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IN-2r~shop
Manual
: Golf
1998'-,
Bora 1999 ~,
,L
-,
~~
.. -
.1
AGZ
Engine
code
,~
i
1
- -
'
,!
i
,,
Edition 10.97
/
J
___
~ ~..,..~
_ ~.
".-.~~~~ _-"ll::t~J.L;,,:,I;\'-
,{
~'
Service.
List of Workshop Manual Repair Groups
Golf
1998~
IAGzl
Engine
code
Booklet
When filing a Technical Bulletin enter the Bulletin No. in the adjacent column. When using the Workshop
Manual you can then see at a glance whether Technical Bulletins have been published in respect of the
particular Repair Group in which you are looking.
Technical Bulletins
Repair Group
00 Technical Data
10 Removing and installing engine
13 Crankshaft group
15 Cylinder head, Valve gear
17 Lubrication
19 Cooling
20 Fuel supply system
26 Exhaust system
..
-~-.
--,-
_ J __
..
..
Technical Information should always be available to all foremen and mechanics, because their com
pliance with the instructions given is essential to ensure vehicle roadworthiness and safety. In addition,
the normal safety precautions to be observed when working on motor vehicles are also applicable.
All rights reserved.
Printed in Germany
KOO.51 07.29.20
Contents
00
Technical data
Page
Technical data ............................................................................ 00-1
- Engine number .......................................................................... 00-1
- Engine data ......' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 00-2
10
13
15
11
19
Page
10-1
10-3
10-9
10-11
10-14
10-15
Crankshaft group
Page
13-1
13-8
13-11
13-27
13-30
13-33
13-37
13-40
1345
13-53
Page;,
Removing and installing cylinder head ..................................................... 15.t~ti
15-9
15-17
15-24
1527
15-34
15-37
15-42
15-44
15-45
15-47
Lubrication
Page
'171
Cooling system
Page
191
19-2
19-5
19-9
19-11
19-14
19-19
19-22
19-24
19-27
17-8
17-10
17-13
17-16
20
Page
- Removing and installing fuel delivery unit.. ............................ ........ .............. 20-10
Accelerator mechanism .
o. 20-28
- Servicing parts of the activated charcoal filter system......... ... . . . . . . . ... ... .. .. . . . .. ... .... 20-34
26
,'
Exhaust system
Page
00
00.
26-1
26-7
26-7
26-8
26-13
26-16
Technical data
Engine number
The engine number (engine code and serial number) is located next to
the Cylinder head on the cylinder block. It is found by looking down
wards between the crankcase breather heater element and the
throttle valve control part.
Additionally there is a sticker on the cylinder head cover with" Engine
code" and "Serial number".
The engine code is also included on the vehide data plate.
00-1--
Engine data
Engine code
AGZ
Manufactured
10.96>
VRll
Arrangement of cylinders
Cylinder angle
Displacement
15
Itrs.
2.3
Output
kWat rpm
110/6000
Torque
Nm at rpm
205fJ200
Bore
0mm
Stroke
Compression ratio
1} VR
mm
81
90.2
10.0:1
00-2--
AGZ
Engine code
RON
min.
95 unleaded ll
Injection system
Motronic M3.8.3
Ignition system
Motronic M3.8.3
Firing order
1-2-4-5-3
Knock control
yes
Self-diagnosis
yes
Lambda control
yes
Catalyst
yes
no
yes
Charging
no
1)
00-3--
! W1 ()-()()()8!
10-1--
V..A..G 1331
V.A.G 1306
V.A..G 1332
fIG ,
"
V.A.G 1921
n.<,:
I
W10-00091
10-2--
..
Notes on removing
Note:
Check' whether a coded radio is installed as during the forthcoming
work sequences the battery earth strap mustbe disconnected. Obtain
radio code first if necessary.
I
I
10-3--
Note:
Warning!
10-4--
10-5--
10-6---
....
:1
;;
4
\.F~4-..-f=:::::.::::~.....
"1
:~
,1
Ii
..
V
1\
p
.....
I N1G-01<121
10-7--
.....
- Fit engine bracket 3395 onto cylinder block and tighten securing
nuts -1- to 40 Nm.
- lift engine and gearbox lightly using engine/gearbox jackVAG1383
A.
I N10-0a70 I
.....
Nate:
To remove securing bolts use step ladder VA.s 5085.
li
P
it
,
-,I
10-8--
....
Note:
Work sequence
- Remove gearbox.
....
- Attach lifting device 2024 A as follows and lift engine out of enginel
.gearbox jack using workshop crane.
Pulley end:
Flywheel end:
Warning!
Notes:
The positions marked 1.. .4 on the bar must be towards the pulley
end.
The holes in the hooks are counted up from the hook.
10-10--
Notes on installing
L
(
'
10-11--
;
=> Running gear; Repair group 40; Removing and installing drive shafts
TE'
pi
th
- Install front exhaust pipe=> Page 26-1. Removing and installing parts
of exhaust system.
- Install intake manifold upper part => Page 15-9. Removing and instal
ling cylinder head cover.
10-12--
10-13--
lightening torques
lightening
torque
Bolted joint
Bolts. nuts
M6
10Nm
MS
20Nm
M10
45Nm
M 12
60Nm
in variation of this
Assembly mounting to gear
box.carrierll
60 Nm + 900
(1/4 turn)
Assembly mounting to en
gine carrierll
60Nm + 90
(1/4 turn)
40Nm + goo
(1/4 turn)
box1)
40Nm + 900
(1/4 turn)
20Nm +90
(1/4 turn)
1)
1o-14~--
i
'
Note:
To prevent damage to condenser also to the refrigerant pipeS/hoses,
ensure that the pipes and hoses are not stretched, kinked or bent.
frigerant circuit:
:i
I
',j
compressor bracket
- Secure air conditioner compressor to body so that the refrigerant
hoses/pipes are relieved.
I
1015--
1
P
tI
Notes:
II
I N13-0367 I
13-1--
II
I N13-0367 I
13-2--
f
'
-:
Part I
I'
~
~
5 6
21---/
19----.../
I
18---17---~
16
1514
'I
13 12 11
2 -Sender wheel
When installing contact surface on
timing chain and sender wheel must
be dry
For Hall sender (G40)
Removing and installing
=> Page 15-37, removing and instal
ling camshafts
3-100Nm
Oil bolt head contact surface when in
stalling
To remove and install counter-hold
with 24 mm open jaw spanner on
camshaft => Page 15-37, removing
and installing camshafts
20---'
I.
10
4 - Pivot pin, 18 Nm
For tensioning plate item 7
I N1:H>280 I
13-3--
5 -Seal
Renew if damaged or leaking
6 Chain tensioner, 40 Nm
For camshaft roller chain item 9
Only rotate engine when chain ten
sioner is installed
7 Tensioning plate
For camshaft roller chain item 9
8-Sprocket
For roller chain item 15
Installing => Page 13-11, Adjusting
valve timing
20--./
19----/
18---
17---../
16
1514
'I
13 12 11
10
J.
( .
I N1:H>280 I
13-4--
10 -100.Nm
Use counter-hold 3406 when loosen
ing and tightening => Page 13-11. Ad
justing valve timing
11 - Sprocket
For camshaft roller chain item 9
Installing => Page 13-11. Adjusting
valve timing
12 -10 Nm
21-----"
20-----"
19------/
18---
17---
16
1514
13 12 11
10
I N1:Hl280 I
13-5--
14 -Crankshaft sprocket
Integral. part of crankshaft
Ground down tooth aligned with main
bearing joint =TDC No.1 Cyl.
=> Page 13-11. Adjusting valve timing
15 - Roller chain
Mark D.O.R. before removing (in
sta lIation position)
=> Fig. 1
Installing => Page 13-11. Adjusting
valve timing
. 16 - Guide rail
For roller chain item 15
Remove together with roller chain
=> Page 13-11. Adjusting valve timing
21
20
19
18
17
16 .
1514
13 12 11
10
I N1~280 I
13-6--
19-20Nm
Insert with locking fluid "D6"
20 -20Nm
21 - Guide rail
For camshaft roller chain item 9
22-10Nm
Insert with locking fluid "D6"
23 -Thrust washer
23----'~~~~~f-~
.
\
24 -Intermediate shaft
22---"
21---"
20---'"
19------'
,, I
..
18----"
17----'
13
10
'
I N13-0280 I
13-7---
:-1
;
....
....
Tee
pliE:
the
1\"
No
_:
Iwoo-o468l
13-8--
Test sequence
- Removing insulation tray:
::} General body repairs exterior; Repair group 50; Body front: Assem
bly overview
- Remove cylinder head cover::} Page 15-9.
~
Nate:
This condition is only obtained every 2nd TDC position.
If the notch cannot be seen:
IN13-G213 I
13-9--
- The camshaft jig 3268 must locate in the shaft groove of the longer
camshaft and align with the shoulder of the shorter camshaft.
13-10--
3268
,
\.
VAG 1331
3406 Counter-hold
VAG 1331 Torque wrench (5...50 Nm)
r::
VAG 1332
,i
@J"I
I W13-0024 I
111I
!
;, l!
13-11--
;, : f
!
Work sequence
Engine removed
ac
ia
I Vl3-1052 I
Ie
fr
) f
ip'f
13-12--
....
thrust washer.
I V13-10S21
I N13-0290 I
13-13--
l00Nm.
I V13-10S21
Install camshaft roller chain and chain tensionerwith tensioning plate:
13-14--
Note:
With cylinder head removed:
- Installing cylinder head => Page 15-17 Removingand installing cylin
derhead.
- Place guide rail on locating pin. Insert short securing bolt with locking
fluid .. 06" and tighten both bolts to
20Nm.
....
,~~
;;
'Ii
, I
1'[
,
1:
j.
Ji
(I
III!
I N1:Hl281 I
,}
i~!
13-15--
.I
Note:
~ ~
Note:
Only counter-hoJd with 24 mm open jaw spanner on the camshaft
arrow.. The camshaft jig must not be fitted when tightening/Joosening
the sprockets.
I N15-0157 I
11I
~i
- Coat sealing surface of sealing flange with AMV 188 001 02 and in
stall. lighten securing bolt to
10 Nm.
t '
- Prepare cylinder head gasket for assembly
=> Page 15-7, Fig. 2
- Coat sealing surface of cover with AMV 188 001 02.
13-16--
- Lubricate O-Ring for oil channel seal and insert into cover part.
- Install cover, insert all securing bolts and tighten lightly.
-- First tighten M8 securing bolt to
25Nm
then M6 securing bolts to
10 Nm.
Nate:
13-17--
....
....
Nate:
If the crankshaft is turned with the cylinder head removed, a 2nd
mechanic should guide the camshaft roller chain by hand to prevent it
jamming.
- Position both camshafts at TDC No. 1 cylinder..
13-18--
- The camshaft jig 3268 must locate in the shaft groove of the longer
camshaft and align with the shoulder of the shorter camshaft.
- Install camshaft chain sprocket (with sender wheel for Hall sender)
and camshaft roller chain on camshaft for cylinder bank 2 and 4 and
pull tight by hand.
Note:
Lubricate bolt head contact surfaces when installing.
13-19--
Note:
Only counter-hold with 24 mm open jaw spanner on the camshaft
arrow-. The camshaft jig must not be fitted when tightening//oosening
the sprockets.
I N15-0157I
- Lubricate O-Ring for oil channel seal and insert into cover part.
- Install cover; insert all securing bolts and tighten lightly.
- First tighten M8 securing bolt to
25Nm
then M6 securing bolts to
10Nm.
- Install chain tensionerfor camshaft roller sprocket and tighten to
40Nm.
13-20---
Ul
Note:
Only crank engine with chain tensioner installed otherwise the cam
shaft roller chain will jump.
- Turn crankshaft two full turns in engine D.O.R. and check valve tim
ing ~ Page 13-8.
~
Fig. 1
- Mark roller chains before removing (e.g. with paint arrow pointing
in D.O.R.'.
Note:
Do not mark chain with a centre punch or any similar means!
I N13-0281 I
13-21---
29
28J~
30
31
'-----1
..
~1IIiI~---2
'---'----3
Pm II
1-10Nm
4
2 - Oil pump drive cover
3 -O-Ring
Renew
Oil before assembling
5 - Cylinder block
23 - - - - - - : " ' t f t .
21---...../"'-..-.....
6 -Intermediate shaft
7 - Thrust washer
1~F---16
20---"
18 17
I N13-0146 I
13-22--
,
lWr"1
.,
- . '. .
i
"
29
! 1,
\ r
28J~
30
'....- - - - 1
2 7 - - - -..............",.---....
~
..!""-----2
'-----"'----3
4
810 Nm
Insert with locking fluid "06"
9 - Knock sensor 2 (G66)
Checking:
=> Repair Group 01; Self-diagnosis; Interro
gating and erasing fault memory
1020Nm
lightening torque influences the
function of the knock sensor
11 - Engine speed sender (G28)
Checking:
.
=> Repair Group 01; Seff-diagnosis; Interro
gating and erasing fault memory
12 - Coolant pipe
Removing and installing
=> Page 19-5, parts of cooling system
- engine side
21-~"'/
r---._......
.I
~
"
20---'
18 17
I N13-0146 I
13-23--
30
-----'1
~1IIiiIi!1L----2
'-------:3
1"-,
27--------...
26-----" ~.~\.iii_ .,.~,,~
FF--------,4
13 - Drive .shaft
For oil pump drive
14-0il pump
Dismantling and assembling => Page
17-10
Coat oil pressure pipe on cylinder
block and oil pump housing with AMV
188 001 02
15-25Nm
16-Sump
24
3~~~~~l]rJj
23 - - - - " " ' t f l .
; j
22~'
18-Seal
Renew
!
I
15----~r-7""'T
1915 Nm
21--"""""'"r---._.......
n~~-16
20---
18 17
I N13-0146 I
13-24--
29
30
28~~
r------1
1Iii!JiIIL-----2
"------:3
4
27------...
26------'"
21 Oil cooler
Coat contact area outside the seal
with AMV 188 100 02
Ensure clearance to adjacent comp(r
nents
See note
~ Page 13-1
22 - Fitted bolt, 25 Nm
25~i,.
(Ii
23 Compact bracket
24--.1>'
3
".
23 - - - - - l o t l t .
24 - Vibration damper
Removing and installing ribbed belt
~ Page 13-27
21--..../
Renew
Counter-hold with 3406 to loosen and
tighten ~ Fig. 1
lighten using torque wrench VAG
1601
.....
~-
9=---18
20-----'
18 17
I N13-{)146 I
13-25---
29
28~~
30
26-5Nm
Z1 Guide tube
For dipstick
Secured with bolt on inlet manifold
upper part
27------..
---".-.;;;:
26------'"
2845Nm
29 - Engine bracket
30 - Dipstick
The oil level must not be above the
max. mark!
24
3 ---=~~::::::~~~,~
23 - - - - " t t l ' .
~ Page 13-1
~--16
18 17
I N13-0146 I
13-26--
....
Fig. 1
Note:
Renew securing bolt for vibration damper.
I N13-02!1O I
.6mm0 pin
Straight 16 mm ring spanner
13--27--
~'
1
1
....
':
I
"1:
Note:
A second mechanic is required for this.
- Remove ribbed belt.
13-28--
Notes:
Ensure, before installing ribbed belt, thataI/ancillaries (altemator, air
conditioner compressor, PAS vane pump) are secured tightly.
When fitting the ribbed belt observe belt direction of rotation and
that the belt is seated correctly in the belt pulleys.
.... - Fit ribbed belt.
After completing repairs always:
- Start engine and check belt running.
I N13-03721
13-29--
1 2
3 4
738
Notes:
For repairs to the clutch:
=> 5-Speed manual gearbox 02J; Repair.
54O!1B.
'1,
1 -100 Nm +
tum (90 )further
Renew
Counter-hold with 3406 to loosen and
tighten => Page 13-33. Renewing
vibration damper end crankshaft oil
seal
11
10
I N13-0373I
13-30--
2 Vibration damper
310Nm
1 2
3 4
738
4 -Oil seal
Renewing ~ Page' 13-33
5 - Sealing flange
Coat sealing surfaces with
AMV18800102
6 Cylinder block
Removing and installing crankshaft
~Page 1340
Dismantling and assembling pistons
and conrods
~ Page 13-45
7 -Sealing flange
Coat sealing surfaces with
AMV18800102
11
10
I N13-0373 r
13-31--
1 2
3 4
8 -Oil seal
Remove with extractor hook 2086
Lightly oil sealing lip
Install over sleeve 2003/2A
Pull in onto stop with installing tool
738
200313
"
,
I
Ii
11
.1
J
I' ,
I! .
11
10
I N13-0373 I
13-32--
3266
3203
V.A.G1332
W-'
f'
V.A.G 1601
I W13-00251
13-33--
Removing
I N13-(129() I
....
13-34--
. .,
!f'r
.1
I'
i .
I '
f ~
I.
Installing
....
....
- Press oil seal in onto stop with press sleeve from 3266. To do this
use an old vibration damper securing bolt.
13-35--
....
I N13-0290 I
.i
f.
I;
13-36--
VAG 1331
V.A.G1332
Depth gauge
@!"!
Straight edge
I w13-00281
13-37--
Removing
...
I N13-Q!90 I
InstaFmg
- Fit drive plate onto crankshaft.
- Insert at least 3 old securing bolts and tighten to
3ONm.
...
- Check dimension 08- to cylinder block through the three holes for se
curing the torque converter using a straight edge and depth gauge
and calculate average.
- Compare average with specification (measured distance + thick
ness of straight edge).
Specification: 15.7 ... 16.5 mm
13-38--
Note:
Only one shim of the appropriate thickness may be used.
I V13-1281 I
13-39
1
2
3
4
4
7
3
8
,,<
1 - Bearing cap
Bearing cap 1: Vibration damper end
Bearing cap 4 with recesses
thrust washers
Bearing shell retaining lugs cyr
block/bearing cap must be on
same side
<
I N13-0324 I
13-40--
~-----------1
--2
....-----3
...----4
4-----1
;-----5
,----6
4 - Thrust washer
For bearing cap 4
Note fixing arrangement
8----..
----7
'----3
~~~---8
I N13-0324 I
13-41--
~----------1
-----3
4----.....,
---4
...-----5
,----6
---7
'-----3
5 Crankshaft
See notes before removing ~
Pagel3-40
Axial clearance new: 0.07 ... 0.23 mm
Wear limit: 0.30 mm
Check radial clearance with Plasti
gage
New: 0.02 ...0.06 mm
Wear limit: 0.10 mm
Do not rotate the crankshaft when
checking the radial clearance
Crankshaft dimensions:
Main journal:
Crankshaft journal:
6 - Sender wheel
For engine speed sender (G28)
Renew
Installing ~ Fig. 1
:::::5!!;;----8
I N13-0324 I
13-42--
T!I Ii!
'
; I
--------------------1
J-l==--2
-----3
-----4
~--5
4------~
.----6
,!
See note
=> Page 13-1
;!
, i
,!
------7
8---""""
'-------3
~~----8
I N13-0324 I
13-43--
rig. 1
13-44--
I,
i~htl
2 -Piston
Checking => Fig. 3
Mark installation position to conrod
and cylinder number
High point of piston crown faces to
centre of cylinder block
Install with piston fitting tool 3278
=> Fig. 5
I N13-02861
13-45
~--'T'--r-----1
3 -Conrod
Only renew as a set
Mark cylinder number -8
Installation position:
Marks -A- must be above one another
&1-------4
rl!------5
I N13->0286 I
13-46--
6 - Bearing shell
'I ;.'
,
'
--V~---"----
,: I,
,l
; i
,,
shells
New: 0.05...0.31 mm
=> Fig. 4
.4....L...-----4
e------5
! N13-02SSI
13-47--
~-~~----
8 - Piston pin
If difficult to remove, heat piston to
6O.()C
Remove and install with drift vw
222a
9 -Circlip
P---V-~----2
;r------4
11------5
! N13-02SS!
13-48--
Fig. 1
Test sequence
- Push ring squa rely from above down to approx. 15 mm from bottom
end of cylinder. To do this use a piston without rings.
Gap
Piston ring
New
Wear
limit
Compression ring
mm 0.20...0.40
1.0
Tapered stepped
ring
mm 0.20...0.40
1.0
mm 0.25...0.50
1.0
13-49--
Fag. 2
Piston ring
Clearance
New
Wear
limit
Compression ring
mm 0.02...0.07
0.15
Tapered stepped
ring
mm 0.03...0.06
0.15
mm 0.02...0.06
0.15
Fig. 3
Checking piston
I V13-0C1101
13-50--
....
F'~.
Test sequence
Measure bores at 3 locations in both directions ~A-across the engine
and -8- in line with crankshaft.
Deviation from nominal dimension
max.0.08mm
Note:
Measuring the cylinder bores must not be done when the cylinder
block is mounted on a repair stand with adapter bracket 3269" as in
correct measurements would then be possible,
13-51--
I
....
Fig. 5
Work sequence
- Oil tool and push piston in by hand. High point of the piston crown
must face to the lug on the fitting tool -arrow-,
- Hold tool (with piston inserted) on upper edge and press piston in
with both thumbs.
- Push piston in until it protrudes approx. 15 mm from the lower edge
of the fitting tool.
- Place piston in appropriate cylinder bore. Lug on fitting tool-arrow
must face to centre of cylinder block.
13-52--
- Hold fitting tool tight against cylinder block and push piston in.
Piston-0
Cylinder
bore-0
Basic dimen.
mm
80.985
81.01
1st oversize
mm
81.485
81.51
2nd oversize
mm
81.985
82.01
13-53--
,PITT
.
,)
[
Notes:
'f
I!
22 21 10 20 19 7 18 17 16 6
15 14 6
I N15-0078 I
15-1--
~ Repair
3-10Nm
4-Cap
Renew seal if damaged
22 21 10 20 19 7 18 17 16 6
15 14 6
I N15-0078 I
152--
--'0
---1
-z.4.~~-13
-~3
--..---=:000--7
22 21 10 20.19 7 18 17 16 6
7-26Nm
8 ~lIIder head bott
Renew
Note installation instructions and se
quence when loosening and tighten
ing
=> Page 15-17
9 - Cylinder head
Check for distortion => Fig. 1
Removing and installing
15 14 6
I N15-0078 I
16-3--
10 -O-Ring
Renew
11-Cover
Can be removed and installed with
cylinder head fitted
Coat sealing surfaces with AMV 188
00102
If only the cover has been removed,
prepare cylinder head gasket for as
sembly
=> Page 15-7, Fig. 2
. 12 - Chain tensioner, 40 Nm
For camshaft roller chain
Only tum engine with chain tensioner
installed
13 -Seal
Renew
22 21 10 20 19 7 18 17 16 6
15 14 6
I N15-0078 I
16-4--
Checking:
Repair Group 28; Servicing ignition part
16 - Thermostat housing
Dismantling and assembling ~ Page
19-11
17 -Gasket
Renew
part
Renew if damaged
21-5Nm
22 21 10 20 19 7 18 17 16 6
15 14 6
I N15-007SI
15-5--
22 - Combi-valve
Checking ~ Page 26-13
Removing and installing
~ Page 26-16
23 - Gasket for
part
i......
manifold lower
Renew if damaged
24 - Tensioning element
For ribbed belt
25-5Nm
26 -Bracket
For secondary air inlet valve (N112)
and intake manifold change-over
valve (Nl56)
27 - Vacuum positioning element
For intake manifold change-over
22 21 10 20 19 7 18 17 16 6
15 14 6
I N15-0078 I
15-6--
.....
~~~~~......I
Fig- 1
.....
Fig. 2
15-7---
Nate:
With the cylinder head installed the holes are only half v;sible.
15-8--
VAG 1331
:1
-I
I
I:
VAG 1921
I W15-00301
15-9--
Removing
Nate:
15-10--
.....
.....
- Detach the accelerator cable from the support bracket and the
throttle valve control part -arrow- (do not remove locating clip).
1511--
.....
ft g
- Pull coolant hoses -1- and -2- off throttle valve control part and seal
hose ends.
- Now pull off vacuum hose connections -3-, ..4- and -5- as well as the
connector for intake temperature sender-6-.
a==4>
1 2
- Pull off supply pipe/hose -1- (with white marking) and return pipe/
hose -2- (with blue marking) and collect fuel that leaks out with a
cloth.
Note:
Press buttons on hose couplings to do this.
15-12--
Warningl
Fuel srstem is under pressurel Before opening the ,system
place a doth BI'OUnd the connection. Then release pressure by
carefully loosening the connection.
- Seal the pipes so that the fuel system is not contami nated by dirt etc.
Notes:
15-13--
The opening ofthe refrigerant circuit can only be carried out in work
shops, which have trained personnel and the necessary range of
tools and workshop equipment.
To prevent damage to condenser and the refrigerant pipes/hoses,
ensure that the pipes and hoses are not stretched. kinked or bent.
- Then unbolt intake manifold upper part from intake manifold lower
part.
- Take off intake manifold upper part and place on a suitable surface
so that the vacuum actuator is not damaged.
15-14--
Nate:
Seal the intake parts in the intake manifold lower part or in cylinder
head with a clean cloth.
- Remove the cylinder head cover.
Installing
Install in reverse order.
Notes:
Replace cylinder head cover if damaged or leaking.
Bolt intake manifold upper part to intake manifold lower part, then
tighten both bolts for the intake manifold supports.
Ensue fuel hoses are tight.
- If necessary top-up coolant => Page 19-14
- Adjusting accelerator cable => Page 20-28, SeNicing accelerator
mechanism.
- Interrogate fault memory:
=> Repair group 01; Self-diagnosis; Interrogating and erasing fault
memory
15-15--
lightening torques
Bolted joint
lightening
torque
10Nm
25Nm
25Nm
25Nm
15-16--
3268
VAG 1306
V.A.Gl332
@!-,
V.A.G 1921
I Wl5-0031 I
15-17--
Prerequisites
The engine must be no more than warm to touch.
Removing
Note:
Check whether a coded radio is installed as during the forthcoming
work sequences the batteryearth strap must be disconnected. Obtain
radio code first if necessary.
15-18--
....
- Pull off fuel return pipe -2- (blue marking) and fuel supply pipe -1
(white marking).
Note:
Warning!
- Seal the pipes so that the fuel system is not contami nated by dirt etc.
- Separate connector to injectors and pull vacuum hose off fuel pres
sure regulator.
- Loosen hose clips and pull coolant hoses off coolant thermostat
housing.
- Now remove the thermostat housing.
- Then unclip the electric continued coolant circulation pump (V51)
from its bracket. Coolant hoses can remain connected.
15-19--
- Pull 3 pin connector off hall sender (G40), sender remains installed.
- Now remove the ignition coils.
- Remove the bracket and then the camshaft cover part.
- Remove camshaft chain sprocket, hold camshaft with a 24 mm AF
open jaw spanner.
I Nl~l571
....
- Loosen socket head bolts in the sequence given and then remove
completely.
- Carefully lift cylinder head off.
15-20--
Installing
....
Notes:
Only remove the new cylinder head gasket from its packing im
mediately before installing.
Handle the new gasket with extreme care. Damaging will lead to
leaks.
15-21--
18
....
Fit new cylinder head gasket. Lettering (Part No.) must be readable.
- Ensure dowel sleeves are inserted into cylinder block holes 15 and
16. and the cylinder head gasket is located.
- Position the camshafts in cylinder head to TOC No. 1 cylinder.
15
....
- The camshaft jig 3268 must locate in the shaft groove of the longer
camshaft and align with the shoulder of the shorter camshaft.
- Now prepare the cylinder head gasket for assembly => Page 15-7
Fig. 2.
- Fit cylinder head, screw cylinder head bolts in and tighten hand tight.
15-22--
- Then tighten all bolts a '/4 tum (90) further using a ridged wrench.
Ensure the O-ring for sealing the oil channel in the cover part is fitted.
pairs.
15-23--
sures
Special tools. workshop equipment, test
and measuring appnances and aux. items
required
V.A.G 1331
I W15-0032 I
15-24--
Test conditions
Engine oil tempe~ture at least 30 OC.
Test sequence
- Pull con nector off heater element (N79) and remove intake hose be
tween air cleaner upper pa rt and throttle valve control part (J338) to
gether with the crankcase breather valve:
~ Repair group 24; Motronic injection and ignition system; Servicing
injection part
- Remove spark plug connectors with tool 3277 Aand unclip ignition
cables:
~ Repair group 28; Motronic injection and ignition system; Servicing
ignition part
- Remove intake manifold cover.
- Remove spark plugs with spark plug spanner 3122 B.
- Pull 6 pin connector (brown) -1- off final output stage -2-.
- Fully open throttle valve.
- Check compression pressure with compression tester VAG 1763.
15-25--
Note:
Using the compression tester ~ Operating instructions.
- Operate starter until tester shows no further pressure increase.
Compression pressure:
New: 10...13 bar
t
:~
15-26--
,,-------1
r------2
Note:
----3
1 - Bearing cap
Installation position ~ Fig. 2
Installation sequence
=* Pagel5-37, removing and instal
ling camshafts
11---
2-20Nm
10--~
~----8
~~~--------9
I N15-0161 I
15-27--
.--------1
r------2
----3
3 - Camshafts
Checking axial clearance =* Fig. 1
Removing and installing
~ Page 15-37
5 - Sender wheel
For Hall sender (G40)
When installing contact surface on
timing chain and sender wheel must
be dry .
Removing and installing
=* Page 15-37, removing and instal
ling camshafts
11----
10--~
!~-----8
~~-,--------9
I N15-0161 I
15-28--
;!rn
,
"
-;f
6-100 Nm
To remove and install counter-hold
with 24 mm OJ spanner on camshaft
~ Page 15-37, removing and instal
ling camshafts
Oil bulkhead contact surface when in
stalling
7 Cylinder head height
Minimum height: a =139.5 mm
8 - Cylinder head
See note
~ Page 15-27
Reworking valve seats
~ Page 15-34
. 12
11
10
9-Valves
Do not rework only grinding-in i~ per
mitted
Valve dimensions ~ Fig. 3
>
8
9
I N15-0161 I
15-29
10 - Valve guide
Checking ~ Page 15-44
Renewing ~ Page 15-45
Service version with collar
11 Valve stem seal
Renewing ~ Page 15-47
12 . Valve springs
Removing and installing:
Cylinder head
removed: with 2037
installed: ~ Page 15-47, Renewing
valve stem seals
':
11
10
14 - Valve cotters
"
'7""'------ 8
~*-~~-----------9
I N15-0161 I
15-30--
....------1
------2
15 - Bucket tappet
.----3
Do not interchange
With hydraulic valve clearance com
pensation
Checking =* Page 15-42
Store with cam contact surface
downwards
Before installing check camshaft
axial clearance =* Fig. 1
Oil contact surface
15-31--
....
Fig. 1
Test sequeIIC8
Wear limit: max. 0.15 mm
Check with bucket tappets removed and with first and last bearing
caps fitted to appropriate camshaft.
....
rig.
I Nl5-()111 I
15-32--
...
rig.
Valve cfnnensions
Note:
Valves must not be reworked. Only lapping-in is permitted.
Dimension
Inlet valve
Exhaust valve
39.0
34.20
6.967
6.96
mm
mm
mm
105.95
106.95
L'
45
45
0a
0b
15-33--
Notes:
15-34--
Note:
If the valve is to be renewedas part ofa repair. use a new valve for the
calculation.
~
- Measure distance -a- between end of valve stem and upper edge of
cylinder head.
- Calculate max. permissible reworking dimension from measured
distance -a-and minimum dimension.
Minimum dimension:
Example:
Measured distance -a
- Minimum dimension
34.8 mm
34.1 mm
0.7 mm
15-35--
a
b
c
Z
X
IS
'Y
= 038.3 mm
a
b
c
Z
X
IS
'Y
:: 033.5mm
15-36--
....
V.A.G 1331
....
Inmrrll.!
@1'-
Iwoo-o427l
15-37--
Removing
.,
....
!
,{
Note:
I Nl5-0157 I
15-38--
....
Longer camshaft:
- First remove bearing cap 1.
- Slacken off bearing caps 3 and 5 alternately and diagonally.
I Nl5-G111 I
Shorter camshaft:
- First remove bearing cap 4.
- Loosen bearing caps 2 and 6 slowly.
.!
Installing
.'!,
....
Notes:
When installing the camshafts the recess for the camshaft
sprockets -arrows- must be at top.
When installing bearing caps ensure that the identification mark is
readable from the exhaust side of cylinder head and. that the arrow
points to vibration damper end.
I Nl5-0112I
15-39--
....
Longer camshaft:
- Tighten bearing caps 3 and 5. to guide camshaft. alternately and
diagonally to
20Nm.
I N15-G111 I
20 Nm.
Shorter camshaft:
- "Tighten bearing caps 4 and 6, to guide camshaft, alternately and
diagonally to
20Nm.
20Nm.
15-40--
....
Nate:
With the cylinder head installed the holes in the cylinder head gasket
are only half visible.
- Install camshaft chain sprockets with camshaft roller chain ~ Page
13-11, Adjusting valve timing.
- Fill 3 mm holes in cylinder head gasket with sealant AMV 188 001
02.
- Coat sealing surface of cover with AMV 188 001 02.
Note:
Ensure the O-ring for sealing the oil channel in the cover part is fitted.
- Install cover, insert all securing bolts and tighten lightly.
- First tighten M8 securing bolts to
25Nm
10Nm.
15-41--
Note:
When new tappets have been installed the engine must not be
started for about 30 minutes. Hydraulic compensation elements
must settle (otherwise valves will strike pistons).
Test sequence
Notes:
If the hydraulic tappets are still noisy, locate defective tappets as fol
lows:
-Remove cylinder head cover => Page 15-9.
- Rotate crankshaft clockwise on vibration dampersecuring bolt, until
cam of the tappet to be checked is pointing upwards.
- Determine play between cam and bucket tappet.
- If the play is in excess of 0.2 mm, renew bucket tappet. If the play
is less than 0.1 mm or no play, proceed with check as follows:
- Press bucket tappet down with a wooden or plastic wedge. If free
travel in excess of 0.2 mm is felt before tappet opens valve. renew
tappet.
Note:
After installing new tappets the engine must not be started for approx.
30 minutes. Hydraulic compensation elements must settle (otherwise
valves will strike pistons).
15-43--
....
Iwoo-l37l
_Test sequence
....
- Insert new valve into guide until end of valve stem is flush with end
of guide. Due to the slight difference in stem dimensions. ensure
that onlyan inlet valve is used in the inlet guideand an exhaust va Ive
in the exhaust guide.
- Determine rock.
- Wear limit:
15-44--
....
.3121 Drift
Iwoo-oM>l
15-45--
,J
Removing
3121
- Clean and check cylinder head. Cylinder heads in which the valve
seats can no longer be reworked"or cylinder heads which have al
ready been machined to the minimum dimension (height) =>
Page15-29. Pos. 7. or already have service version valve guides
fitted. are not suitable to have the valve guides replaced.
- Press out wom valve guides with 3121 from the camshaft side.
Installing
- Coat new guides with oil and press in with 3121 from the camshaft
side (cylinder head cold) until shoulder makes contact. When doing
this the cylinder head must be laying flat.
Note:
When the shoulder on guide makes contact. the pressure must not
exceed 1.0 t otherwise shoulder may break off.
- Ream guides out with hand reamer 3120 using plenty of cutting
fluid.
- Rework valve seats => Page 15-34.
15-46--
l~
,
required
2036 Assembly appliance
3047A Puller
31228
VW541I1A
VW541J5
I W15-00331
15-47--
VW65313
.....
Removing
- Remove camshafts => Page 15-37.
- Remove bucket tappets (do not interchange) and store with the con
tact surface downwards.
- Remove gpark plugs with gpark plug spanner 3122 B.
Note:
Tight cotters can be loosened by tapping lightly on the lever.
15-48--
Installing
- To prevent damage to the new valve stem seals, place plastic sleeve
-A- on valve stem.
- Oil valve stem seal-8-, place it in the tool 3129 and push carefully
onto the valve guide.
15--49--
I~
Nates:
If when repairing an engine, metal shavings or large quantities of
crankshaft and conrad bearings are found in the engine oil one
must apart from thoroughly cleaning oil passages, renew all oil
spray jets, the oil non-retum valve, the oil cooler and oil filter el
ement to prevent consequential damage.
The oil level must not be above the max. mark - danger of damage
to catalyst!
I:
l'
Ii
f'
IIJ
17-1
3
4
21
20
5
6
7
1-10Nm
3 -O-Ring
Renew
Oil before installing
I,
5 - Cylinder block
8
9
6 . Intermediate shaft
7 Thrust washer
I
f
8-10Nm
10
11
12
13
14
15
19
I
!"
i
,::,.,1
o
, ';J
IN17-00291
172
~
21
20
1
2
3
4
5
6
7
~ Fig. 1
~ Page 17-1
10 - Drive shaft
For oil pump drive
9
o
Ii<
10
11
12
13
14
15
19
11 -Oil pump
Dismantling and assembling ~ Page
17-10
Coat oil pressure pipe at cylinder
block and oil pump housing with AMV
188 00102
12-25Nm
13-8Nm
I N17-0029 ~
17-3
:t
1
2
14 - Baffle plate
3, 15-Sump
Removing and installing
21
20
5
6
7
Page 17-13
10
11
12
13
14
15
19
r'
,
,i
l:
21 Guide tube
For dipstick
Secured with a bolt on inlet manifold
upper part
I N17-OO29 I
17-4
":''1'1
, ::
'rr
' , 'm , ,
21
20
3
4
22 - Dipstick
The oil level must not be above the
max. markl
Markings ~ Page 17-7. Fig. 2
See note
~ Page 17-1
I
Il
i
iI
II
10
11
12
13
14
15
19
,J"
I N17-Q029 I
17-5--
rIG. 1
I.'
.4 mm0drift
Note:
"
I,
,r:
Crankshaft removed
Removing
- Press out oil spray jet out towards bearing using a 4 mm 0 punch.
\
Installing
17-6--
....
rig. 2
Dipstick markings
1 -max. mark
2-min. ma~
a - Area above hatched field up to max. mark: Do not top-up with en
gineoil!
b - Oil level within hatched field: can be topped-up with engine oil
c -Area from min. mark up to hatched field: fill with max. 0.5 Itr. of
engine oil!
I N17-0037 I
17-7---
3 -0 ring
~~------------
I~~~----~----
Renew
Oil before installing
4 Oil cooler
Ensure clearance to adjacent
nents
See note
=> Page 17-1
_J
r-~~----------
~-------------
N17--Q056 I
17-8-..........
1 2
6-25Nm
7 - Oil filter element
Observe change intervals
See note
=> Page 17-1
r------7
N~----8
--3
irell----- 9
N17-Q056 I
17-9--
9---------~
1 - Drive shaft
For oil pump drive
8------------------~
3'-25Nm
..-::...-2
:~ ~-.
valve
4-Gears
Checking backlash .
=> Fig. 1
Checking axial clearance
=> Fig. 2
I N17-00061
1710-.,--
.,
II
~
6-10Nm
Renew
Install with locking fluid "06"
9~----------------~
8----------------~
810Nm
"""--- 2
90 ring
Renew if damaged
~+-~-4
I N17-00061
17-11--
-~----I
..
....
li:",
I:
J;
17-12--
Removing
- Remove centre. left and right insulation tray:
=> General bodv repairs exterior; Repair group 50; Body front; Assembly overview
I,
- Remove SOO'1P
- Loosen surnpwilh rlQht blows of a rubber headed hammer if necess
ary.
- Remove sealant residue on cylinder block with a flat scraper.
17-13--
....
I N17~121
NOIIs
Note the use by date of the sealant.
SurtJJ must be installed wfthin 5 minutes of applying silicone seal
ing COIIJ1OUIId.
....
2...3 mm thick.
I N17~191
17-14--
i"
, ' 'f"IjT
Note:
The sealing compound bead must not be thicker; otherwise excess
sealing compound will enter the sump and may block the oil suction
pipe strainer. ,
....
I A17-0041 I
Note:
After installing sump the sealant must be allowed to dry for approx. 30
minutes before engine oil is filled
.
The rest of the assembly is basically a reverse of the dismantling se.
Quence.
17-15--
V.A.G 1527 B
V.A.G 1342
~~
/'
__________________________________
______________________
I:
I W17-oD011
17-16--.....
Test sequence
Nate:
Functional check and servicing the optical and acoustic oil pressure
waming:
~ Current flow diagrams, Electrical fault finding and Fitting locations
....
- Remove 1.4 bar oil pressure switch (F1) (black insulation) and screw
into test unit.
- Screw test unit into oil filter in place of the oil pressure switch.
- Connect brown wire of tester to earth
I V17-0540 I
H.
- Connect diode test lamp V.A.G 1527 B using aux. cables from VAG
1594A to battery positive (+) and oil pressure switch. LED must not
light up.
- If the LED lights up, renew 1.4 bar oil pressure switch (F1) .
When the LED does not light up:
- Start engine and run at idling speed
at
17-17--
the LED must light up, otherwise renew 1.4 bar oil pressure switch
(F1 ).
- Increase engine speed further.
At 2000 rpm and an oil temperature of 80 C the oil pressure ~hould
be at least 2.0 bar.
At higher engine speed the oil pressure must not exceed
7.0 bar.
- Replace oil pump if necessary ~ Page 17-10, dismantling and as
sembling oil pump.
17-18--
18-1--
2 -0 ring
Renew if damaged
3 Upper caoImd hose
Secured to radiator by a quick release
coupling
Check securely seated
Coolant hose connection diagram ==
Page 19-9
4 Air ducting
510Nm
10
7 8
I N19-0182 I
18-2--
8 Retaining clip
Check seated securely
9 Connector
10 Radiator fan CV35)
15
, I'
-1
11Bracket
For radiator fan connector
:l
"
coupling
15
14
t,
Ii
13 0 ring
Renew
1:'
; ~
13
12
11
10
7 8
I N19-{)182 I
19-3--
off: 84...91 C
Stage 2
on: 99...105 OC
off: 91 ...98 QC
"
15 -Bracket
For radiator
Note fitting position
1615Nm
:\
II
10
7 8
I N19-{)182 I
19-4--
1.2 3 4 5
6 7 8
,.
1 - Sealing cover
4 -------'=:::--1"
2 -0 ring
Renew if damaged
~--9
3 - Expansion tank
4-10Nm
3
4
Page 19-9
16
N19-0186
I
19-5--
1 2 3 4 5
6 7 8
6 - To top of . .lilt.
Coolant hose comection diagram =>
Page 19-9
7 -0 ring
Renew
8 - To heat.- ~t.Rger
Coolant hose connection diagram =>
Page 19-9
~--9
9 -10 Nrn
. 10 - Throttle wive control part
Heated by coolant
11 - To top of radiator
Coolant hose connection diagram =>
Page 19-9
3
12 - Gasket
Renew
13 - To bottom of raal8tor
Coolant hose connection diagram =>
Page 19-9
17----6]~
16
I N19-0186 I
19-6--
1 2 3 4 5
678
14 -Thermostat housing
Dismantling
Pagel9-11
and
assembling
4---~""""'"""
(V51)
17 -2SNm
18 - Oil cooler
Removing and installing
~ Page 17-8. item 4
19 - Seali_D9 plug
20 - Coolant pipe
Page 19-9
18---!-~~
\
""
17~ ....
- -
16
N19-0186
I
19-7--
1 2 3 4 5
678
21 - Coolant pump
Note installation pOSition
Check arm for ease of movement
If damaged and leaking renew com
plete
Removing and installing
~ Page 19-27
4 ---~,,-..I:J1
22-15 Nm
23 -Pulley
For coolant pump
24-25 Nm
- -
16
I N19-0186]
19-8--....
: I
15 16
gram
1 - Heater unit heat exchanger .
2 - Non-return valve
3 - Continued coolant circulation pump
(V51)
4 - ATf cooler
Only on vehicles with automatic gear
14
+----+-4
box
5 - Upper coolant hose
13
8 -Cooler
12
8 - Thermostat housing
9 - Lower coolant pipe
10 - Oil cooler
11-Coolant pump
11
109 8 7
I N19-02021
19-9--
15 16
2 3
12 Cylinder block
13 - Cylinder head
14 - Expansion tank
15 - Upper coolant pipe
14
-I-------+-4
13---tt---t=--..:.-..-l
12--
5
11
109 8 7
I N19-0202 r
19-10--
12
1m
Note:
Connecting the coolant hoses to thermostat
housing
=> Page 19-5, parts ofcooling system engine
side.
1 - Thermostat housing
2-10Nm
9--+
3 - Coolant thermostat
j..-...::....------3
:-+------- 4
valve uppermost
water
----5
"
I N19-0125 I
19-11--
12
1m
11
4 -Seal
Renew
.!
5 Connection
...---1
.,
"
6-Bush
7-10Nm
8'-O-Ring
Renew
9 - Connection
9--+
:---:----- 3
-l------4
.---5
sender (G2)
Checking:
.
/
=> Repair Group 01; Fault memory; Interro
gating and erasing fault memory
,ill
:: i'l
;.,
!II
I N19-012SI
19-12---
I i,l
8
11
12
11 Air concfrtionercut-off
switch (F163)
Jm
thermo
~-1
12 Retaining clip
Check seated securely
9-->'
,Ii--:------ 3
-+-------4
.------5
I N19-0125 I
19-13--
I woo-o5121
V.A.G 1921
....
IWllO-0464I
19-14 --...;-
Draining
- Open cap on coolant expansion tank.
- Remove insulation tray:
=> General body repairs exterior; Repair group 50; Body front; Assem
. bly overview
....
....
- To drain coolant from engine also remove coolant hose from oil
cooler -arrow-.
"~I
Note:
Observe disposal regulations!
!.
1&-15--
Filling
Notes:
Only use coolant additive G 12 in accordance with TL VW 774 D.
DN prevent frost and corrosion damage, scaling and also raise boil
ing point of coolant. For this reason the system must be filled al/
loaded.
protection
Anti-freeze
G 121)
Water1)
3.61
4.51
5.41
4.51
amouJrt
to
-250(;
-35OC
40%
50%
ment.
- Screw drain plug into radiator retum.
- Push coolant hose onto oil cooler connection and tighten.
19-17--
- Set heater controls to maximum heat position and switch off air
conditioning system if fitted.
- Start engine and maintain an engine speed of about 2000 rpmforap
prox. 3 minutes.
- Run engine until radiator fan cuts-in.
- Check coolant level and top-up if necessary. When the engine is at
normal operating temperature, the coolant level must be on the
max. mark. when the engine is cold. between the min. and max.
marks.
!
I
19-18--
V.A.G 1306
V.A.G 1331
required
VAG 1306 Drip tray
V.A.G1921
Anti-freeze tester
I W19-0001!
1919--
Removing
- Drain coolant ~ Page 19-14.
- Removing from bumper:
~ General body repairs, exterior, Repair group 63; Front bumper, Re
moving and installing front bumper
- Pull coolant hoses quick
relea~e
InstaDing
Installation is carried out in the reverse order, when doing this note the
following:
- Filling with coolant ~ Page 19-14
1920--
"
I,
"
1-"
. : 1lte _ _erre!rigerM1t _
mBIt.not be _ e d
Note:
To prevent damage to condenser a/so to the refrigerant pipeS/hoses,
ensure that the pipes and hoses are not stretched, kinked or bent.
19-21--
V.A.G 15278
I woo-om I
19-22--
"
'.:1'.'.':L'1~.,'."
I
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ii'
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Check conartions
....
Fuse No. 160K.
Test sequence
;
I N19-0175 I
19-23--
....
"
I
,j
i
Nate:
This check must be performed within 10 minutes of switching ignition
off.
19-24--
--"--
....
Check conc:fdions
....
Test sequence
19-,25--
1
....
- Bridge contact -1- and contact -2- of conneaor using auxiflary cables
from VAG 1594.
1st speed for radiator fans fII7) and (V35J must run.
- Switch on ignition.
I Ntt-Ot9t I
- Bridge contact -2- and contact -3- of connector with auxiliary cables
from v.A.G 1594.
2nd speed for radiator fans fII7) and (V35) must run.
If fan 1st or 2nd speeds do not run:
- Locate and rectify open circuit using current flow diagram:
=> Current flow diagrams, Electrical fault finding and Fitting locations
19-26--
VAG 1306
VAG 1921
I W1!HXJ041
- - _ . 19-27 - -
Removing
1~27.
- Remove securing bolts ~, ~ for coolant pump belt pulley ~2~ and
move belt pulley.
r~
Note:
Use pin wrench 3387 when removing and installing coolant pump belt
pulley.
....
Instalrmg
Installation is carried out in the reverse order; when doing th is note the
following:
Note:
The coolant pump plug faces downwards.
- Moisten new a ring with coolant.
19-28--
- Insert coolant pump into cylinder block and tighten securing bolts.
lightening torque: 15 Nm
- Install ribbed belt => Page 13-27.
.! :
19-29--
':
20-1--
10
~---11
~.-----12
2 - Gravity valve
. To remove valve unclip upwards out
of support
Check valve for through-flow
valve vertical: open,
valve tilted 45 0: closed
3 -Yentpipe
Check securely seated
Clipped onto top of fuel tank
To activated charcoal filter
=> Page 20-34, item 2
4-Cap
18
14 13 I N20-0108 I
20-2--
5 -Seal
Renew if damaged
6 - Securing screw
9 - e.th connection
Check securely seated
10 -10 Nm
11-Vent~
.BIacIc
Cf!pped onto side of fuel tan k
Check securely seated .
Secure with spring-type clips
20-3--
I
I
12 - Fuel tank
. k
Supportwithengineandge~rboxJac
VAG 1383 A when removing
Removing and installing
=> Page~14
13 - Clamping ___
14 - Heat shield
For fuel tank
15-25Nm
16 -Locknut
17 - Fuel tank caver
18 - Securing SInp
Note <frffering length
. .
.
Installation po~itio~: FIxing pOint
(holes) point in direction of travel
20-4--
19 Supply pipe
Black
Secure with spring-type clips
Check securely seated
To fuel supply pipe on fuel rail:
~ Repair group 24; Servicing injection sys
tem; Dismantling and assembling fuel rail
and injectors
20 - Fuel filter
Fitting position: Arrow points in
through-flow direction
21 Screw-type clip
22 Sealing ring
Renew jf damaged
Coat with fuel when installing
I
i
,. ,
20-5--
~Page 20-10
l!
i
ii
:, ii
20-6--
;I:
'~
....
Fig. 1
Marking on s~nder must align with the marking on fuel tank -arrows-,
Blue or blue marked retum pipe -1- to connection with identification
~
After installing fuel delivery unit flange, check that the supply, retum
and breather pipes are still clipped onto the fuel tank.
....
Fig. 2
Note:
Before installing vent valve remove fuel tank sealing cover.
I '120-1040 I
20-7--
When removing and installing the fuel gauge sender or fuel pump (fuel
delivery unit) from a full or partly full fuel tank the follOwing must be
observed:
Before commencing work, switch on exhaust exctraction system
and place an extraction hose close to the sender opening in the fuel
tank to extract escaping petrol fumes.
If no exhaust extraction system is available, a radial fan (as long as
motor is not in air flow) with a displacement greater than 15 m3/h
can be used.
Prevent skin contact with petrol! Wear fuel-resistant gloves!
20-8--
mas
in..~.:;
'I, ,
,,'
,i
i
Thoroughly clean all unions and the adjacent areas before discon
necting.
Place parts that have been removed on a clean surface and cover.
Do not use fluffy cloths!
Carefully cover opened components or seal, if the repair cannot be
carried out immediately.
Only install clean mmponents:
Only unpack replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in tool boxes etc.).
When the system is open:
Do not VtIOrk with mmpressed air if this can be avoided.
20-9--
....
....
I woo-o2911
V.A.G1332
I W!lO-0428\
I
I
l
. i
20-10---
;I,
II
Removing
- Note safety precautions before starting work ~ Page 20-8
Note:
Check whether a coded radio is installed as during the forthcoming
work sequences the battery earth strap must be disconnected Obtain
radio code first if necessary.
Note:
Press buttons on hose couplings to do this.
Warningl
Fuel supply lines lITe under pressunll ..".. removing from
hose t:OIInection wrap a cloth 1ITOfI1III""" f:OIIItfIf:Iion. Then re
lesse pt'eSSUTe by carefully pulling IJoIe "" COIJIIef:tion.
20-11--
Note:
If the delivery unit is to be renewed then drain old delivery unit before
disposal.
I A20-01OS I
Installing
- Installing the fuel delivery unit is carried out in the reverse order.
Notes:
Do not bend fuel sender when installing.
Coat flange seal with fuel when fitting.
Ensure fuel hoses are seated securely.
Secure fuel hoses with sprinrrtype clamps.
After installing fuel delivery unit, check that the supply. retum and
vent pipes are still clipped onto fuel tank.
20-12--
....
f.'.!~
I[
:!!;
I Itt
Li'
rows-.
!
I: t:
~ Page 20-10.
....
- Release and pull off the terminals for wires -3- and -4-.
- Lift retaining tabs -1- and -2- with a screwdriver and pull fuel gauge
sender out downwards -arrows-.
Installing
- Insert fuel gauge sender in the guides on the fuel delivery unit and
push up until it engages.
I A2IHl1osi
20-13--
....
Iwoo-o427l
20-14--
,,
Removing
- Note safety precautions before starting work => Page 2().8
Note:
Check whether a coded radio is installed as during the forthcoming
work sequences the battery earth strap must be disconnected. Obtain
radio code first if necessary.
20-15--
- Remove fuel gauge sender cover plate and detach connector.
- Remove cover from under the fuel1ank.
Remove rear axle:
=> Running gear; Repair group 42; Servicing rear axle; Removing and
installing rear axle.
....
- Disconnect return hose -2- (blue), supply hose -1- (black) and
breather hose -3- (white) at connecting point.
Note:
Press buttons on hose couplings to do this.
WlITning!
Fuel supply Hnes lITe under ,."...,,1 Before removing from
hose connection WTIIP B doth around the connettion. Then re
lase pressure by t:llrefully pulling hose off connettion.
- Remove tensioning strap. When doing this support fuel tank with
engine/gearbox jack VAG 1383 A.
-Lower fuel tank.
20-16--
I'
If I
Installing
I:;
Installation is carried out in the reverse order, when doing this note the
following:
Breather and fuel hoses are to be installed kink-free.
Secure fuel hoses with spring-type clamps.
Fuel hoses are to be installed kink-free.
Ensure fuel hoses are seated securely.
Do not interchange supply and return hose (return hose blue or blue
markings, supply hose black).
Note:
After installing fuel gauge sender, check that the supply, return and
V.A.G 1318
3217
20-17--
I us_I
I
0_
---==:;l
V.A.G 1318111
V.A.G 131811
. .tI---H--_EJ
V.A.G 1318117
VAG 13141/11-1
VAG 1311111....
VAG 131....7...
VAG 1311117-4
~. "iI-~
I W20-0011 I
20-18--
.:i
~:
V.A.G 1332
p
V.A.G 1466 Test system
V.A.G 1527 B Diode test lamp
VAG 1594 A Adapter set
VAG 1715 Multimeter
VAG 1527 B
~~
Measuring container
Current flow diagram
",
VAG 1715
I W20-00121
20-19--
Check conditions
heard to run.
20-20--
VAG 1466 A:
=> Current flow diagrams, Electrical fault finding and Fitting locations
, I,
- Connect diode test lamp VAG 1527 B with aux. cables from V.A.G
1594 A to the outer contacts of the connector.
' :'
2021--
....
Check conadions
Test sequence
- Remove filler cap from fuel tank filler neck.
....
- Pull off supply pipe/hose -1- (with white marking) and collect fuel that
leaks out with a cloth.
Note:
Press buttons on hose couplings to do this.
20-22--
! ; I
Warning!
V.A.G 1318
V.A.G 13181'11
V.A.G 1318f23 ...
I Na0-01091
20-23--
- Operate remote control for
30 seconds
om~3CIs")
1000
...
lIIIO
.-"'"
L.,...--'"
,.....
10
10,2
11
V""
~I
12
lIIIO
2110
Example:
13 Y"')
I NaO-01&91
20-24--
- Remove the fuel delivery unit and check the strainerfifter for soiling.
20-25---
Nate:
If the fuel system malfunction is intermittent, you can perform the
check during a test drive, to do this a 2nd person is necessary.
Test conditions
Remote control VAG 1348fJA is still connected.
Pressure gauge VAG 1318 is still connected.
Test sequence
Note:
With this check the fuelsupplypipe connections from the fuel delivery
unit to the pointat which the pressure gauge VA. G 1318is connected
will be checked for leaks at the same time.
20-26--
....
- Close pressure gauge cut-off tap (lever at right angles to throughflow direction -position B-).
- Operate reroote control at short intervals, until a pressure of
Approx. 3 bar
has built up.
Waming!
I N20-01091
Page 20-10, Re
20-27--
~~~--1
Accelerator mechanism
'H--+---2
I
I
I
2 -Cable cam
3 -Retainer
Adjusting throttle cable
20-30
Page
4 - Support bracket
For accelerator cable
5 - KickdoWn switch (FI)
On bulkhead
Checking ~ Page 20-30, Adjusting
throttle cable on vehicles with auto
matic gearbox
10----..
1 3 - - -...""
12----""""
11---~
I N20-0t35 I
20-28--
,;:,
'it
' 1: j ~
II!
~
it
I
I'
6 - Connector
Black. 2-pin
7 - Balance weight
8 - Accelerator pedal
9 - Spacer sleeve
10 -Bush
11-Washer
-'- --- -
.,.-
,
I
12 - Stop bolt
13-20Nm
i'
!'
10------.
13---
12-------11--~
I N2<H>1351
20-29--
Work sequence
...
20-30--
IJ
V.A.G 1526 A
....
....
I WOIHI4311
Iwoo-oml
20-31--
Work sequence
....
....
- Connect hand multimeter V.A.G 1526 with aux. cables from VAG
1594 to kick-down switch.
- Check resistance at switch.
Specification: 00 n
On.
At this point the accelerator pedal must be just oft the stop_
20-32--
;.
',I
Th'
I;'
! :
,,
!
!,
,
'
ii
20-33--
3
Servicing parts of the activated
charcoal filter system
,l ,i
1-10 Nm
1 - -...
~4
t
3 - Connector
Black. 2-pin
For solenoid valve 1 ,
I N2D-0170 I
20-34--
4-Ventpipe
Black
Check securely seated
From gravity valve on fuel tank
=> Page 20-2. Item 2
1 - ...
6-T-piece
i-4
t
8 - Breather connection
I N20-0170 I
.....
, I
20-38--
~.
f. ...1;.
Test sequence
1
.A.G.1368
.~
....
- Pull breather pipe/hose -2- from activated charcoal filter -1- off at
throttle valve control part -3- T-piece.
- Connect hand vacuum pump V.A.G 1390 to pipe/hose -2-.
6V.:~~~"~
- Pull breather pipe/hose -5- from fuel tank off activated charcoal filter
and connect to -connection A- of vacuum tester V.A.G 1368.
- Connect vacu um tester V.A.G 1368 -connection 8- to breather pipe!
hose -4-.
- Set vacuum tester to position -8-.
- Introduce final control diagnosis and select activated charcoal filter
solenoid valve (NSO):
=> Repair group 01; Final control diagnosis; Performing final control di
agnOSis
- Operate hand vacuum pump V.A.G 1390 several times.
Vacuum must not
build-up.
If, vacuum builds-up:
- Check breather connection -6- on activated charcoal filter -1- for soil
ing, clean if necessary.
20-37--
, I
I I
! ;
not build-up.
If vacuum builds-up:
build-up.
20-38--
Nate:
If the fuel level in the tank is low the hand vacuum must be operated
at least 20...30 times. \
If vacuum builds-up:
- Replace fuel tank cap.
20-39--
~,
II"
Aher working on the exhaust system ensure that the system is not
under stress, and that it has sufficient clearance from the body
work. If necessary, loosen double and single clamps and align si
lencer and exhaust pipe so that sufficient clearance is maintained to
the bodywork and the support rings are evenly loaded.
26-1----
4 2
4
, j
Note:
Components marked with an * are
checked by the self-diagnosis:
Repair Group 01; Self diagnosis; Interrogat
ing and erasing fault memory
.---5
16..;.1'.,...;::.....::-__
1
.......
2-25Nm
3 - Heat shield
4 -Bracktrt
~-10
..---6
1-
Renew
.---7
.---8
~- ---9
1-Seal
.",---.6
17----~
.~t1
I
Xl~~~ ~)
I N26-0210 I
26-2--
,!
4 2
6-10 Nm
7 -Clip
8 -Catalyst
.---5
~--6
~--7
~-8
17 -------.;~
16 r-- ......
------10
---6
9 - Double clamp
Note fitting position:::;. Fig. 3
10-40Nm
11 - Mounting
12 -Centre and rear silencer
As standard. central and rear si
lencers are installed as a single com
ponent. In repair cases the central
and rear silencer are supplied individ
uallyand with a double clamp for con
necting.
Separating point:
:::;. Fig. 1
Aligning rear silencer free of stress
:::;. Fig. 2
I N26-0210 I
26-3--
4 2
1 2 3
iii-
13 - Mounting
With retaining ring
.',
14 - Tunnel bridge
,.,:~:~:,.
'",
19
"
...
"""
18
7
8
9
17
16
r--.,
I
10
6
......
.....
15 - Mounting
Note installation position
:::;. Fig. 4
16 Heat shield
For catalyst
17 - Front exhaust pipe with catalyst
18 -Gasket
Renew
19 - Exhaust manifold
......
I N26-0210 I
26-4 ---....;.
~
..
: I: '
..... rig. 1
..... rig.
- The mounting pins on exhaust pipe must run parallel with tunnel
bridge (dimension -x- on left and right the same).
I A2tI-0131 I
26-5--
..... rig.
AI
Nate:
Mark -A- is valid for vehicles with manual and automatic gearboxes.
I N26-021SI
i,
i
Ii
..... rag.
I
. ,,
I:
I A26-01281
26-6--
26-7--
7
~--8
9
10
"'"'-----11
'----12
~----,--13
are
1 - Combi-valve
Checking =>Page 26-13
Removing and installing
2-5Nm
...."~----14
)-------3
16 15
N26-0199 I
26-8--
3 -O-Ring
Renew
25
4 - Air channel
In cylinder head
5 -Bracket
For secondary air inlet valve (N112)
and intake manifold change-over
valve (N156)
23
22
20
10
20
9 - Connector
Black, 2-pin
11
12
13
14
3
19
18
17
16 15
N26-0199
10 - Non-return valve
White connection faces towards sec
ondary air inlet valve (N112)
I
26-9
6
11 - To vacuum reservoir
12 - To vacuum positioning element for
intake manifold change-over
1'
10
16 - Connector
Black, 2-pin
For secondary air pump motor
17 -Bracket
For secondary air pump motor
11
12
13
14
3
18
17
16 15
,i
I
N26-0199 \
26-10
18 -Rubber bush
3
25
3
19 ~Housing
20~10Nm
22 - Connection
23
'*---8
22
20
10
23 - Pressure hose
24Gasket
Renew
25 Connection
For combi-valve
---11
"----12
"""-"----13
...." 'i'-----14 '
N-------3
19
18
17
16 15
N26-01991
26-11--
....
Fig. 1
Before disconnecting battery earth strap obtain code for radios with
anti-theft coding.
- - - 26-12--
Checking combi-valve
V.A.G 1331
~:::
I WQO-Oot27I
....
I WOO-OS1s1
26-13--
Check conditions
No fault stored in fault memory
=> Repair group 01; Self-diagnosis; Interrogating fault memory
26-14--
.....
I N:2&-02131
Note:
.....
- Detach hose to combi valve at air cleaner upper part -arrow- and
pressurize slightly by blowing into hose.
Combi-valve must be closed.
- Operate hand vacuum pump.
I N:2&-0212 I
26-15--
.....
Note:
Check whether a coded radio is installed as during the forthcoming
work sequences the batteryearth strap must be disconnected. Obtain
radio code first if necessary.
Ii'
1..
11
ti,
26-16--
Notes:
26-17--
Installing
Install in reverse order.
28-1R_-
<D
100-24981
Service.
<tP
Ii~--------------------------------------------------------
Ii
Golf 1998 ~
With this supplement you will receive the new Assembly group
,,
l'
I:
i'
..
and revised
~.
Technical information is only of use if it is cared for and kept up-to-date. We will
supply you with the latest information please take care to keep it up-to-date
and file this supplement.as follows:
lIArt. No. of the complete Assembly Group including Assembly Group folder
..
---'
'
.......
KOO.5107.29.20