VW 1.8L 4-Cylinder Turbo Engine Guide

1.
8L 4-CYLINDER TURBO 5-VALVE

Article Text
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ARTICLE BEGINNING
ENGINES
1.8L 4-Cylinder Turbo 5-Valve
* PLEASE READ THIS FIRST *
NOTE: For engine repair procedures not covered in this article,

see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article
in the GENERAL INFORMATION section.
ENGINE IDENTIFICATION
Engine identification number is stamped on a machined pad on

front of engine block, below cylinder head. See Fig. 1.
ENGINE CODES
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Application Code
Audi
A4
1997-1999 ........................................ AEB
2000 ............................................. ATW
Volkswagen
Passat
1997-1999 ........................................ AEB
2000 ............................................. ATW
Fig. 1: Locating Engine Identification Number

Courtesy of Volkswagen United States, Inc.
ON-VEHICLE SERVICE
THERMOSTAT
Removal & Installation
WARNING: The cooling system is pressurized when the engine is warm.

When opening the expansion tank, wear gloves and other
appropriate protection, cover the cap with a cloth and open
carefully to relieve system pressure slowly.
1) Raise vehicle, remove lower engine shield (noise

insulator). See Fig. 2. Drain coolant. See DRAINING COOLING SYSTEM.
2) Thermostat is located at the bottom of water pump housing.
See Fig. 3. Remove bolts from thermostat cover, remove thermostat.
3) Clean mating surfaces. Lube new O-ring gasket with
coolant. Install thermostat. Tighten thermostat housing bolts to 7 ft.
lbs (10 Nm). To install, reverse removal procedure. Fill and bleed
cooling system. See COOLING SYSTEM BLEEDING.
Fig. 2: Identifying Lower Engine Shield (Noise Insulator)
Mounting Points
Courtesy of Audi of America, Inc.
Fig. 3: Identifying Location Of Thermostat & Coolant Drain Plug

WATER PUMP
CAUTION: Coolant/water mixture should be used at all times. Use only

ethylene glycol based (phosphate-free) coolant.
NOTE: Water pump is located behind accessary drives, this will

require accessory drive belts, generator, P/S pump, fan,
pulleys and lower timing belt cover to be removed.
1) Disconnect negative battery cable. Raise vehicle, remove
lower engine shield (noise insulator). See Fig. 2. Remove complete
front bumper assembly. Disconnect all necessary electrical connectors
from front of vehicle.
2) Attach Alignment Tools to chassis. Remove bolts securing
front of body to vehicle. Slide front of body forward onto alignment
tool. This will allow servicing of front engine components. See
LOCK CARRIER.
3) Remove accessory drive belts. Drain engine coolant. See
DRAINING COOLING SYSTEM. Remove generator. Unbolt power steering pump
assembly and set aside with hoses attached. See Fig. 4.
4) Label and remove coolant hoses from water pump. Remove
water pump pulley. See Fig. 3.
5) Remove timing belt lower cover (ensure all bolts are
removed). Remove mounting bolts and remove water pump assembly. To
install, reverse removal procedure. Tighten bolts to specification.
See TORQUE SPECIFICATIONS. Fill and bleed cooling system. See
COOLING SYSTEM BLEEDING.
Fig. 4: Identifying Cooling System Components

PROGRAMMING
NOTE: When battery is disconnected, vehicle computer and memory

systems may lose memory data. Driveability problems may exist
until computer systems have completed a relearn cycle.
After any repair which required that the battery be

disconnected, the following should be performed. Refer to owners
manual for additional information.
1) Ensure ignition switch is in OFF position. Reconnect

battery positive cable first then connect the negative ground strap.
2) After connecting battery, enter anti-theft code for radio
(if equipped).
3) Fully close all power windows, operate each window door
switch in up position for at least one second (windows closed) to
activate "one touch" opening/closing function (if equipped).
4) Set clock to correct time.
ADJUSTMENTS
ACCELERATOR PEDAL
1) Remove clip for accelerator pedal cable on throttle body.

Depress accelerator pedal to Wide Open Throttle (WOT) position.
2) On manual transmission vehicles, pull sleeve on
accelerator pedal cable off curved washer on throttle body until
throttle body has opened completely. On automatic transmission
vehicles, pull accelerator pedal cable sleeve back to WOT position far
enough so throttle has opened completely and kickdown switch audibly
clicks.
3) On all vehicles, hold pedal tight in position. Install
securing clip for accelerator pedal cable sleeve. Release accelerator
pedal. Adjustment is complete. After adjustment, verify WOT position
and check idle speed.
VALVE CLEARANCE
Engine is equipped with non-adjustable, non-serviceable

hydraulic valve adjusters. Irregular valve adjuster noise during
cranking is normal. If valve adjuster(s) are noisy under any other
condition inspect valve adjusters. See HYDRAULIC VALVE ADJUSTERS under
REMOVAL & INSTALLATION.
TROUBLESHOOTING
NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in the

GENERAL TROUBLE SHOOTING section.
REMOVAL & INSTALLATION
CAUTION: Radio/cassette or radio/CD player is equipped with an

anti-theft protection circuit. Whenever battery is
disconnected, radio will go into anti-theft mode. When
battery is reconnected, radio will display CODE, and will be
inoperative until proper code number is entered. Obtain
security code before disconnecting battery.
NOTE: When battery is disconnected, vehicle computer and memory

systems may lose memory data. Driveability problems may exist
until computer systems have completed a relearn cycle.
NOTE: For reassembly reference, label all electrical connectors,
vacuum hoses and fuel lines before removal. Place mating
marks on other major assemblies before removal.
ACCESSORY DRIVE BELTS
CAUTION: If reusing old serpentine or other accessory drive belt(s),

mark the running direction of belt with crayon or marker.
Reinstalling a used belt in reversed direction could damage
the belt, and cause component(s) or engine damage.
NOTE: Serpentine belt may also be referred to as ribbed belt or

V-belt.
For help in identifying accessory drive belt(s) routing and

component locations, refer to illustration. See Fig. 5.
Removal & Installation (A/C Belt)

insulator). Move lock carrier to service position. See LOCK CARRIER.
Loosen 2 mounting bolts at A/C belt tensioner, release tension from
belt.
2) Remove belt. To install, reverse removal procedure. Ensure
pulleys are free of debris. Using a torque wrench tension belt to 25
Nm (18 ft. lbs). Tighten mounting bolts to 20 Nm (15 ft. lbs).
3) Start engine and check belt running condition.
Removal & Installation (Serpentine Belt)

insulator). See Fig. 2. Move lock carrier to service position. See
LOCK CARRIER. Install wrench on ear of serpentine belt tensioner, move
clockwise to remove tension off belt. See Fig. 5. Tensioner can be
locked into released position by inserting a properly sized Hex wrench
into hole in tensioner.
pulleys are free of debris. Belt is automatically tensioned.
3) Start engine and check belt running condition.
Removal & Installation (Water Pump Belt)

LOCK CARRIER. Release tension off serpentine belt. See REMOVAL &
INSTALLATION (SERPENTINE BELT). Remove viscous fan with pulley from
its bearing. See IVISCOUS FAN (ENGINE COOLING).
2) Using a drift punch to lock up the P/S pump pulley (1),
remove fasteners from belt pulley for water pump. See Fig. 6.
pulleys are free of debris. Place belt around P/S pulley then between
the 2 halves of the water pump pulley. Slowly go around as you tighten
the fasteners (pulleys are also turning). The belt should walk its way
out in the pulley groove. Using a torque wrench tighten pulley bolts
to 20 Nm (15 ft. lbs).
4) Tension the serpentine belt. DO NOT install fan at this
time. Start engine only for a moment to seat the belt and check belt
running condition. Turn ignition switch to OFF position. Recheck
torque on water pump pulley bolts.
Fig. 5: Identifying Accessory Drive Belts & Components
Fig. 6: Removing Water Pump Pulley & Belt

DRAINING COOLING SYSTEM

NOTE: Drain coolant into clean container if coolant is in good

condition and is going to be reused.
Open cap on engine coolant expansion tank. Remove lower

engine shield (noise insulator). Remove lower radiator hose (1). Drain
coolant from radiator and hose. Remove drain plug (2) from coolant
pump and allow coolant to drain from block. See Figs. 7 and 8. To fill
cooling system, see COOLING SYSTEM BLEEDING.
Fig. 7: Draining Engine Coolant

Courtesy of vag of america
Fig. 8: Coolant Hose Connection & Routing Diagram
Courtesy of volkwagen of america inc.
COOLING SYSTEM BLEEDING
1) Ensure coolant pump drain plug with NEW O-ring and all
hoses are secure. See Fig. 7.
2) Install fill adaptor to coolant expansion tank. See
Figs. 9 and 10. If special tools are not used, loosen expansion tank
and raise about 4 INCHES. Keep in this position while filling. Expose
vent hole on heater pipe at firewall connection by pulling back heater
hose. See Fig. 11. Fill cooling system through expansion tank until
coolant comes out of vent hole. Tighten heater hose and bleed screw.
3) Fill expansion tank to proper level. Install expansion
tank cap. Put heater controls in hot position. Start engine and raise
engine speed to 2000 RPM for about 3 minutes. Ensure cooling fan
operates. Return engine to idle. Check coolant level in expansion
tank. Fill as necessary. With engine at normal operating temperature,
coolant should be at the Max mark indicated on expansion tank. Once
engine has completely cooled, coolant should be at the low mark. Add
coolant as necessary.
Fig. 9: Installing Fill Adaptor To Coolant Expansion Tank With

Large Cap
Fig. 10: Installing Fill Adaptor To Coolant Expansion Tank With

Small Cap
Fig. 11: Locating Heater Hose Vent Hole

FUEL PRESSURE RELEASE
Remove fuel pump relay from fuse/relay block under left side
of instrument panel. Start engine. Allow engine to run until it stops.
Turn ignition off. Disconnect negative battery cable. Install fuel
pump relay. Slight pressure may remain in system. Before disconnecting
any fuel system line, cover connector with a clean shop towel.
LOCK CARRIER
First Design
Remove noise insulation. See Fig. 2. Disconnect intake air
ducting located near radiator support. Disconnect headlight and turn
signal electrical connectors. Disconnect harness connectors at horns.
See Fig. 18. Disconnect coolant fan thermal switch. Disconnect power
steering cooling coil. Remove front bumper.
Unbolt air guide between lock carrier and air filter on lock
carrier. See Fig. 12. Unscrew bolt (No. 3) and replace with support
tool (Part No. 3369) onto right and left-hand longitudinal member. See
Fig. 13Unscrew bolts (No. 2 and 4) and pull lock carrier in area of
support tool (Part No. 3369) forward (moving to service position). To
return, reverse procedure.
Fig. 12: Identifying Lock Carrier Components (First Design)

Fig. 13: Identifying Support Tool (Part No. 3369)
Second Design
Remove noise insulation. See Fig. 2. Disconnect intake air
steering cooling coil. Remove front bumper.
Unbolt air guide between lock carrier and air filter at lock
carrier. See Fig. 14. Remove bolts (No. 5) and replace with guide rods
(No. 3411) to right and left longmember. Remove bolts (No. 2 and 3).
Lock carrier can be pulled forward approximately 4 INCHES (10 cm) on
guide rods (No. 3411). See Figs. 15 and 16.
Fig. 14: Identifying Lock Carrier Components (Second Design)

Fig. 15: Identifying Guide Rods (Part No. 3411)
Fig. 16: Identifying Installed Location Of Guide Rods (Part No. 3411)
ENGINE
WARNING: ALWAYS release fuel pressure before disconnecting fuel

injection related component. DO NOT allow fuel to contact
engine or electrical components.
NOTE: Obtain radio code before disconnecting battery. Remove

engine, without transmission, through front of engine
compartment.
NOTE: For help in identifying components and component locations,

refer to illustrations. See Figs. 17-36.
Removal
1) Release fuel pressure. See FUEL PRESSURE RELEASE. Turn
ignition on, operate windshield wipers till wiper arms are in the
vertical position (pointing up) turn off ignition. Remove battery.
Remove lower engine shield (noise insulator). See Fig. 2. Drain engine
oil. Drain coolant, see DRAINING COOLING SYSTEM.

2) Remove cover for fuel injectors. Disconnect fuel supply
and return lines at fuel rail. See Fig. 17. Disconnect intake air
steering cooling coil, located at lower left of radiator. Let cooling
coil hang free. See Fig. 19. Remove front bumper. See LOCK CARRIER.
3) Remove Motronic Engine Control Module (E-Box) cover and
disconnect harness connectors. See Fig. 20 and Fig. 21. Disconnect
Kickdown switch harness connector. See Fig. 22. Disconnect Vehicle
Speed Sensor (VSS). On Manual Transmission (M/T) disconnect harness
connector from transmission (backup lights). Disconnect Anti-Lock
Brake System (ABS) harness connectors. See Fig. 23.
4) Disconnect Oxygen Sensor harness connect, remove fasteners
and ground wires and set harness bracket aside. See Fig. 24 and
Fig. 25.
5) Disconnect power steering line clamps on frame and
radiator brace. See Fig. 19. Disconnect turbocharger, air intake and
throttle valve control module ducts. Disconnect chassis grounds and
all electrical connectors, disconnect cables and hoses that would
interfere with engine removal.
NOTE: DO NOT open the air conditioning refrigerant circuit.

Disconnect green electrical connector to A/C compressor.
See Fig. 26. Disconnect A/C refrigerant line brackets at
support points only. After A/C compressor is removed from
bracket, support with wire and set A/C compressor carefully
aside, avoid damage from bending or kinking refrigerant
lines.
6) Remove left and right side air ducts (4). Remove condenser
mounting bolts (1) and (2). Disconnect harness connector (3) for A/C
pressure switch. See Fig. 28. Pull condenser up out of its bracket,
rotate it to side and use wire to secure it on or near right front
wheel.
7) Disconnect front exhaust pipe from exhaust manifold.
Disconnect front exhaust pipe from catalytic converter. Remove front
catalytic converter from turbocharger. Disconnect harness connectors
from around air cleaner box. Remove air cleaner box. See Fig. 27.
Disconnect accelerator pedal cable from the throttle valve control
module. DO NOT remove locking clip on accelerator pedal cable. See
Fig. 30. Disconnect Leak Detection Pump (LDP) vacuum lines. See
Fig. 31.
8) Disconnect all coolant and heater hoses. Remove coolant
system expansion reservoir and set aside. See Fig. 29. Remove starter
motor. Remove bracket from ATF line from transmission.
9) Remove upper engine-to-transmission bolts. Mark positions
of left and right engine mount locating sleeves from bottom. See
Fig. 32. Remove lower left and right engine mount nuts. If equipped
with automatic transmission, raise vehicle, remove 3 torque converter
bolts accessed through starter pinion hole at bell housing. See
Fig. 33. Lift engine and transmission slightly using (VAG 1202 A)
workshop crane to allow lower engine/transmission connecting bolts to
be removed. See Fig. 34. Remove lower engine/transmission connecting
bolts.
10) Install Engine Support Bracket (10-222A) and Hooks (10-
222A/2) to engine. Install Transmission Support (3147) to transmission
bellhousing bolt hole. See Figs. 35 and 36. Carefully raise engine out
of vehicle.
CAUTION: DO NOT allow torque converter to fall out of bell housing.

Fig. 17: Identifying Fuel Lines & Brake Booster Vacuum Hose
Fig. 18: Identifying Horns Harness connectors

Fig. 19: Identifying Power Steering Cooler Line Mounting Points

Fig. 20: Identifying Motronic Engine Control Module (E-Box) Cover
Fasteners
Fig. 21: Identifying Motronic Engine Control Module (E-Box) With

Harness Connectors Removed
Fig. 22: Identifying Kickdown Switch Harness Connector
Fig. 23: Identifying Anti-Lock Brake System Harness Connectors

Fig. 24: Identifying Oxygen Sensor Harness Connector

Fig. 25: Identifying Harness Connector Bracket
Fig. 26: Identifying A/C Compressor Harness Connector (Green)

Fig. 27: Identifying Wastegate, EVAP, Power Output Stage, Mass

Air flow Sensor Harness Connectors & Air Box Components Locations
Fig. 28: Identifying Location Of A/C Pressure Switch
Fig. 29: Identifying Coolant Expansion Tank (Location Of Coolant

Level Sensor Connector Not Shown)
Fig. 30: Identifying Accelerator Pedal Cable, Cable Flange,

Throttle Body Air Intake Duct
Fig. 31: Identifying Leak Detection Pump Hose, Remove From Intake
Fig. 32: Identifying Location Of Locating Sleeves (Mark Sleeves

For Reinstallation)
Fig. 33: Identifying Access To Torque Converter Bolts

Fig. 34: Using Hoist Crane (VAG 1202 A) To Raise Engine &
Transmission
Fig. 35: Installing Support Bridge (10-222A) & Trans Support

Adaptor (3147)
Fig. 36: Installing Engine Sling (2024) & Hoist Crane (VAG 1202 A)
Installation
1) To install, reverse removal procedure. Engine alignment

adjustment is necessary whenever engine is removed or mounts are
loosened. To adjust, loosen through-bolt on engine mount. Loosen
transmission mount bolts. Loosen front engine mount and bracket.
2) Lightly rock engine and transaxle to shift as necessary.
Evenly tighten mount bolts in reverse order of loosening. Align
exhaust so components are free of stress. Tighten all bolts and nuts
to specification. See TORQUE SPECIFICATIONS.
3) Adjust accelerator pedal. See ACCELERATOR PEDAL under
ADJUSTMENTS. Verify engine fluid levels are filled to proper levels.
Adjust clutch pedal (if equipped).
CAMSHAFTS
CAUTION: DO NOT turn crankshaft or camshaft with timing belt removed.

Valve damage may result.

refer to illustration. See Fig. 37.
Removal
1) Remove upper timing belt cover. Remove camshaft cover.
Place crankshaft at TDC with No. 1 cylinder on compression stroke.
Release tensioner, using Torx T45 bit, loosen bolt (1) at timing belt
tensioner. Push timing belt tensioner pulley (2) downward and remove
timing belt from camshaft sprocket. See Figs. 73-75.
2) Turn crankshaft back slightly. Using Camshaft Holder
(3036), remove camshaft sprocket bolt. Remove camshaft sprocket.
Remove wood drift key. Install camshaft sprocket bolt and washer until
washer is tight against camshaft.
3) Clean camshaft drive chain and chain sprockets. Moving
only the cams align the marks on the cam sprocket with arrows on the
bearing caps. Using paint, mark chain and sprockets opposite arrows on
bearing caps. Distance between both arrows (and between paint
markings) is 16 rollers on the chain. See Fig. 39. If a new chain is
being installed, distance between Notch "A" and "B" must equal 16
drive chain rollers. Notch "A" is slightly off set inward toward drive
chain roller (1). See Fig. 40.
4) Remove camshaft position sensor housing. Mark installation
position on bearing caps with a colored marker. Secure chain
tensioner, install Chain Tensioner (3366) and tighten to keep slight
pressure on chain between camshafts. DO NOT overtighten chain
tensioner. See Fig. 41. Remove camshaft caps as follows:
* Remove camshaft intake and exhaust bearing caps No.

3 and 5. Loosen bolts in small amounts evenly in a
criss-cross manner. See Fig. 38.
* Remove double bearing cap.
* Remove both bearing caps at chain sprockets on intake
and exhaust camshafts.
* Remove chain tensioner securing bolts.
* Remove intake and exhaust camshaft 2nd and 4th bearing
caps using alternate and cross-over sequence.
5) Remove intake and exhaust camshafts with chain tensioner

and retainer for chain tensioner (3366) from cylinder head.
Fig. 37: Identifying Cylinder Head Components
Fig. 38: Identifying Camshafts Bearing Caps 1-5 & Double Bearing Cap
Fig. 39: Identifying Marks On Cam Chain Gears & Arrows On Cam Caps
Courtesy of volkswagon united states inc.
Fig. 40: New Camshaft Drive Chain Install Dimensions

Fig. 41: Identifying Usage Of Camshaft Chain Adjuster Retainer Tool
Inspection
Check camshaft bearing oil clearance. See CAMSHAFT table
under ENGINE SPECIFICATIONS. If oil clearance is not within
specification, install new camshaft and recheck clearance. If
clearance still exceeds specification, replace cylinder head. Check
camshaft end play. See VALVE TRAIN under OVERHAUL.
CAUTION: If cam followers are charged with oil, allow 30 minutes for
followers to bleed down before starting engine. Pistons may
strike valves, resulting in bent valves.
Installation
NOTE: When installing the bearing caps, ensure that the cap
markings can be read from the intake side of the cylinder
head.
1) Place camshafts in cylinder head. Ensure lobes for No. 1

cylinder are pointed upward. See Fig. 37. Fit drive chain onto both
camshafts relative to the marks. Replace chain tensioner rubber/metal
gasket and coat shaded area lightly with sealant (D 454 300 A2). See
Fig. 42. Slide chain tensioner between drive chain.
NOTE: Take note of dowel sleeves.
2) Oil running surfaces of camshafts. Place camshafts with

drive chain in cylinder head. Tighten chain tensioner to 10 Nm (7 ft.
lbs). Tighten camshaft bearing caps No. 2 and 4 evenly to 10 Nm (7 ft.
lbs). Install both bearing caps at chain sprockets for intake and
exhaust camshafts. Ensure camshafts are positioned correctly. Tighten
bearing caps to 10 Nm (7 ft. lbs). Remove retainer for chain tensioner
(3366).
3) Lightly coat hatched area of double bearing cap with
sealant (D 454 300 A2). See Fig. 43. Install and tighten to 10 Nm (7
ft. lbs.), remember dowel sleeves.
4) Install remaining bearing caps and tighten to 10 Nm (7 ft.
lbs.), remember dowel sleeves. Check position of marks made on
camshafts sprockets relative to one another (positioning should be
close to prior to removal). See Fig. 39. If a new chain is being
installed, distance between Notch "A" and "B" must equal 16 drive
chain rollers. Notch "A" is slightly off set inward toward drive chain
roller (1). See Fig. 40.
5) To complete installation, reverse removal procedure. If
cam followers are charged with oil, allow 30 minutes for followers to
bleed down before starting engine.
Fig. 42: Applying Sealant (D 454 300 A2) To Chain Tensioner

Mounting Surface
Fig. 43: Applying Sealant (D 454 300 A2) To Double Bearing Cap
CAMSHAFT OIL SEALS

CAUTION: DO NOT allow camshaft to turn when removing camshaft sprocket

bolt.
Removal (Exhaust Cam)

1) Remove upper timing belt cover. Place crankshaft at TDC
with No. 1 cylinder on compression stroke. Release tensioner, using
Torx(R) T45 bit, loosen bolt (1) at timing belt tensioner. Push timing
belt tensioner pulley (2) downward and remove timing belt from
camshaft sprocket. See Figs. 73-75.
2) Turn crankshaft back slightly. Using Camshaft Holder
(3036), remove camshaft sprocket bolt. Remove camshaft sprocket.
Install camshaft sprocket bolt and washer until bolt comes to a stop
(hand tight) against camshaft. See Fig. 44.
3) Unscrew inner part of (2085) oil seal extractor 2 turns
(approx. 3 mm) out of the outer section and lock with knurled screw.
Lubricate threaded head of oil seal extractor, place in position and
while exerting firm pressure, screw as far as possible into oil seal.
See Fig. 45.
4) Loosen knurled screw and turn inner part against
crankshaft until oil seal is pulled out.
Fig. 44: Camshaft Sprocket bolt Installed In Camshaft
Fig. 45: Installing Seal Puller (2085)

Installation
Coat new seal lip lightly with engine oil. DO NOT oil outer
circumference of oil seal. Using guide sleeve (3241/2), slide seal
until flush with head. See Fig. 46. Using seal installer with press
sleeve (3241/1) and bolt (3241/5), install new camshaft oil seal flush
into cylinder head. See Fig. 47. Install CMP sensor. To complete
installation, reverse removal procedure.
Fig. 46: Installing Guide Sleeve (3241/2) Onto Camshaft

Fig. 47: Installing Cam Oil Seal Using Press Sleeve (3241/1) &
Bolt (3241/5)
Removal (Intake Cam)

1) Remove upper timing belt cover.
2) Unbolt Camshaft Position (CMP) sensor housing. Remove CMP
sensor-to-rotor bolt. Carefully pry off rotor. See Fig. 48.
3) Screw tool (2058/1 bolt) into camshaft. See Fig. 49.
Unscrew inner part of (2058) oil seal extractor 2 turns (approx. 3 mm
or 0.118") out of outer part and lock with Knurled screw. See Fig. 50.
4) Lubricate thread head of oil seal extractor, place it in
position while applying firm pressure screw it as far as into oil
seal. Loosen knurled screw and turn inner part of extractor against
camshaft until oil seal has been extracted.
Fig. 48: Identifying Cam Position (CMP) Sensor Harness Connector

Fig. 49: Installing Adaptor (2085/1) Into Intake Camshaft
Fig. 50: Installing Seal Puller (2085)

Installation
Coat new seal lip lightly with engine oil. DO NOT oil outer
circumference of oil seal. Using guide sleeve (3241/2), slide seal
until flush with head. See Fig. 51. Using seal installer with press
sleeve (3241/1) and bolt (3241/3), install new camshaft oil seal flush
into cylinder head. See Fig. 52. Install CMP sensor, tighten shutter
wheel for sensor to 25 Nm (18 ft. lbs.) and the Camshaft Position
(CMP) sensor housing to 10 Nm (7 ft. lbs.). To complete installation,
reverse removal procedure.
Fig. 51: Installing Guide Sleeve (3241/2) Over Intake Cam

Fig. 52: Installing Seal Using Press Sleeve (3241/1) & Bolt (3241/3)
CORE PLUG (CYLINDER HEAD)
CAUTION: Ensure core plug (sealing cap) is installed in cylinder head.
Removal
Removal procedure of core plug not provided by manufacturer
at this time.
Installation
Coat outside circumference of core plug (sealing cap) with
sealant (AMV 188 001 02). Using needle bearing drift (VW295), drive in
core plug until outside rim is flush with end of chamfer in cylinder
head. See Fig. 53.
Fig. 53: Identifying Installed Depth Of Core Plug (Sealing Cap)

CRANKSHAFT FRONT OIL SEAL

Removal
1) Remove timing belt. See TIMING BELT.
2) Remove crankshaft toothed belt sprocket, by counter-
holding sprocket with locking fixture (3099) tool. See Fig. 55. To
guide oil seal extractor, screw bolt from tool kit (3083) as far into
crankshaft as possible. See Fig. 56.
3) Unscrew inner part of (2085) oil seal extractor 2 turns
(approx. 3 mm) out of the outer section and lock with knurled screw.
Lubricate threaded head of oil seal extractor, place in position and
while exerting firm pressure, screw as far as possible into oil seal.
See Fig. 57.
4) Loosen knurled screw and turn inner part against
crankshaft until oil seal is pulled out.
Fig. 54: Identifying Cylinder Block Front & Rear Crankshaft Seals
Fig. 55: Removing Crankshaft Tooth Timing Belt Sprocket (3099)
Fig. 56: Installing Guide Bolt From Tool Kit (3083) Into Crankshaft
Fig. 57: Removing Crankshaft Seal With (2085)

Installation
Lubricate lip of new seal. Place guide sleeve from Seal
Installer (3083) onto crankshaft. Push oil seal over guide sleeve.
Press seal completely into position with press sleeve (3083). See
Figs. 58 and 59. Reinstall crankshaft toothed belt sprocket, by
holding sprocket with 3099 tool. See Fig. 55. To complete
installation, reverse removal procedure. See TORQUE SPECIFICATIONS.
Fig. 58: Installing Guide sleeve From Tool Kit (3083) Onto Crankshaft
Fig. 59: Installing Crankshaft Front Oil Seal With Press Sleeve
From Tool Kit (3083)
CRANKSHAFT REAR OIL SEAL
NOTE: Crankshaft rear oil seal and carrier are serviced as an

assembly.


1) Remove transmission. For M/T, see appropriate article in
CLUTCHES. For A/T, see TRANSMISSION REMOVAL & INSTALLATION article in
TRANSMISSION SERVICING. Remove drive plate (A/T) or dual-mass flywheel
(M/T).
2) Remove crankshaft oil seal carrier bolts and remove
carrier with oil seal. Lightly oil lip with clean engine oil. Install
NEW oil seal with carrier using supplied sleeve. Tighten crankshaft
oil seal carrier bolts to 25 Nm (18 ft. lbs). See
TORQUE SPECIFICATIONS.
CYLINDER HEAD
CAUTION: DO NOT start engine for about 30 minutes after installing

camshafts. Hydraulic valve lifters must settle or valves may
strike pistons. Rotate crankshaft by hand 2 revolutions
before starting engine to ensure valves do not strike
pistons.
Removal
1) Release fuel pressure. See FUEL PRESSURE RELEASE.
Disconnect negative battery cable. Label and disconnect electrical
connectors and vacuum hoses. Drain coolant. See
DRAINING COOLING SYSTEM. Remove cover for fuel injectors, wrap a rag
around fuel supply and fuel return lines. Disconnect fuel lines at
fuel rail connector. See Fig. 17. Seal fuel line to prevent dirt
entry. See Fig. 66.
2) Disconnect power steering cooling coil located at lower
left of radiator. Drain coolant from radiator. See Fig. 7. Disconnect
lower radiator hose.
3) Disconnect intake air ducting located near radiator
support. Disconnect headlight and turn signal electrical connectors.
Disconnect coolant fan thermal switch located near lower coolant hose
on left side of radiator.
4) Pull cover for power steering fluid reservoir upward.
Disconnect 4 harness connectors located under cover. Disconnect anti-
theft alarm connector at upper left cowl. Disconnect coolant hose at
upper left side of engine.
5) Disconnect both horn connectors. See Fig. 18. Attach
Alignment Tools to chassis. Remove bolts securing front of body to
vehicle. See LOCK CARRIER. Slide front of body forward onto alignment
tool. This will allow servicing of front engine components and
facilitate removal of cylinder head.
6) Disconnect both ignition coil power output stages harness
connectors. Disconnect EVAP canister purge regulator valve from
bracket and disconnect electrical connector. Disconnect wastegate by-
pass regulator valve electrical connector. Remove intake air duct
between air cleaner and turbocharger. See Figs. 84-86.
7) Pry rubber sleeve off on air cleaner housing and
disconnect Mass Airflow (MAF) sensor electrical connector. Disconnect
EVAP canister hose connections. Remove air cleaner. See Fig. 27.
8) Remove timing belt. See TIMING BELT. Disconnect ignition
coils and ground wire from cylinder head valve cover and set aside.
Cut cable tie on cylinder head valve cover and set wiring aside.
9) Disconnect crankcase breather hose at wastegate,
Disconnect engine coolant temperature sensor on rear of cylinder head.
Disconnect accelerator pedal. Disconnect Camshaft Position (CMP)
sensor on front of cylinder head. See Fig. 48.
10) Disconnect coolant expansion tank. Disconnect hoses from
left coolant line over intake manifold.
11) Remove intake manifold and manifold support. See
INTAKE MANIFOLD. Disconnect coolant line at rear of cylinder head.
Disconnect heated oxygen sensor connector at left side of plenum and
set aside. Disconnect turbocharger oil and coolant lines and front
pipe on top of turbocharger. See TURBOCHARGER.
NOTE: When valve cover has been removed, take note of oil deflector
positioning.
12) Disconnect oil and coolant lines and front pipe from
lower part of turbocharger. Disconnect exhaust system bracket on
transmission, then disconnect front pipe from turbocharger. Remove
cylinder head valve cover, remove cylinder head bolts using sequence.
Loosen head bolts a little at a time, till all bolts are loose. See
Fig. 60. Remove cylinder head from vehicle.
Inspection
Thoroughly clean all gasket mating surfaces. Check cylinder
head for warpage. Maximum warpage is .004" (.100 mm). Check minimum
cylinder head height and replace cylinder head (if necessary). See
CYLINDER HEAD under OVERHAUL, also see CYLINDER HEAD under ENGINE
SPECIFICATIONS.
Installation
CAUTION: If cam followers or camshaft have been removed and followers

are charged with oil, allow 30 minutes for followers to bleed
down before starting engine. Pistons may strike valves,
resulting in bent valves.
NOTE: DO NOT reuse antifreeze after replacing cylinder block,

cylinder head, head gasket, radiator and/or heater core.
1) Ensure part number on cylinder head gasket faces up.

Install gasket on cylinder block. DO NOT use any type of sealant.
Align camshaft timing marks and position crankshaft at TDC. See
TIMING BELT.
2) Install guide pins (VAG 3070 tool set) in head bolt holes
No. 8 and 10. Carefully position cylinder head on cylinder. Install
remaining head bolts finger tight. Remove guide pins with guide pin
removal tool from (VAG 3070) and install remaining bolts. Tighten
cylinder head bolts (in 4 steps) in sequence to specification. See
Fig. 61. Also see TORQUE SPECIFICATIONS. To complete installation,
reverse removal procedure. Before installation of valve cover apply a
thin layer of sealer (D 454 300 A2) at the points of valve cover where
leakage may occur. See Fig. 62.
Fig. 60: Cylinder Head Bolt Loosening Sequence

Fig. 61: Cylinder Head Bolt Tightening Sequence

Fig. 62: Identifying Location To Apply Sealer Before Valve Cover
Installation
DRIVE PLATE (A/T) & FLYWHEEL (M/T)
NOTE: The following procedure is given assuming the transmission

has been removed or the engine has been removed for
servicing.
NOTE: For flywheel (M/T) pilot needle bearing inspection. See

PILOT NEEDLE BEARING (M/T).
Removal
1) Mark the position of the drive plate (A/T), also marking
the positions of the washer (1) and the shim (2) between the drive
plate and the crankshaft flange. See Fig. 63. Loosen the bolts in a
cross pattern and remove drive plate or flywheel.
Fig. 63: Identifying Washer, Driveplate & Shim

Fig. 64: Identifying Location Of Bearing Bushing For Torque Converter
Installation
1) Install driveplate or flywheel. See Fig. 63. Using 3 of
the old bolts inserted into flange, evenly spaced torque to 30 Nm (22
ft. lbs.) Check dimension "A" at 3 points. Specification is
approximately 12.3 mm (0.484 INCHES). See Fig. 65.
NOTE: Only one shim of the proper size may be used. Tighten flange
bolts in a cross pattern.
2) If specification is incorrect, replace shim to obtain

proper dimension. Once specification is attained: install NEW bolts
and torque in a criss-cross pattern to 60 Nm (44 ft. lbs.) and 1/4
turn (90ø) further (Additional 1/4 turn can be done in several steps).
Fig. 65: Calculating Dimension For Shim Size

INTAKE MANIFOLD

compartment.

1) Remove battery. Remove lower engine shield (noise
insulator). See Fig. 2. Drain coolant, see DRAINING COOLING SYSTEM.

2) Remove cover for fuel injectors. Remove bolts securing

fuel rail to intake manifold. Remove fuel injectors and rail together
and rest aside on a clean shop towel. See Fig. 66.
3) Disconnect harness connectors from around air cleaner box.
Remove air cleaner box. See Fig. 27. Disconnect Cam Position (CMP)
Sensor. See Fig. 48. Disconnect accelerator pedal cable from the
throttle valve control module. DO NOT remove locking clip on
accelerator pedal cable. See Fig. 30. Disconnect Leak Detection Pump
(LDP) vacuum lines. See Fig. 31. Disconnect vacuum lines at brake
booster.
4) Disconnect coolant hoses at upper coolant line. See
Fig. 66. Disconnect upper coolant line at intake line and rear coolant
flange at rear of cylinder head. See Fig. 67.
5) Disconnect crank case ventilation hose (1) at manifold.
Remove brace (2). See Fig. 68. Remove oil dipstick, unbolt intake
manifold at flange and remove manifold. Block intake ports in cylinder
head with clean shop towels. To install, reverse removal procedure.
Tighten bolts to specification. See TORQUE SPECIFICATIONS.
Fig. 66: Identifying Intake Manifold & Fuel Rail Components

Fig. 67: Identifying Coolant Pipe Connection At Rear Of Cylinder Head
Fig. 68: Identifying Brace & Hose Connected To Intake Manifold

EXHAUST MANIFOLD
Removal and installation procedures are not available from

manufacturer. See TURBOCHARGER. On installation, tighten bolts to
specification. See TORQUE SPECIFICATIONS.
HYDRAULIC VALVE ADJUSTERS
WARNING: ALWAYS release fuel pressure before disconnecting fuel

injection related component. DO NOT allow fuel to contact
engine or electrical components.
camshafts. Hydraulic valve lifters must bleed down or valves
may strike pistons. Rotate crankshaft by hand 2 full
revolutions before starting engine to ensure valves do not
strike pistons.
NOTE: Valve lifters are not repairable or adjustable. Replace

faulty lifters. Irregular valve train noise is normal when
starting engine.
Checking
1) Start engine and run until cooling fan cycles at least
once. Increase engine speed to 2500 RPM for 2 minutes or test drive
vehicle and observe valve train noise. If valve train noise is still
considered noisy, go to next step.
2) Turn engine off. Remove valve cover. Rotate crankshaft
until camshaft lobes point upward on lifter being checked. Using a
wooden or plastic wedge, push down on top of lifter. See Fig. 69. Try
inserting a .008" (.20 mm) feeler gauge between top of lifter and
camshaft. If feeler gauge fits between top of lifter and camshaft,
replace faulty lifter.
Fig. 69: Placement Of Wedge On Lifter (Push Down)

PILOT NEEDLE BEARING (M/T)

1) Remove transmission. For M/T, see appropriate article in
CLUTCHES. Remove flywheel (M/T).
2) Using an appropriate puller, remove pilot needle bearing.
See Fig. 70. To complete installation, reverse removal procedure. Use
bearing driver (VW 207C) to install pilot needle bearing. See Figs. 71
and 72. For flywheel installation. See
DRIVE PLATE (A/T) & FLYWHEEL (M/T).
Fig. 70: Removing Pilot Needle Bearing
Fig. 71: Installing Pilot Needle bearing Using (VW 207C)

Fig. 72: Pilot Needle Bearing Insertion Depth (A=1.5 mm)

TIMING BELT

Removal
1) Disconnect negative battery cable. Remove lower engine
shield (noise insulator). See Fig. 2. Remove complete front bumper
assembly. Disconnect all necessary electrical connectors from front of
vehicle.
2) Remove bolts securing front of body to vehicle. Move lock
carrier to service position. Attach Alignment Tools to chassis. Slide
front of body forward onto alignment tool. This will allow servicing
of front engine components. See LOCK CARRIER.
3) Remove accessory drive belts, see ACCESSORY DRIVE BELTS.
4) Rotate crankshaft by hand to Top Dead Center (TDC). See
Fig. 73. Remove crankshaft vibration damper pulley. Remove lower
timing belt cover.
5) If timing belt is to be reused, mark direction of rotation
on belt. Mark timing belt running direction. Using Torx(R) T45 bit,
loosen bolt (1) at timing belt tensioner. Push timing belt tensioner
pulley (2) downward and remove timing belt. See Fig. 75. Remove timing
belt.
Fig. 73: Aligning Crankshaft Timing Mark To Top Dead Center (TDC)
Fig. 74: Identifying Accessory Drive Belts & Timing Belt Components
Fig. 75: Releasing Tension Off Of Timing Belt
Installation
1) Align mark on camshaft sprocket with mark on cylinder head
cover and/or timing belt guard. See Fig. 76. Install timing belt.
Install lower timing belt cover. Install vibration damper pulley and
tighten to specification. See TORQUE SPECIFICATIONS.
2) Using a 2-hole spanner (Matra V159 Pin wrench), rotate
camshaft belt tensioner until tensioner piston No. 1 is all the way
extended and tensioner piston No. 2 lifts approximately .04" (1 mm).
See Fig. 77. Tighten timing belt tensioner Torx(R) screw (just enough
to hold tensioner).
3) Using center bolt at crankshaft pulley, rotate crankshaft
2 revolutions in running direction and stop on TDC. Check if upper
edge of tensioner piston No. 2 lines up within area "A". See Fig. 78.
When tensioner piston No. 2 is within area "A", this corresponds to
dimension "D" of .98-.14" (25-29 mm). Adjust as necessary.
4) If upper edge of tensioner piston No. 2 is within area
"B", this is acceptable. If upper edge of tensioner piston No. 2 is
within area "C", readjust and/or check belt drive including pulley for
wear. If tensioner piston No. 2 is within an acceptable area, tighten
Torx screw to specification. See TORQUE SPECIFICATIONS. Once again,
rotate crankshaft 2 revolutions in running direction and stop on TDC
and recheck. To complete installation, reverse removal procedure.
Fig. 76: Aligning Timing Marks

Fig. 77: Identifying Tensioner Pistons
Fig. 78: Identifying Tensioner Dimensions

TURBOCHARGER


compartment. Always replace gaskets and self locking nuts.

refer to illustrations. See Fig. 79-Fig. 86.

1) Remove battery. Remove engine cover(s). Raise vehicle,
remove lower engine shield (noise insulator). See Fig. 2. Drain
coolant, see DRAINING COOLING SYSTEM.
NOTE: DO NOT let hang by hoses, do not open the A/C system.
2) Unbolt A/C compressor, move compressor aside, support with

wire.
3) Unbolt turbo support bracket (2), disconnect oil return
line (1) from turbo and move aside. Remove ducting from turbo (4 & 5).
Remove pressure line banjo fitting (3). See Fig. 80.
4) Disconnect hose from support for charge air pressure
regulator valve. Unbolt bracket for coolant supply line at charge air
pressure regulator valve. Remove air intake duct between cowl and air
cleaner housing.
5) Disconnect harness connectors from around air cleaner box.
Remove air cleaner box. See Fig. 27.
6) Unbolt crankcase ventilation hose (1). Unbolt oil supply
line bolts (3) at heat shield. Remove heat shield (4). Remove sleeve
(2) from coolant return hose. Remove turbo return hose at line to
turbo. The line remains bolted to turbocharger. Unbolt the oil supply
line (7) from turbo. See Fig. 81.
7) Unbolt catalytic converter from turbo, remove bolts (5)
from exhaust manifold. Position turbo to gain access to coolant supply
line banjo fitting and remove. Remove turbocharger.
NOTE: Before tightening turbocharger, loosely bolt coolant supply

line to vacuum diaphragm for air pressure regulator valve.
Tighten banjo fitting, then tighten mounting bolts for
bracket to proper torque.
8) To install, reverse removal procedure. Tighten bolts to

specification. See TORQUE SPECIFICATIONS. For help in identifying
intake ducting components, vacuum line routing and component
locations, refer to illustrations. See Figs. 82-86.
Fig. 79: Identifying Exhaust Manifold & Turbocharger Components
Fig. 80: Removing Turbocharger (1 of 2)
Fig. 81: Removing Turbocharger (2 of 2)

Fig. 82: Identifying Intake Ducting & Components (1 of 2)
Fig. 83: Identifying Intake Ducting & Components With Charge Air
Cooler (2 of 2)
Fig. 84: Identifying Charge Air Pressure Control System Component
& Vacuum Line Routing (Audi AEB Engine)
& Vacuum Line Routing (Passat AEB Engine)
& Vacuum Line Routing (ATW Engine)
VISCOUS FAN (ENGINE COOLING)

INSTALLATION (SERPENTINE BELT).
2) Remove viscous fan with pulley from its bearing. Use a
drift punch to lock up the coupling/pulley (1). Using an 8 mm hex
wrench (2) remove fasteners from viscous coupling, remove coupling and
Pulley. See Fig. 87. To remove viscous fan bushing (bearing). See
VISCOUS FAN BUSHING (BEARING). or go to next step.
3) To install, reverse removal procedure. Ensure pulleys are
free of debris. Bolt coupling/pulley to bracket/bearing, Using a
torque wrench, tighten mounting bolts to 45 Nm (33 ft. lbs).
4) Using a torque wrench tighten fan to viscous coupling to
10 Nm (7 ft. lbs).
5) Start engine and check viscous fan and belt running
condition.
Fig. 87: Removing Viscous Fan, Coupling & Pulley

VISCOUS FAN BUSHING (BEARING)

INSTALLATION (SERPENTINE BELT). Remove viscous fan and pulley. See
VISCOUS FAN (ENGINE COOLING).
2) With fan and pulley removed, remove circlip (1) from
bracket. See Fig. 88. Pull bearing out of bracket using (VAG 3367/3,
3350, and 3301). See Fig. 89.
3) Press Bearing back into bracket using (VAG 3367/1, 3367/2,
3367/3, and 3301). SeeFig. 90.
4) To complete install, reverse removal procedure. Ensure
pulleys are free of debris. Bolt coupling/pulley to bracket/bearing,
Using a torque wrench, tighten mounting bolts to 45 Nm (33 ft. lbs).
5) Using a torque wrench tighten fan to viscous coupling to
10 Nm (7 ft. lbs).
6) Start engine and check viscous fan and belt running
condition.
Fig. 88: Identifying Location of Bearing & Circlip In Bracket

Fig. 89: Removing Bearing From Bracket
Fig. 90: Installing Bearing Into Bracket

OVERHAUL

strike pistons.
CYLINDER HEAD
Cylinder Head Resurfacing

Measure cylinder head warpage, measure at several points
along gasket surface using straight edge and feeler gauge. See Fig. 91
. If warpage exceeds specification, machine cylinder head. See
CYLINDER HEAD table under ENGINE SPECIFICATIONS. If machining causes
cylinder head height to be less than specification, replace cylinder
head. When checking dimensions for cylinder head height, measure at
(A) through the holes for the head bolts. See Fig. 92.
Fig. 91: Checking Cylinder Head For Warpage
Fig. 92: Checking Cylinder Head Height

Valve Guides Checking
NOTE: Intake valve stem diameter differs from exhaust valve stem
diameter. Use appropriate valve when measuring valve guide
wear.
1) To measure valve guide wear, attach dial indicator to

cylinder head. Insert valve into guide until valve stem tip is even
with top end of guide.
2) Lightly push edge of valve head against dial indicator
tip. Zero dial indicator. Push valve away from dial indicator, in
direction opposite of camshaft axis.
3) Maximum allowable deflection is .032" (.8 mm) on intake or
exhaust valve. If deflection does not exceed specification, guide is
okay. If deflection exceeds specification, recheck using new valve. If
deflection still exceeds specification, replace worn guides. See
Fig. 93.
Fig. 93: Checking Valve Guide Wear
Valve Guide Removal
NOTE: Hand lap valves check sealing, also check cylinder head
sealing surface can be refaced. If a problem is found in
either case, valve guides should not be replaced.
1) Set the cylinder support (3361) as soon. See Fig. 94.

2) Install mounting pins for cylinder head bolts (A) into
threaded holes (2) and (3). See Fig. 94.
3) Install pin (B) into relevant hole for valve angle. Outer
inlet valves: 21.5 degrees, center Inlet valve: 15 degrees and exhaust
valve: 20 degrees.
4) Press worn valve guides out with drift (3360) from
camshaft side. See Fig. 95.
5) Lubricate new valve guides with oil. Using Valve Guide
Installer (3360), press valve guide in cold cylinder head as far as
guide will go (until shoulder makes contact) from camshaft side. DO
NOT exceed one ton pressure. Using Valve Guide Reamer (3363), ream
guides to proper stem-to-guide clearance. See CYLINDER HEAD table
under ENGINE SPECIFICATIONS.
Fig. 94: Identifying Cylinder Head Support Fixture (3361) & Settings
Fig. 95: Pressing Valve Guide From Cylinder Head
Valves Stem Seals Replacement (Head Installed)

1) Remove camshafts. See CAMSHAFTS under REMOVAL &
INSTALLATION.
2) Remove valve lifters and place them with contact surface
downward. During removal make sure lifters are not interchanged.
3) Remove spark plugs with spark plug removal tool (3122B).
4) Set piston of relevant cylinder to Bottom Dead Center
(BDC).
5) Screw VW pressure hose (653/3) into spark plug thread. See
Fig. 96.
NOTE: DO NOT remove valve springs at this time.
6) Secure (3362) valve spring compressor to cylinder head

with tool securing bolt and position installing tool for compressing
valve springs to following positions. Outer intake valves: lower
position, Center intake valve: upper position and Exhaust valve: lower
position. See Fig. 96.
7) Connect pressure hose to compressed air system supplying
at least 6 bar (87 psi) and remove valve springs.
8) Remove valve stem seals with puller (3364) for valve shaft
seal. See Fig. 97.
Fig. 96: Installing Air Pressure Hose (653/3) Into Spark plug
Hole & Valve Spring Compressor (3362) Onto Cylinder Head.
Fig. 97: Identifying Valve Stem Seal Puller (3364)
Installing Valves Stem Seals

1) Slide plastic sleeve (A) supplied over relevant valve
stem. This will prevent the new valve stem seal (B) from being
damaged. See Fig. 98.
2) Place new valve stem seal into installation tool (3365).
3) Oil valve stem seal sealing lip and press carefully onto
the valve guide. See Fig. 98. The assembly is basically a reverse of
the dismantling sequence.

strike pistons.
Fig. 98: Identifying Plastic Sleeve Placement, Valve Stem Seal &
Installation Tool (3365)
Valve Seats
NOTE: When repairing engines with leaking valves, it is not

sufficient to replace or renew valve seats and valves. It is
also necessary to check the valve guides for wear. This is
particularly important on high mileage engines. The valve
seats should only be refaced just enough to produce a perfect
seating pattern. The maximum permissible refacing dimension
must be calculated before beginning refacing. If the refacing
dimension is exceeded, the function of the hydraulic valve
lifters can no longer be guaranteed and the cylinder head
should be replaced. If the valve is to be replaced as part of
a repair, use a new valve for the calculation.
1) Insert valve into guide. Press valve tightly against valve

seat. Lay a straightedge across top of cylinder head. Measure distance
between valve stem tip and bottom of straightedge. See Fig. 99. This
is valve installed height. If a new valve is going to be installed,
use new valve to make this measurement.
2) This measurement determines installed valve height.
Subtract measured distance from minimum specification. See
MINIMUM VALVE INSTALLED HEIGHT table. If valve installed height is too
low or too high, cam followers will not work correctly. If valve stem
height is less than 1.339" (34.0 mm) on intake valve (outer), 1.327"
(33.7 mm) intake valve (center), or 1.354" (34.4 mm) on the exhaust
valve, install a new valve and measure again. See Fig. 100.
3) If valve stem height measurement is still less than
specification, replace cylinder head. If valve stem height exceeds
specification, seat can be machined; however, DO NOT machine enough
material away from seat to cause valve stem height to be less than
minimum specification.
Fig. 99: Measuring Valve Installed Height
Fig. 100: Calculating Stem Height & Valve Seat Refacing Dimension
MINIMUM VALVE INSTALLED HEIGHT
Application In. (mm)
Intake Valve
Outer .................................... 1.370 (34.80)
Center ................................... 1.326 (33.70)
Exhaust Valve .............................. 1.354 (34.40)
VALVE TRAIN
CAUTION: If lifters are charged with oil, allow 30 minutes to bleed

down before starting engine. Pistons may strike valves,
resulting in bent valves.

strike pistons.
Lifters (Cam Followers)

Test lifters, see HYDRAULIC VALVE ADJUSTERS under REMOVAL &
INSTALLATION. If lifter(s) can be pushed down more than .007" (.20
mm), replace lifters.
Camshaft Axial Play (Audi)

Measure camshaft axial play (intake and exhaust) with lifter
and camshaft chain removed. Measure with chain side camshaft bearing
caps and cam sprocket side double bearing cap installed. See Fig. 101.
Remove all other caps, note their locations for reassemble. See
Fig. 102. Maximum wear limit .008" (.2 mm).
Fig. 101: Setting Up To Measure Axial Play Intake & Exhaust Cams
Fig. 102: Identifying Camshaft Bearing Caps
Camshaft Axial Play (Passat)

Measure camshaft axial play (intake and exhaust) with lifter
and camshaft chain removed. Camshaft bearing caps No. 2. and No. 4.
installed. Remove all other caps, note their locations for reassemble.
See Fig. 102. Maximum wear limit .008" (.2 mm). See Fig. 103.
Fig. 103: Checking Camshaft Axial Play

Valves
CAUTION: Sodium-filled exhaust valves must not be disposed of until

they have been properly treated as follows: By HAND (no air
tools), saw the valves into two sections using a metal saw at
a point between the center of the valve stem and the valve
head. The valves must not come into contact with water when
this is done. Throw the valves into a bucket of water (not
more than ten at a time) and step back. A sudden chemical
reaction will occur during which the sodium filling burns.
After this treatment the valves can be disposed of as normal
scrap.
Measure valve stem diameter and valve margin. If not within

specification, replace valves. Replace as necessary. See
VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.
Valves must not be refaced by grinding. Hand lap only. If

lapping does not produce proper sealing, check valve seat. See VALVE
SEATS.
Valve Springs
Information is not available from manufacturer.
CYLINDER BLOCK ASSEMBLY
Piston & Rod Assembly

1) Ensure piston, connecting rod and rod caps are marked with
matching cylinder number prior to removal. Ensure engine front arrow
is marked on top of piston and front mark "A" exists on rod and cap.
See Fig. 104. Pistons and rods are to be replaced in sets of 4. Rod
cap bolts and nuts must be replaced after removing or loosening.
Fig. 104: Assembling Piston & Rod

2) Mark piston in relation to pin. Remove circlips from ends

of pin bore. Use Piston Pin Replacer/Installer (VW 222A) to remove and
install piston pin. If pin is too tight, heat piston to 140ø F (60ø
C). Ensure rod is properly positioned with piston. See Fig. 104.
Fitting Pistons
Measure clearances with cylinder block supported on work
bench. Check clearance of piston-to-cylinder bore. Piston diameter is
stamped on top of piston in millimeters. See
PISTON-TO-CYLINDER BORE DIMENSIONS.
PISTON-TO-CYLINDER BORE DIMENSIONS

ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Size Piston Diameter (1) Cylinder Bore
Standard .............. 3.187" (80.96 mm) ........ 3.189" (81.01 mm)

1st Oversize .......... 3.207" (81.46 mm) ........ 3.209" (81.51 mm)
(1) - Measurement does not include graphite coating, thickness

of .02mm (.0008"). Graphite coating wears away.
Piston Rings
Install piston ring with TOP mark (if present) facing upward.
Insert ring from bottom of cylinder block to a depth of about .591 (15
mm) and measure ring end gap. See Fig. 105. Measure ring side
clearance with piston. See Fig. 106. If not within specification,
replace as necessary. See PISTONS, PINS & RINGS table under ENGINE
SPECIFICATIONS. Install rings on piston with TOP mark facing upward.
Recessed edge on outside of center ring must face piston pin (down).
Position ring gaps on piston at 120 degree intervals. See Fig. 104.
Fig. 105: Checking Piston Ring End Gap

Fig. 106: Checking Piston Ring Side Clearance

Rod Bearings
Mark rod caps for reinstallation. Use Plastigage to measure
bearing oil clearance. DO NOT turn additional 90 degrees. Measure
connecting rod side play. Replace or machine as necessary. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE
SPECIFICATIONS. Lubricate bolt threads when installing connecting rod
caps. Tighten evenly to specification in several steps. See
TORQUE SPECIFICATIONS.
Crankshaft & Main Bearings
Main bearing caps are marked with matching journal for
installation in original position. See Fig. 107. Use Plastigage(R) to
measure oil clearance. Measure crankshaft end play. See THRUST WASHER.
Fig. 107: Crankshaft Assembly

Thrust Washer
Insert feeler gauge between No. 3 main bearing and crankshaft
thrust face to measure end play. Replace thrust washer as necessary.
See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE
SPECIFICATIONS.
Cylinder Block
Measure cylinder bore diameter in 3 places: at center of bore
and .39" (10 mm) from top and bottom of bore. See Fig. 108. If
cylinder bore diameter is not within specification, hone cylinder bore
until diameter meets first oversize specification. See CYLINDER BLOCK
under ENGINE SPECIFICATIONS. When measuring cylinder bore, maximum
allowable difference between actual measurement and standard
specification is .0031" (.08 mm).
Fig. 108: Identifying Locations For Checking Cylinder Bore
ENGINE OILING
ENGINE LUBRICATION SYSTEM
Crankcase Capacity
See CRANKCASE CAPACITY table.
CRANKCASE CAPACITY
Application Qts. (L)
Without Filter Replacement ..................... 3.2 (3.0)

With Filter Replacement ........................ 3.7 (3.5)
Oil Pressure
Check oil pressure with engine at normal operating
temperature. Oil pressure at idle should be is 14-36 psi (1-2.5 bar)
at 3000 RPM, 44-73 psi. (3-5 bar). At higher RPM oil pressure should
not exceed 100 psi (7.0 bar). Inspect oil pump. See OIL PUMP.
OIL PUMP


Remove oil pan. Remove oil pump attaching bolts and remove
oil pump assembly. To install, reverse removal procedure.
Inspection
Check oil pump backlash and oil pump axial play. See
Figs. 110 and 111. If not within specification, replace oil pump
assembly. See OIL PUMP SPECIFICATIONS table.
Fig. 109: Identifying Engine Oiling System Components

Fig. 110: Checking Oil Pump Gear Backlash
Fig. 111: Checking Oil Pump Axial Clearance

OIL PUMP SPECIFICATIONS

Backlash
New ......................................... .002 (.05)
Service Limit ............................... .008 (.20)
Axial Play Limit .............................. .006 (.15)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Camshaft Drive Gear Bolt .................................. 74 (100)

Catalytic Converter-To-Turbocharger Bolt ................... 18 (25)
Catalytic Converter-To-Front Exhaust Pipe
Bolt ...................................................... 18 (25)
Connecting Rod Bearing Cap Nut (1)
Step 1 ................................................... 22 (30)
Step 2 ..................................... Additional 90 Degrees
Crankshaft Main Bearing Cap Bolt (1)
Step 1 ................................................... 48 (65)
Crankshaft Timing Sprocket Bolt (1)
Step 1 ................................................... 66 (90)
Cylinder Head Bolt (1)
Step 1 ................................................... 30 (40)
Step 2 ................................................... 44 (60)
Driveplate (Flywheel) (1)
Step 1 ................................................... 22 (30)
Step 2 ................................................... 44 (60)
Engine Mount-To-Frame Bolt ................................. 18 (25)
Engine Mount-To-Engine Support Bolt ........................ 18 (25)
Engine-To-Torque Rod Bracket Bolt .......................... 18 (25)
Exhaust Manifold-To-Cylinder Head Bolt & Nut ............... 18 (25)
Exhaust Pipe-To-Manifold Nut ............................... 30 (40)
Intake Manifold Bracket Bolt ............................... 18 (25)
Intermediate Shaft Sprocket Bolt ........................... 59 (80)
Oil Pan Bolt ............................................... 11 (15)
Oil Pump Cover Long Bolt ................................... 18 (25)
Oil Pump Cover Short Bolt ...................................... (2)
Oil Pan Drain Plug ....................................... 36.9 (50)
Piston Oil Pressure Relief Valve ........................... 20 (27)
Pressure Plate-To-Flywheel Bolt (1)
Step 1 ................................................... 22 (30)
Step 2 ................................................... 44 (60)
Sender Wheel (Sensor Trigger) ............................ 7 (10 Nm)
Starter Mount Bolt ......................................... 48 (65)
Timing Belt Tensioner Nut .................................. 18 (25)
Transmission Mount-To-Frame Bolt ........................... 18 (25)
Transmission Support-To-Mount Bolt ......................... 30 (40)
Water Pump-To-Housing Bolt ................................. 22 (30)
INCH Lbs. (N.m)
Camshaft Bearing Cap Bolt .................................. 89 (10)

Transaxle/Engine Cover Plate Bolt .......................... 89 (10)
Valve Cover Retaining Nut .................................. 89 (10)
Water Pump Nut .............................................. 7 (10)
(1) - Use NEW bolts.

(2) - Tighten bolt to 89 INCH lbs. (10 N.m).
ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Specification
Displacement .......................... 110 Cu. In. (1.8L)

Bore ....................................... 3.189 (81.01)
Stroke ................................... 3.40" (86.4 mm)
Compression Ratio .................................. 9.5:1
Fuel System ................................. Motronic SFI
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

Crankshaft End Play

Standard ..................................... .003-.009 (.07-.23)
Service Limit ......................................... .011 (.30)
Main Bearings
Journal Diameter
Standard
Nominal ...................................... 2.1260 (54.000)
Maximum ...................................... 2.1268 (54.022)
Minimum ...................................... 2.1243 (53.958)
1st Undersize
Nominal ...................................... 2.1161 (53.750)
Maximum ...................................... 2.1170 (53.772)
Minimum ...................................... 2.1145 (53.708)
2nd Undersize
Nominal ...................................... 2.1063 (53.500)
Maximum ...................................... 2.1071 (53.522)
Minimum ...................................... 2.1046 (53.458)
3rd Undersize
Nominal ...................................... 2.0965 (53.250)
Maximum ...................................... 2.0973 (53.272)
Minimum ...................................... 2.0948 (53.208)
Journal Out-Of-Round ......................................... (1)
Journal Taper ................................................ (1)
Oil Clearance
Standard ............................... .0008-.0024 (.020-.060)
Service Limit ....................................... .005 (.15)
Connecting Rod Bearings
Journal Diameter
Standard
Nominal ...................................... 1.8819 (47.800)
Maximum ...................................... 1.8828 (47.823)
Minimum ...................................... 1.8802 (47.758)
1st Undersize
Nominal ...................................... 1.8720 (47.550)
Maximum ...................................... 1.8729 (47.572)
Minimum ...................................... 1.8704 (47.508)
2nd Undersize
Nominal ...................................... 1.8622 (47.300)
Maximum ...................................... 1.8631 (47.323)
Minimum ...................................... 1.8605 (47.258)
3rd Undersize
Nominal ...................................... 1.8524 (47.051)
Maximum ...................................... 1.8532 (47.074)
Minimum ...................................... 1.8507 (47.008)
Journal Out-Of-Round ......................................... (1)
Journal Taper ................................................ (1)
Oil Clearance
Standard ................................... .002-.012 (.05-.31)
Service Limit ....................................... .015 (.37)
(1) - Information is not available from manufacturer.

CONNECTING RODS
CONNECTING RODS
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Bore Diameter
Pin Bore ............................................... (1)
Crankpin Bore .......................................... (1)
Center-To-Center Length .................................. (1)
Side Play
Standard ............................... .002-.012 (.05-.31)
Service Limit ................................... .015 (.37)

ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
PISTONS, PINS & RINGS
PISTONS, PINS & RINGS

ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Pistons
Clearance ................................... .0017 (.045)
Standard Diameter .......................... 3.187 (80.96)
1st Oversize ............................... 3.207 (81.46)
Pins
Diameter ............................................. (1)
Piston Fit ........................................... (1)
Rod Fit .............................................. (1)
Rings
No. 1 & 2
End Gap
Standard ......................... .007-.016 (.20-.40)
Service Limit ............................. .031 (.80)
Side Clearance
Standard ......................... .002-.003 (.06-.09)
Service Limit ............................. .007 (.20)
No. 3 (Oil)
End Gap
Standard ......................... .010-.020 (.25-.51)
Service Limit ............................. .031 (.80)
Side Clearance
Standard ......................... .001-.002 (.03-.06)
Service Limit ............................. .006 (.15)

ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
CYLINDER BLOCK
CYLINDER BLOCK
Cylinder Bore
Standard Diameter ........................ 3.189 (81.01)
1st Oversize ............................. 3.209 (81.51)
Maximum Taper ............................... .003 (.08)
VALVES & VALVE SPRINGS
VALVES & VALVE SPRINGS

Intake Valves
Face Angle ................................................... 45ø
Head Diameter ................................... 1.059" (26.9 mm)
Length ........................... 4.127-4.147" (104.84-105.34 mm)
Minimum Margin ............................................... (1)
Stem Diameter .................................... .234" (5.96 mm)
Valve Stem Installed Height
(Minimum)
Center ............................................. 1.32 (33.7)
Outer .............................................. 1.29 (34.0)
Exhaust Valves
Face Angle ................................................... 45ø
Head Diameter ................................... 1.177" (29.9 mm)
Length ........................... 4.080-4.100" (103.64-104.14 mm)
Minimum Margin ............................................... (1)
Stem Diameter .................................... .233" (5.94 mm)
Valve Stem Installed Height
(Minimum) ........................................... 1.35 (34.4)
(1) - DO NOT machine valves; hand lap only.

CYLINDER HEAD
CYLINDER HEAD
Cylinder Head Height (Minimum) ................... 5.480" (139.2 mm)

Maximum Warpage ..................................... .004" (.10 mm)
Valve Seats
Intake Valve
Seat Angle ................................................. 45ø
Seat Width ............................ .059-070" (1.50-1.80 mm)
Exhaust Valve
Seat Angle ................................................. 45ø
Seat Width ..................................... .070" (1.80 mm)
Valve Guides
Intake Valve
Valve Guide Installed Height ............................... (1)
Valve Stem-To-Guide Oil Clearance ........... (2) .031" (.80 mm)
Exhaust Valve
Valve Guide Installed Height ............................... (1)
Valve Stem-to-Guide Oil Clearance ........... (2) .031" (.80 mm)
(1) - Valve guide shoulder flush with cylinder head.

(2) - New valve installed in cylinder head. Dial indicator used
to measure valve wobble in guide.
CAMSHAFT
CAMSHAFT
Journal Diameter
Standard ........................................... (1)
Undersize .......................................... (1)
End Play ...................................... .007 (.20)
Runout ...................................... .0004 (.010)
Oil Clearance (Maximum) ....................... .004 (.10)

END OF ARTICLE

VW 1.8L 4-Cylinder Turbo Engine Guide

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VW 1.8L 4-Cylinder Turbo Engine Guide

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1.

8L 4-CYLINDER TURBO 5-VALVE

* PLEASE READ THIS FIRST *

NOTE: For engine repair procedures not covered in this article,

Engine identification number is stamped on a machined pad on

Fig. 1: Locating Engine Identification Number

Removal & Installation

WARNING: The cooling system is pressurized when the engine is warm.

1) Raise vehicle, remove lower engine shield (noise

Fig. 3: Identifying Location Of Thermostat & Coolant Drain Plug

CAUTION: Coolant/water mixture should be used at all times. Use only

NOTE: Water pump is located behind accessary drives, this will

Fig. 4: Identifying Cooling System Components

NOTE: When battery is disconnected, vehicle computer and memory

After any repair which required that the battery be

1) Ensure ignition switch is in OFF position. Reconnect

1) Remove clip for accelerator pedal cable on throttle body.

Engine is equipped with non-adjustable, non-serviceable

NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in the

REMOVAL & INSTALLATION

* PLEASE READ THIS FIRST *

CAUTION: Radio/cassette or radio/CD player is equipped with an

NOTE: When battery is disconnected, vehicle computer and memory

ACCESSORY DRIVE BELTS

CAUTION: If reusing old serpentine or other accessory drive belt(s),

NOTE: Serpentine belt may also be referred to as ribbed belt or

For help in identifying accessory drive belt(s) routing and

Removal & Installation (A/C Belt)

Removal & Installation (Serpentine Belt)

Removal & Installation (Water Pump Belt)

Fig. 6: Removing Water Pump Pulley & Belt

WARNING: The cooling system is pressurized when the engine is warm.

NOTE: Drain coolant into clean container if coolant is in good

Open cap on engine coolant expansion tank. Remove lower

Fig. 7: Draining Engine Coolant

COOLING SYSTEM BLEEDING

Fig. 9: Installing Fill Adaptor To Coolant Expansion Tank With

Fig. 10: Installing Fill Adaptor To Coolant Expansion Tank With

Fig. 11: Locating Heater Hose Vent Hole

Fig. 12: Identifying Lock Carrier Components (First Design)

Fig. 14: Identifying Lock Carrier Components (Second Design)

WARNING: ALWAYS release fuel pressure before disconnecting fuel

NOTE: Obtain radio code before disconnecting battery. Remove

NOTE: For help in identifying components and component locations,

WARNING: The cooling system is pressurized when the engine is warm.

NOTE: DO NOT open the air conditioning refrigerant circuit.

CAUTION: DO NOT allow torque converter to fall out of bell housing.

Fig. 18: Identifying Horns Harness connectors

Fig. 19: Identifying Power Steering Cooler Line Mounting Points

Fig. 21: Identifying Motronic Engine Control Module (E-Box) With

Fig. 23: Identifying Anti-Lock Brake System Harness Connectors

Fig. 24: Identifying Oxygen Sensor Harness Connector

Fig. 26: Identifying A/C Compressor Harness Connector (Green)

Fig. 27: Identifying Wastegate, EVAP, Power Output Stage, Mass

Fig. 29: Identifying Coolant Expansion Tank (Location Of Coolant

Fig. 30: Identifying Accelerator Pedal Cable, Cable Flange,

Fig. 32: Identifying Location Of Locating Sleeves (Mark Sleeves

Fig. 33: Identifying Access To Torque Converter Bolts

Fig. 35: Installing Support Bridge (10-222A) & Trans Support

1) To install, reverse removal procedure. Engine alignment

CAUTION: DO NOT turn crankshaft or camshaft with timing belt removed.

NOTE: For help in identifying components and component locations,