhaust gas turbocharger 183

Removing
– Observe rules for cleanliness
– Remove charge air cooler
page 196 .
– Release and pull off connector -1- for position sender for
charge pressure regulator - G581- and pull off hose -2-.
– Release clamp -3- and disconnect coolant hose.
– Unscrew screws -3- and remove air guide hose with pulsation
damper -2-.
– Remove exhaust gas cleaning module
page 275 .

– Tie off heat shield collar and release and pull off connector
-1-.
– Remove radiator for exhaust gas recirculation -2- downwards.
– Unscrew screws -1-, -3-, -4- and -6-, -7-, -8-.

– Remove oil feed line -2- and oil return-flow line -5-.
– Unscrew screw -2- and remove heat shield -1-.
– Unscrew screws -2-, screw off nuts -3- and remove exhaust
gas recirculation -1-.

– Screw off nuts -2- and remove exhaust gas turbocharger -1-
downwards.
Installing
Note
♦ Replace sealing rings, gaskets, O-rings and the self-locking

nuts after disassembly.
♦ Fill the exhaust turbocharger with engine oil at the connection
fitting for the oil feed line.
♦ Observe the assembly instruction for hose connections with
screw clamps.
♦ Hose connections and air guide pipes and hoses must be free
of oil and grease before being installed.
inal Parts .
♦ To ensure the oil supply to the exhaust gas turbocharger,
leave the engine running for about 1 minute after installing the
exhaust gas turbocharger; do not rev up immediately.
– Install exhaust gas cleaning module

page 275 .
– Install radiator for exhaust gas recirculation
page 196 .
page 266 .
page 196 .
– Install air filter housing
Note



♦ 0001 - Adaption
Note

♦ Exhaust gas turbocharger

page 182
1.3 Replacing exhaust gas turbocharger

pressure box
⇒ “1.3.1 Replace pressure sump for turbocharger, for engines
with code letters CUSA, CUSB”, page 187
⇒ “1.3.2 Replace pressure sump for turbocharger, for engines
with code letters CUTA”, page 191
1.3.1 Replace pressure sump for turbocharg‐

er, for engines with code letters CUSA,
CUSB
Note
♦ For engines with suffix CUSA, CUSB.

♦ Before removing the pressure box for the exhaust gas turbo‐
charger, check whether the repair set is available ⇒ ETKA -
Electronic Catalogue of Original Parts . Otherwise, the entire
exhaust gas turbocharger must be replaced.

♦ Hand vacuum pump , e.g. -VAS 6213-
Removing

– Remove vacuum hose -3- pull off the plug -2- from Position
transmitter for boost pressure plate - G581- .
– Remove screws -arrows-.
Note
When removing and installing the circlip, keep the force exerted
on the lever hoist to a minimum. Pushing the circlip e.g. with a
large screwdriver can damage the exhaust gas turbocharger.
– Turn the vacuum unit -1- and circlip -4- and remove them so
that the exhaust gas turbocharger is not damaged.
– Unhook the control rod from the adjuster lever and remove the
pressure box with position sender for charge pressure regu‐
lator - G581- .
Installing
– Screw counter nut and end piece onto the control rod of the
pressure can from the repair kit.
– For the first adjustment, compare the pressure box from the
repair kit with the original pressure box.
– Adjust the position of the end piece from the repair kit to the
thread length of the end piece of the original pressure box.
– Unscrew the end piece and align horizontally ± 2 °.

– Hold the end piece in place and tighten the counter nut to 7.5
Nm.
– Use new screws and a new circlip from the repair kit!

– Hook the vacuum unit -1- with tail on adjusting lever of the
exhaust gas turbocharger. Position the pressure box and
screw in the screws -arrows- by hand up to the stop.
– Attach the plug -2- on the position sender for charge pressure
regulator - G581- .
– Tighten screws -arrows- to 10 Nm.
– Start engine. Connect vehicle diagnostic tester .
– To perform basic adjustments:
♦ Systems capable of diagnostics
♦ 01 - Engine electronics, functions
♦ 01 - Basic setting
♦ Adaptation of the exhaust gas turbocharger
Check the voltage value
– Check raw voltage. In addition, use the Vehicle diagnostic
tester .
– The voltage value in the:
♦ Self-diagnosis
– 3Put the sliding ring -1- of the hand vacuum pump - VAS 6213-
in position -A- for “vacuum”.
– Connect the hand vacuum pump - VAS 6213- to the pressure

box -arrow-.
NOTICE
Risk of damage to the pressure box from excessive vacuum!
♦ Under no circumstances may a vacuum greater than 0.08
MPa (800 mbar) be generated.
– Using the hand vacuum pump - VAS 6213- continue pumping

until the pressure gauge indicates a vacuum of approx. 700
mbar.
– At the Vehicle diagnostic tester the set point voltage value is
displayed.
♦ Set value: 0.75 ± 0.02 V

– Put the sliding ring -1- of the hand vacuum pump - VAS 6213-
into position -B- to ensure the pressure box is vented until the
pressure reaches the ambient pressure.
Voltage value o.k.
Note
– Install the circlip -4-.

Voltage not OK.
– Remove pressure cell ⇒ page 187 .
– Compare the measured voltage values with the table and de‐
termine the speed of the end piece.
Voltage V Turn the end piece
from to direction of ro‐
tation
0.3 0.36 2.5 Right (direc‐
0.36 0.44 2.0 tion to the
pressure cell)
0.44 0.53 1.5
0.53 0.62 1.0
0.62 0.7 0.5
0.7 0.8 OK
0.8 0.88 -0.5 Left (direction
0.88 0.97 -1.0 from the pres‐
sure cell)
0.97 1.06 -1.5
1.06 1.15 -2.0
1.15 1.23 -2.5
1.23 1.32 -3.0
– Hold the end piece and loosen the counter nut on the control
rod.
– Turn the end piece as indicated in the table.
– Hold the end piece and tighten the counter nut on the control
rod to 7.5 Nm.

– Hook the vacuum unit -1- on the adjusting lever of the turbo‐
charger. Position the pressure box and screw in the screws
-arrows- by hand up to the stop.
– Check voltage ⇒ page 189 .
Voltage not OK.
– Repeat the process ⇒ page 190 .
Voltage value o.k.
– Tighten the screws of the pressure box ⇒ page 191 .
screws Tightening torque
Screws -arrows- 10 Nm
1.3.2 Replace pressure sump for turbocharg‐

er, for engines with code letters CUTA
Note
♦ For engines with engine identification characters CUTA

♦ Before removing the pressure box for the exhaust gas turbo‐
charger, check whether the repair set is available ⇒ ETKA -
Electronic Catalogue of Original Parts . Otherwise, the entire
exhaust gas turbocharger must be replaced.

♦ Hand vacuum pump - VAS 6213-
Removing
– Remove vacuum hose -1- pull off the plug -2- from Position
transmitter for boost pressure plate - G581- .
Note
– Remove detention ring -4-.

– Unscrew screws -3- from the pressure box.
– Unhook the control rod from the adjuster lever and remove the
pressure box with position sender for charge pressure regu‐
lator - G581- .
Installing
– Use new screws and a new circlip from the repair kit!

– Hook in the control rod at the adjuster lever, attach the pres‐
sure box, and turn in the screws -3- as far as they can go by
hand.
Note
– Install the circlip -4-.

– Connect the plug connection -2- to the position sender for
charge pressure regulator - G581- .
– Tighten screws -3- to 10 Nm again.
– To perform basic adjustments:
♦ Systems capable of diagnostics
♦ Adaptation of the exhaust gas turbocharger
Check the voltage value
– Check raw voltage. In addition, use the Vehicle diagnostic
tester .
– The voltage value in the:
♦ Self-diagnosis
– 3Put the sliding ring -1- of the hand vacuum pump - VAS 6213-
in position -A- for “vacuum”.

– Connect the hand vacuum pump - VAS 6213- to the pressure

box -arrow-.
NOTICE
Risk of damage to the pressure box from excessive vacuum!
♦ Under no circumstances may a vacuum greater than 0.08
MPa (800 mbar) be generated.
Adjust the voltage value
– Release screws -1-.

– Using the hand vacuum pump - VAS 6213- continue pumping
until the pressure gauge indicates a vacuum of approx. 700
mbar.
– Slide the pressure box in the -direction of arrow- until the
specified voltage is displayed on the ⇒ Vehicle diagnostic test‐
er.
♦ Set value: 0.75 ± 0.02 V
– Tighten screws -1- to 10 Nm.

– Put the sliding ring -1- of the hand vacuum pump - VAS 6213-
into position -B- to ensure the pressure box is vented until the
pressure reaches the ambient pressure.
Voltage value o.k.:
Voltage not OK:
– Release screws -1-.
– Adjust the voltage value ⇒ page 193 .
– Coat the screws with sealing varnish from the repair kit.
Tightening torques
screws Tightening torque
Screws -1- 10 Nm

2 Charge-air system
⇒ “2.1 Summary of components - charge air system”, page 195
⇒ “2.2 Removing and installing charge air cooler”, page 196
⇒ “2.3 Removing and installing charge pressure sender G31 ”,
page 199
⇒ “2.4 Removing and installing charge air temperature sender”,
page 200
⇒ “2.5 Checking the charge-air system for leak-tightness”,
page 201
⇒ “2.6 Leak testing the charge air cooler”, page 203
2.1 Summary of components - charge air system
1 - Air guide pipe

⇒ Fig. ““Tightening tor‐
ques of screw clamps”“ ,
page 231
installing bracket for
charge air cooler”,
page 198
3 - Screw
❑ 20 Nm
4 - Hose clamp
5 - Charge air temperature
sender before charge air cool‐
er - G810-
❑ 22 Nm
6 - O-ring
7 - Air guide pipe
⇒ Fig. ““Tightening tor‐
ques of screw clamps”“ ,
page 231
8 - Screw
❑ 20 Nm
9 - Charge air cooler
⇒ “2.2.1 Removing and installing charge air cooler”, page 196
❑ Check for leaks ⇒ “2.6 Leak testing the charge air cooler”, page 203
10 - Double screw
❑ 20 Nm
2. Charge-air system 195

11 - Hose clamp
12 - Screw
❑ 8 Nm
13 - Throttle valve control unit - J338-
❑ Removing and installing ⇒ “5.3 Removing and installing the throttle valve control unit J338 ”, page 238
❑ Throttle valve control unit - J338-
15 - Double screw
❑ 20 Nm
16 - Screw
❑ 20 Nm
17 - O-ring
18 - Air guide pipe
19 - O-ring
20 - Charge air temperature transmitter after charge air cooler - G811-
❑ 22 Nm
21 - O-ring
Charge pressure sender - G31- - tightening torque

– Tighten screws -2- to 9 Nm.
2.2 Removing and installing charge air cool‐

er
⇒ “2.2.1 Removing and installing charge air cooler”, page 196
page 198
2.2.1 Removing and installing charge air cool‐

er
Removing



– Close coolant hoses -4- with suitable clamps, release hose
clamps -3- and remove coolant hoses.
– Loosen hose clamp -2-.
– Unscrew screws -2-, -3- and nut -5-.

– Remove holders -1- for intercoolers -4-if available.

– Unscrew screws -2- and then screws -3-, -4-, -5-, detach and
remove charge air cooler -1-.
Installing
NOTICE
If a new charge air cooler has been fitted, the cooling system
must be flushed and the coolant must be replaced to ensure
optimum protection of the surfaces
If the existing charge air cooler is installed:

– Refill and bleed cooling system ⇒ page 132 .
Note

page 195
2.2.2 Removing and installing bracket for

charge air cooler
Removing
– Remove radiator for exhaust gas recirculation (high pressure)
⇒ “4.2.1 Removing and installing radiator for high pressure
exhaust gas recirculation”, page 288 .

– Disconnect vacuum lines -1- and -2- and unscrew screw -3-.
– Release screw -4-. Release vacuum line and remove bracket
for charge air cooler.
Installing
– Install radiator for exhaust gas recirculation (high pressure)
⇒ “4.2.1 Removing and installing radiator for high pressure
exhaust gas recirculation”, page 288 .
Note

page 195
2.3 Removing and installing charge pres‐

sure sender - G31-
Removing
– Screw off nuts -1-, unscrew screw -3- and remove bracket
-2-.


– Unscrew screw -2- and remove charge pressure sender -
G31- .
Installing
Note

♦ Charge pressure sender

⇒ Fig. ““ Charge pressure sender -G31- - tightening torque”“ ,
page 196
2.4 Removing and installing charge air tem‐

perature sender
⇒ “2.4.1 Removing and installing charge air temperature trans‐
mitter before charge air cooler G810 ”, page 200
⇒ “2.4.2 Removing and installing charge air temperature trans‐
mitter after charge air cooler G811 ”, page 201
2.4.1 Removing and installing charge air tem‐

perature transmitter before charge air
cooler - G810-
Removing
– Release and pull off connector -1- and screw out charge air
temperature sender before charge air cooler - G810- -2-.
Installing
Note

page 195

2.4.2 Removing and installing charge air tem‐

perature transmitter after charge air
cooler - G811-
Removing
– Release and pull off connector -1- and screw out charge air
temperature sender after charge air cooler - G811- -2-.
Installing
Note

page 195
2.5 Checking the charge-air system for

leak-tightness
♦ Charge air system tester , e.g. -V.A.G 1687-
♦ Adapter e.g. -V.A.G 1687/11-
♦ Adapter , e.g. -V.A.G 1687/16-
♦ Adapter , e.g. -V.A.G 1687/19-
♦ Hose binding claw
Test sequence


– Connect adapter - V.A.G 1687/11- with -V.A.G 1687/16- and

-V.A.G 1687/19- to the exhaust gas turbocharger.
– Connect testing device for charge-air systems - V.A.G 1687-
to adapter.
Prepare tester for charge air system - V.A.G 1687- as follows:
– Unscrew pressure control valve -2- fully and close the valves
-3- and -4-.
Note
The rotary knob must be pulled to the top in order to rotate the
pressure control valve -2-.

– Connect the pneumatic hose -1- (pneumatic support) to tester

for charge air system.
Note
If there is water in the transparent drain container, drain water via

the drain plug -6-.
– Open valve -3-.
NOTICE
The pressure must not be greater than 0.05 MPa (0.5 bar)! A
too high pressure can damage the engine.
– Set the pressure to 0.05 MPa (0.5 bar) with the pressure con‐
trol valve -2-.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary, re-adjust the pressure to 0.05 MPa (0.5 bar).
– Listen to, touch or use commercially available leak search
spray or the ultrasonic measuring device e. g. -V.A.G 1842- to
check the charge-air system with exhaust gas turbocharger for
leak points.
Note
♦ Minor leaks are permissible on the suction side of the turbo‐

charger, because the intake hoses are not designed for over‐
pressure.
♦ A small amount of air escapes via the valves into the engine.
For this reason no pressure test is possible.
♦ Using the ultrasonic tester - V.A.G 1842- ⇒ Owner's Manual .
♦ In case of a leak point, observe the assembly instructions for
charge air system.
♦ Before removing the adapter, depressurize the test circuit by
detaching the hose coupling.
2.6 Leak testing the charge air cooler
Note
The charge air cooler generates a pressure of 0.05 MPa (0.5 bar)
on the suction side. The pressure in this case is measured in the
cooling system.

♦ Charge air system tester , e.g. -V.A.G 1687-
♦ Adapter e.g. -V.A.G 1687/11-
♦ Adapter , e.g. -V.A.G 1687/16-
♦ Adapter , e.g. -V.A.G 1687/19-
♦ Y distributor , e.g. -VAS 691 005/1-
♦ Adapter e.g. -VAS 691 005/5-
♦ Turbocharger tester - V.A.G 1397A-

Conditions
• The coolant temperature must be at least 40 °C.
Connect turbocharger tester - V.A.G 1397A-
– Screw the adapter - VAS 691 005/5- onto the coolant expan‐
sion reservoir.
– Mount Y distributor - VAS 691 005/1- onto the adapter - VAS
691 005/5- .
– Connect valve -1- of connection »C« and open valve -2- of
connection »A«.
– Connect hose of the connection »A« Y distributor to connec‐
tion »II« of the turbocharger tester - V.A.G 1397A- .
– Put turbocharger tester - V.A.G 1397A- in switch position
»II« (measuring relative pressure) and switch on. The »II«
must be visible.
Connect tester for charge air systems - V.A.G 1687-

– Connect adapter - V.A.G 1687/11- with -V.A.G 1687/16- and

-V.A.G 1687/19- to the exhaust gas turbocharger.
– Connect testing device for charge-air systems - V.A.G 1687-
to adapter.
Prepare tester for charge air system - V.A.G 1687- as follows:

– Unscrew pressure control valve -2- fully and close the valves
-3- and -4-.
Note
The rotary knob must be pulled to the top in order to rotate the
pressure control valve -2-.
– Connect the pneumatic hose -1- (pneumatic support) to tester

for charge air system.
Note
If there is water in the transparent drain container, drain water via

the drain plug -6-.
– Open valve -3-.
NOTICE
The pressure must not be greater than 0.05 MPa (0.5 bar)! A
too high pressure can damage the engine.
– Set the pressure to 0.05 MPa (0.5 bar) with the pressure con‐
trol valve -2-.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary, re-adjust the pressure to 0.05 MPa (0.5 bar).
Note
A small amount of air escapes via the valves into the engine. For
this reason no pressure test is possible.

Read off the turbocharger tester - V.A.G 1397A-

• Monitor the turbocharger tester for 5 minutes.
• The pressure displayed on the turbocharger tester must not
increase!
– If the pressure shown on the turbocharger tester increases,
compressed air is escaping into the cooling system on the ex‐
haust side. The intercooler is leaking. Replace radiator for
exhaust gas recirculation.
Note
Depending on cooling of the coolant, a vacuum may be generated

when the radiator for exhaust gas recirculation is sealed. A vac‐
uum is indicated on the turbocharger tester by a »minus« symbol.
Clean Y distributor - VAS 691 005/1-
Note
After completing the leakage test, the Y distributor - VAS 691

005/1- must be cleaned to remove any moisture that has got in.
– Insert washer jet -D- into the hose connection -A- of the Y dis‐
tributor.
– Position test adapter - VAS 691 005/5- on the hose at con‐
nection -B-.
– Connect pressure hose to connection -C-.
– Open the shut-off tap and blow air through the hose for approx.
15 seconds.

23 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Schematic overview - fuel system”, page 207
⇒ “1.2 Installation location overview - fuel injection system”, page
208
⇒ “1.3 Filling/bleeding the fuel system”, page 211
⇒ “1.4 Check the fuel system for tightness”, page 212
1.1 Schematic overview - fuel system
Note
♦ Green = fuel feed line

♦ Blue = fuel return-flow line
♦ The arrows point in the fuel flow direction.
1 - Fuel tank
❑ With fuel system pres‐
surisation pump - G6-
nents ⇒ Fuel system;
Rep. gr. 20 ; Fuel tank;
Summary of compo‐
nents - Fuel tank
2 - Injection units
nents
ponents - injection units
(injectors)”, page 215
3 - High-pressure accumulator
(fuel distributor)
❑ with fuel pressure send‐
er - G247-
❑ with fuel pressure regu‐
lating valve - N276-
nents
ponents - High pressure
reservoir (fuel distribu‐
tor)”, page 217
❑ with fuel dosage valve -
N290-
nents
ponents - high pressure
pump”, page 253
1. Injection system 207

5 - Fuel temperature transmitter - G81-

❑ Removing and installing ⇒ “6.6 Removing and installing fuel temperature transmitter G81 ”, page 247
6 - Fuel filter
❑ Summary of components ⇒ Fuel system; Rep. gr. 20 ; Fuel filter; Summary of components - Fuel filter
1.2 Installation location overview - fuel in‐

jection system
Installation location overview - engine compartment
1 - Fuel pressure regulating

valve - N276-
nents
ponents - High pressure
reservoir (fuel distribu‐
tor)”, page 217
2 - Injection unit
❑ Injection valve for cylin‐
der 1 - N30-
nents
ponents - injection units
(injectors)”, page 215
3 - Hall sender - G40- (cam‐
shaft position sensor)
nents
ponents - Glow plug
system”, page 294
mitter - G505-
nents
ponents - lambda
probe”, page 258
5 - Exhaust gas pressure sen‐
sor 1 - G450-
nents
⇒ “9.1 Summary of com‐ Volkswagen Technical Site: https://vwts.ru
ponents - lambda
probe”, page 258
6 - Injection unit
❑ Injection valve for cylinder 2 - N31-
❑ Summary of components ⇒ “3.1 Summary of components - injection units (injectors)”, page 215
7 - Position transmitter for charge pressure regulator - G581-
8 - Injection unit
❑ Injection valve for cylinder 3 - N32-
❑ Summary of components ⇒ “3.1 Summary of components - injection units (injectors)”, page 215
208 Rep. gr.23 - Mixture preparation - injection

9 - Engine control unit - J623-

10 - Solenoid valve for charge pressure control - N75-
❑ ⇒ “2.1 Connection diagram - Vacuum system”, page 213
11 - Changeover valve for intake manifold flap - N239-
12 - Exhaust gas recirculation valve 1 - GX5-
❑ consists of:
♦ Exhaust gas recirculation control motor - V338-
♦ Exhaust gas recirculation potentiometer - G212-
13 - Air mass meter - G70-
❑ Summary of components ⇒ “4.1 Assembly overview - air filter housing”, page 230
14 - Fuel pressure sender - G247-
❑ Summary of components
⇒ “3.2 Summary of components - High pressure reservoir (fuel distributor)”, page 217
15 - Glow plug
❑ Glow plug 3 - Q12-
❑ Summary of components ⇒ “1.1 Summary of components - Glow plug system”, page 294
16 - Glow plug
17 - Glow plug
❑ with fuel dosage valve - N290- (do not open)
19 - Fuel temperature sender - G81-
❑ in the fuel feed line
❑ Removing and installing ⇒ “6.6 Removing and installing fuel temperature transmitter G81 ”, page 247
Installation location overview - engine from left

1 - Coolant valve for cylinder

head - N489-
stalling coolant valve for
cylinder head N489 ”,
page 166
2 - Charge pressure sender -
G31-
nents
⇒ “5.1 Assembly over‐
view - intake manifold”,
page 233
sender downstream of charge
air cooler - G811-
nents
ponents - charge air
system”, page 195
sender before charge air cool‐
er - G810-
nents
ponents - charge air
system”, page 195
5 - Throttle valve control unit -
J338-
nents
⇒ “5.1 Assembly over‐
view - intake manifold”,
page 233
6 - Oil pressure switch - F1-
❑ Summary of components
⇒ “3.1 Summary of components - oil filter housing/oil pressure switch”, page 120
7 - Oil pressure control valve - N428-
⇒ “3.5 Removing and installing valve for oil pressure control N428 ”, page 126
8 - Engine speed transmitter - G28-
9 - Active intake manifold position sender - G513-
❑ Summary of components ⇒ “5.1 Assembly overview - intake manifold”, page 233
10 - Knock sensor 1 - G61-
❑ Removing and installing ⇒ “1.4 Removing and installing knock sensor 1 G61 ”, page 297
11 - Coolant temperature transmitter - G62-
❑ Summary of components ⇒ “2.3 Summary of components - coolant temperature transmitter”, page 160
Installation location overview - engine from right

1 - Exhaust gas recirculation

valve 2 - GX6-
nents
ponents - Exhaust gas
recirculation”,
page 285
sender 1 - G235-
nents
ponents - lambda
probe”, page 258
3 - Lambda probe 1 upstream
of catalytic converter - GX10-
nents
ponents - lambda
probe”, page 258
sender 3 - G495-
nents
ponents - lambda
probe”, page 258
5 - Lambda probe 1 down‐
stream of catalytic converter -
GX7-
nents
ponents - lambda
probe”, page 258
❑ Summary of components ⇒ “2.2 Summary of components - electric coolant pump”, page 159
7 - Heating backup pump - V488-
❑ Summary of components ⇒ “2.2 Summary of components - electric coolant pump”, page 159
1.3 Filling/bleeding the fuel system

NOTICE
In order to prevent the high pressure pump from running dry
(very narrow tolerances) and to achieve a quick engine start
after parts are replaced, the following must be observed:
♦ If fuel system between tank and pump parts/components
have been removed or replaced the fuel system must be fil‐
led/bled before the engine is started up for the first time!
In order to fill up the high pressure pump with fuel, proceed as

follows:
• Vehicle must be refuelled.


♦ 0001 - Activate fuel pump
♦ Venting air from the fuel system
• The fuel pump activates.
• The fuel pump must run for approximately 3 minutes to ensure
that the high pressure pump is sufficiently filled with fuel.
– After filling the fuel system, start the engine.
– Run the engine at medium speed for several minutes, then
turn it off again.
– Test fuel system for seal-tightness.
– Delete event memory entry with Vehicle diagnosis tester .
– Afterwards, carry out a test drive with at least one full load
acceleration.
– Then check the high-pressure system again for air-tightness.
Note
If air is still present in the fuel system the engine may enter dry-
running operation during the test drive. Switch off engine and
delete the event memory. Then proceed with the test drive.
– Delete event memory entry with Vehicle diagnosis tester .
1.4 Check the fuel system for tightness

– Let the engine run at idling speed for a few minutes.
– Carry out a visual inspection of the complete fuel system for
leaks after switching off the engine.
If there is leakage despite the correct tightening torque:
– Replace the affected component part and repeat the test se‐
quence.
If no leaks are found:
– Carry out a test drive with minimum one full load acceleration
up to max. speed.
– Then once again carry out a visual inspection of the complete
fuel system for leaks.

2 Vacuum system
⇒ “2.1 Connection diagram - Vacuum system”, page 213
⇒ “2.2 Inspect the vacuum system”, page 213
2.1 Connection diagram - Vacuum system
1 - Vacuum unit
❑ for charge pressure
control
❑ at exhaust gas turbo‐
charger
2 - Air deflector
3 - Solenoid valve for charge
pressure control - N75-
♦ a - Vacuum supply
♦ b - To intake manifold
♦ c- To the vacuum unit for
charge pressure control
♦ d - To hose of the vent line
4 - Changeover valve for intake
manifold flap - N239-
♦ a - Vacuum supply
♦ b - To intake manifold
♦ c- To the vacuum unit for
charge pressure control
♦ d - To hose of the vent line
5 - Non-return valve
6 - Intake manifold flap
7 - Cylinder block
8 - Cylinder head cover
❑ with vacuum unit
2.2 Inspect the vacuum system

Work procedure
– Check all the vacuum lines in the complete vacuum system
for:
♦ tears
♦ Interruption (marten bites)
♦ Crimping
♦ porous points and other leaks
2. Vacuum system 213

– Check vacuum line to the solenoid valve and check solenoid

valve for the respective component.
– In the event of an event memory entry, check the vacuum lines
to the mentioned component and also the remaining vacuum
lines to the other components.
– If no vacuum can be created or the vacuum drops immediately
with the hand vacuum pump - VAS 6213- , check hand vacuum
pump and connecting hoses for leaks.

3 Injection units / high pressure accu‐

mulators (fuel distributors)
⇒ “3.1 Summary of components - injection units (injectors)”, page
215
⇒ “3.3 Check injection unit return quantity with engine running”,
page 218
⇒ “3.4 Checking the injection units in open state”, page 219
⇒ “3.5 Removing and installing the injection units”, page 221
⇒ “3.6 Removing and installing high pressure lines”, page 224
⇒ “3.7 Removing and installing high pressure reservoir (fuel dis‐
tributor)”, page 227
3.1 Summary of components - injection units (injectors)
1 - High pressure line

❑ between fuel distributor
and injection units
❑ follow all instructions for
installation of high pres‐
sure lines
⇒ “3.6.3 Installing high
pressure line”,
page 225
❑ install free of stress
❑ 28 Nm
2 - Connector
❑ to the injection unit
3 - Fuel return-flow line
❑ to fuel tank
❑ must not be kinked,
damaged or blocked
❑ do not disassemble
❑ fill/bleed fuel system af‐
ter replacing
4 - Return connection
❑ to the injection units
❑ do not disassemble
5 - Injection unit
❑ removed injection units,
high pressure lines and
clamping claws to be re-
installed must only be
mounted again at the
same cylinder.
stalling the injection
units”, page 221
6 - Screw
3. Injection units / high pressure accumulators (fuel distributors) 215

❑ 8 Nm + 270°.
7 - Clamping claw, cylinders 1 and 2
❑ removed injection units and clamping claws to be re-installed must only be mounted again at the same
cylinder
❑ Fitting position ⇒ Fig. ““Fitting position of the clamping claw”“ , page 216
8 - Screw
❑ 8 Nm + 270°.
9 - Clamping claw, cylinder 3
❑ removed injection units and clamping claws to be re-installed must only be mounted again at the same
cylinder
❑ Fitting position ⇒ Fig. ““Fitting position of the clamping claw”“ , page 216
10 - Ball stud
❑ 20 Nm
11 - Special screw
❑ 20 Nm
Fitting position of the clamping claw

• One clamping claw has 2 injection units.
• The bulge -arrow- of the clamping claw points upwards.
• The injection unit cylinder 3 has its own clamping claw.

3.2 Summary of components - High pressure reservoir (fuel distributor)
1 - Control valve for fuel pres‐

sure - N276-
❑ Check
⇒ “6.2 Check fuel pres‐
sure regulating valve
N276 ”, page 241
stalling the fuel pressure
regulating valve N276 ”,
page 240
❑ replace after each re‐
moval
❑ After replacing, readjust
the learnt values in “Tar‐
geted Functions” ⇒ Ve‐
hicle diagnostic tester
❑ 80 Nm
2 - Connector
❑ Fuel pressure regulat‐
ing valve - N276-
3 - Hose clamp
4 - Fuel return-flow line
❑ must not be kinked,
damaged or blocked
5 - Hose clamp
❑ between the high pres‐
sure pump and the fuel
distributor
❑ follow all instructions for
installation of high pres‐
sure lines
⇒ “3.6.3 Installing high
pressure line”, page 225
❑ 28 Nm
7 - Fuel pressure transmitter - G247-
❑ Removing and installing ⇒ “6.3 Removing and installing fuel pressure sender G247 ”, page 242
❑ Reuse possible
❑ 100 Nm
8 - High-pressure accumulator (fuel distributor)
⇒ “3.7 Removing and installing high pressure reservoir (fuel distributor)”, page 227
9 - Double screw
❑ 20 Nm
❑ between the high pressure pump and the fuel distributor
❑ follow all instructions for installation of high pressure lines
⇒ “3.6.3 Installing high pressure line”, page 225
❑ 28 Nm

11 - Screw
❑ 8 Nm
3.3 Check injection unit return quantity with

engine running
♦ Return flow quantity measuring device - VAS 6684-
♦ Unlocking tool , e.g. -T10236-
Work procedure
Note
Each injection unit has a small amount of return. If this return flow
quantity is relatively great (in relation to the return flow quantity of
the other injection units), this injection unit is probably defective.

– Before removing, clean all return flow connections (for exam‐
ple with a commercially available cold cleaner).
Note
♦ Pay attention to cleanliness, no dirt must get into the fuel sys‐
tem!
♦ Check cylinders one after another.
– Dry all the cleaned component parts.

Start with cylinder 1.
– Unscrew screws -1- and push down the coolant pipe -2- to the
rear.
Note
Do not lever out with a screwdriver!

– Take hold of the lowest recess -arrow- and carefully unlock the
centre part -1- of the return-flow connections in
-direction of arrow-.
– Pull off return-flow line connections on injection unit by pulling
release buttons -2- upwards with removal tool - T10236-
-arrows-.
– Pinch off coolant hose -arrow- using a hose clamp of up to 25

mm - MP7-602 (3094)- -1-.
Note
Pay attention to cleanliness; no dirt must get into the removed

return lines or the connections of the injection units!
– Place the hose lines of the return flow meter -VAS 6684- on
the return connections.
– Start engine and run in idle for a few minutes.
Speed Measured time Quantity per VAS 6684
injection unit scale
(max.)
Idle speed 4 minutes 25 ml between the
2nd and 3rd
line from the
top
2500 rpm 2 minutes 35 ml Measuring
glass is full
– When the engine is at operating temperature while the engine
is idling there must be only minimal difference in the return flow
quantity of all 3 return-flow lines (example -1-).
– If one injection unit has a significantly higher return flow quan‐

tity (example -2-), this injection unit must be replaced
page 221 .
Assembly of fuel return-flow lines
– Carefully press the connections of the return-flow lines onto
the injection units.
– The cap must click audibly into place.
– Then carefully press the unlocking bolt downwards.
– Check fuel system for tightness
3.4 Checking the injection units in open

state

♦ Adapter C7 from return quantity measuring device - VAS

6684-
NOTICE
Risk of damaging the injection units!
♦ Observe rules for cleanliness
– Delete event memory entry with vehicle diagnosis tester ⇒ Ve‐

hicle diagnostic tester.
– Before removing, clean all connections (for example with a
commercially available cold cleaner).
Note
♦ Pay attention to cleanliness, no dirt must get into the fuel sys‐
tem!
♦ Check cylinders one after another.
– Dry all the cleaned component parts.

Start with cylinder 1.
rear.
Note
-arrows-.
Clean and blow out adapter C7 of the return flow quantity meas‐
uring device - VAS 6684- .

– Connect the clean, blown through adapter on the injection unit

to be tested.
– A vacuum of 500 mbar is built up using the hand vacuum pump
- VAS 6213- .
If the injection units are O.K, the vacuum remains constant for
more than 30 s.
If the injection units are defective, the vacuum drops to 0 bar
within 2 to 3 seconds.
If necessary repeat the test, pay attention to the vacuum loss on
the hand vacuum pump - VAS 6213- .
– Replace injection units
page 221 .
3.5 Removing and installing the injection

units
♦ Assembly sleeve - T10377-
Removing
NOTICE
rear.
– release and pull off connector -3- of the injection unit that is to
be removed.
Note

-arrows-.
Note
The clamping claw of cylinder 1 and cylinder 2 clamps 2 injection

units and can only be removed if both injection units »come out«.
– Remove corresponding high-pressure line to the injection unit

⇒ “3.6 Removing and installing high pressure lines”,
page 224 .
– Unscrew screws -1- and/or -2-.

– Remove clamping claw.

– Position extractor - T10055- with the extractor - T10537- as

shown in the illustration and pull out injection unit upwards.
Installing
NOTICE
Risk of damage to injection unit sealing surfaces!
♦ To remove the soot particles on the sealing surface of the
injection unit, clean the injection unit shaft in the cylinder
head with cleaning set - VAS 6811- or with a cloth soaked in
engine oil.
Installing new injection units

When installing a new injection unit the following must be re‐
placed:
♦ Copper gasket
♦ O-ring for the injection unit shaft
♦ O-ring for fuel return-flow line connection
– Follow all instructions for installation of high pressure lines
⇒ “3.6.3 Installing high pressure line”, page 225 .
Installing used injection units
When reinstalling a used injection unit the following must be re‐
placed:
♦ Copper gasket
♦ O-ring for the injection unit shaft
♦ O-ring for fuel return-flow line connection
– Spray the tip of the injection unit with a rust solvent spray. Re‐
move soot particles or oil particles with a cloth after approxi‐
mately 5 minutes.
– To disassemble the old copper sealing ring from the injection
unit, carefully tighten the sealing ring in a vice until the copper
sealing ring is prevented from spinning between the chuck
jaws. Pull the injection unit out of the copper sealing ring with
slight turning and pulling movements of the hand.
– Clean the deposit below the copper gasket ring.

– Replace the sealing ring for the injection unit, using the as‐
sembly sleeve - T10377- .
Continued for used and new injection units
– Coat all O-rings with assembly oil, engine oil or diesel fuel be‐
fore installation.
– Install the injection units.
– First tighten the union nuts of the high pressure lines hand-
tight. Check that seating is free of tension.
– After replacement of one or more injection units the correction
values for the new injection units must be written to the engine
control unit ⇒ Vehicle diagnostic tester.
– Filling and bleeding the fuel system
Note

♦ Injection units
page 215
3.6 Removing and installing high pressure

lines
⇒ “3.6.1 Removing the high pressure line between the high pres‐
sure pump and the high pressure reservoir (fuel distributor)”, page
224
⇒ “3.6.2 Removing the high pressure line between the high pres‐
sure reservoir (fuel distributor) and the injection units”,
page 225
3.6.1 Removing the high pressure line be‐

tween the high pressure pump and the
high pressure reservoir (fuel distributor)
Removing
NOTICE


– Clean fuel line and line end with cold cleaner and blow dry with
compressed air.
– Release screw -1-.

– Unscrew union nuts -2- and unclip high pressure line -3- up‐
wards.
– Close open lines and connections with clean plugs.
3.6.2 Removing the high pressure line be‐

tween the high pressure reservoir (fuel
distributor) and the injection units
Removing
NOTICE

– Clean fuel line and line end with cold cleaner and blow dry with
compressed air.
– Unscrew union nuts -1- for high pressure line and remove high
pressure line -2-, -3-, -4-.
– Close open lines and connections with clean plugs.
3.6.3 Installing high pressure line

♦ Tool insert SW 17

♦ Socket wrench insert - T40055-

Work procedure
Note
♦ Clean fuel line and line end with cold cleaner before removal,
and blow dry with compressed air.
♦ Pay attention to the cylinder specific marking when re-using
the high pressure lines.
♦ The high pressure lines can be re-used after the following
tests:
♦ Check the sealing cone of the respective high pressure line for
deformations and cracks.
♦ The line borings must not be deformed, constricted or dam‐
aged.
♦ Corroded lines must no longer be used.
NOTICE
Risk of line break because of high pressure line being under
tension!
♦ Slacken the fuel distributor and the clamping claws for im‐
proved and stress-free positioning of the injection lines.
♦ If necessary, move the fuel distributor slightly and turn the
corresponding injection unit slightly. The lines must be never
bent or twisted.
– Suction off dirt from the sealing cone at the fuel distributor.
– Moisten thread of the nut with clean engine oil.
– Hand-tighten union nuts, ensure that the fit is tension-free.

– To tighten the high pressure lines on the fuel distributor and

injection units, use torque wrench -1- with tool insert SW 17 or
socket wrench insert - T40055- .
Note

♦ Injection units
page 215
3.7 Removing and installing high pressure

reservoir (fuel distributor)
Removing
NOTICE

– Removing the high pressure line between the high pressure
pump and the high pressure reservoir (fuel distributor)
⇒ “3.6.1 Removing the high pressure line between the high
pressure pump and the high pressure reservoir (fuel distribu‐
tor)”, page 224 .
reservoir (fuel distributor) and the injection units
pressure reservoir (fuel distributor) and the injection units”,
page 225 .

– Cut the cable strap -3- on the oil pipe -1-.
– Unlock and disconnect connectors -1- and -2-.

– Pull off connector -3- and pull the cable strip -4- upwards off
the high pressure reservoir.
– Release fuel hoses and unscrew pin screw -1- and screw -3-
for the fuel return-flow line -2-.
Note
-arrows-.

– Loosen clamp -1- and remove return-flow line. Unscrew nut

-2-.
– Pull coolant pipe -3- downwards off the double screws.
– Unscrew double screws -1- and remove the high pressure

reservoir (fuel distributor) -2-.
Installing
to the following:
– Follow the notes
Note

♦ Injection units
page 215

4 Air filter
⇒ “4.2 Removing and installing air filter housing”, page 231
4.1 Assembly overview - air filter housing
1 - Air deflector
❑ on the air filter lower part
2 - Air guide lower part
❑ on the lock support
3 - air guide pipe top
❑ on the lock support
4 - Cover
❑ for air guide
5 - Screw
❑ 2 Nm
6 - Air filter top part
❑ remove mechanical
contaminations
7 - Air mass meter - G70-
Removing and installing
⇒ “6.4 Removing and installing
air flow mass meter G70 ”,
page 243
8 - Hose clamp
9 - Hose clamp
10 - intake hose
11 - Screw
❑ 2 Nm
12 - O-ring
13 - Air filter element
❑ Pay attention to change Volkswagen Technical Site: https://vwts.ru
intervals:
14 - Air filter bottom part
❑ remove mechanical contaminations
15 - O-ring
16 - Drain pipe
❑ with valve
❑ clean
17 - Screw
❑ 5 Nm

18 - Rubber bearing
20 - Nut
❑ 20 Nm
21 - Nut
❑ 10 Nm
22 - Screw
❑ 8 Nm
Tightening torques of screw clamps
Note
♦ Connections, charge air pipes and hoses of charge air system

must be free of oil and grease before being installed.
♦ Only install approved screw clamps for securing the hose con‐
nections ⇒ ETKA - Electronic Catalogue of Original Parts .
♦ In order to secure the charge air hoses on their connection
fittings, the threads must be treated with rust solvent if the
screw clamps have been used beforehand.
♦ After a repair, check all the charge air pipes, charge air hoses
and vacuum lines for tight connection and leaks.
1- Screw clamp -a- = 12 mm wide: 5.5 Nm

2- Screw clamp -b- = 9 mm wide: 3 Nm
4.2 Removing and installing air filter hous‐

ing
Removing
– Release and pull off connector -1-, loosen clamp -2- and pull
off air deflector.
– Pull air deflector -3- in -direction of arrow- off the lock support.
– Unclip the coolant line -4- and pull the air filter housing up‐
wards out of the support.
Installing
Note
♦ Connections, charge air pipes and hoses of charge air system

must be free of oil and grease before being installed.
♦ Use a silicone lubricant to assemble the suction hose.
♦ Only install approved spring strap clips for securing the hose
connections ⇒ ETKA - Electronic Catalogue of Original Parts .
4. Air filter 231

– Release and pull off drain pipe -2- from air filter housing -1-.
– Clean connection and air filter lower part and hose to remove
dirt and leaves.
– Observe the assembly markings -arrow- when placing the in‐
take hose on the air filter housing.
– Place air filter housing onto the support and push in until there
is an audible click.
– Press air filter down again and check by pulling that the air
filter is fully engaged.
Note



5 Intake manifold
⇒ “5.1 Assembly overview - intake manifold”, page 233
⇒ “5.2 Removing and installing intake manifold”, page 233
⇒ “5.3 Removing and installing the throttle valve control unit J338
”, page 238
5.1 Assembly overview - intake manifold
1 - Screw
❑ 20 Nm
2 - Bushing
3 - Screw
❑ 20 Nm
4 - Intake manifold
❑ with an intake manifold
flap and active intake
manifold position send‐
er - G513- .
stalling intake manifold”,
page 233
5 - Connector
❑ Charge pressure send‐
er - G31-
6 - Charge pressure transmit‐
ter - G31-
stalling charge pressure
sender G31 ”, page 199
7 - Screw
❑ 8 Nm
8 - Seal
sembly
9 - Connector
❑ Active intake manifold
position sender - G513-
10 - Vacuum line
❑ for intake manifold flap
11 - Screw clamp
12 - Air deflector
5.2 Removing and installing intake manifold

♦ Socket - T10535-
5. Intake manifold 233

Removing

– Cut cable strap -arrow-. Release and pull off all connectors
visible in the illustration.
– Pull the electric harness -1- up slightly.
noise insulation .

– Unscrew screw -1- for oil pipe on the oil pan.
– Unscrew screw -2- for oil pipe on the intake manifold and pull
out the oil pipe -1- upwards.
– Unscrew screws -1- and -4- and remove throttle valve control
unit - J338- -3-.
– Remove the high pressure line between the high pressure
tor)”, page 224 .
– Unscrew screws -1- and remove support -2-.

– Remove charge air temperature transmitter after charge air
cooler - G811-
⇒ “2.4 Removing and installing charge air temperature send‐
er”, page 200 .

Note
The screw connection of the intake manifold with High pressure

pump is covered and fitted with an “open” bore. This screw is re‐
leased in one turn. Screw -4- and bush -5- remain on the cylinder
head.
– Pull off vacuum line -3- and unscrew screws -1-.
– Release screw -1- with the adapter piece - T10535- by one

turn.

– Pull the intake manifold in direction of arrow -A- so that dowel

sleeves -arrows- are exposed.
– Pull out the intake manifold -1- off the screw connection -3- in
direction of arrow -B- and remove the intake manifold.
Installing
– Insert screw -5- into the bore.

– Push the intake manifold -1- in direction of arrow -A- onto the
screw connection -3-.
– Fit the intake manifold -1- in direction of arrow -B- onto the
cylinder head. The dowel sleeves -arrows- must set in the
bores.
– Tighten the screws -1- crosswise from the inside outwards and
connect the vacuum line -3-.
– Tighten screw -4- with adapter piece - T10535- .
– Install high pressure lines
Note

♦ Intake manifold

5.3 Removing and installing the throttle

valve control unit - J338-
Removing



– Unscrew screws -1- and -4- and remove throttle valve control
unit - J338- -3-.
Installing
Note
Replace gaskets and O-rings after disassembly.

Note

♦ Intake manifold

6 Senders and sensors

⇒ “6.1 Removing and installing the fuel pressure regulating valve
N276 ”, page 240
⇒ “6.2 Check fuel pressure regulating valve N276 ”, page 241
⇒ “6.3 Removing and installing fuel pressure sender G247 ”, page
242
⇒ “6.4 Removing and installing air flow mass meter G70 ”,
page 243
⇒ “6.5 Removing and installing differential pressure transmitter
G505 ”, page 245
⇒ “6.6 Removing and installing fuel temperature transmitter G81
”, page 247
⇒ “6.7 Removing and installing pressure sensor for exhaust gas
1 G450 ”, page 247
6.1 Removing and installing the fuel pres‐

sure regulating valve - N276-
Removing
– Release fuel hose line and unscrew pin screw -1- and screw
-3- for the return-flow line -2-.
– Unlock and disconnect connectors -1- and -2-.

– Pull off connector -3- and pull the cable strip -4- upwards off
the high pressure reservoir.
– Before removing, clean the threaded area of the fuel pressure
regulating valve - N276- .
• No dirt must get into the hole of the high pressure reservoir.
• No cleaning agent must get into the plug connection, clean
carefully.
– Dry fuel pressure regulating valve - N276- .

– Loosen union nuts -1- - to do so, counterhold hex on the high

pressure reservoir. Afterwards release by hand.
– Suction the dirt out of the fuel distributor hole (thread and con‐
tact surface). To do so do not use any mechanical tools.
– Close the open port on the fuel rail with a clean plugs.
Installing
Note
♦ Replace the fuel pressure regulating valve - N276- each time

it is removed.
♦ Moisten the threaded insert and the biting edge of the fuel
pressure regulating valve - N276- with diesel fuel.
– Tighten the union nut by hand.

– Align the new control valve so that the connecting cable is re-
installed free of tension after the connectors have positioned.
– Counterhold housing hexagon of the regulating valve in this
position using a wrench or pliers (such as water pump pliers).
– To tighten the union nuts use a suitable torque wrench with an
open-end wrench (size 30).
– Filling and bleeding the fuel system
Note


6.2 Check fuel pressure regulating valve -

N276-
♦ Suitable auxiliary hose for connection to the fuel return-flow
line
♦ Fuel tank, approx. 200 ml
– Safety precautions when working on the fuel supply system
⇒ “2.1 Safety precautions when working on fuel supply sys‐
tem”, page 2 .
6. Senders and sensors 241

– Loosen hose clamp -1-, remove fuel return-flow hose from the
fuel distributor.
– Close the return-flow line connection with a blind plug.
– Connect the auxiliary hose on the return line of the fuel dis‐
tributor.
– Hold this hose line in a suitable vessel in order to measure the
return flow quantity.
1) Test with engine running
– Start engine and run in idle.
• Specified value of minimum return flow quantity in 30 seconds:
0 ml
• A drop-leakage is permissible.
If the specified value is not reached, the fuel pressure regulating
valve - N276- is defective.
2) Test with engine running
If the condition under point 1) is fulfilled, increase the engine
speed to ≥ 2000 rpm.
• Set value of the return flow quantity: 0 ml.
• A drop-leakage is permissible.
3) The engine will no longer start
Perform the test at starter speed.
• Set value of the return flow quantity: 0 ml
• A drop-leakage is permissible
– Replace fuel pressure regulating valve - N276-
⇒ “6.1 Removing and installing the fuel pressure regulating
valve N276 ”, page 240 .
6.3 Removing and installing fuel pressure

sender - G247-
♦ Socket size 27 - T40218-
Removing
– Before removing, clean the thread area around the fuel pres‐
sure sender - G247- with a grease remover (no dirt must get
into the hole of the fuel distributor).
Note
No grease remover must get into the plug connection, carefully

clean.

– Dry the fuel pressure sender - G247- .

– Unlock and disconnect connector -1- and screw out the fuel
pressure sender - G247- with the socket insert size 27 -
T40218- .
– Suction the dirt out of the fuel distributor hole (thread and con‐
tact surface). To do so do not use any mechanical tools.
– Close the fuel distributor hole immediately with a suitable
screw plug in order to prevent dirt from penetrating.
Installing
Note
♦ Look out for damage to the sealing surfaces (biting edge seal)
and the thread of the new fuel pressure sender - G247- . It is
possible to use the fuel pressure sender - G247- again.
♦ Also check the sealing surface in the hole of the fuel distributor.
♦ Coat the threaded insert and deformable sealing lip of the fuel
pressure sender - G247- with diesel fuel.
– Screw in fuel pressure sender - G247- by hand.

– Tighten the transmitter:
♦ Tightening torque:
– Fill and bleed the fuel system
Note


6.4 Removing and installing air flow mass

meter - G70-
Removing

– Unscrew screws -1- and turn and pull off air mass meter - G70-
-2-.
Installing
It is essential that the following work instructions be performed to
ensure perfect functioning of the air mass meter - G70- :
Note
♦ If the air filter is heavily soiled or soaked, dirt particles or mois‐

ture can enter the air mass meter and distort the measured air
flow values. This results in a reduction of output, because a
lower injection quantity is calculated.
♦ Always use an original air filter element.
♦ Always replace any damaged gasket rings (unmetered air).
♦ Use a silicone-free lubricant for installing the air guide hose
and gasket ring.
♦ The hose- and pipe supports and the air guide hoses must be
de-oiled and degreased before installing.
inal Parts .
– Check air mass meter as well as air guide hose (on the side
of the fresh air) for salt residues, dirt and leaves.
– Check suction channel up to air filter insert for dirt. if you find
it is dirty, remove salt residues, dirt and leaves from the air filter
housing (top and bottom section) (clean by washing or using
a vacuum as required).
– Insert and turn the air mass meter - G70- -2- to install it. Screw
in bolts -1-.
– After replacement of the Air flow sensor , the Vehicle diag‐
nostic tester was connect ⇒ Vehicle diagnostic tester,
♦ 0001 - Reset engine control learnt values
♦ Reset after replacing the air mass meter
Note



6.5 Removing and installing differential

pressure transmitter - G505-
Note
The differential pressure transmitter - G505- determines the load‐

ing status of the particle filter.
Removing
differential pressure sender.
– Tie off heat shield collar.

– Unscrew screw -1-, and release and pull off connectors -2- and
-3-
NOTICE
Risk destroying the differential pressure sender - G505- !
♦ Disconnect hose carefully and straight from the connection
fitting (the connection fitting very easily breaks off the differ‐
ential pressure sender - G505- ).
– Remove differential pressure transmitter - G505-

⇒ “9.1 Summary of components - lambda probe”, page 258 .
Installing
Note
♦ Blow out control lines of the differential pressure transmitter -

G505- to the particle filter with compressed air before instal‐
lation in particle filter direction (it may be blocked or iced up by
condensation water).
♦ Pay attention to the tight connection and leaktightness of the
hose.

– After replacing the differential pressure transmitter - G505- ,
an adaption must be performed in the function “Targeted func‐
tions” ⇒ Vehicle diagnostic tester.
Note

♦ Lambda probe
⇒ “9.1 Summary of components - lambda probe”, page 258
page 81

6.6 Removing and installing fuel tempera‐

ture transmitter - G81-
Removing
– Release and pull of connector -1- and screw off the fuel tem‐
perature sender - G81- -2-.
Installing
6.7 Removing and installing pressure sen‐

sor for exhaust gas 1 - G450-
Removing
differential pressure sender.

– Unscrew screws -1- and release and pull off connectors -2-
and -3-
NOTICE
Risk of destruction of the pressure sensor as a result of the
connection fitting breaking!
♦ Pull hoses off carefully and straight from the connection fit‐
ting.
– Remove exhaust gas pressure sensor 1 - G450- from the

holders
⇒ “9.1 Summary of components - lambda probe”, page 258 .
Installing
Note
♦ Blow out control lines of exhaust gas pressure sensor 1 -

G450- to the particle filter with compressed air before instal‐
lation in particle filter direction (it may be blocked or iced up by
condensation water).
♦ Pay attention to the tight connection and leaktightness of the
hose.
– After replacing the exhaust gas pressure sensor 1 - G450- ,

an adaption must be performed in the function “Targeted func‐
tions” ⇒ Vehicle diagnostic tester.
Note

♦ Lambda probe
page 81

7 Engine control unit

⇒ “7.1 Removing and installing engine control unit J623 ”,
page 249
⇒ “7.2 Removing and installing engine control unit J623 with pro‐
tective housing”, page 249
7.1 Removing and installing engine control

unit - J623-
Note
♦ If the engine control unit is replaced, the ⇒ Vehicle diagnostic

tester must be connected and the function “Replace engine
control unit” must be carried out.
♦ If the adjustment values of the injection units can no longer be
read from the old (defective) engine control unit, these adjust‐
ment values must be manually entered into the new engine
control unit and adapted to it.
NOTICE
Risk of engine control unit destruction!
♦ The engine control unit must not touch the positive pole of
the battery
– Unlock catch in -direction of the arrow- and remove the engine

control unit -1-.
– Unlock plug connections for engine control unit - J623- and
pull off.
Installing
The installation occurs in reverse order.
After installing a new engine control unit, the following work step
must be performed:
♦ 0001 - Replace the engine control unit
7.2 Removing and installing engine control

unit - J623- with protective housing
♦ commercially available miniature grinder
♦ Hot air blower , e.g. -VAS 1978/14A- with push-on nozzle from
wiring harness repair set , e.g. -VAS 1978 B-
7. Engine control unit 249

Note
♦ If the engine control unit is replaced, the ⇒ Vehicle diagnostic

tester must be connected and the function “Replace engine
control unit” must be carried out.
♦ If the adjustment values of the injection units can no longer be
read from the old (defective) engine control unit, these adjust‐
ment values must be manually entered into the new engine
control unit and adapted to it.
Unscrew shear bolts -1- to remove the protective housing -2- as

follows:
– Make a slot for a screwdriver in the head of shear screw -1-

with a miniature grinder -2-.
Note
♦ The threads of the shear screws are equipped with locking

agent. Warming the shear bolt when grinding a slot for a
screwdriver makes it easier to loosen the screw afterwards.
♦ If the shear screws still cannot be undone, warm the, up with
a hot air blower.
Undoing pull-off screws with a hot air blower
– Set the temperature adjustment potentiometer -2- to maximum

heating performance and set the air flow two stage switch
-3- to position 3.
CAUTION
Risk of burns due to the hot air blower!
♦ Only warm up the shear screws with a hot air blower.
♦ By warming the shear screws, the cover plate and parts in
its vicinity are heated up strongly too. Where necessary,
protect these parts by a piece of sheet covering.

– Heat the shear screw head -1- for approximately 20 to 30 sec‐

onds.
Continued for slackened screws
– Unscrew shear screw -1- with a screwdriver -2-.
– Remove protective housing -2-.
NOTICE
Risk of engine control unit destruction!
♦ The engine control unit must not touch the positive pole of
the battery
7. Engine control unit 251

– Unlock catch in -direction of the arrow- and remove the engine

control unit -1-.
– Unlock plug connections for engine control unit - J623- and
pull off.
Installing
– It is imperative for the protective housing to be put back in
place on the engine control unit - J623- .
– Clean the threaded holes for the shear bolts to remove resi‐
dues of locking agent. Cleaning can be done using a tapper.
– Secure the protective housing with new shear bolts.
After installing a new engine control unit, the following work step
must be performed:
♦ 0001 - Replace the engine control unit

8 High pressure pump

⇒ “8.1 Summary of components - high pressure pump”,
page 253
⇒ “8.2 Removing and installing the high pressure pump”,
page 254
8.1 Summary of components - high pressure pump
1 - Screw
sembly
❑ 20 Nm + 180°
2 - Nut
❑ to release and tighten
use counterholder -
T10051-
❑ 95 Nm
3 - Toothed belt gear on the
high pressure pump
4 - Hub
❑ to remove, use extractor
-T10489-
5 - Screw
sembly
❑ 20 Nm + 45°
6 - Bracket for auxiliary units
stalling bracket for aux‐
iliary units”, page 34
7 - Fuel intake hoses
8 - Fuel return-flow hoses
9 - Hose clamp
10 - Connector
❑ Fuel dosage valve -
N290-
❑ between the high pressure reservoir (fuel distributor) and high pressure pump
❑ removing
⇒ “3.6.1 Removing the high pressure line between the high pressure pump and the high pressure res‐
ervoir (fuel distributor)”, page 224
❑ follow all instructions for installation of high pressure lines
12 - Screw
❑ 20 Nm + 45°
13 - Screw
❑ 20 Nm + 45°
14 - Support
❑ between the high pressure pump and the cylinder head
8. High pressure pump 253


❑ with fuel dosage valve - N290- (do not remove valve)
❑ Removing and installing ⇒ “8.2 Removing and installing the high pressure pump”, page 254
❑ After replacing, readjust the learnt values in “Targeted Functions” ⇒ Vehicle diagnostic tester
8.2 Removing and installing the high pres‐

sure pump
♦ Extractor -T10489-
♦ Locking pin -T10492-
Removing
NOTICE
Risk of damage to the high pressure pump through running dry.
♦ If the high pressure pump is removed or replaced, the fuel
system must be filled/bled before the engine is started for
the first time


– Release and pull off connector -1- and loosen clamp -2-.
– Unscrew screws -4- and -5- and remove air deflector with ex‐
haust gas recirculation pipe -3-.
tor)”, page 224 .
page 93 .
– Release retaining clips -1- and disconnect fuels hoses -2- and
-3- from the high pressure pump.
– Unscrew nuts -arrow- and remove counterholder - T10051- .

– Pull out the rig pin -T10492- .
– Remove the high pressure pump toothed belt pulley.

– Suspend extractor -T10489- at the hub by turning to the right.

– Remove the hub of the high pressure pump.
– Unscrew screws -1- and remove support -2-.
– Unscrew screws -1- and carefully remove the high pressure

pump -2-.
Installing
– Place hub -arrow- on the high pressure pump shaft.

• The key on the high pressure pump shaft must engage into
the slot in the hub.
– Mount the toothed belt pulley onto the hub.
• There must not be any oil present between the counterholder
and the toothed belt pulley

– Turn nuts -arrow- to the thread of the high pressure pump

shaft.
– Place counterholder on toothed belt pulley and tighten nuts
hand-tight -arrow-.
– Turn high pressure pump toothed belt pulley using the coun‐
terholder - T10051- until it can be locked with the rig pin -
T10492- .
– To do so, insert the rig pin -T10492- into fork -2- of the hub
and into the bore behind it -1- in the auxiliary units bracket.
– Loosen nuts -arrow- again.

• It must still be possible to just turn the high pressure pump
toothed belt pulley, however it must not hang loose.
– Installing high pressure line
NOTICE
Risk of damage to the high pressure pump through running dry.
♦ If the high pressure pump is removed or replaced, the fuel
system must be filled/bled before the engine is started for
the first time.
– After replacing the high pressure pump, re-adjust the learnt

values in “Targeted Functions” ⇒ Vehicle diagnostic tester.
Note

♦ High pressure pump

⇒ “8.1 Summary of components - high pressure pump”, page
253

9 Lambda probe
⇒ “9.2 Removing and installing Lambda probe”, page 259
9.1 Summary of components - lambda probe

installing the exhaust
gas temperature trans‐
mitter 1 G235 ”,
page 282
❑ 45 Nm
❑ consists of:
♦ Lambda probe - G39-
♦ Lambda probe heater -
Z19-
installing Lambda probe
1 after catalytic convert‐
er GX10 ”, page 259
❑ 55 Nm
3 - Screw
❑ 8 Nm
sor 1 - G450-
stalling pressure sensor
for exhaust gas 1 G450
”, page 247
mitter - G505-
⇒ “6.5 Removing and installing differential pressure transmitter G505 ”, page 245
7 - Exhaust gas temperature transmitter 3 - G495-
⇒ “3.2.2 Removing and installing the exhaust gas temperature transmitter 3 G495 ”, page 283
❑ the thread of the exhaust gas temperature transmitter is coated and must not be coated additionally with
hot bolt paste
❑ 45 Nm
8 - Lambda probe 1 downstream of catalytic converter - GX7-
❑ consists of:
♦ Lambda probe - G130-
♦ Lambda probe heater - Z29-
⇒ “9.2.2 Removing and installing Lambda probe 1 after catalytic converter GX7 ”, page 260

❑ 52 Nm
9.2 Removing and installing Lambda probe

⇒ “9.2.1 Removing and installing Lambda probe 1 after catalytic
converter GX10 ”, page 259
⇒ “9.2.2 Removing and installing Lambda probe 1 after catalytic
converter GX7 ”, page 260
9.2.1 Removing and installing Lambda probe

1 after catalytic converter - GX10-
♦ Extension piece (No. 22) - T10491-
Removing
– Release and pull off connector -2- and unclip cable from the
support.
9. Lambda probe 259

– Unscrew lambda probe 1 in front of the catalytic converter -

GX10- -arrow- with extension (No. 22) - T10491- .
Installing
NOTICE
♦ New lambda probes are coated with an assembly paste; the
paste is not allowed to reach to slots on the body of the
probe.
♦ For a re-used lambda probe, only coat the thread with hot
bolt paste .
♦ This paste must not come into contact with the slots of the
lambda probe body.
♦ The electrical wiring of the lambda probe must be attached
to the same position when installing. This prevents the lamb‐
da probe cable from coming into contact with the exhaust
pipe.

Note

♦ Lambda probe
9.2.2 Removing and installing Lambda probe

1 after catalytic converter - GX7-
♦ Extension piece (No. 22) - T10491-
Removing
noise insulation .
– Remove the right underfloor trim panel ⇒ Exterior body work;
Rep. gr. 66 ; Underfloor trim panel; Summary of components
- Floor reinforcement panels .

– Release and pull off connector -1- and undo line of lambda
probe.
9. Lambda probe 261

– Unscrew lambda probe 1 after catalytic converter - GX7-

-arrow- with extension (No. 22) - T10491- .
Installing
NOTICE
♦ New lambda probes are coated with an assembly paste; the
paste is not allowed to reach to slots on the body of the
probe.
♦ For a re-used lambda probe, only coat the thread with hot
bolt paste .
♦ This paste must not come into contact with the slots of the
lambda probe body.
♦ The electrical wiring of the lambda probe must be attached
to the same position when installing. This prevents the lamb‐
da probe cable from coming into contact with the exhaust
pipe.

Note

♦ Lambda probe
♦ Underwear ⇒ General body repairs, exterior; Rep. gr. 66 ;
Underfloor trim panel; Summary of components - Floor rein‐
forcement panels

26 – Exhaust system
1 Exhaust pipes/silencers
⇒ “1.1 Assembly overview - silencers”, page 263
⇒ “1.2 Separating exhaust pipes/silencers”, page 265
⇒ “1.3 Removing and installing pre-exhaust pipe”, page 266
⇒ “1.4 Removing and installing middle silencer”, page 267
⇒ “1.5 Removing and installing rear silencer”, page 268
⇒ “1.6 Align exhaust system free of stress”, page 270
⇒ “1.7 Inspecting the exhaust system for leaks”, page 271
⇒ “1.8 Installation position of clamping sleeve”, page 271
1.1 Assembly overview - silencers

⇒ “1.1.1 Assembly overview - silencer, Fabia III”, page 263
⇒ “1.1.2 Summary of components- silencer, Rapid NH”,
page 265
1.1.1 Assembly overview - silencer, Fabia III
1. Exhaust pipes/silencers 263

1 - Clamping sleeve
⇒ “1.8 Installation posi‐
tion of clamping sleeve”,
page 271
2 - Tunnel bridge
3 - Nut
❑ 20 Nm
4 - Retaining strap
5 - Hanger
6 - screws
❑ 23 Nm
7 - Separation point
8 - Silencer
264 Rep. gr.26 - Exhaust system

1.1.2 Summary of components- silencer, Rapid NH
1 - Separation point
❑ for first equipment rear
part of exhaust system
one building unit with
middle part of exhaust
system
❑ Replace individually
when carrying out re‐
pairs
❑ Position clamping
sleeve on the marking
when installing
stalling middle silencer”,
page 267
❑ Installing the exhaust
system without tension
⇒ “1.6 Align exhaust
system free of stress”,
page 270
2 - Retaining strap
3 - Middle and rear part of the
exhaust system
4 - Screw
❑ 23 Nm
5 - Nut
❑ 20 Nm
6 - Tunnel bridge
7 - Clamping sleeve
❑ 23 Nm
1.2 Separating exhaust pipes/silencers

⇒ “1.2.1 Disconnect exhaust pipes / silencers, Rapid NH”,
page 265
1.2.1 Disconnect exhaust pipes / silencers,

Rapid NH
♦ For individually replacing the middle silencer, a coupling point
is provided in the connecting pipe.
♦ The coupling point is marked by indentation on the circumfer‐
ence of the exhaust pipe.
♦ The separation point is in the area of the rear axle.
♦ Chain pipe cutter , e.g. -VAS 6254-

Work procedure
– Separate exhaust pipe at the separation point -arrow 2- with
chain pipe cutter (e.g. -VAS 6254- ) at a right angle.
– When installing clamping sleeve -4-, centre it on the side
markings -1- and -3-.
– Install clamping sleeve in the angle position shown.

• Angle -a- = 45°.
• bolted connection points to the right.
• Nuts upwards.
– When installing the clamping sleeve, centre it at the same dis‐

tance as -dimension a- from the side markings -arrows-.
– The distance -a- should be approx. 5 mm.
– Align exhaust system free of stress
⇒ “1.6 Align exhaust system free of stress”, page 270 .
Tightening torques
Screw Tightening torque
Screws on 30 Nm
clamping sleeve
1.3 Removing and installing pre-exhaust

pipe
Removing
noise insulation .

– Unscrew screws -2- of the clamping sleeve -1- and slide the
clamping sleeve backwards.
– Release and pull off connectors -6- of the exhaust flap control
unit - J883- .
– Slacken screw clamp -4-.
– Pull front exhaust pipe -3- off the retaining strap -5- and re‐
move.
Installing
Note
Replace gasket.
– Observe installation position of clamping sleeve and gasket

between exhaust gas cleaning module and pre-exhaust pipe.
– Set up the front exhaust pipe so that the dimension -a- is the
same on left and right.
Note

♦ Screw clamp: 8 Nm
♦ Installation position of clamping sleeve
⇒ “1.8 Installation position of clamping sleeve”, page 271
1.4 Removing and installing middle silencer

⇒ “1.4.1 Removing and installing selector mechanism, Fabia III”,
page 267
1.4.1 Removing and installing selector mech‐

anism, Fabia III

Removing
Note
♦ For replacing the middle silencer, a separation point is provi‐

ded in the connecting pipe for repairs.
♦ The separation point is marked by indentations on the circum‐
ference of the exhaust pipe.
CAUTION
To avoid injury from metal shavings, wear eye protection and
protective clothing!
– Loosen the screws on clamping sleeve and slide the clamping

sleeve backwards pos. -1- ⇒ Item 1 (page 264) .
chain pipe cutter (right-angled).
– When installing, position clamping sleeve -4- at the side mark‐
ings arrow -1- and arrow -3-.
– Remove the middle silencer.
Installing
– Note installation position of clamping sleeve
⇒ “1.8 Installation position of clamping sleeve”, page 271 .
Note

♦ Silencer ⇒ “1.1 Assembly overview - silencers”, page 263 .
1.5 Removing and installing rear silencer

⇒ “1.5.1 Removing and installing selector mechanism, Fabia III”,
page 268
⇒ “1.5.2 Removing and installing the catalysor, Rapid NH”, page
269
1.5.1 Removing and installing selector mech‐

anism, Fabia III

Note
♦ For replacing the rear silencer, a separation point is provided

in the connecting pipe for repairs.
♦ The separation point is marked by indentations on the circum‐
ference of the exhaust pipe.
Removing
Separation point without clamping sleeve
chain pipe cutter (right-angled).
Separation point with clamping sleeve
– Loosen clamping sleeve -1- and slide in the direction of the

silencer -2-.
– Unscrew screws from the rear silencer's bracket and remove.
– Remove the rear silencer.
Installing
– Note installation position of clamping sleeve
⇒ “1.8 Installation position of clamping sleeve”, page 271 .
Note

1.5.2 Removing and installing the catalysor,

Rapid NH
Removing
– Observe safety measures ⇒ “2 Safety instructions”, page 2 .
– Disconnect rear silencer
⇒ “1.2.1 Disconnect exhaust pipes / silencers, Rapid NH”,
page 265 .

– Loosen screws on clamping sleeve -2- and slide it backwards.
CAUTION
Risk of accident from weight of the rear silencer!
♦ A second mechanic is required to remove the rear silencer.
– Unhook retaining strap for the rear silencer on the rear axle
⇒ “1.1.2 Summary of components- silencer, Rapid NH”, page
265 .
– Unscrew screws of the retaining strap for the rear silencer
265 .
– Remove the rear silencer.
Installing
– Align the mounting brackets for the rear silencer. Align so that
the mountings for the retaining straps are parallel.
– Tighten screws for retaining strap.
♦ Silencer
265 .
1.6 Align exhaust system free of stress

• The exhaust system is aligned when cold.
– Slacken bolted connections of clamping sleeve -2-.
– Push the rear silencer so far forward until the pre-tensioning

on the retaining strap on the exhaust pipe is -a- = 5 mm.

– Install clamping sleeve in the angle position shown.

• Vehicles with front-wheel drive: Angle -α- = approx. 20°.
• Bolted connection to the right.
• Nuts upwards.
– Tighten screws of clamping sleeve evenly.
Note

1.7 Inspecting the exhaust system for leaks

– Start engine and run in idle.
– Close off exhaust pipes for the duration of the leak test, e.g.
with cloths or plugs.
– Check all connection points for tightness by listening: exhaust
manifold to cylinder head, turbocharger to pre-exhaust pipe,
etc.
– Eliminate any leak found.
1.8 Installation position of clamping sleeve
Note
Only continuous clamping sleeves may be used.
Positioning of clamping sleeve
The dimension -a- must be complied with.

a - Distance to marking: approx. 5 mm
1 - Clamping sleeve
2 - Exhaust pipe
3 - Securing nuts

Installation position of front clamp

• The bolted connection points downwards (direction of road
surface).
• The angle -α- = approx. 15 ° must not be exceeded.
Installation position of rear clamp

• The bolted connection points downwards (direction of road
surface).
• The angle -α- = approx. 15 ° must not be exceeded.
Tightening torque
Component Tightening torque
Clamping sleeve 23 Nm

2 Cleansing exhaust emissions

⇒ “2.1 Summary of components - exhaust gas cleaning”,
page 273
page 275
⇒ “2.3 Removing and installing the exhaust flap control unit J883
”, page 279
2.1 Summary of components - exhaust gas cleaning

circulation, low pressure
installing radiator for low
pressure exhaust gas
recirculation”,
page 289
❑ Check for leaks
⇒ “4.3 Test air-tightness
of the radiator for ex‐
haust gas recirculation”,
page 291
2 - Screw
recirculation”,
page 285
3 - Screw
recirculation”,
page 285
❑ for radiator for exhaust
gas recirculation
stalling exhaust gas tur‐
bocharger”, page 183
6 - Nut
tightening order ⇒ Fig. ““Tightening order for exhaust gas cleaning module”“ , page 279
7 - Screw
⇒ Fig. ““Tightening order for exhaust gas cleaning module”“ , page 279
❑ for exhaust gas cleaning module
2. Cleansing exhaust emissions 273

10 - Screw
11 - Screw
12 - Screw
❑ 9 Nm
13 - Nut
❑ 10 Nm
14 - Measurement pipe
❑ to differential pressure transmitter - G505-
❑ Union nut tightening torque 45 Nm
15 - Measurement pipe
❑ for exhaust gas pressure sensor 1 - G450-
❑ Union nut tightening torque 45 Nm
16 - Screw
❑ 9 Nm
17 - Screw
19 - Screw
21 - Screw
22 - Screw
23 - Screw clamp
❑ 8 Nm
24 - Seal
25 - Exhaust pipe
❑ Removing and installing ⇒ “1.3 Removing and installing pre-exhaust pipe”, page 266
❑ Installing the exhaust system without tension ⇒ “1.6 Align exhaust system free of stress”, page 270
26 - Exhaust gas cleaning module
❑ Particle filter with catalyser
❑ Removing and installing ⇒ “2.2 Removing and installing exhaust gas cleaning module”, page 275
27 - Seal

28 - Screw clamp
❑ 8 Nm
29 - Screw clamp
30 - Seal

cleaning module
♦ Tool - T10533-
♦ XZN socket - T10385-
Removing
noise insulation .
⇒ “1.3 Removing and installing pre-exhaust pipe”, page 266 .
– Remove the assembly carrier ⇒ Chassis, axles, steering; Rep.
carrier without steering gear .
– Remove drive shaft right from gearbox ⇒ Chassis, axles,
steering; Rep. gr. 40 ; Drive shaft; removing and installing
drive shaft .
– Release and pull off connectors -1- and -2- and unclip cable
from the support.
– Unscrew screw -4-, loosen clamp -5- and pull off hose.
– Remove the right underfloor trim panel ⇒ Exterior body work;
Rep. gr. 66 ; Underfloor trim panel; Summary of components
- Floor reinforcement panels .

– Release and pull off connector -1- and undo line of lambda
probe.
– Release and pull off connectors -1-, -2- and -3- and loosen
line.
– Attach tool - T10533- and tighten screws by hand. Screw -1-

is an original screw of the pendulum support.
– Slide the engine/gearbox unit with the tool - T10533- as far
backwards as possible. Rotate the spindle so that parts on the
fan shroud are not damaged.

– Release retaining clip -1- and pull coolant hose off the radiator
for exhaust gas recirculation.
– Release hose clamp -2-, unscrew screws -4- and remove ex‐
haust gas recirculation -1-.
– Release clamp -3- and pull coolant hose off the bulkhead ple‐
num chamber.
– Unscrew screw -1- with socket insert XZN - T10385- and re‐
lease clamp -3-.
– Remove radiator for exhaust gas recirculation -2- from ex‐
haust gas cleaning module.

Exhaust gas cleaning module disassembly sequence

Lev‐ Screw Level
el
1. Loosen nut -2- and by one turn.
screws -4- and -6-
2. Screw -3- unscrew
3. Screws -7- and -8- Unscrew, remove support
4. Screws -5- and -9- unscrew
5. Screw clamp -1- release and remove clamp
– Swivel the exhaust gas cleaning module downwards away
from the engine and push it upwards.
– Remove exhaust gas cleaning module downwards.
Installing
Note
♦ Replace self-locking nuts and screws as well as sealing rings,

gaskets and O-rings after disassembly.
♦ Secure all hose connection ends with spring-type clips that
comply with the series design ⇒ ETKA - Electronic Catalogue
of Original Parts .
♦ Fit all cable straps on again in the same place when installing.
– Disconnect the gasket -1- at the exhaust gas cleaning module.

– Unhook clamp screw and lay clamp -2- entirety on the flared
opening of the exhaust gas cleaning module. Do not bend
clamp
– Bring exhaust gas cleaning module from the bottom into fitting
position.
– Screw in screws -4-, -5-, -6- and -9- by hand and until the screw
heads are in contact with the surface.

Tightening order for exhaust gas cleaning module

Level Screw Level
1. Clamping Position via the sealing flange, lock
sleeve -1-: screw
2. Clamping tighten to 8 Nm
sleeve -1-:
3. Nuts -2- tighten to 20 Nm
4. Screw -3- tighten to 20 Nm
5. Insert support -B-
6. Screws -7- Screw in by hand
and -8-
7. Screws -4- to tighten to 20 Nm
-9-
– Install radiator for exhaust gas recirculation
⇒ “4.2 Removing and installing radiator for exhaust gas recir‐
culation”, page 288 .
– Install the right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Install assembly carrier ⇒ Running gear, axles, steering; Rep.
carrier without steering box .
– Connect hoses -5- and screw in screw -4-.

– Insert line into the support and connect connectors -1- and
-2-.
– After replacing the exhaust gas cleaning module, connect the
diagnostic unit ⇒ Vehicle diagnostic tester.
♦ 0001 - Adapt learnt values of particle filter
2.3 Removing and installing the exhaust

flap control unit - J883-
Removing
– Tie off heat shield collar and disconnect plug connections
-1-.
– Unscrew screws -arrows- and remove exhaust flap control unit
- J883- -2-.
Installing

– Mount new exhaust flap control unit . When doing so, ensure
that the driver of the control unit -1- engages into the tab of the
exhaust flap -2-.
– Insert new securing bolts and screw on new nuts.
– Tighten the top bolts first, then the bottom bolt. Tightening tor‐
que: 10 Nm.
– Remove protective cap for the electrical plug connection and
connect connector -1-. Secure the heat shield collar.
– After replacing the exhaust flap control unit - J883- , the learnt
values must be changed in the engine control unit.
♦ Adaption of the exhaust flap
Note

Component Tightening torque

Screws for exhaust 10 Nm
flap control unit -
J883-

3 Exhaust temperature regulation

⇒ “3.1 Summary of components - exhaust temperature regula‐
tion”, page 281
⇒ “3.2 Removing and installing exhaust gas temperature sender”,
page 282
3.1 Summary of components - exhaust tem‐

perature regulation
NOTICE
Malfunction caused by loose exhaust gas temperature trans‐
mitter.
♦ The thread of the exhaust temperature transmitter 3 -G495-
is coated.
♦ It must NOT be coated additionally with hot bolt paste and
must be tightened to the specified tightening torque.

installing the exhaust
gas temperature trans‐
mitter 1 G235 ”,
page 282
❑ Coat threads with hot
bolt paste; hot bolt paste
⇒ ETKA - Electronic
Catalogue of Original
Parts
❑ 45 Nm
❑ consists of: lambda
probe - G39- and lamb‐
da probe heater - Z19-
installing Lambda probe
1 after catalytic convert‐
er GX10 ”, page 259
3 - Screw
❑ 8 Nm
sor 1 - G450-
stalling pressure sensor
for exhaust gas 1 G450
”, page 247
mitter - G505-
⇒ “6.5 Removing and installing differential pressure transmitter G505 ”, page 245
3. Exhaust temperature regulation 281

7 - Exhaust gas temperature transmitter 3 - G495-

⇒ “3.2.2 Removing and installing the exhaust gas temperature transmitter 3 G495 ”, page 283
❑ the thread of the exhaust gas temperature transmitter is coated and must not be coated additionally with
hot bolt paste
❑ 45 Nm
8 - Lambda probe 1 downstream of catalytic converter - GX7-
❑ consists of: lambda probe - G130- and lambda probe heater - Z29-
⇒ “9.2.2 Removing and installing Lambda probe 1 after catalytic converter GX7 ”, page 260

temperature sender
⇒ “3.2.1 Removing and installing the exhaust gas temperature
transmitter 1 G235 ”, page 282
⇒ “3.2.2 Removing and installing the exhaust gas temperature
transmitter 3 G495 ”, page 283
3.2.1 Removing and installing the exhaust

gas temperature transmitter 1 - G235-
♦ Extension SW 17 , e.g. -V.A.G 1331/10-
Removing
NOTICE
♦ Wear safety gloves and safety goggles!
♦ Fit all cable straps on again in the same place when instal‐
ling.
♦ When removing, the electric cable must be not cut off, since
doing so would mean that fault diagnosis would no longer be
possible.

– Take electrical plug connection-3 - out of the holder, discon‐
nect and expose electric wiring loom.

– Unscrew exhaust gas temperature sender 1 - G235- -1- using

extension SW 17 - V.A.G 1331/10- .
Installing
Note
♦ Protect exhaust gas temperature transmitter against impact

and hammering: do not use exhaust gas temperature trans‐
mitter if it has fallen onto the floor.
♦ Coat thread with hot bolt paste; Hot bolt paste ⇒ ETKA - Elec‐
tronic Catalogue of Original Parts .

Note

♦ Exhaust temperature control system

⇒ “3.1 Summary of components - exhaust temperature regu‐
lation”, page 281
3.2.2 Removing and installing the exhaust

gas temperature transmitter 3 - G495-
♦ Tool set - T10395- or -T10395A-
Removing
NOTICE
♦ Wear safety gloves and safety goggles!
♦ Fit all cable straps on again in the same place when instal‐
ling.
♦ When removing, the electric cable must be not cut off, since
doing so would mean that fault diagnosis would no longer be
possible.

3. Exhaust temperature regulation 283

– Pull off connector -1- and expose the cable.

– Unscrew exhaust gas temperature sender 3 - G495- using a
tool from the tool kit - T10395- and a suitable insertion tool
lation”, page 281 .
Installing
NOTICE
Malfunction caused by loose exhaust gas temperature trans‐
mitter.
♦ The threads of the exhaust gas temperature transmitter -
G235- and -G495- are coated.
♦ It must NOT be coated additionally with hot bolt paste and
must be tightened to the specified tightening torque.
Note
Protect exhaust gas temperature transmitter against impact and

hammering: do not use exhaust gas temperature transmitter if it
has fallen onto the floor.

Note

♦ Exhaust temperature control system

lation”, page 281

4 Exhaust gas recirculation

⇒ “4.1 Summary of components - Exhaust gas recirculation”,
page 285
⇒ “4.2 Removing and installing radiator for exhaust gas recircu‐
lation”, page 288
⇒ “4.3 Test air-tightness of the radiator for exhaust gas recircu‐
lation”, page 291
⇒ “4.4 Removing and installing exhaust gas recirculation valve 2
GX6 ”, page 291
4.1 Summary of components - Exhaust gas

recirculation
⇒ “4.1.1 Summary of components - Low pressure exhaust gas
recirculation”, page 285
⇒ “4.1.2 Summary of components - High pressure exhaust gas
recirculation”, page 287
4.1.1 Summary of components - Low pressure exhaust gas recirculation

valve 2 - GX6-
❑ consists of:
♦ Control engine 2 for ex‐
haust gas recirculation -
V339-
♦ Exhaust gas recirculation
potentiometer 2 - G466-
stalling exhaust gas re‐
circulation valve 2 GX6
”, page 291
2 - Sealing ring
sembly
3 - Screw
❑ 9 Nm
4 - Air deflector
❑ to exhaust gas turbo‐
charger
5 - Screw
❑ 9 Nm
6 - Seal
sembly
circulation, low pressure
⇒ “4.2.2 Removing and installing radiator for low pressure exhaust gas recirculation”, page 289
4. Exhaust gas recirculation 285

❑ Check for leaks ⇒ “4.3 Test air-tightness of the radiator for exhaust gas recirculation”, page 291
8 - Screw
❑ Tightening torque and tightening order ⇒ page 286
9 - Threaded bushing
❑ integrated in bracket, Pos. -11-
10 - Screw
❑ for radiator for exhaust gas recirculation
12 - Screw clamp
❑ Fitting position ⇒ page 286
13 - Seal
14 - Exhaust gas cleaning module
❑ Removing and installing ⇒ “2.2 Removing and installing exhaust gas cleaning module”, page 275
Installation position for radiator for exhaust gas recirculation

• Angle -α- = 10 … 15°.
Radiator for exhaust gas recirculation - tightening torques and

tightening order
– Tighten screws in the specified sequence:
1. Clamping 7 Nm
sleeve -3-:
2. -1- Tighten by hand as far as the stop
3. -1- 20 Nm

4.1.2 Summary of components - High pressure exhaust gas recirculation
1 - Screw clamp
sembly
❑ 8 Nm
2 - Exhaust gas circulation
❑ for air guide
4 - Screw
❑ 9 Nm
5 - Screw
❑ 20 Nm
❑ for charge air cooler and
refrigerant hoses
7 - Ball stud
❑ for engine cover
❑ 4 Nm
valve 1 - GX5-
consists of:
control motor - V338-
potentiometer - G212-
9 - Seal
sembly
10 - Exhaust gas circulation
❑ from exhaust manifold
11 - Screw
❑ 9 Nm
12 - Nut
❑ 20 Nm
13 - Screw
❑ 20 Nm
14 - Screw
❑ 9 Nm
16 - Screw
❑ 20 Nm
17 - Seal
18 - Screw
❑ 20 Nm

4.2 Removing and installing radiator for ex‐

haust gas recirculation
⇒ “4.2.1 Removing and installing radiator for high pressure ex‐
haust gas recirculation”, page 288
⇒ “4.2.2 Removing and installing radiator for low pressure ex‐
haust gas recirculation”, page 289
4.2.1 Removing and installing radiator for high

pressure exhaust gas recirculation
Removing
– Release hose clamp -1-, unscrew screw -3- and remove ex‐
– Close coolant hoses with suitable clamps, release hose

clamps -1- and -2- and pull off hoses.
– Remove charge air cooler
⇒ “2.2 Removing and installing charge air cooler”, page 196 .

– Unscrew screws -1- and remove pulsation damper -2-.

– Unscrew screws -3- and -5- and remove exhaust gas recircu‐
lation -4-.
– Remove screws -1- and -2-.
– Unscrew screws -1- to -4- and remove radiator for exhaust gas
recirculation -5-.
Installing
⇒ “2.2 Removing and installing charge air cooler”, page 196 .
– Install battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Re‐
moving and installing battery .
Note


page 285
4.2.2 Removing and installing radiator for low

pressure exhaust gas recirculation
♦ Tool - T10533-

Removing
– Remove exhaust gas recirculation valve 2 - GX6-
⇒ “4.4 Removing and installing exhaust gas recirculation valve
2 GX6 ”, page 291 .
– Remove shift cable with cable support from gearbox and place
laterally ⇒ Rep. gr. 34 ; Shift operation; Removing and in‐
stalling selector mechanism .
– Remove selector cable with cable support from gearbox and
place sideways ⇒ Rep. gr. 34 ; Shift operation; Removing and
installing selector mechanism .
– Unlock latch -arrow-, loosen coolant hose holder, if present.
– Just loosen screw -1-, remove screw -2- with plug insert XZN
- T10385- .

– Loosen clamp -3- and move to the emission control module.

– Remove radiator for low pressure exhaust gas recirculation
-2- downwards.
Installing
Note
♦ Check heat shield collar for damage, renew if necessary.

♦ If heat shield collar is defective, check exhaust gas recircula‐
tion valve 2 - GX6- for heat damage and replace if necessary.
♦ Replace gaskets, clamp and spring strap clips after disassem‐
bly.
inal Parts .
– Install exhaust gas recirculation valve 2 - GX6-

⇒ “4.4 Removing and installing exhaust gas recirculation valve
2 GX6 ”, page 291 .
– Install pendulum support
⇒ “2.4 Removing and installing pendulum support”, page 24 .
Note


page 285
4.3 Test air-tightness of the radiator for ex‐

haust gas recirculation
Air-tightness of the radiator for exhaust gas recirculation is tested
with the ⇒ Vehicle diagnostic tester.
– Connect the ⇒ Vehicle diagnostic tester to the vehicle and
check function:
♦ Cooling system leak-tightness
Note
The specified path may vary slightly, depending on vehicle, en‐

gine and the version of the data on the vehicle diagnosis tester.
4.4 Removing and installing exhaust gas re‐

circulation valve 2 - GX6-

♦ Tool - T10533-
Exhaust gas recirculation valve 2 - GX6-
consists of:
♦ Control engine 2 for exhaust gas recirculation - V339-
♦ Exhaust gas recirculation potentiometer 2 - G466-
Removing
– If present, remove heat shield for underbody.
– Remove pendulum support
⇒ “2.4 Removing and installing pendulum support”, page 24 .
– Unscrew screws -1- for steering gear.
– Attach tool - T10533- and tighten screws by hand. Screw -1-

is an original screw of the pendulum support.
– Slide the engine/gearbox unit with the tool - T10533- as far
backwards as possible.
Note
Rotate the spindle so that parts on the fan shroud are not dam‐
aged.
– Release retaining clip -1- and release clamp -2-. Detach cool‐
ant hoses from radiator for exhaust gas recirculation.

– Release hose clamp -2-, unscrew screws -4- and remove ex‐
– Remove exhaust gas recirculation valve 2 - GX6- -3- down‐
wards.
Installing
Note
♦ Replace gaskets and O-rings after disassembly.

inal Parts .

Note


page 285

28 – Glow plug system

1 Glow plug system
⇒ “1.1 Summary of components - Glow plug system”, page 294
⇒ “1.2 Removing and installing glow plugs”, page 295
⇒ “1.3 Removing and installing automatic glow period control unit
J179 ”, page 297
⇒ “1.4 Removing and installing knock sensor 1 G61 ”,
page 297
⇒ “1.5 Removing and installing Hall sender G40 ”, page 298
⇒ “1.6 Removing and installing the engine speed transmitter G28
”, page 298
1.1 Summary of components - Glow plug system
1 - Glow plug
♦ Glow plug 1 - Q10-
♦ Glow plug 2 - Q11- with
combustion chamber pres‐
sure sender for cylinder 2 -
G678-
♦ Glow plug 3 - Q12-
❑ Glow plug variants
⇒ Fig. ““Glow plug var‐
iants”“ , page 295
stalling glow plugs”,
page 295
❑ Glow plugs without
combustion chamber
pressure transmitter
17 Nm
❑ Glow plugs with com‐
bustion chamber pres‐
sure transmitter 12 Nm
2 - Electrical plug connection
❑ for glow plugs
3 - O-ring
❑ no spare parts, in case
of damage replace to‐
gether with Hall sender -
G40-
4 - Hall transmitter - G40-
stalling Hall sender G40
”, page 298
5 - Screw
❑ 4.5 Nm
6 - Rotor
❑ Engine speed sender - G28-
294 Rep. gr.28 - Glow plug system

7 - Sealing flange on the gearbox side

❑ Removing and installing ⇒ “2.3 Removing and installing sealing flange on gearbox side”, page 45
8 - Engine speed transmitter - G28-
❑ Removing and installing ⇒ “1.6 Removing and installing the engine speed transmitter G28 ”, page 298
9 - Screw
❑ 9 Nm
1.2 Removing and installing glow plugs

♦ Flexible-head wrench SW 10 -3220-
♦ Pliers - 3314-
♦ Socket insert 12 mm - VAS 6454- for cylinder 2
Removing
Glow plug variants
1- Glow plug with combustion chamber pressure sender - only
for cylinder 2
2- Glow plugs without combustion chamber pressure transmit‐
ter
– Switch off ignition and pull out ignition key.
NOTICE
Risk of damaging support sleeves.
♦ Only press pliers - 3314- for disconnecting glow plug con‐
nectors together so that they grip the support sleeve collar
securely without damaging it.
– Open holding clamps of the electrical wiring loom and discon‐

nect the electrical plug connections from the glow plugs as
follows.
1. Glow plug system 295

– Position pliers - 3314- using the pliers groove arrow -A- on the
support sleeve collar arrow -B-, as shown.
– Carefully disconnect the plug from the glow plugs.
– Clean glow plugs in the cylinder head (no dirt must fall into the
cylinder).
NOTICE
Wear protective gloves and protective goggles when working
with grease remover!
Note
♦ When cleaning, for example:

♦ Suction off heavy dirt using a vacuum cleaner.
♦ Spray the pencil type glow plug channel using a brake cleaner
or a suitable cleaner, let it take effect for a short period of time
and blow out with compressed air.
♦ Then clean the pencil type glow plug channel with a cloth
which is wetted with oil.
– To release the glow plugs, use socket wrench SW 10 - 3220- .
Note
Socket 12 mm - VAS 6454- used on cylinder 2.
Installing
– Place the glow plug connectors -1- back onto the glow plugs
-arrows-.
Note
Make sure the glow plug connectors fit tightly.
Note

♦ Glow plug system

page 294

1.3 Removing and installing automatic glow

period control unit - J179-
Removing
– Unlock locks in -direction of arrow- and remove cover -1- from
support -2-.
– Unlock locks -arrow- and pull out the automatic glow period
control unit - J179- -1- upwards.
Installing
The installation occurs in reverse order.
1.4 Removing and installing knock sensor 1

- G61-
Removing


– Release and pull off connector -1- and unscrew screw -2-.
– Remove knock sensor 1 - G61- -3-.
Installing
♦ Tightening torque: 20 Nm
1.5 Removing and installing Hall sender -

G40-
Removing
– Release and pull off connector -1- and unscrew screw -2-.
– Remove hall encoder - G40- -3- upwards.
Installing
Note


page 294
1.6 Removing and installing the engine

speed transmitter - G28-
♦ Insertion tool - T10118-

♦ Socket size 4 - T10370-

Removing
noise insulation .
– Pull off connector -1- using assembly tool - T10118- .
Note
To unlock the plug connections without the assembly tool -

T10118- , use a screwdriver to press the plug on the engine speed
sender and simultaneously raise the release button with a thin
wire hook.
– Unscrew screw -2-, remove engine speed transmitter - G28- .

Installing
– Insert the engine speed sender - G28- so that the lug -3- en‐
gages in the guide on the sealing flange -4-.
– Tighten screw -2- and insert plug -1-.
Note


page 294

Engine Cusb Cuta Cusa Repair Manual Eng

Uploaded by

Copyright:

Available Formats

Engine Cusb Cuta Cusa Repair Manual Eng

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Engine Cusb Cuta Cusa Repair Manual Eng

Uploaded by

Copyright:

Available Formats

Service

Service Department. Technical Information

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.1 Assembly overview - piston and conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

2.2 Summary of components - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

1.1 Engine number, engine data

Engine codes CUTA CUSA CUSB

Volkswagen Technical Site: https://vwts.ru

2.1 Safety precautions when working on

2 Rep. gr.00 - Technical data

Check the filling level of the fuel tank:

Observe the following points to prevent injury to persons and/or

♦ Disconnect and connect wires of the preheating and injection

2.2 Safety precautions for working on vehi‐

2.3 Safety precautions during road tests in

4 Rep. gr.00 - Technical data

2.4 Safety precautions when working on

2.5 Safety precautions when working on the

Risk of damaging the decoupling element.

3.1 Rules of cleanliness

3.2 Foreign bodies in the engine

3.3 Contact corrosion

3.4 Cable routing and securing

6 Rep. gr.00 - Technical data

3.5 Assembly of radiators and condensers

10 – Removing and installing engine

1.1 Removing engine

– Remove engine cover

8 Rep. gr.10 - Removing and installing engine

– Unscrew screws -1- and remove air inlet -2-.

– Unlock and disconnect connectors -1-, -2- and -3-.

– Touch a conductive component with the hands (without

– Remove the cap of the connector -1- on the double clutch

Label the connectors on the solenoid valves. There is a risk of

1. Removing and installing engine 9

– Loosen hose clamps -1- to -4-, remove coolant hoses.

– Detach quick couplings -1- to -4- and disconnect fuel hoses

10 Rep. gr.10 - Removing and installing engine

– Release nuts -1- and remove earth cable -2-.

– Pull connector off exhaust gas temperature transmitter 1 -

– Pull off cap -2- of line 30/B+ -1-.

– Loosen hose clamp -1- and disconnect coolant hoses.

1. Removing and installing engine 11

– Unscrews screws -1- for electrical coolant pumps and release

– Unscrew nuts -1- and remove cover -2-.

– Pull off connector -1- and undo line of lambda probe.

12 Rep. gr.10 - Removing and installing engine

– Fit the engine mount - T10536- as shown and secure with

– Completely unscrew engine mount screws -3- for engine

– Completely unscrew screws -1- for gearbox mount -4-.

– Carefully lower the engine with gearbox.

1. Removing and installing engine 13

1.2 Disconnecting engine and gearbox

1.2.1 Disconnect the engine from the gearbox

14 Rep. gr.10 - Removing and installing engine