4 Cylinder Tdi Engine 2 0 LTR 4 Valve Common Rail Generation II

Service
4-cylinder TDI engine (2.0 ltr. 4-valve common rail -

generation II)
CJCB CGL
Engine ID
CGL CJCA CMF CJC CMG CMF CJC
C D A C B B D
Edition 10.2016
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2016 Audi AG, Ingolstadt D3E8033D040

Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II) - Edition 10.2016
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine identification number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 4
2.3 Safety precautions when using testers and measuring instruments during a road test . . . . 4
2.4 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Safety precautions when working on the subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.6 Safety precautions when working on the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Foreign particles in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.7 Installing radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Securing engine to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.1 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.2 Removing and installing engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.3 Removing and installing torque reaction support and cross member . . . . . . . . . . . . . . . . 45
3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.1 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.1 Exploded view - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.2 Exploded view - sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.4 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.6 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.7 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.8 Removing and installing sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.1 Exploded view - cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.3 Removing and installing sealing flange (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.4 Renewing needle bearing in drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.1 Exploded view - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.3 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.4 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.5 Pulling spur gear off crankshaft and shrink-fitting new spur gear . . . . . . . . . . . . . . . . . . . . 81
Contents i
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

4.1 Exploded view - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.2 Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.4 Checking radial clearance of conrod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.1 Exploded view - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.2 Exploded view - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.4 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.5 Removing and installing seals for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.1 Exploded view - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.1 Exploded view - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.2 Measuring axial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.3 Measuring radial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3.4 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.5 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.6 Checking hydraulic compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3.7 Removing and installing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.1 Machining valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.3 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4.4 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.1 Exploded view - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.3 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.4 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.5 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.6 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 151
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2.1 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
3 Oil filter/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
3.1 Exploded view - oil filter housing/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
3.2 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3.3 Checking oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3.4 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
3.5 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4 Balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4.1 Removing and installing balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1.3 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
ii Contents
2 Coolant pump/thermostat assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

2.1 Exploded view - coolant pump/thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.2 Exploded view - pump for exhaust gas recirculation cooler V400 . . . . . . . . . . . . . . . . . . . . 181
2.3 Exploded view - continued coolant circulation pump V50 . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2.4 Exploded view - coolant valve for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
2.6 Checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
2.7 Removing and installing 4/2-way valve with thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
2.8 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 187
2.9 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 188
2.10 Removing and installing pump for exhaust gas recirculation cooler V400 . . . . . . . . . . . . 189
2.11 Removing and installing coolant circulation pump V50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
2.12 Removing and installing coolant valve for gearbox N488 . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3.1 Exploded view - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3.2 Removing and installing coolant pipe (top left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.3 Removing and installing coolant pipe (bottom left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3.4 Removing and installing coolant pipe (rear right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
3.5 Removing and installing coolant pipe (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4 Radiator/radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4.1 Exploded view - radiator/radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4.2 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.3 Removing and installing radiator cowl with radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
4.4 Removing and installing radiator fan control unit J293 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
4.5 Removing and installing radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
1.1 Exploded view - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
2.1 Overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
2.2 Exploded view - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
2.4 Removing and installing charge pressure sender G31 / intake air temperature sender G42
........................................................................ 228
2.5 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
1.2 Overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.3 Filling and bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
1.4 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
2.1 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
3.1 Exploded view - air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
3.2 Removing and installing air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
4.1 Exploded view - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
4.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
4.3 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
5 Injectors/high-pressure reservoir (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
5.1 Exploded view - injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Contents iii
5.2 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

5.3 Performing adaption of correction values for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
5.4 Checking for injectors sticking open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
5.5 Checking return flow rate of injectors with engine running . . . . . . . . . . . . . . . . . . . . . . . . . . 258
5.6 Checking return flow rate of injectors at starter cranking speed . . . . . . . . . . . . . . . . . . . . 261
5.7 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
5.8 Removing and installing high-pressure pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
5.9 Removing and installing high-pressure reservoir (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
6 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
6.1 Exploded view - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
6.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
6.3 Performing first fuel filling operation after installing high-pressure pump . . . . . . . . . . . . . . 275
7 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
7.1 Checking fuel pressure (low pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
7.2 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
7.3 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 280
7.4 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
7.5 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
8.1 Exploded view - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
8.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
9 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
9.1 Wiring and component check with test box V.A.G 1598/42 . . . . . . . . . . . . . . . . . . . . . . . . 288
9.2 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

1 Exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
1.1 Exploded view - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
1.2 Removing and installing front exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
1.3 Separating exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
1.4 Renewing tailpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
1.5 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
1.6 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
2 Emission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
2.1 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
2.2 Removing and installing pressure differential sender G505 . . . . . . . . . . . . . . . . . . . . . . . . 303
3 Exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
3.1 Exploded view - exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
3.2 Removing and installing exhaust gas temperature sender 1 G235 . . . . . . . . . . . . . . . . . . 306
4 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
4.1 Exploded view - exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
4.2 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 314
4.3 Checking exhaust gas recirculation cooler change-over . . . . . . . . . . . . . . . . . . . . . . . . . . 316
5 Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
5.1 Exploded view - exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
5.2 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
1.1 Exploded view - glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
1.2 Removing and installing glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
1.3 Checking glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
iv Contents
1.4 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324

1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Contents v
vi Contents
00 – Technical data
1 Identification
(ARL004978; Edition 10.2016)
⇒ “1.1 Engine identification number/engine data”, page 1
1.1 Engine identification number/engine da‐

ta
Engine number
♦ The engine number (“engine code” and “serial number”)
-arrow- can be found on the left side (seen in the direction of
travel) at the joint between engine and gearbox.
♦ There is also a sticker with “engine code” and “serial number”
attached to the toothed belt cover.
♦ Engine codes starting with the letter “C” have four letters (pre‐
viously three letters).
♦ The first 3 characters of the engine code stand for the engine
capacity and the mechanical construction and design. They
are stamped onto the cylinder block together with the serial
number.
♦ The 4th character indicates the power output and torque of the
engine and is determined by the engine control unit.
Note
♦ The four-letter engine code is found on the type plate (country

specific version), vehicle data sticker and engine control unit.
♦ Fitting locations of the type plate (certain countries only) and
the vehicle data sticker ⇒ Maintenance ; Booklet 811 or
⇒ Maintenance ; Booklet 812 .
For engine data refer to:

♦ A4 ⇒ Technical data for diesel engines; Rep. gr. 00 ; Overview
of engines
♦ A5 Coupé ⇒ Technical data for diesel engines; Rep. gr. 00 ;
Overview of engines
♦ A5 Cabriolet ⇒ Technical data for engines; Rep. gr. 00 ;
Overview of engines
1. Identification 1
2 Safety precautions
⇒ “2.1 Safety precautions when working on the fuel supply sys‐
tem”, page 2
⇒ “2.2 Safety precautions when working on vehicles with start/
stop system”, page 4
⇒ “2.3 Safety precautions when using testers and measuring in‐
struments during a road test”, page 4
⇒ “2.4 Safety precautions when working on the cooling system”,
page 4
⇒ “2.5 Safety precautions when working on the subframe”,
page 5
⇒ “2.6 Safety precautions when working on the exhaust system”,
page 5
2.1 Safety precautions when working on the

fuel supply system
When working on the fuel system note the following warnings:
WARNING
Fuel under pressure - risk of injuries!

♦ Wrap a cloth around the connection before opening the
fuel system. Then carefully loosen the connection to re‐
lieve the pressure.
The fuel can become extremely hot. This can cause injuries.
♦ In extreme cases the temperature of the fuel lines and the
fuel can be up to 100 °C after the engine is switched off.
Let fuel cool off before opening any connections; other‐
wise there is a danger of scalding!
♦ Put on protective gloves.
♦ Put on safety goggles.
Escaping fuel can cause a risk.
♦ Depending on the version, the power supply for the fuel
system pressurisation pump - G6- must be disconnected
before opening the fuel system, since -G6- will be activa‐
ted briefly when the driver's door is opened with the battery
still connected.
♦ Remove fuse for fuel pump control unit - J538- ; for iden‐
tification of fuses refer to ⇒ Current flow diagrams, Elec‐
trical fault finding and Fitting locations.
2 Rep. gr.00 - Technical data

Caution
The high-pressure pump has very close tolerances and must

not be allowed to run without fuel. To prevent this and to enable
the engine to start quickly after parts have been renewed, it is
important to observe the following:
♦ If components of the fuel system between the fuel tank
and the high-pressure pump are removed or renewed, the
fuel system must be bled ⇒ page 240 .
♦ If the high-pressure pump is removed or renewed, the first
fuel filling operation must be performed before the engine
is started for the first time ⇒ page 240 .
Observe the following points to prevent personal injuries and

damage to the injection and glow plug system:
♦ Persons wearing a cardiac pacemaker must at all times main‐
tain a safe distance from high-voltage components such as
injectors and gas-discharge headlights.
♦ Always switch off the ignition before connecting or discon‐
necting tester cables or electrical wiring for the injection or
glow plug system.
♦ Do not open any fuel line connections while the engine is run‐
ning.
♦ Always switch off ignition before washing engine.
♦ Erase any entries in event memory resulting from repairs
⇒ Vehicle diagnostic tester, Guided Functions , then In-
terrogate event memory .
Caution
To prevent irreparable damage to the electronic components

when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
♦ Always switch off the ignition before disconnecting the
battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Dis‐
connecting and connecting battery .
WARNING
Escaping fuel can cause a risk.

♦ The power supply for the fuel system pressurisation pump
- G6- must be disconnected before opening the fuel sys‐
tem, since -G6- will be activated briefly when the driver's
door is opened with the battery still connected.
2. Safety precautions 3
2.2 Safety precautions when working on ve‐

hicles with start/stop system
When performing repairs on vehicles with start/stop system, note
the following:
WARNING
Risk of injury due to automatic engine start on vehicles with

start/stop system.
♦ On vehicles with activated start/stop system (indicated by
a message in the instrument cluster), the engine may start
automatically if it needs to.
♦ Therefore it is important to ensure that the start/stop sys‐
tem is deactivated when performing repairs (switch off
ignition, if required switch on ignition again).
2.3 Safety precautions when using testers

and measuring instruments during a
road test
Note the following if testers and measuring instruments have to
be used during a road test:
WARNING
Accidents can be caused if the driver is distracted by test

equipment while road-testing, or if test equipment is not prop‐
erly secured.
Persons sitting in the front passenger's seat could be injured if
the airbag is triggered in an accident.
• The use of test equipment while driving causes distraction.
• There is an increased risk of injury if test equipment is not
secured.
♦ Test equipment must always be secured on the rear seat
with a strap and operated from the rear seat by a second
person.

cooling system
When working on the cooling system note the following warnings:
WARNING
Hot steam/hot coolant can escape - risk of scalding.

♦ The cooling system is under pressure when the engine is
hot.
♦ To allow pressure to dissipate, cover filler cap on coolant
expansion tank with cloth and open carefully.
Risk of injury as the radiator fans may start up automatically.
♦ Unplug electrical connectors before starting to work in the
area of radiator cowl.

Caution
Overheating can occur if the filler cap is not fitted properly.

♦ Close filler cap on coolant expansion tank (make sure it
engages).

subframe
When working on the subframe note the following warnings:
Caution
Risk of damage to running gear components.

♦ The vehicle must NOT be lowered onto its wheels if the
engine/gearbox mountings, steering rack or subframe
cross brace are not properly installed.
♦ The vehicle must NOT be supported by applying a trolley
jack or similar to the subframe or subframe cross brace.

exhaust system
WARNING
Please note the following warnings when working on all parts

of the exhaust system:
♦ Wear gloves (e.g. rubber, not textile) and safety goggles
to avoid contact with eyes and skin - risk of injury.
♦ Do not dismantle exhaust gas temperature sender - risk
of injury.
Caution
Risk of damage to flexible joint.

♦ Do not bend flexible joint more than 10°.
♦ Install flexible joint so that it is not under tension.
♦ Take care not to damage wire mesh on flexible joint.
2. Safety precautions 5
3 Repair instructions
⇒ “3.1 Rules for cleanliness”, page 6
⇒ “3.2 General notes”, page 6
⇒ “3.3 General repair instructions”, page 7
⇒ “3.4 Foreign particles in engine”, page 8
⇒ “3.5 Contact corrosion”, page 8
⇒ “3.6 Routing and attachment of pipes, hoses and wiring”, page
8
⇒ “3.7 Installing radiators and condensers”, page 8
3.1 Rules for cleanliness

Even small quantities of dirt can lead to defects. For this reason,
please observe the following rules when working on the fuel sup‐
ply system, injection system and turbocharger:
♦ Clean connections and surrounding area thoroughly with en‐
gine cleaner or brake cleaner and dry cleaned area before
loosening.
♦ Immediately seal open lines and connections with clean plugs,
for example from engine bung set - VAS 6122- .
♦ Do not remove sealing caps from components until immedi‐
ately prior to installation. Keep components that are to be re-
used in new, sealable plastic bags.
♦ After removal, place parts on a clean surface and cover them.
Use lint-free cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have not been stored in the proper packaging (e.g. in tool
boxes etc.).
♦ Do not work with compressed air when the system is open. If
possible, do not move vehicle.
♦ Make sure that no fuel runs onto the fuel hoses. Should this
occur, the fuel hoses must be cleaned again immediately.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
3.2 General notes

♦ The engine control unit has a self-diagnosis capability. Before
carrying out repairs and fault finding, the event memory must
be interrogated. The vacuum hoses and connections must al‐
so be checked (unmetered air).
♦ A voltage of at least 11.5 V is required for proper operation of
the electrical components.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and will
damage the Lambda probe.

♦ The vehicles are fitted with a crash/fuel shut-off system. This

system is designed to reduce the risk of a vehicle fire after a
crash by deactivating the fuel pump via the fuel pump relay.
♦ At the same time, this system also improves the engine's start‐
ing performance. When the driver's door is opened, the fuel
pump is activated for 2 seconds in order to build up pressure
in the fuel system ⇒ page 2 .
3.3 General repair instructions
Caution

fuel system must be filled and bled before the engine is
started for the first time ⇒ page 240 .
♦ Clean tools and workbench etc. before working on the injection

system.
♦ Before installing, check the injectors and their surroundings
visually; they must be undamaged and clean. Make sure the
injector bores in the cylinder head are clean. Wipe out if nec‐
essary using a clean cloth, taking care not to cause damage.
Do not use sharp objects of any kind.
♦ If the high-pressure fuel lines are to be re-used, you must mark
them before removal. High-pressure pipes must always be re-
installed on the same cylinder.
♦ Take care not to damage the injectors when removing the old
copper seals.
♦ Check all new O-rings for damage before installing. Lubricate
O-rings with engine oil or assembly oil before installing.
♦ Position high-pressure pipes so they are free of stress. Tighten
all unions lightly to start with before tightening to final torque.
♦ Never attempt to bend high-pressure fuel lines to shape.
♦ When working on any parts of the high-pressure fuel system,
tools may only be used for loosening and tightening pipe un‐
ions. All other components must always be removed and
installed by hand without using tools or other equipment.
♦ Press the fuel return hoses onto the injectors by hand from
above so that they engage audibly on each injector (do not
press in the release pins when doing this). Then press down
the release pin after connecting the return line. Check that the
fuel return hoses are seated securely and sealed properly by
pulling them by hand from above.
♦ Do not dismantle individual common rail components. If there
is a fault, the complete components must be renewed.
♦ When the engine is running, do not perform any repairs to the
common rail system.
♦ Do not bleed the common rail system by unfastening high-
pressure components after the engine has been started.
♦ All cable ties which are released or cut open when removing
must be refitted in the same position when installing.
3. Repair instructions 7
♦ Fuel hoses in engine compartment must only be secured with

spring-type clips. O-type clips or screw-type clips must not be
used.
3.4 Foreign particles in engine

When working on the engine, all open inlet and exhaust ports
must be sealed with suitable plugs (e.g. from engine bung set -
VAS 6122- ) to prevent foreign particles from entering the engine.
3.5 Contact corrosion

Contact corrosion can occur if unsuitable fasteners are used (e.g.
bolts, nuts, washers, etc.).
For this reason, only fasteners with a special surface coating are
fitted.
Additionally, all rubber and plastic parts and all adhesives are
made of non-conductive materials.
Always install new parts if you are not sure whether used parts
can be re-fitted ⇒ Electronic parts catalogue .
Please note:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.
♦ We recommend the use of Audi accessories.
♦ Damage caused by contact corrosion is not covered by war‐
ranty.
3.6 Routing and attachment of pipes, hoses

and wiring
♦ Mark fuel lines, hydraulic lines, vacuum lines, lines for activa‐
ted charcoal filter and electrical wiring etc. before removal so
they can be re-installed in the original positions and correctly
connected. Make sketches or take photographs if necessary.
♦ To prevent damaging pipes, hoses and wiring, ensure suffi‐
cient clearance from all moving or hot components in engine
compartment (little space in engine compartment).
3.7 Installing radiators and condensers

Even when the radiator, condenser and charge air cooler are cor‐
rectly installed, slight impressions may be visible on the fins of
these components. This does not mean that the components are
damaged. If the fins are only very slightly distorted, this does not
justify renewal of the radiator, condenser or charge air cooler.

10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 9
⇒ “1.2 Securing engine to engine and gearbox support”,
page 31
⇒ “1.3 Installing engine”, page 32
1.1 Removing engine
Caution
When installing a new base engine, it is essential that the

clamping pieces for the injectors are tightened to the specified
torque ⇒ page 268 after installing the high-pressure pipes. The
clamping pieces are only secured hand-tight at the factory so
the injectors can be aligned during installation. If these instruc‐
tions are not observed, the engine could be damaged.
Special tools and workshop

equipment required
♦ Support bracket - 10 - 222
A-
♦ Removal lever - 80 - 200-
♦ Lifting tackle - 2024 A-
♦ Gearbox support - 3147- for
vehicles with manual gear‐
box or multitronic gearbox
0AW
♦ Pin wrench - 3212-
♦ Workshop hoist -
VAS 6100-
1. Removing and installing engine 9

♦ Drip tray for workshop hoist - VAS 6208-
♦ Hose clip pliers - VAS 6362-
♦ Lifting tackle - T40013- for vehicles with dual clutch gearbox

0B5
♦ Locking tool - T40098-
10 Rep. gr.10 - Removing and installing engine

Procedure
Note
♦ The engine is removed upwards without gearbox.

♦ Fit cable ties in the original positions when installing.
Caution
To prevent irreparable damage to the electronic components

when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
– Disconnect earth wire -2- from battery terminal ⇒ Electrical

system; Rep. gr. 27 ; Battery, Disconnecting and connecting
battery .
– Remove engine cover panel -arrows-.
WARNING

hot.
– Open filler cap on coolant expansion tank.

– Remove wheel housing liners (front left and front right) ⇒
General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front) .

– Remove noise insulation -1- and -2- ⇒ General body repairs,

exterior; Rep. gr. 66 ; Noise insulation; Exploded view - noise
insulation .
– Remove cross member (if one is fitted) ⇒ page 45 .
– Place drip tray for workshop hoist - VAS 6208- beneath en‐
gine.
– Open radiator drain tap -1- at connection and drain off coolant;
then detach connection -2- from radiator (lift retaining clip).
Note
Collect drained coolant in a clean container for re-use or disposal.
– Move coolant hose clear at longitudinal member.
– Release hose clip -arrow-, disconnect air hose and press to

one side.
Vehicles with manual gearbox with gear oil cooling:

– Release hose clips -1 and 2-, disconnect coolant hoses and
drain off coolant.

– Unplug electrical connector -2- at coolant valve for gearbox -

N488- .
Note
-Item 1- and -arrows- can be disregarded.
Vehicles with multitronic gearbox 0AW or dual clutch gearbox

0B5:
– Remove bolt -arrow-.
Note
Disregard items -1 and 2-.
– Remove plenum chamber partition panel ⇒ General body re‐

pairs, exterior; Rep. gr. 50 ; Bulkhead; Exploded view - plenum
chamber partition panel .
Caution
Risk of irreparable damage to gearbox control unit (mecha‐

tronic unit) because of static discharge.
♦ Before unplugging or plugging in electrical connector, me‐
chanic must discharge static electricity. To do so, touch
vehicle earth, heater radiator, or lifting platform, with your
hand.
♦ Do NOT touch connector contacts in gearbox connector
with your hands.
Vehicles with multitronic gearbox 0AW:

– Turn retainer catch anti-clockwise -arrow- and unplug electri‐
cal connector at gearbox.
– Move clear electrical wiring.
Note

Vehicles with dual clutch gearbox 0B5:

– Turn retainer catch anti-clockwise -arrow- and unplug electri‐
cal connector at gearbox.
– Move clear electrical wiring.
Continued for all vehicles:

– Remove nuts -arrows- for front exhaust pipe.
Caution
Risk of damage to flexible joints in front exhaust pipe

♦ Do not bend flexible joints in front exhaust pipe more than
10°.
– Loosen bolts -arrows-, push back clamp and detach front ex‐
haust pipe.
– Remove bolt -2- on mounting for particulate filter.
Note
Disregard -item 1-.

Vehicles with power steering pump:

– If fitted, unplug electrical connector -arrow- on steering rack.
Vehicles without power steering pump:

– Unplug electrical connector -1- at power steering control unit
- J500- .
– Move electrical wiring harness clear.
Note
Disregard -item 2-.
– Detach bottom cover -1- from gearbox -arrow-.
– Detach cap from vibration damper.

– Counterhold crankshaft on central bolt for vibration damper
using angled ring spanner -1- when loosening bolts for drive
plate.
Note
When performing the next step, turn the crankshaft only in the
normal direction of rotation -arrow-.

– Remove bolts -arrow- (3x) for drive plate (turn crankshaft 120°
in normal direction of rotation each time via central bolt for vi‐
bration damper).
Vehicles with manual gearbox or multitronic gearbox 0AW:

– Remove bolts -1, 7, 8, 9, 10- securing engine to gearbox.
Note
Disregard -item A-.

– Remove bolts -1, 7, 8 and 9- securing engine to gearbox.
Note
Disregard -item A-.
Caution
Wrong direction of rotation for a used poly V-belt can lead to

irreparable damage.
♦ Before removing the poly V-belt mark the direction of ro‐
tation with chalk or a felt-tip pen for re-installation.
– Swivel tensioner in clockwise direction -arrow-, detach poly V-

belt from pulley for air conditioner compressor and lock ten‐
sioner using locking tool - T40098- .
– Take off poly V-belt.
Note
The illustration shows a vehicle with power steering pump.

– Unplug electrical connectors -1- and -2- and move electrical

wiring clear.
WARNING
Risk of injury caused by refrigerant.

♦ The air conditioner refrigerant circuit must not be opened.
– Remove bolts -arrows- for air conditioner compressor.
Caution
Danger of damage to refrigerant lines and hoses.

♦ Do NOT stretch, kink or bend refrigerant lines and hoses.
– Tie up air conditioner compressor together with lines to one

side (lines remain connected).
Note
Disregard -item 3-.
– Take electrical connector -1- for radiator fan out of bracket and
unplug connector (push retainer to the rear -arrow- and press
down release catch).
– Move clear electrical wiring harness going to radiator fan con‐
trol unit.
– Remove bolt -arrow-, release fastener and move radiator fan

control unit - J293- -item 1- clear to one side.
Note

– Remove bolts -arrows- (counterhold at central bolt).

– Remove vibration damper.
– Pull off cover cap for idler roller.

– Remove bolt -arrow- and detach idler roller.
– Unscrew nut -arrow- on longitudinal member (right-side) and

move earth cables clear.
– Lift retaining clips -1- and -3- and disconnect coolant hoses.
Note
-Item 2- and -arrows- can be disregarded.

Air hose, version 1:

– Release hose clips -arrows- and remove air hose.
– Unplug electrical connector for charge pressure sender -
G31- / intake air temperature sender - G42- -item 1- and move
wiring clear.

– Unplug electrical connector -1- for charge pressure sender -
G31- / intake air temperature sender - G42- and move clear
electrical wiring.
– Open hose clip -arrow-, detach air hose and move clear to one
side.
– Unscrew terminal 30/B+ -item 1-.

– Unplug electrical connector -2-.
– Remove bolts -arrows-.

– Move coolant pipe (top left) to side and detach alternator -1-.
Note
♦ If alternator sticks in its bracket, screw bolts back in again

down to the last 2 turns.
♦ Tap carefully on bolt heads with flat side of hammer to release
bushes of alternator mountings.

– Mark position of poly V-belt pulley for power steering pump

relative to hub -arrow- for re-installation.
– Remove bolts -arrows- (counterhold with pin wrench - 3212- )

and detach poly V-belt pulley for power steering pump.
– Remove bolts -arrows- and tie power steering pump up to one

side (hydraulic lines remain connected).
– Lift retaining clip -2- and disconnect coolant hose.
Note
Disregard -item 1-.

– Remove bolt -1- and take off poly V-belt tensioner -2-
-arrow-.
– Pull intermediate flange -2- off air duct -1- and air cleaner
housing.
Note
Disregard -arrows-.
– Unplug electrical connector -3- at air mass meter - G70- .

– Release hose clip -4- and detach air hose from air mass meter
- G70- .
– Disconnect vacuum hose -arrow-.
– Detach air cleaner housing -2- and, if fitted, unplug electrical
connector -1- at air filter bypass flap valve - N275- on reverse
side of air cleaner.
– Release hose clips and disconnect fuel hoses.
Caution
Protect fuel system against contamination.

♦ Rules for cleanliness when working on the injection sys‐
tem ⇒ page 6 .
1- Fuel hose (yellow)

2- Fuel hose (blue)
3- Fuel hose (white)

– Lift off foam plastic block -1- on both sides of vehicle.
– Remove plenum chamber cover -1- ⇒ General body repairs,

exterior; Rep. gr. 50 ; Bulkhead; Exploded view - plenum
– If fitted, remove nuts -arrows- and push coolant valve for gear‐
box - N488- to rear.
– Release hose clip -1- and detach coolant hose.
Note
– Release retainer -arrow A- and open cover -arrow B-.

– Remove nuts -1 ... 4- for electrical wiring.

– Detach electrical connector -5- from bracket and unplug.
– Remove bolt -6- and detach terminal 30 wiring junction 2 -
TV22- from plenum chamber partition panel -arrow-.
– Unplug electrical connector at brake servo pressure sensor -

G294- -arrow-.
– Working from wheel housing, release catches using a 5.5 mm

ring spanner -item 1- and remove wiring protector -2- from
above.
– Release wiring harness -3- leading to alternator and starter
using removal lever - 80 - 200- and move clear.
– Release catch -arrow- to open wiring duct -1- and move elec‐
trical wiring harness clear.

– Disconnect vacuum hose -2- on rear of plenum chamber par‐

tition panel -arrow- and detach vacuum connection -1- from
plenum chamber partition panel.
– Remove nut -1- and swivel filler neck for washer fluid reservoir
slightly upwards -arrow A-.
– Pull filler neck -2- with filler pipe out of washer fluid reservoir
and through opening in body -arrow B-.
– On vehicles with auxiliary heater: remove bolts -2- and move

pump unit -1- clear to one side.
– Remove bolts -arrows- and detach cover for electronics box in

engine compartment.
– Remove nut -1- and move electrical wiring clear.

– Release catches -arrows A- and take out engine control unit

-arrow B-.
– If fitted, unplug electrical connector -2-.

– Unplug electrical connectors -4- and unscrew nut -3- for wiring.
– Release catches -arrow- and detach relay carrier with fuse
holder -1-.
– Disengage engine wiring harness at electronics box in engine
compartment and move clear.
– Release catches -arrows A- and lift off wiring protector -2-

-arrow B-.
– Move wiring harness clear, place on engine and secure engine
control unit to prevent it from dropping.
Note
Disregard -item 1-.
Vehicles without auxiliary heater:

– Unscrew nut -5-.
– Release retaining clips -1, 2- and disconnect coolant hoses.
– Guide coolant hoses through plenum chamber partition panel
and move clear.
Note

Vehicles with auxiliary heater:

– Release hose clips -1, 2- and disconnect coolant hoses.
– Guide coolant hoses through plenum chamber partition panel
and move clear.

– Release hose clip -3-, lift retaining clips -1- and detach coolant
hoses.
– Remove nut -2-.
– Remove plenum chamber partition panel.

– Unplug electrical connector -3- for pressure differential sender
- G505- .
– Remove bolt -2- and move hoses -1- clear at bracket.
– Move pressure differential sender - G505- to rear.
– Move clear electrical wiring harness -arrow-.

– Remove nuts -1- and detach bracket -2-.
– Remove Lambda probe ⇒ page 286 .

– Detach electrical connector from bracket and unplug:

4 - For exhaust gas temperature sender 3 - G495-
Note
– Remove nuts -arrows- and move particulate filter to rear.
Vehicles with multitronic gearbox 0AW:

– Detach electrical connector -1- from bracket and move wiring
harness -2- clear using removal lever - 80 - 200- .
Note
Place a cloth below the connection to catch ATF.
– Unscrew bolts -1- and -2-, detach ATF lines from gearbox and
tie up ATF lines.
– Seal off open pipes/lines and connections with clean plugs
from engine bung set - VAS 6122- .

Note
Lay a cloth under the separating point to catch escaping ATF.
– Unscrew bolts -arrows -, detach ATF lines -1, 2- from ATF-filter

housing and tie up ATF lines.

– Unplug electrical connector -1- for coolant circulation pump -
V50- .
Vehicles with manual gearbox:

– Remove bolt -3- for connecting rod.
– Unplug electrical connector -2- at reversing light switch - F4- .
Note
Disregard -item 1-.

– Unclip electrical wiring -A- from gearbox and unplug electrical

connector -C-.
Note
Disregard -item B-.
– If fitted, unplug electrical connector -arrow- for gearbox neutral

position sender - G701- and move wiring clear.
– Remove bolts -2 ... 6- securing gearbox to engine.
Note
♦ The illustration shows a vehicle with manual gearbox/multi‐

tronic gearbox 0AW.
♦ Disregard -item A-.
Note
Bolt -2- secures the starter to the gearbox and is provided with an
additional spacer sleeve -arrow-.


– Set up support bracket - 10 - 222 A- on suspension turrets (left
and right) as illustrated.
– Attach gearbox support - 3147- to gearbox and to hook - 10 -
222 A /2- using hook - 10 - 222 A /10- .
– Take up weight of gearbox slightly.
Note
For illustration purposes, the installation position is shown with

the engine removed.

– Attach lifting tackle - T40013- to gearbox and close lock.
– Attach shackle - 10 - 222 A /12- to spindle - 10 - 222 A /11-
and to lifting tackle - T40013- .
– Take up weight of gearbox slightly.
Note

the engine removed.

– Remove lifting eye of lifting tackle - 2024 A- (pull out split pin
and press out pin).
– Reinsert lifting eye in 4th hole from front on lifting tackle.
– Secure pin with split pin again.
– Attach lifting tackle - 2024 A- to engine and workshop hoist -
VAS 6100- as shown in illustration.
WARNING
Accident risk from loose components of lifting tackle.

♦ The support hooks and retaining pins on the lifting tackle
must be secured with locking pins.

– Remove bolts -1- for engine mounting on both sides.

– Remove nut -2- and move bracket with electrical wiring clear.
– Take electrical connectors (left and right) -arrow- out of brack‐
et and unplug connectors.
– Raise engine until engine mountings are clear.
– Tighten spindle - 10 - 222 A /11- further.
Caution
Danger of damage to hoses, pipes and wiring connections and

to engine compartment.
♦ Check that all hoses and wiring connections between en‐
gine, gearbox, subframe and body have been detached.
♦ Carefully guide engine out of engine compartment when
lifting out.
Note
A second mechanic is required to carefully open bonnet as much

as possible when lifting engine out.
– Use small screwdriver to slightly lift retaining clip -arrow- at

both ends and detach gas strut -1- from ball stud -2- at top.
– Separate engine from gearbox and lift engine out of engine
compartment.
– Press gas struts back onto ball studs.
1.2 Securing engine to engine and gearbox

support
Special tools and workshop equipment required
♦ Engine and gearbox support - VW 540-

♦ Engine and gearbox support - VAS 6095-
Procedure
– Secure engine to engine and gearbox support - VW 540- .
– Secure engine to engine and gearbox support - VAS 6095-
using -VW 540- .
1.3 Installing engine

♦ Ring spanner insert AF 16 - V.A.G 1332/14-
♦ Counterhold tool - T10355-

♦ Assembly aid - T40169-
♦ Transport lock - T40170-
Tightening torques
Note
♦ Tightening torques apply only to lightly greased, oiled,

phosphated or black-finished nuts and bolts.
♦ Additional lubricants such as engine or gearbox oil may be
used, but do not use lubricants containing graphite.
♦ Do not use de-greased parts.
♦ Tolerance for tightening torques: ± 15 %.
Component Nm
Bolts/nuts M6 9
M7 15
M8 20
M10 40
M12 65

Assembly mountings
⇒ “2.1 Exploded view - assembly mountings”, page 41
Engine to manual gearbox/multitronic gearbox 0AW
Item Bolt Nm
1 1) M10x50 2) 65
2 3) M12x100 4) 30 + 90°
3 5), 6 M12x75 4) 30 + 90°
4, 5 5) M12x120 4) 30 + 90°
7…9 M10x75 4) 15 + 90°
10 M12x50 4) 30 + 90°
A Dowel sleeves for centralising
• 1) Also secures starter
• 2) Property class 10.9. The steel bolt may be re-used as often
as necessary.
• 3)Also secures starter, with additional spacer sleeve be‐
tween starter and gearbox
• 4)Bolts must not be used more often than twice
⇒ page 35 .
• 5) Also secures wiring retainer
Engine to dual clutch gearbox 0B5

Item Bolt Nm
1 1) M10x50 2) 65
2 3) M12x100 4) 30 + 90°
3 5),6 M12x75 4) 30 + 90°
4, 5 M12x120 4) 30 + 90°
7, 8 M10x40 4) 15 + 90°
9 M12x50 4) 30 + 90°
A Dowel sleeves for centralising
• 1) Also secures starter.
• 2) Property class 10.9. The steel bolt may be re-used as often
as necessary.
• 3)Also secures starter, with additional spacer sleeve be‐
tween starter and gearbox.
• 4)Bolts must not be used more often than twice
⇒ page 35 .

♦ Aluminium bolts must not be used more than twice. After first
use, bolts must therefore be identified with an “X” made by two
chisel marks -arrow-.
♦ To avoid damaging the bolts when making this mark, do not
clamp them directly in a vice. Clamp a 14 mm socket with 1/
2" drive in a vice and insert the bolt as shown.
♦ Bolts already marked with an “X” must not be used again.
Procedure
Note
♦ Renew the bolts tightened with specified tightening angle.

♦ Renew self-locking nuts and bolts as well as seals, gaskets
and O-rings.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
♦ Fit all cable ties in the original positions when installing.
On vehicles with manual gearbox, a needle bearing must be fitted

in the drive plate. Before installing, check whether a needle bear‐
ing is fitted. Press needle bearing into drive plate ⇒ page 77 .
– The following preparations are required before joining engine

and gearbox:
– Insert assembly aid - T40169- into gearbox housing between
flywheel/torque converter and gearbox housing from below, as
illustrated.
• The assembly aid - T40169- must engage in the semi-circular
recess -1- and in the inspection hole -2-.
Note
There is only one inspection hole on the circumference; turn the

dual-mass flywheel accordingly.
– Insert pin of assembly aid into hole on gearbox housing.

– Insert transport lock - T40170- into gearbox housing from be‐

low and clamp onto flange shaft -1-.
– Check whether aluminium bolts securing engine to gearbox
can be reused; if so, apply marking ⇒ page 35 .
– Check whether dowel sleeves -A- for centring engine and

gearbox are fitted in cylinder block; install missing dowel
sleeves.
– Bring engine into position on gearbox, fit bolts -2 … 6- and
tighten.
Note
The illustration shows a vehicle with manual gearbox/multitronic

gearbox 0AW.
Note
♦ Bolt -2- secures the starter to the gearbox and is provided with
an additional spacer sleeve -arrow-.
♦ The spacer sleeve must be fitted between starter and gearbox.
– Slacken spindle - 10 - 222 A /11- .

– Lower workshop hoist and place engine/gearbox assembly
onto engine mountings.
– Install engine mountings ⇒ page 41 .
– Detach workshop hoist - VAS 6100- and lifting tackle - 2024
A- .
– Tighten bolts -1, 7, 8, 9, 10- to secure engine to gearbox.


– Tighten bolts -1, 7, 8, 9, 10- to secure engine to gearbox.

– Tighten bolts -1, 7, 8 and 9- to secure engine to gearbox.
– Remove transport lock - T40170- and assembly aid - T40169- .
– Use assembly lever -1- to press dual-mass flywheel -2- slightly

against drive plate -3- in direction of -arrow-.
Note
This step is necessary to ensure that the dual-mass flywheel is

straight and that it makes even contact with the drive plate.
– Turn crankshaft at vibration damper with counterhold tool -

T10355- 360° in direction of engine rotation.

– The inspection hole -arrow- should be visible again in the re‐

cess on the gearbox housing.
– Bolt dual-mass flywheel onto drive plate as follows:

– Screw in first bolt -arrow-, tighten to 10 Nm and then slacken
again to 2 Nm (hand tight).
– Turn crankshaft at vibration damper with counterhold tool -
T10355- 120° further in direction of engine rotation.

– In this crankshaft position, screw in next bolt -arrow- and tight‐

en to 60 Nm.
– Turn crankshaft a further 120°, then screw in next bolt and
tighten to 60 Nm.
– Turn crankshaft a further 120° and tighten last bolt to 60 Nm.
Remaining installation steps are carried out in reverse sequence;
note the following:
When installing a new base engine, you must check whether
there is a sticker on the cylinder head cover.
If a sticker is attached which states Spannpratzen auf vor-
geschriebenes Drehmoment angezogen (clamping pieces tight‐
ened to specified torque), the clamping pieces have already been
tightened to the specified final torque at the factory.
If no sticker is attached, it is essential that the clamping pieces for
the injectors are tightened to the specified torque
⇒ Item 8 (page 254) after installing the high-pressure pipes. If
these instructions are not observed, the engine could be dam‐
aged.
– Install particulate filter ⇒ page 302 .
– Install pressure differential sender - G505-
⇒ “2.2 Removing and installing pressure differential sender
G505 ”, page 303 .
– Install vibration damper
⇒ “1.5 Removing and installing vibration damper”,
page 58 .
– Install idler roller and tensioning roller
⇒ “1.1 Exploded view - poly V-belt drive”, page 49 .
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;
Removing and installing alternator .
– Install power steering pump (if one was originally fitted) ⇒
Running gear, axles, steering; Rep. gr. 48 ; Hydraulic power
steering; Removing and installing power steering pump .
– Install ATF lines (if originally fitted) ⇒ Rep. gr. 37 ; ATF circuit;
Removing and installing ATF lines .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Detaching and at‐
taching air conditioner compressor at bracket .
– Install poly V-belt
⇒ “1.3 Removing and installing poly V-belt”, page 54 .
– If previously fitted, re-install cross member ⇒ page 45 .
– Install wheel housing liners ⇒ General body repairs, exterior;
Rep. gr. 66 ; Wheel housing liners; Exploded view - wheel
housing liner (front) .
– Fit front wheels ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Tightening torque for wheel bolts .
– Install plenum chamber partition panel ⇒ General body re‐
– Install body brace ⇒ Running gear, axles, steering; Rep. gr.
40 ; Suspension strut, upper links; Removing and installing
body brace .
– Install connecting rod ⇒ Rep. gr. 34 ; Selector mechanism .

– Install air cleaner housing

⇒ “3.2.1 Removing and installing air cleaner (bottom section)”,
page 244 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Install engine control unit
⇒ “9.2 Removing and installing engine control unit J623 ”, page
289 .
– Install electrical wiring, terminal 30 wiring junction 2 - TV22-
and cover for electronics box in engine compartment ⇒ Elec‐
trical system; Rep. gr. 97 ; Relay carriers, fuse carriers,
electronics boxes .
– Install filler neck for washer fluid reservoir ⇒ Electrical system;
Rep. gr. 92 ; Windscreen washer system; Removing and in‐
stalling washer fluid reservoir .
– Observe steps required after re-connecting battery ⇒ Electri‐
cal system; Rep. gr. 27 ; Battery; Disconnecting and connect‐
ing battery .
Caution
Risk of irreparable damage to control units because of exces‐

sive voltage.
♦ Never use battery charging equipment for boost starting.
– Install air hoses with screw-type clips ⇒ page 226 .

– Check oil level ⇒ Maintenance ; Booklet 811 or ⇒ Mainte‐
nance ; Booklet 812 .
– Connect coolant hoses with plug-in connector
⇒ Fig. ““Connecting coolant hose with plug-in connector”“ ,
page 205 .
– Fill up with coolant
⇒ “1.3 Draining and filling cooling system”, page 171 .
– Bleed fuel system
⇒ “1.3 Filling and bleeding fuel system”, page 240 .
– Install noise insulation panels ⇒ General body repairs, exte‐
rior; Rep. gr. 66 ; Noise insulation; Exploded view - noise
insulation .

2 Assembly mountings
⇒ “2.1 Exploded view - assembly mountings”, page 41
⇒ “2.2 Removing and installing engine mountings”, page 42
⇒ “2.3 Removing and installing torque reaction support and cross
member”, page 45
2.1 Exploded view - assembly mountings
1 - Retainer
❑ For electrical connector
2 - Bolt
❑ 20 Nm
3 - Bracket
❑ For engine mounting
❑ Renew bracket if engine
mounting is defective
❑ Check bracket on oppo‐
site side; renew if nec‐
essary
4 - Retainer
❑ For hydraulic line (vehi‐
cles with power steering
pump)
5 - Nut
❑ For vehicles with power
steering pump
❑ 9 Nm
6 - Bolt
❑ 40 Nm
7 - Engine support
❑ Version fitted in vehicle
may differ from illustra‐
tion
8 - Bolt
❑ 10 Nm
9 - Heat shield
tion
10 - Bolt
❑ Renew
❑ 90 Nm + 90°
11 - Engine mounting
❑ With left electrohydraulic engine mounting solenoid valve - N144- (left-side only)
❑ On some vehicle versions, the engine mounting on the other side of the vehicle has to be renewed as
well; for allocation refer to ⇒ Electronic parts catalogue
❑ Removing and installing ⇒ page 42
2. Assembly mountings 41
12 - Subframe
13 - Bolt
❑ 55 Nm
Torque reaction support and cross member - tightening torques

1- Bolt, 25 Nm
2- Bolt, 40 Nm
2.2 Removing and installing engine mount‐

ings
Note
♦ To avoid repeat repairs, proceed as follows if an engine

mounting is defective:
♦ Renew engine mounting and corresponding bracket.
♦ On some vehicle versions, the engine mounting on the other
side of the vehicle has to be renewed as well; for allocation
refer to ⇒ Electronic parts catalogue .

♦ Support bracket - 10 - 222 A-
Removing




– Attach spindles -10 - 222 A /11- to engine lifting eyes.
– Partly take up weight of engine with spindles.
– Remove wheel housing liners ⇒ General body repairs, exte‐

rior; Rep. gr. 66 ; Wheel housing liners; Exploded view - wheel
– Remove front noise insulation -1- ⇒ General body repairs,
insulation .

– Remove nut -2- and move bracket -1- clear.

– Move clear and unplug electrical connector -3- for electrohy‐
draulic engine mounting solenoid valve.
– Remove bolts -1, 4, 5- for engine mounting.
– Detach bracket -2- and engine mounting.
Installing
Installation is carried out in the reverse order; note the following:
Tightening torques
♦ ⇒ “2.1 Exploded view - assembly mountings”, page 41
Note
Renew the bolts tightened with specified tightening angle.
– Install wheel housing liners ⇒ General body repairs, exterior;

Rep. gr. 66 ; Wheel housing liners; Exploded view - wheel
– Install noise insulation (front) ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
– Install pressure differential sender - G505- ⇒ page 303 .

2.3 Removing and installing torque reaction

support and cross member
Removing
– Remove front noise insulation ⇒ General body repairs, exte‐
insulation .
Vehicles with auxiliary heater:
– Remove nut -1-, loosen clamp -3- and detach exhaust pipe
-2- for auxiliary heater.

– Remove bolt -1- and nut -3- and detach strut -2- for lock carrier.
Vehicles with multitronic gearbox:

– Position used oil collection and extraction unit - V.A.G 1782-
below connection point.
Note
Observe rules for cleanliness when working on gearbox ⇒ Rep.

gr. 00 ; Repair instructions; Rules for cleanliness .
– Unscrew bolts -arrows- and detach ATF lines from radiator.
Note
Tie ATF lines up onto longitudinal member to prevent fluid es‐

caping.

– Move electrical wiring -3- clear at cross member.

– Remove bolts -1- and take torque reaction support out of cross
member.
– Remove bolts -2- from cross member.
– Loosen subframe bolts -2- (left-side as seen in direction of

travel) only as much as is necessary for cross member -1- to
move freely in direction of -arrow-.
WARNING
Accident risk if subframe mountings are detached.

♦ Subframe bolts must not be fully removed.
– Push cross member -1- slightly towards left side -arrow- so

that cross member (right-side) can be removed from below at
longitudinal member.
Installing
Note
♦ Renew bolts tightened with specified tightening angle.

♦ Remove and renew subframe bolts one after the other.

– Push torque reaction support -1- upwards -arrow- until it

makes contact with cross member.
• The buffer stop -2- must be free of stress and must lie against
the cross member without play.
– Tighten bolts -3- in this position.
Tightening torques
♦ ⇒ page 42 .
♦ Subframe ⇒ Running gear, axles, steering; Rep. gr. 40 ; Sub‐
frame; Exploded view - subframe
♦ Lock carrier brace ⇒ General body repairs, exterior; Rep. gr.
50 ; Lock carrier; Exploded view - lock carrier
♦ Exhaust pipe for auxiliary heater ⇒ Auxiliary heater, supple‐
mentary heater; Rep. gr. 82 ; Overview of fitting locations -
auxiliary/supplementary heater; Overview of fitting locations -
components not located in passenger compartment
tion .
3 Engine cover panel

⇒ “3.1 Removing and installing engine cover panel”, page 48
3.1 Removing and installing engine cover

panel
Removing
– Carefully pull engine cover panel off retaining pins one after
another -arrows-. Do not jerk engine cover panel away, and
do not try to pull on one side only.
Installing
– To avoid damage, do not strike the engine cover panel with
your fist or with any kind of tool.
– When fitting engine cover panel, take care not to damage oil
filler neck.
– First press engine cover panel onto rear rubber grommets and
then onto front rubber grommets with both hands.

13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Exploded view - poly V-belt drive”, page 49
⇒ “1.2 Exploded view - sealing flange (pulley end)”, page 54
⇒ “1.3 Removing and installing poly V-belt”, page 54
⇒ “1.4 Removing and installing tensioner for poly V-belt”,
page 57
⇒ “1.5 Removing and installing vibration damper”, page 58
⇒ “1.6 Removing and installing bracket for ancillaries”,
page 59
⇒ “1.7 Renewing crankshaft oil seal (pulley end)”, page 62
⇒ “1.8 Removing and installing sealing flange (pulley end)”, page
64
1.1 Exploded view - poly V-belt drive

⇒ “1.1.1 Exploded view - poly V-belt drive without power steering
pump”, page 49
⇒ “1.1.2 Exploded view - poly V-belt drive with power steering
pump”, page 52
1.1.1 Exploded view - poly V-belt drive without power steering pump
1. Cylinder block (pulley end) 49

1 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tip pen. If
the belt runs in the op‐
posite direction when it
is refitted, this can
cause breakage.
❑ Removing and installing
⇒ page 54
❑ When installing, make
sure it is properly seated
on pulleys.
2 - Bolt
❑ Renew
❑ 10 Nm + 90°
3 - Cap
❑ For vibration damper
4 - Vibration damper
❑ Can only be installed in
one position
⇒ page 58
5 - Tensioner
❑ For poly V-belt
❑ Use locking tool -
T40098- to lock tension‐
er.
⇒ page 57
6 - Bolt
❑ Tightening torque ⇒
Electrical system; Rep. gr. 27 ; Alternator; Exploded view - alternator
7 - Bracket
❑ For ancillaries
8 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
9 - Bolt
❑ Bolt can be re-used; tightening torque for re-used bolt: 20 Nm + 90°
❑ New bolt: 20 Nm +180°
10 - Bolt
❑ Renew
❑ Tightening torque and sequence ⇒ page 51
11 - Dowel sleeves
❑ Ensure correct seating in bracket
12 - Air conditioner compressor
❑ Do not unscrew or disconnect refrigerant hoses or pipes.
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Detaching
and attaching air conditioner compressor at bracket
❑ Pay attention to dowel sleeves ⇒ Item 11 (page 50) when installing
50 Rep. gr.13 - Crankshaft group

13 - Bolt
❑ Tightening torque ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Removing and
installing air conditioner compressor
14 - Idler roller
❑ For poly V-belt
❑ With cover cap
❑ Note installation position
15 - Bolt
❑ Renew
❑ 20 Nm + 90°
16 - Cap
❑ For idler roller
Bracket for ancillaries - tightening torque and tightening sequence
Note
– Fit bolts in the following sequence:

♦ Bolts -1, 5, 6- M10x60.
♦ Bolt -2- M10x40
♦ Bolts -3, 4- M10x155.
– Tighten bolts in 5 stages in the sequence shown:
Stage Bolts Tightening torque/angle specification
1. -1 … 6- Screw in by hand until contact is made
2. -1 … 6- 40 Nm
3. -1- and -2- Turn 60° further

1.1.2 Exploded view - poly V-belt drive with power steering pump
1 - Poly V-belt
❑ Check for wear
chalk or felt-tip pen. If
the belt runs in the op‐
posite direction when it
is refitted, this can
cause breakage.
⇒ page 54
❑ When installing, make
sure it is properly seated
on pulleys.
2 - Vibration damper
one position
⇒ page 58
3 - Cap
❑ For vibration damper
4 - Bolt
❑ Renew
❑ 10 Nm + 90°
5 - Bolt
❑ 22 Nm
6 - Poly V-belt pulley
❑ For power steering
pump
7 - Tensioner
❑ For poly V-belt
❑ Use locking tool -
T40098- to lock tensioner.
8 - Bracket
❑ For ancillaries
9 - Bolt
❑ Tightening torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Exploded view - alternator
10 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
11 - Bolt
❑ Bolt can be re-used; tightening torque for re-used bolt: 20 Nm + 90°
❑ New bolt: 20 Nm +180°
12 - Power steering pump
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 48 ; Hydraulic power steering; Re‐
moving and installing power steering pump
13 - Bolt
❑ Renew


14 - Dowel sleeve
❑ Ensure correct seating in bracket
15 - Air conditioner compressor
❑ Do not unscrew or disconnect refrigerant hoses or pipes.
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Detaching
and attaching air conditioner compressor at bracket
❑ Pay attention to dowel sleeves ⇒ Item 14 (page 53) when installing
16 - Bolt
❑ Tightening torque ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Exploded view
- air conditioner compressor drive unit
17 - Bolt
❑ Tightening torque ⇒ Running gear, axles, steering; Rep. gr. 48 ; Hydraulic power steering; Removing
and installing power steering pump
18 - Idler roller
❑ For poly V-belt
❑ With cover cap
❑ Note installation position
19 - Bolt
❑ Renew
❑ 20 Nm + 90°
Bracket for ancillaries - tightening torque and tightening sequence
Note
– Fit bolts in the following sequence:

♦ Bolts -1, 5, 6- M10x60.
♦ Bolt -2- M10x40
♦ Bolts -3, 4- M10x155.
2. -1 … 6- 40 Nm

1.2 Exploded view - sealing flange (pulley end)
1 - Bolt
❑ Tightening torque
⇒ Item 27 (page 112)
2 - Crankshaft sprocket
❑ Contact surface be‐
tween sprocket and
crankshaft must be free
of oil
one position
3 - Oil seal
❑ For crankshaft (pulley
end)
❑ Renewing ⇒ page 62
❑ Do not lubricate with oil
4 - Sealing flange (pulley end)
❑ Should be positioned on
dowel pins
⇒ page 64
5 - Cylinder block
6 - Dowel pin
❑ 2x
7 - Bolt
❑ Tightening torque and
sequence ⇒ page 54
Sealing flange (pulley end) - tightening torque and sequence

Stage Bolts Tightening torque
2. -1 … 6- Tighten in stages and in diagonal se‐
quence; final torque 15 Nm
3. -7 … 10- 15 Nm
1.3 Removing and installing poly V-belt


Removing
– Open clips -arrows- and remove toothed belt cover.
Vehicles with power steering pump
Caution

irreparable damage.

belt from alternator pulley and lock tensioner using locking tool
- T40098- .

Vehicles without power steering pump
Caution

irreparable damage.

belt from alternator pulley and lock tensioner using locking tool
- T40098- .
Installing
– Fit poly V-belt on all poly V-belt pulleys as follows:

1- Vibration damper
2- Air conditioner compressor
3- Poly V-belt pulley for power steering pump
4- Idler roller
5- Poly V-belt tensioner
6- Alternator
Vehicles without power steering pump

1- Vibration damper
2- Air conditioner compressor
3- Idler roller
4- Poly V-belt tensioner
5- Alternator
Note
When installing poly V-belt, make sure it is properly seated on

pulleys.
– Start engine and check that poly V-belt(s) run properly.

1.4 Removing and installing tensioner for

poly V-belt
♦ Ratchet wrench 13 mm - T10384-
Removing

– Remove poly V-belt ⇒ page 54 .

wiring clear.


electrical wiring.
side.
– Remove bolt -1-.
Note
♦ If bolt -1- makes contact with engine bracket, leave bolt in in‐
stallation position.
♦ Due to lack of space, the tensioner must be guided out up‐
wards by rotating it.
– Lift out poly V-belt tensioner -2-.

Installing
Tightening torques
♦ ⇒ “1.1 Exploded view - poly V-belt drive”, page 49
– Install poly V-belt ⇒ page 54 .
1.5 Removing and installing vibration damp‐

er
Removing
insulation .
– Vehicles with torque reaction support: remove cross member
for torque reaction support ⇒ page 45 .
– Remove radiator fan control unit - J293- ⇒ page 212 .
– Remove poly V-belt ⇒ page 54 .


– Counterhold crankshaft on central bolt using angled ring span‐
ner -1- when loosening bolts for vibration damper.
– Loosen bolts -arrows- for vibration damper.

– Remove bolts and take off vibration damper.
Installing
Tightening torques
♦ ⇒ “1.1 Exploded view - poly V-belt drive”, page 49
Note
• Installation position: hole -arrow- in vibration damper must be

positioned over raised section of crankshaft sprocket.
– Install radiator fan control unit - J293- ⇒ page 212 .
– Vehicles with torque reaction support: install cross member for
torque reaction support ⇒ page 45 .
1.6 Removing and installing bracket for an‐

cillaries

♦ Pin wrench - 3212-
Removing
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
– Remove high-pressure pump ⇒ page 273 .
– Remove 4/2-way valve ⇒ page 184 .
– Remove bolt -arrow-.
– Remove bolts -1- and -2- and remove idler rollers for toothed
belt.

– Mark position of poly V-belt pulley for power steering pump
relative to hub -arrow- for re-installation.
– Remove bolts -arrows- (counterhold with pin wrench - 3212- )

and detach poly V-belt pulley for power steering pump.

– Remove bolts -arrows- and tie power steering pump up to one

side (hydraulic lines remain connected).

– Unplug electrical connectors -1- and -2- and move electrical
wiring clear.
WARNING
Risk of injury caused by refrigerant.

♦ The air conditioner refrigerant circuit must not be opened.
– Remove bolts -arrows- for air conditioner compressor.
Caution
Danger of damage to refrigerant lines and hoses.

♦ Do NOT stretch, kink or bend refrigerant lines and hoses.
– Tie up air conditioner compressor together with lines to one

side (lines remain connected).
Note
Disregard -item 3-.

– Remove bolts -1 ... 6- and detach bracket for ancillaries.

Installing
Tightening torques
♦ ⇒ page 51
Note
– Check that dowel sleeves are fitted at top right between brack‐
et for ancillaries and cylinder block; insert dowel sleeves if
necessary.
– Tighten bolts for bracket for ancillaries ⇒ page 51 .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Detaching and at‐
taching air conditioner compressor at bracket .
– Install power steering pump ⇒ Running gear, axles, steering;
Rep. gr. 48 ; Hydraulic power steering; Removing and instal‐
ling power steering pump .
– Install 4/2-way valve ⇒ page 184 .
– Install high-pressure pump ⇒ page 273 .
– Install toothed belt (adjust valve timing) ⇒ page 116 .
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;
Removing and installing alternator .
1.7 Renewing crankshaft oil seal (pulley

end)
♦ Oil seal extractor - 3203-

♦ Counterhold tool - 3415-
♦ Assembly tool - T10053-
Procedure
– Remove toothed belt ⇒ page 113 .
– Loosen bolt for crankshaft sprocket using counterhold tool -
3415- .
– Remove bolt and detach crankshaft sprocket.
– Adjust inner section of oil seal extractor -3203- so it is flush

with the outer section and lock in position with knurled screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and screw it into oil seal as far as possible (applying firm
pressure).
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
– Clamp flats of oil seal extractor in vice and use pliers to remove
oil seal.
– Clean contact surface and sealing surface for oil seal.
– Remove oil residue from crankshaft journal with a clean cloth.
Note
Do not lubricate sealing lip and outer rim of oil seal before press‐
ing in.

– Fit guide sleeve -T10053/1- onto crankshaft journal.

– Push oil seal over guide sleeve onto crankshaft journal.
– Press in oil seal using bolt for crankshaft sprocket and thrust
sleeve of assembly tool - T10053- until flush.
– Install crankshaft sprocket ⇒ page 111 .
1.8 Removing and installing sealing flange

(pulley end)
♦ Counterhold tool - 3415-
♦ Electric drill with plastic brush attachment

♦ Safety goggles
♦ Sealant ⇒ Electronic parts catalogue
Removing
– Loosen bolt for crankshaft sprocket using counterhold tool -
3415- .
– Remove bolt and detach crankshaft sprocket.

– Remove bolts -1 ... 10- and carefully release sealing flange

from bonded joint.
– Drive out oil seal with sealing flange removed.
Installing
Tightening torques
♦ ⇒ “1.2 Exploded view - sealing flange (pulley end)”, page 54
Caution
Make sure sealant residue does not enter lubrication system.

♦ Place a clean cloth over the exposed section of the sump.
– Carefully remove sealant residue on cylinder block and sump.
WARNING
Risk of eye injury.

– Use e.g. rotating plastic brush to remove sealant residue on

sealing flange.
– Clean surfaces; they must be free of oil and grease.
Note
Note the use-by date of the sealant.
– Cut off nozzle of tube at front marking (nozzle ∅ approx.

2 mm).
– Apply a thin bead of sealant at the edge of the joint between

the cylinder block and the sump -arrows-.

Caution
Make sure lubrication system is not clogged by excess sealant.

♦ The bead of sealant must not be thicker than specified.
– Apply bead of sealant -arrow- onto clean sealing surface of

sealing flange as shown in illustration.
• Thickness of sealant bead: 2 ... 3 mm
– Apply a thin coat of sealant to bottom sealing surface

-shaded- on sealing flange.
Note
The sealing flange must be installed within 5 minutes after apply‐

ing the sealant.
– Carefully fit sealing flange onto dowel pins in cylinder block.
– Tighten sealing flange bolts ⇒ page 54 .

– Install crankshaft oil seal (pulley end) ⇒ page 62 .

2 Cylinder block (gearbox end)

⇒ “2.1 Exploded view - cylinder block (gearbox end)”, page 67
⇒ “2.2 Removing and installing drive plate”, page 68
⇒ “2.3 Removing and installing sealing flange (gearbox end)”,
page 69
⇒ “2.4 Renewing needle bearing in drive plate”, page 77
2.1 Exploded view - cylinder block (gearbox end)
1 - Cylinder block
2 - Dowel pins
3 - Engine speed sender -
G28-
⇒ page 325
4 - Bolt
❑ 4.5 Nm
5 - Sealing flange (gearbox
end)
❑ With oil seal
❑ Renewing
⇒ “2.3 Removing and in‐
stalling sealing flange
(gearbox end)”,
page 69
6 - Bolt
❑ 15 Nm
7 - Drive plate
❑ Lock with counterhold
tool - 3067- to slacken
off bolts
8 - Bolt
❑ Renew
❑ 60 Nm + 90°
9 - Needle bearing
❑ For vehicles with man‐
ual gearbox
⇒ “2.4 Renewing needle
bearing in drive plate”,
page 77
10 - Intermediate plate
❑ Do not damage or bend when assembling
❑ Installing ⇒ page 68
2. Cylinder block (gearbox end) 67

Installing intermediate plate

– Engage intermediate plate on sealing flange -top arrow- and
push onto dowel sleeves -bottom arrows-.
Sealing flange (gearbox end) - tightening torque and sequence

2. -1 … 6- Tighten in stages and in diagonal se‐
quence; final torque 15 Nm
2.2 Removing and installing drive plate

♦ Counterhold tool - 10 - 201-

Removing
• Gearbox removed
– Insert counterhold tool - 10 - 201- in hole on cylinder block
-item B-, slacken bolts for drive plate.
Caution
Take care not to damage outer surface of bearing flange on

drive plate.
♦ Use a multi-point socket bit with a length of at least 40 mm
to slacken and tighten the drive plate bolts.
– Remove bolts and take off drive plate.

Installing
Tightening torques
♦ ⇒ “2.1 Exploded view - cylinder block (gearbox end)”,
page 67
Note

♦ On vehicles with manual gearbox, a needle bearing is fitted in
the drive plate. Before installing, check that the needle bearing
is fitted. Removing and installing needle bearing in drive plate
(pressing in and out) ⇒ page 77 .
– Pay attention to dowel pin when installing drive plate.

– Insert counterhold tool - 10 - 201- in hole on cylinder block
-item A-, tighten bolts for drive plate.
2.3 Removing and installing sealing flange

(gearbox end)
♦ Open end spanner insert, AF 24 - V.A.G 1332/11-

♦ Depth gauge - VAS 6082-
♦ Bolt M6x35 (3x)

♦ Bolt M7x35 (2x)
Pressing out sealing flange with sender wheel
• Gearbox removed
– Remove drive plate ⇒ page 68 .
Note
For illustration purposes, the following procedure is shown with

the engine removed.
– Remove engine speed sender - G28- -item 1-

⇒ “1.5 Removing and installing engine speed sender G28 ”,
page 325 .
Note
Disregard -item 2-.

– Pull intermediate plate off dowel pins -bottom arrows- and de‐
tach from sealing flange -top arrow-.
– Rotate crankshaft by turning bolt for toothed belt sprocket until

crankshaft is positioned at “TDC”, as shown in illustration.
– Remove sump ⇒ page 147 .
– Remove bolts -1 ... 6- for sealing flange.

Note
The sealing flange is pressed off the crankshaft together with the
sender wheel.
– To press off, screw 3 bolts M6x35 -arrows- alternately into

sealing flange not more than 1/2 turn at a time.
– Take off sealing flange with sender wheel.
Pressing in sealing flange with sender wheel
Note
♦ The sealing flange with PTFE oil seal is fitted with a sealing lip
support ring. This support ring acts as an assembly sleeve and
must not be removed before installation.
♦ Sealing flange and sender wheel must not be separated or
rotated out of position after removal from packaging.
♦ The sender wheel is held in its installation position by a locat‐
ing pin on the assembly tool - T10134- .
♦ The sealing flange and oil seal are one unit and must always
be replaced together with the sender wheel.
♦ The assembly tool - T10134- is held in the correct position rel‐
ative to the crankshaft by a guide pin which is inserted into a
hole in the crankshaft.
Construction of assembly tool - T10134-

A - Tensioning flats
B - Hexagon nut
C - Assembly housing
D - Locating pin
E - Hexagon socket-head bolt
F - Guide pin for diesel engines (black handle)
G - Guide pin for petrol engines (red handle)
A - Fitting sealing flange with sender wheel onto assembly tool -

T10134- :
– Turn hexagon nut -B- on threaded spindle until it is just in front
of flats -A-.

– Clamp assembly tool - T10134- in a vice on tightening flats

-A- of threaded spindle.
– Press assembly housing -C- downwards so that it lies on hex‐
agon nut -B- -arrow-.
• Inner part of assembly device and assembly housing must
align (be level) with each other.
– Remove the securing clip -arrow- from new sealing flange.
Note
The sender wheel must not be taken out of the sealing flange or
rotated out of position.
• The locating hole -A- on the sender wheel -C- must align with
the marking -B- on the sealing flange.
– Place sealing flange (with front side downwards) on a clean
flat surface.
– Press the sealing lip support ring -A- downwards in direction

of -arrows- until it lies against the flat surface.

• The upper edge of the sender wheel and the front edge of the
sealing flange must align -arrows-.
– Place front side of sealing flange on assembly tool - T10134- ,

so that locating pin -B- can be inserted in hole -A- in sender
wheel.
• Ensure that sealing flange lies flat on assembly tool.
– Press the sealing flange and sealing lip support ring -B- onto
the surface of the assembly tool - T10134- while tightening the
3 knurled screws -A- so that the locating pin will not slip out of
the hole in the sender wheel.
• Ensure that the sender wheel remains fixed on the assembly
tool when installing the sealing flange.
B - Installing assembly tool - T10134- with sealing flange on

crankshaft flange:
• Crankshaft flange must be free of oil and grease.
• Engine is at “TDC” position.
– Screw hexagon nut -B- to end of threaded spindle.
– Press the threaded spindle of assembly tool - T10134- in di‐
rection of -arrow- until the hexagon nut -B- lies on the assem‐
bly housing -A-.

– Position flat edge of assembly housing towards sealing sur‐

face for sump on cylinder block.
– Secure assembly tool - T10134- to crankshaft flange by screw‐
ing hexagon socket head bolts -A- approx. 5 threads into
crankshaft flange.
– Screw two bolts M7×35 mm -item A- into cylinder block to

guide sealing flange.
C - Securing assembly tool - T10134- onto crankshaft flange:

– Press the assembly housing -C- by hand in the direction of the
-arrow- until the sealing lip support ring -B- lies on the surface
of the crankshaft flange -A-.
Caution
Do not interchange components.

♦ The guide pin for PETROL engines (red handle) -F- MUST
NOT be inserted into the threaded hole in the crankshaft.
– Push guide pin for diesel engine (black handle) -D- into hole
in crankshaft. This brings the sender wheel into its final instal‐
lation position.
– Tighten the two hexagon socket head bolts on assembly tool
hand-tight.
– Screw hexagon nut -E- onto threaded spindle by hand until it
lies against the assembly housing -C-.
D - Pressing sender wheel onto crankshaft flange with assembly

tool - T10134- :
– Tighten hexagon nut on assembly tool - T10134- to 35 Nm.
• A small air gap must be present between cylinder block and
sealing flange after tightening hexagon nut to 35 Nm.

E - Checking installation position of sender wheel on crankshaft:

– Screw hexagon nut -E- to end of threaded spindle.
– Remove bolts -A- from cylinder block.
– Unscrew knurled screws -B- from sealing flange.
– Remove hexagon socket head bolts.
– Unbolt assembly tool - T10134- from crankshaft flange (re‐
move hexagon socket head bolts from crankshaft flange).
– Detach sealing lip support ring.
– Apply depth gauge - VAS 6082- to crankshaft flange.
– Measure distance between crankshaft flange -A- and sender

wheel -B-.
• Specification: Distance -a- = 0.5 mm.
– Press sender wheel in further if distance -a- is too small
⇒ page 76 .
– If reading matches specification, continue with assembly
⇒ page 77 .
F - Pressing sender wheel in further:

– Secure assembly tool - T10134- to crankshaft flange by tight‐
ening hexagon socket head bolts -A- hand-tight.
– Press assembly tool onto sealing flange by hand.

– Screw hexagon nut -E- onto threaded spindle by hand until it

lies against the assembly housing -C-.
– Tighten hexagon nut on assembly tool - T10134- to 40 Nm.

– Check installation position of sender wheel on crankshaft
again ⇒ page 76 .
– If distance “a” is still too small, tighten hexagon nut on assem‐
bly tool - T10134- to 45 Nm.
– Check installation position of sender wheel on crankshaft
again ⇒ page 76 .
Assembling:
– Tighten sealing flange bolts ⇒ page 68 .
– Install engine speed sender - G28- ⇒ page 325 .
– Install sump ⇒ page 147 .
– Install intermediate plate ⇒ page 68 .
– Install drive plate ⇒ page 68 .
2.4 Renewing needle bearing in drive plate

♦ Tube - VW 418 A-

♦ Tube - VW 421-
♦ Support - 40 - 103-
Procedure
• Gearbox removed
– Remove drive plate ⇒ page 68 .
– Place support - 40 - 103- under drive plate when pressing out
and pressing in needle bearing.
– Use tube - VW 421- and workshop press and press out needle
bearing.
• Smaller diameter of tube -VW 421- faces drive plate.
– Carefully press in needle bearing as far as stop, using tube -

VW 418 A- and workshop press.
• Installation position: closed side of needle bearing faces en‐
gine.
– Install drive plate ⇒ page 68 .

3 Crankshaft
⇒ “3.1 Exploded view - crankshaft”, page 79
⇒ “3.2 Crankshaft dimensions”, page 80
⇒ “3.3 Measuring axial clearance of crankshaft”, page 80
⇒ “3.4 Measuring radial clearance of crankshaft”, page 80
⇒ “3.5 Pulling spur gear off crankshaft and shrink-fitting new spur
gear”, page 81
3.1 Exploded view - crankshaft
1 - Bearing shell
❑ For cylinder block (with
oil groove)
❑ Renew used bearing
shells
2 - Spur gear
❑ For balance shaft as‐
sembly
❑ Pulling spur gear off
crankshaft and shrink-
fitting new spur gear
⇒ page 81
3 - Bearing shell
❑ For bearing cap (without
oil groove)
shells
4 - Thrust washers
❑ For bearing No. 3
❑ Different types for cylin‐
der block and bearing
cap
❑ Note location
5 - Bolt
❑ Renew
❑ 65 Nm + 90°
❑ When measuring radial
clearance, tighten used
bolt to 65 Nm and turn
90° further
6 - Bearing caps
❑ Bearing cap 1: Pulley
end
❑ Bearing cap 3 with recesses for thrust washers
❑ Installation position: retaining lugs on bearing shells in cylinder block and bearing caps must be on the
same side
7 - Crankshaft
❑ Crankshaft dimensions ⇒ page 80
❑ Measuring axial clearance ⇒ page 80
❑ Measuring radial clearance ⇒ page 80
3. Crankshaft 79
3.2 Crankshaft dimensions

Crankshaft Conrod
main bearing journal journal ∅
∅ mm mm
Basic dimension 54.00 -0.022 50.90 -0.022
-0.042 -0.042
3.3 Measuring axial clearance of crankshaft

♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge - VAS 6079-
Procedure
– Bolt dial gauge - VAS 6079- with universal dial gauge bracket
- VW 387- onto cylinder block (as shown in illustration) and set
it against crank web.
– Press crankshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Push crankshaft away from dial gauge and read off value.
Axial clearance:
• New: 0.07 ... 0.17 mm.
• Wear limit: 0.37 mm
3.4 Measuring radial clearance of crank‐

shaft
♦ Plastigauge
Procedure
– Remove bearing cap and clean bearing journal.

– Place a length of Plastigauge corresponding to the width of the

bearing on the bearing journal or in the bearing shell.
• The Plastigauge must be positioned in the centre of the bear‐
ing shell.
– Fit bearing cap and secure with old bolts ⇒ Item 5 (page 79)
without rotating crankshaft.
– Remove bearing cap again.
– Compare width of Plastigauge with measurement scale.
Radial clearance:
• New: 0.03 ... 0.08 mm.
• Wear limit: 0.17 mm.
3.5 Pulling spur gear off crankshaft and

shrink-fitting new spur gear
♦ Fitting tool - 10 - 203-
♦ Temperature gauge - VAS 6519-

♦ Hotplate (commercially available)
Procedure
– Remove sealing flange (pulley end) ⇒ page 64 .
Note
If the balance shaft assembly does not have to be renewed, it is

sufficient just to remove the idler gear.
– Remove balance shaft assembly ⇒ page 160 .
3. Crankshaft 81
Pulling off spur gear

– Insert thrust piece -T10392/1- in end of crankshaft.
– Insert puller -T10392- into holes in spur gear, turn clockwise

-arrow- and screw in locating pins -A-.
– Counterhold crankshaft with ring spanner -A- and pull spur

gear off end of crankshaft by screwing in spindle with ring
spanner -B-.
Shrink-fitting spur gear
Note
♦ While heating up the new spur gear, monitor the temperature

with the temperature gauge -VAS 6519- .
♦ When the temperature reaches 200 ℃, you have approx. 4
seconds to fit the spur gear on the crankshaft.
♦ A higher temperature increases the amount of time available
(220 ℃ = approx. 6 seconds).
♦ Make sure the end of the crankshaft is clean.
Caution
Do not exceed a maximum temperature of 240 ℃; otherwise

the spur gear can become discoloured and distorted.

– Place the new spur gear flat on a commercially available hot‐

plate and heat it up to at least 200 °C, but not more than 240 °
C. Lettering faces upwards.
– Set temperature gauge - VAS 6519- to measuring range 2.
– Position temperature sensor -VAS 6519/1- on collar of spur
gear (as shown) and read off temperature at temperature
gauge.
WARNING
Risk of burns. Use suitable protective gloves for the following

steps.
– When the required temperature has been reached, pick up the

spur gear with pliers as illustrated.
Note
Take care not to damage the teeth of the spur gear.
– With the aid of fitting tool - 10 - 203- , slide spur gear by hand
onto end of crankshaft as far as stop. This must be done with‐
out delay, taking care to keep the gear straight.
– Wait a few minutes to allow the spur gear to cool down, and
then install the balance shaft assembly.
– Install sealing flange (pulley end) ⇒ page 64 .
3. Crankshaft 83
4 Pistons and conrods

⇒ “4.1 Exploded view - pistons and conrods”, page 84
⇒ “4.2 Measuring piston projection at TDC”, page 88
⇒ “4.3 Piston and cylinder dimensions”, page 89
⇒ “4.4 Checking radial clearance of conrod bearings”,
page 89
4.1 Exploded view - pistons and conrods
Note
♦ All bearing and running surfaces must be oiled before assem‐

bling.
♦ Oil spray jet and pressure relief valve ⇒ page 87
1 - Bolt
❑ Renew
❑ Lubricate threads and
contact surface
❑ 30 Nm + 90°
❑ When measuring radial
clearance, tighten used
bolt to 30 Nm and turn
90° further
2 - Conrod bearing cap
❑ Due to the cracking
method used to sepa‐
rate the bearing cap
from the conrod in man‐
ufacture, the caps only
fit in one position and
only on the appropriate
conrod
❑ Mark cylinder allocation
in colour -B-
❑ Installation position:
Markings -A- face to‐
wards pulley end
3 - Bearing shell
❑ Installation position
⇒ page 87
shells
❑ Note version: Upper
bearing shell (closest to
piston) is constructed
from a more wear-re‐
sistant material; refer to
⇒ Electronic parts cata‐
logue
❑ Check that it is securely
seated
4 - Conrod
❑ Only renew as a complete set

❑ With industrially cracked conrod bearing cap

❑ Separating parts of new conrod ⇒ page 87
❑ Mark cylinder allocation in colour -B-
❑ Installation position: Markings -A- face towards pulley end
❑ Axial clearance: wear limit: 0.37 mm
5 - Circlip
❑ Renew
6 - Piston pin
❑ If difficult to move, heat piston to approx. 60 °C
❑ Remove and install using drift - VW 222 A-
7 - Piston
❑ With combustion chamber
❑ Version fitted in vehicle may differ from illustration
❑ Mark installation position and cylinder number ⇒ page 86
❑ Checking ⇒ page 86
❑ Install using piston ring clamp
❑ Piston and cylinder dimensions ⇒ page 89
❑ Measuring cylinder bore ⇒ page 86
❑ Measuring piston projection at “TDC” ⇒ page 88
8 - Piston rings
❑ Compression rings
❑ Offset gaps by 120°
❑ Use piston ring pliers to remove and install
❑ Installation position: marking “TOP” or side with lettering faces towards piston crown
❑ Measuring ring gap ⇒ page 85
❑ Measuring ring-to-groove clearance ⇒ page 86
9 - Piston ring
❑ Oil scraper ring
❑ Offset gap 120° from bottom compression ring
❑ Use piston ring pliers to remove and install
❑ Measuring ring gap ⇒ page 85
❑ Measuring ring-to-groove clearance ⇒ page 86
Measuring piston ring gap

– Insert ring at right angle to cylinder wall from above and push
down into lower cylinder opening approx. 15 mm from bottom
of cylinder.
– To do so, use a piston without rings.
Piston ring new Wear limit
mm mm
1st compression ring 0.25 … 0.40 1.00
2nd compression ring 0.25 … 0.40 1.00
Oil scraper ring 0.25 … 0.50 1.00
4. Pistons and conrods 85

Measuring ring-to-groove clearance

– Clean groove in piston before checking clearance.
Piston ring new Wear limit
mm mm
1st compression ring 0.06 … 0.09 0.25
2nd compression ring 0.05 … 0.08 0.25
Oil scraper ring 0.03 … 0.06 0.15
Checking piston
– Using a micrometer (75 ... 100 mm), measure approx. 15 mm
from the lower edge, perpendicular to the piston pin axis.
• Maximum deviation from nominal dimension: 0.04 mm.
Nominal dimension
⇒ “4.3 Piston and cylinder dimensions”, page 89 .
Note
Renew piston if cracking is visible on piston skirt.
Installation position of pistons and allocation of piston/cylinder

• Arrow on piston crown points to pulley end -arrows-.
Measuring cylinder bore

– Use a cylinder gauge - VAS 6078- to take measurements at 3
points in transverse direction -A- and in longitudinal direction
-B-.
• Maximum deviation from nominal dimension: 0.10 mm.
Nominal dimension
⇒ “4.3 Piston and cylinder dimensions”, page 89 .

Installation position of bearing shells in conrods

1- Bearing shell with oil drilling -arrow- for conrod.
2- Bearing shell without oil drilling for conrod bearing cap.
– Insert bearing shells centrally in conrod/conrod bearing cap.
• Distance -a- is the same on both sides.
Separating parts of new conrod

It is possible that the two parts of a new conrod are not completely
separated as intended. If it is not possible to take off the conrod
bearing cap by hand, proceed as follows:
– To avoid any risk of damage, the conrod should only be clam‐
ped lightly in a vice using jaw covers as shown in illustration.
• The conrod is clamped in position below the dotted line.
– Unscrew bolts -arrows- approx. 5 turns.
– Using a plastic hammer, carefully knock conrod bearing cap

loose -arrow-.
Oil spray jet and pressure relief valve

1- Bolt with pressure relief valve, 27 Nm
2- Oil spray jet (for cooling of pistons)
• Installation position: align locating edge of oil spray jet with
machined surface of cylinder block.
Caution
Risk of damage to oil spray jets.

♦ Do not bend oil spray jets.
♦ Always renew bent oil spray jets.

4.2 Measuring piston projection at TDC
Note
Piston projection at “TDC” must be measured when installing new

pistons or a short engine.

equipment required
♦ Measuring bridge -
VW 382/7- from measuring
tool - VW 382-
♦ Measuring plate -
VW 385/17- from universal
measuring tool - VW 385-

Procedure
– Secure dial gauge - VAS 6079- with measuring bridge -
VW 382/7- and measuring plate -VW 385/17- to cylinder block
as shown in illustration.
– Measure piston projection at two points marked with
-arrows- for each piston.
Note
If the measured values for piston projection are not the same for
all pistons, use the highest value to determine the correct gasket
size.
– Depending on piston projection, install corresponding cylinder

head gasket according to following table:
Piston projection above top sur‐ Identification
face of cylinder block (No. of holes)
mm
0.91 … 1.00 1
1.01 … 1.10 2
1.11 … 1.20 3
Identification of cylinder head gasket

1- Part number
2- Holes
3- Ignore
Note
If the measured values for piston projection are not the same for
all pistons, use the highest value to determine the correct gasket
size.
4.3 Piston and cylinder dimensions

Piston ∅ Cylinder bore ∅
mm mm
Basic dimension 80.96 1) 81.01
• 1)Dimensions including coating (thickness 0.02 mm). The
coating will wear down in service.
4.4 Checking radial clearance of conrod

bearings
♦ Plastigauge

Procedure
– Remove conrod bearing cap. Clean bearing cap and bearing
journal.
bearing on the bearing journal or in the bearing shell.
– Fit conrod bearing cap and secure with old bolts
⇒ Item 1 (page 84) without rotating crankshaft.
– Remove conrod bearing cap again.
Radial clearance:
– Renew conrod bolts.

15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Exploded view - cylinder head”, page 91
⇒ “1.2 Exploded view - cylinder head cover”, page 93
⇒ “1.3 Removing and installing cylinder head”, page 96
⇒ “1.4 Removing and installing cylinder head cover”, page 105
⇒ “1.5 Removing and installing seals for injectors”, page 108
⇒ “1.6 Checking compression”, page 109
1.1 Exploded view - cylinder head
1 - Cylinder head gasket

❑ Identification of cylinder
head gasket
⇒ page 93
❑ If renewed, change
coolant and engine oil
2 - Bolt
❑ Apply locking fluid when
installing; refer to ⇒
Electronic parts cata‐
logue
❑ 10 Nm
3 - Hall sender - G40-
❑ For camshaft position
4 - Cylinder head
⇒ page 96
❑ To prevent damage to
glow plugs, always
place cylinder head on a
soft foam surface after
removal.
❑ Checking for distortion
⇒ page 93
❑ Must not be machined
❑ Before installing, check
that the two dowel
sleeves for centring cyl‐
inder head are fitted on
cylinder block
❑ If renewed, change
coolant and engine oil
5 - Washer
6 - Bolt
❑ Renew
❑ Correct sequence when slackening ⇒ page 101
1. Cylinder head 91
7 - Oil pressure switch - F1-

❑ Opening/closing pressure 0.3 ... 0.6 bar
❑ 20 Nm
8 - Seal
❑ Renew
9 - Bolt
❑ 20 Nm
10 - Engine lifting eye
11 - Seal
❑ Renew
12 - Plug
❑ 20 Nm
13 - Gasket
❑ Renew
14 - Vacuum pump
❑ Removing and installing ⇒ Brake system; Rep. gr. 47 ; Vacuum system; Removing and installing vacuum
pump
15 - Bolt
❑ Tightening torque ⇒ Brake system; Rep. gr. 47 ; Vacuum system; Exploded view - vacuum pump
16 - Connection
❑ For coolant hoses
❑ with coolant temperature sender - G62-
❑ Version fitted in vehicle may differ from illustration
17 - Bolt
❑ Tightening torque ⇒ Item 12 (page 194)
18 - Gasket
❑ Renew
19 - Bolt
❑ 20 Nm
20 - Engine lifting eye
Cylinder head - tightening torque and sequence
Note

1. -1 … 10- 30 Nm
2. -1 … 10- 50 Nm
3. -1 … 10- Turn 90° further
4. -1 … 10- Turn 90° further
92 Rep. gr.15 - Cylinder head, valve gear

Checking cylinder head for distortion

– Use straight edge 500 mm - VAS 6075- and feeler gauge to
measure cylinder head for distortion at several points.
• Max. permissible distortion: 0.1 mm.
Identification of cylinder head gasket

1- Part number
2- Holes
3- Ignore
Note
Cylinder head gaskets of different thicknesses are fitted depend‐

ing on the amount of piston projection ⇒ page 88 . When renewing
only the cylinder head gasket, the new gasket should have the
same identification as the old one.
1.2 Exploded view - cylinder head cover
Caution
When installing a new base engine, it is essential that the

clamping pieces for the injectors are tightened to the specified
torque ⇒ page 268 after installing the high-pressure pipes. The
clamping pieces are only secured hand-tight at the factory so
the injectors can be aligned during installation. If these instruc‐
tions are not observed, the engine could be damaged.
1. Cylinder head 93
1 - Gasket
❑ Renew if damaged or
leaking
2 - Cylinder head cover
⇒ page 105
3 - Retainer
❑ For vacuum lines and
electrical wiring
4 - O-ring
❑ Renew
5 - Hose
❑ For crankcase breather
❑ Press release tabs to
detach
6 - Sealing bush
❑ For fuel rail
❑ Renew if damaged or
leaking
7 - Grommet
8 - Clamping piece
9 - Bolt
❑ 8 Nm
10 - Fuel rail
❑ Observe rules for clean‐
liness ⇒ page 6
❑ Do not attempt to bend
high-pressure pipes to a
different shape
❑ Installing high-pressure
pipes ⇒ page 268
11 - Bolt
12 - Bolt
❑ Renew
13 - Fuel return line
14 - O-ring
❑ Renew
15 - Injector
❑ Observe rules for cleanliness ⇒ page 6
16 - O-ring
❑ Renew
17 - Copper seal
❑ Renew
18 - Seal
❑ For injector

19 - Filler cap
20 - Seal
❑ For filler cap
21 - Grommet
22 - Bolt
❑ Renew if gasket is damaged
Cylinder head cover - tightening torque and sequence

– Tighten bolts for cylinder head cover in the sequence -1 ... 6-
to 9 Nm.
Note
Take care to keep cylinder head cover straight.
1. Cylinder head 95
1.3 Removing and installing cylinder head

equipment required
♦ Diesel injection pump lock‐
ing pin - 3359-
♦ Hose clip pliers - VAS
6362-
♦ Puller - T10052-
♦ Bit XZN 10 - T10385-
Removing
– Remove air cleaner housing ⇒ page 244 .
– Remove coolant pipe (top left) ⇒ page 195 .


- G505- .

– Remove bolt and nut -arrows-.

– Press coolant pipe (rear right) to one side.
Note

– Release hose clips -arrows- and disconnect coolant hoses
from rear coolant pipe.
– Move coolant pipe to rear.
Note
Disregard -item 2-.
1. Cylinder head 97
– Unplug electrical connector -2- at coolant temperature sender

- G62- .
Note
Disregard -item 1-.
– Unplug electrical connector -arrow- on oil pressure switch -

F1- .
– Remove bolt -1- for dipstick guide tube.

– Unplug electrical connector -3- at throttle valve module -
J338- .
Note
Disregard -item 2-.
– Remove cylinder head cover ⇒ page 105 .
– Lift retaining clip -arrow- and disconnect coolant line.

– Loosen bolt -1- for turbocharger.
Note
Disregard -item 2-.
– Slacken clamp -arrows-.
– Remove nuts -arrows- for turbocharger.
Note
– Move clear electrical wiring harness at cylinder head.
– Remove bolts -1- and detach camshaft sprocket.
1. Cylinder head 99
– Counterhold using counterhold tool - T10051- and loosen bolt

-1- for camshaft hub.
– Unscrew bolt approx. 2 turns.
– Apply puller - T10052- to camshaft hub and screw bolts -1- into
hub.
– Counterhold on hexagon flats (30 mm) of puller and screw in
bolt -2- to pull off camshaft hub.
– Detach hub from taper of camshaft.
– Remove bolt -arrow- for toothed belt cover (rear).
– Remove bolt for Hall sender - G40- -arrow- and move Hall
sender - G40- to one side.

– Slacken cylinder head bolts in the sequence -1 ... 10-.
Note
♦ A second mechanic is required for removal of the cylinder

head.
♦ Toothed belt tensioning roller is detached from stud when lift‐
ing out cylinder head.
– Swivel cylinder head towards front and out of rear toothed belt
cover and detach tensioning roller at the same time.
– Take care not to damage oil return line for turbocharger.
– Take care to place cylinder head down without bending oil re‐
turn line. If necessary, place a block of wood below exhaust
manifold.
Caution
Risk of damage to glow plugs when putting down cylinder

head.
♦ After removal, the cylinder head must not be put down on
the gasket side with the glow plugs still installed, because
the glow plugs project slightly beyond the gasket surface.
Note
Audi A4 and A5 models with a 2.0 ltr. 4-valve common rail TDI
engine are always equipped with steel glow plugs.
Installing
Tightening torques
♦ ⇒ “1.1 Exploded view - cylinder head”, page 91
1. Cylinder head 101

Caution
Risk of damage to sealing surfaces.

♦ Carefully remove sealant residue from cylinder head and
cylinder block.
♦ Ensure that no long scores or scratches are made on the
surfaces.
Risk of damage to cylinder block.
♦ No oil or coolant must be allowed to remain in the blind
holes for the cylinder head bolts in the cylinder block.
Risk of leaks at cylinder head gasket.
♦ Carefully remove any sealant residue from the cylinder
head and cylinder block. Ensure that no long scores or
scratches are made on the surfaces.
♦ Carefully remove any remaining emery and abrasive ma‐
terial.
♦ Do not remove new cylinder head gasket from packaging
until it is ready to be fitted.
♦ Handle the cylinder head gasket very carefully to prevent
damage to the silicone coating or the indented area of the
gasket.
Risk of damage to open valves.
♦ When installing an exchange cylinder head, the plastic
protectors fitted to protect the open valves should not be
removed until the cylinder head is ready to be fitted.
Risk of damage to valves and piston crowns after working on
valve gear.
♦ Turn the crankshaft carefully at least 2 rotations to ensure
that none of the valves make contact when the starter is
operated.
Note

♦ Renew self-locking nuts as well as seals, gaskets and O-rings.
♦ Cylinder heads must not be reworked on TDI engines.
♦ When installing an exchange cylinder head, the contact sur‐
faces between roller rocker fingers and cams must be oiled.
♦ After fitting a new cylinder head or cylinder head gasket,
change the engine oil and the coolant in the entire cooling
system.
– Before fitting cylinder head, remove crankshaft stop - T10050-

and turn crankshaft against normal direction of rotation until
all pistons are positioned approximately equally below “TDC”.
– If not already fitted, install dowel sleeves for centring cylinder
block and cylinder head in cylinder block.

– Note cylinder head gasket identification:

1- Part number
2- Holes
3- Ignore
Note
♦ If the cylinder head gasket or cylinder head have been re‐

placed, select the new cylinder head gasket according to the
number of holes on the old gasket.
♦ If parts of the crankshaft drive have been renewed, the new
cylinder head gasket must be selected by measuring the pis‐
ton projection at “TDC” ⇒ page 88 .
– Fit cylinder head gasket onto dowel sleeves -arrows- in cylin‐

der block.
• Installation position of cylinder head gasket: the word
“oben” (top) or the part number should face towards the cyl‐
inder head.
– Swivel cylinder head so that stud for toothed belt tensioning
roller is inserted into aperture in toothed belt cover (rear) and
attach tensioning roller at the same time.
Note
Make sure that electrical wiring to Hall sender - G40- is properly

routed.
– Fit cylinder head.
– Screw in cylinder head bolts by hand until they make contact.

– Tighten cylinder head bolts ⇒ page 92 .
– Install rear toothed belt cover, camshaft hub and sprocket
⇒ page 111 .

– Lock camshaft hub with diesel injection pump locking pin -

3359- .
Note
Disregard -arrows-.
– Lock high-pressure pump hub with diesel injection pump lock‐

ing pin - 3359- .
Note
Disregard -item 1-.
– Then turn crankshaft in direction of engine rotation until pin

-arrow- on crankshaft stop - T10050- engages in sealing
flange as crankshaft rotates.
note the following:
– Install cylinder head cover ⇒ page 105 .
– Install coolant pipe (rear) ⇒ page 201 .
– Install turbocharger ⇒ page 216 .
– Install dipstick guide tube ⇒ page 143 .
– Install coolant pipe (rear right) ⇒ page 198 .
– Install coolant pipe (top left) ⇒ page 195 .
– Install air cleaner housing ⇒ page 244 .
– Change engine oil ⇒ Maintenance ; Booklet 811 or ⇒ Main‐
tenance ; Booklet 812 .
– Fill cooling system with fresh coolant ⇒ page 173 .

1.4 Removing and installing cylinder head

cover
Removing
– Remove injectors ⇒ page 262 .
– Remove fuel rail ⇒ page 269 .
– Unplug electrical connectors -2, 3, 4- and move electrical wir‐

ing clear.
– Detach vacuum hose -1- and move clear.



– Remove bolts -1, 3-.

– Release hose clips -2- and detach fuel hoses.
– Pull fuel lines upwards off cylinder head cover and press clear
to one side.
Note
Disregard -item 4-.
– Press release tabs and detach crankcase breather hose -2-.
Note
Disregard -item 1-.

– Disconnect vacuum hose -2-.

– Detach bracket -1- for cylinder head cover and move clear to
one side.
Note
Disregard -item 3-.
– Slacken cylinder head cover bolts in the sequence -6 ... 1- and

remove.
Installing
Tightening torques
♦ ⇒ Fig. ““Cylinder head cover - tightening torque and se‐
quence”“ , page 95
Note
♦ Fit new O-ring.

♦ Renew gasket for cylinder head cover and bolts for cylinder
head cover if damaged or leaking.
♦ Renew grommets and seals for injectors if damaged or leak‐
ing.
– Tighten cylinder head cover bolts ⇒ page 95 .

– Make sure that cylinder head cover is clipped properly to

toothed belt cover -arrows-.
Note

the camshaft sprocket removed.
– Make sure there is a clearance between hub and toothed belt

cover.
– Install fuel rail and injectors ⇒ page 269 .
– Bleed fuel system
⇒ “1.3 Filling and bleeding fuel system”, page 240 .
1.5 Removing and installing seals for injec‐

tors
♦ Tool set for FSI engines - T10133-
♦ Socket, AF 24 mm - T10361-

♦ Oil seal extractor - T40195-
Procedure
– Remove corresponding injector ⇒ page 262 .
– Screw oil seal extractor - T40195- into seal -1-.
– Fit striker -T10133/3- with adapter -T10133/2- on oil seal ex‐
tractor, as shown in illustration, and pull out seal upwards by
tapping gently.
– Drive in new injector seal as far as stop using socket, AF 24 -

T10361- and short extension -1-.
1.6 Checking compression

♦ Compression tester - V.A.G 1763- with adapter - V.A.G
1763/8-

Procedure
• Engine oil temperature approx. 80 °C
• Battery voltage at least 12.5 V
– Unplug electrical connector -arrow- for fuel pressure regulat‐

ing valve - N276- at fuel rail.
– Briefly start engine to relieve fuel pressure in fuel rail.
– Remove all glow plugs ⇒ page 321 .
– Screw in adapter - V.A.G 1763/8- in place of corresponding

glow plug and connect compression tester - V.A.G 1763- .
Note
Using the compression tester ⇒ Operating instructions .
– Have a second mechanic operate starter until tester shows no

further pressure increase.
– Repeat procedure on each cylinder.
Compression pressure bar
When new 25.0 … 31.0
Wear limit 19.0
Maximum difference between cylinders 5.0
Assembling
– Install glow plugs ⇒ page 321 .
– Entries are stored in event memory of engine control unit be‐
cause electrical connectors were unplugged and the engine
was started: Interrogate event memory in Vehicle self-
diagnosis ⇒ Vehicle diagnostic tester.

2 Toothed belt drive

⇒ “2.1 Exploded view - toothed belt”, page 111
⇒ “2.2 Removing and installing toothed belt”, page 113
2.1 Exploded view - toothed belt
1 - Toothed belt
chalk or felt-tip pen
❑ Check for wear
❑ Removing ⇒ page 113
❑ Installing (adjusting
valve timing)
⇒ page 116
2 - Idler roller
3 - Nut
❑ Make sure that stud is
fitted securely
❑ 20 Nm
4 - Stud
❑ 15 Nm
5 - Nut
❑ Renew
❑ Make sure that stud is
fitted securely
❑ 20 Nm +45°
6 - Tensioning roller
7 - Stud
❑ 15 Nm
8 - Bolt
❑ 20 Nm
9 - Idler roller
10 - Bolt
❑ Renew
❑ 20 Nm +45°
11 - Camshaft sprocket
12 - Bolt
❑ Slacken and tighten with counterhold tool - T10051-
❑ 100 Nm
13 - Hub
❑ For camshaft
❑ Removing and installing ⇒ “3.5 Removing and installing camshaft”, page 127
14 - Plug
15 - Toothed belt cover (rear)
16 - Bolt
❑ 9 Nm
2. Toothed belt drive 111

17 - Hub
❑ For high-pressure pump
18 - Nut
❑ 95 Nm
19 - High-pressure pump sprocket
20 - Bolt
❑ Renew
❑ 20 Nm
21 - Idler roller
22 - Bolt
❑ Renew
❑ 50 Nm + 90°
23 - O-ring
❑ Renew
24 - Coolant pump
25 - Bolt
26 - Crankshaft sprocket
❑ Contact surface between sprocket and crankshaft must be free of oil
❑ Can only be installed in one position
27 - Bolt
❑ Renew
❑ Slacken and tighten with counterhold tool - 3415-
❑ Do not additionally oil threads and shoulder
Tighten in three stages as follows:
♦ 1st stage: 180 Nm
♦ 2nd stage: Use rigid wrench to turn 90° further
♦ 3rd stage: Use rigid wrench to turn 45° further
Toothed belt cover (bottom) - tightening torque

– Tighten bolts -arrows- to 9 Nm.

2.2 Removing and installing toothed belt

♦ Crankshaft stop - T10050-
♦ Offset screwdriver - T10264-

♦ Locking pin - 3359- or locking pin - T10492-
♦ M10 bit
Note
Diesel injection pump locking pin - 3359- or locking pin - T10492-

can be used to lock camshaft sprocket and high-pressure pump
sprocket.
Removing
Note
Perform adjustments on toothed belt only when engine is cold;

position of tensioner varies according to temperature of engine.

– Remove vibration damper ⇒ page 58 .


– Detach toothed belt cover (bottom).
Caution
Irreparable damage can be caused if the toothed belt slips.

♦ Only turn crankshaft in direction of engine rotation.
– Rotate crankshaft by turning bolt on crankshaft sprocket until

camshaft sprocket is positioned at “TDC”.
3359- or an M6x50 bolt (commercially available).
Note
♦ If it is not possible to push the diesel injection pump locking

pin - 3359- in (lack of space), use an M6x50 bolt (commercially
available).
♦ Disregard -arrows-.
– Lock crankshaft sprocket in position with crankshaft stop -

T10050- .
• The markings on the sprocket -2- and the crankshaft stop -1-
must align -arrow-. The pin of the crankshaft stop must engage
in the aperture in the sealing flange.
Note
The crankshaft stop can only be pushed onto the sprocket from
the front face of the teeth.
– Slacken bolts -arrows- for camshaft sprocket approx. 90°.

– Using an M10 bit , loosen bolts -arrows- for toothed belt

sprocket on high-pressure pump by approx. 90°.
– Slacken nut -1- for tensioning roller.

– Turn eccentric adjuster of tensioning roller with offset screw‐
driver - T10264- anti-clockwise -arrow- until tensioning roller
can be secured with locking tool - T10265- .
– Then use offset screwdriver - T10264- to turn eccentric ad‐

juster of tensioning roller clockwise -arrow- as far as stop and
tighten nut -1- by hand.
Caution
If a used belt runs in the opposite direction when it is refitted,

this can cause breakage.
♦ Before removing, mark direction of rotation of toothed belt
with chalk or felt-tip pen for re-installation.
– Take off toothed belt first from idler roller and then from re‐
maining sprockets.
Installing (adjusting valve timing)
Note
Perform adjustments on toothed belt only when engine is cold.
Tightening torques
♦ ⇒ “2.1 Exploded view - toothed belt”, page 111
Caution
Risk of damage to valves and piston crowns.

♦ The crankshaft must not be at “TDC” at any cylinder when
the camshaft is turned.

Requirements:
• Tensioning roller is locked with locking tool - T10265- and se‐
cured at right stop with nut -1-.
• Lock camshaft hub with diesel injection pump locking pin -

3359- or an M6x50 bolt.
• Bolts -arrows- are fitted but not tightened.
• It should just be possible to turn the sprocket on the camshaft
without axial movement.
Note
♦ If it is not possible to push the diesel injection pump locking

pin - 3359- in (lack of space), use an M6x50 bolt (commercially
available).
♦ Disregard -arrows-.
• Crankshaft is locked in position with crankshaft stop -

T10050- .
• Hub of high-pressure pump locked with diesel injection pump

locking pin - 3359- .
• Bolts -1- are fitted but not tightened.
• The high-pressure pump sprocket should still just turn, but
there must be no axial movement.

Note
If necessary, apply a screwdriver -arrows- to bolt heads -1- and

turn the high-pressure pump hub until it can be locked with the
locking pin.
– Turn the camshaft sprocket and high-pressure pump sprocket

in their elongated holes clockwise as far as the stop.
– Install toothed belt in the specified sequence:
1- Crankshaft sprocket
2- Tensioning roller
3- Camshaft sprocket
4- Coolant pump sprocket
5- High-pressure pump sprocket
6- Idler roller
– Loosen nut -1- for tensioning roller and detach locking tool -
T10265- .
Note
Disregard -arrow-.

Note
Ensure that tensioning roller is seated properly in toothed belt

cover (rear) -arrow-.
– Position counterhold tool - T10172- on camshaft sprocket as

shown in illustration.
– Apply force to counterhold tool in anti-clockwise direction
-arrow- and maintain tension.
– Tighten bolts -1- for camshaft sprocket and bolts -2- for high-
pressure pump sprocket in this position.
♦ Initial tightening torque: 20 Nm
– Carefully turn eccentric adjuster of tensioning roller clockwise

-arrow- using offset screwdriver - T10264- until pointer -2-
aligns with centre of slot on base plate.
• Nut -1- must not turn.
– Hold tensioning roller in this position and tighten nut.
– Remove diesel injection pump locking pin - 3359- or M6x50
bolt and crankshaft stop - T10050- .
Checking valve timing:
Caution

– Turn crankshaft two rotations in direction of engine rotation by

turning bolt for crankshaft sprocket until crankshaft is just be‐
fore “TDC”.
– Fit crankshaft stop - T10050- to crankshaft sprocket again.

– Turn crankshaft in direction of engine rotation until pin
-arrow- on crankshaft stop engages in sealing flange as crank‐
shaft rotates.

• Lock camshaft hub with diesel injection pump locking pin -

3359- or an M6x50 bolt.
Note
Disregard -arrows-.
• It is very difficult to reproduce the locking position of the high-

pressure pump hub. However, a slight deviation -arrow- does
not influence engine operation.
• Pointer -2- on tensioner roller must be centred between tabs

-1- and -3- on base plate.
Note
The maximum permissible sideways deviation from the specified

position is 5 mm.
♦ Re-adjust valve timing if requirements are not met

⇒ page 120 .
♦ If requirements are met, continue with procedure after adjust‐
ing valve timing correctly as described below ⇒ page 121 .
Re-adjusting valve timing:
– If camshaft hub cannot be locked, withdraw crankshaft stop -
T10050- until pin is clear of bore.
– Turn crankshaft in opposite direction of engine rotation slightly
past “TDC”.
– Now turn crankshaft slowly in direction of engine rotation until

it is possible to lock camshaft hub with diesel injection pump
locking pin - 3359- or M6x50 bolt.
– Loosen bolts for camshaft sprocket after locking hub.

A - If pin of crankshaft stop - T10050- is on left side of bore:

– Turn crankshaft in direction of engine rotation until pin
-arrow- on crankshaft stop engages in sealing flange as crank‐
shaft rotates.
– Tighten camshaft sprocket bolts to 20 Nm initially.
B - If pin of crankshaft stop - T10050- is on right side of bore:
– Turn crankshaft slightly in opposite direction to engine rota‐
tion.
– Turn crankshaft in direction of engine rotation again until pin
of crankshaft stop engages in sealing flange as crankshaft ro‐
tates.
– Tighten camshaft sprocket bolts to 20 Nm initially.
Procedure after adjusting valve timing correctly:
– Remove diesel injection pump locking pin - 3359- or M6x50
bolt and crankshaft stop - T10050- .
– Turn crankshaft two rotations in direction of engine rotation by
turning bolt for crankshaft sprocket until crankshaft is just be‐
fore “TDC”.
– Check valve timing once again ⇒ page 119 .
– If camshaft hub can now be locked, tighten camshaft sprocket

bolts -1- to final torque ⇒ Item 10 (page 111) .
– Tighten bolts -2- for high-pressure pump sprocket to final tor‐
que ⇒ Item 20 (page 112) .
– Check valve timing once again ⇒ page 119 .
Assembling
Note
♦ Renew seals and/or gaskets.

– Install vibration damper ⇒ page 58 .

– Install engine cover panel ⇒ page 48 .

3 Valve gear
⇒ “3.1 Exploded view - valve gear”, page 122
⇒ “3.2 Measuring axial clearance of camshaft”, page 123
⇒ “3.3 Measuring radial clearance of camshaft”, page 124
⇒ “3.4 Removing and installing camshaft oil seal”, page 125
⇒ “3.5 Removing and installing camshaft”, page 127
⇒ “3.6 Checking hydraulic compensation elements”, page 133
⇒ “3.7 Removing and installing valve stem oil seals”, page 133
3.1 Exploded view - valve gear
1 - Valve
❑ Must not be machined;
only grinding-in is per‐
missible
❑ Mark installation posi‐
tion for re-installation
❑ Valve dimensions
⇒ page 142
❑ Checking valve guides
⇒ page 141
2 - Cylinder head
3 - Valve stem oil seal
❑ Renewing with cylinder
head installed
⇒ page 133
❑ Renewing with cylinder
head removed
⇒ page 137
4 - Valve spring
5 - Valve spring plate
6 - Valve cotters
7 - Sealing cap
❑ Renew
❑ Removing sealing cap
with retaining frame in‐
stalled: pierce on one
side with an awl and pry
out
❑ Installing: drive in with‐
out sealant using suita‐
ble thrust piece
❑ Installation depth 1 ... 2
mm
8 - Oil seal
9 - Exhaust camshaft


10 - Bolt
❑ Correct sequence when slackening ⇒ page 129
11 - Retaining frame
❑ With integrated camshaft bearings
12 - Inlet camshaft
13 - Roller rocker finger
❑ Mark installation position for re-installation
❑ Check roller bearings for ease of movement
❑ Lubricate contact surfaces before installing
14 - Securing clip
❑ For hydraulic compensation element
15 - Hydraulic compensation element
❑ Mark installation position for re-installation
❑ Lubricate contact surfaces before installing
Retaining frame - tightening torque and sequence

• The retaining frame should make
contact with the cylinder head over
the full surface
2. -1 … 24- 10 Nm
3.2 Measuring axial clearance of camshaft

3. Valve gear 123

Procedure
– Remove retaining frame
⇒ “3.5 Removing and installing camshaft”, page 127 .
– Secure dial gauge - VAS 6079- with universal dial gauge
bracket - VW 387- to retaining frame as shown in illustration.
– Press camshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
Axial clearance on inlet camshaft and exhaust camshaft:
• Specification: 0.048 … 0.118 mm.
3.3 Measuring radial clearance of camshaft

♦ Plastigauge
Procedure
– Remove roller rocker fingers
– Clean bearings and bearing journals.
bearing on the bearing journal or bearing shell to be measured.
• The Plastigauge must be positioned in the centre of the bear‐
ing.
– Fit retaining frame and tighten to 10 Nm without rotating cam‐
shafts ⇒ page 123 .
– Remove retaining frame again.


• Radial clearance: 0.035 ... 0.085 mm
3.4 Removing and installing camshaft oil

seal
♦ Oil seal extractor - 2085-
♦ Fitting sleeve - 3265-
♦ Bolt -T10071/2- from assembly tool - T10071-
♦ Fitting tool -T10132-
3. Valve gear 125

♦ Adapter 3/8” to 1/2”
♦ Washer 12x14
Procedure
– Remove camshaft sprocket and hub
– Insert adapter 3/8” to 1/2” -item 1- into oil seal extractor - 2085- .
– Screw inner section of oil seal extractor -2085- two turns (ap‐
prox. 3 mm) out of outer section and lock with knurled screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and screw it into oil seal as far as possible (applying firm
pressure).
– Loosen knurled screw and turn inner section against camshaft
until oil seal is pulled out.
– Clamp flats of oil seal extractor in vice and use pliers to remove
oil seal.
– Clean contact surface and sealing surface.
Note
The sealing lip of the oil seal must not be additionally oiled or
greased.
– Apply guide sleeve -T10132/1- to camshaft as shown in illus‐

tration.
– Carefully push oil seal -1- over guide sleeve and onto cam‐
shaft.
– Use fitting sleeve - 3265- , bolt -T10071/2- and washer 12x14

-item 1- to pull in oil seal onto stop.
– Install camshaft sprocket and hub

3.5 Removing and installing camshaft

equipment required
♦ Puller - T10052-
♦ Camshaft fitting tool -
T40094-
♦ Camshaft fitting tool -
T40095-
♦ Clamping tool -T40096/1-
♦ Electric drill with plastic
brush attachment
♦ Safety goggles
♦ Sealant ⇒ Electronic parts
catalogue
Removing
• Cylinder head installed.
– Take toothed belt off camshaft sprocket and high-pressure
pump sprocket ⇒ page 113 .
3. Valve gear 127


– Loosen hose clip -1- and remove air hose.
– Remove bolts -1, 3-; exhaust gas recirculation cooler remains

installed.
– Remove bolts -1- and detach camshaft sprocket.
– Counterhold using counterhold tool - T10051- and loosen bolt

-1- for camshaft hub.
– Unscrew bolt approx. 2 turns.

– If it is not possible to take off the hub by hand:

– Apply puller - T10052- to camshaft hub and screw bolts -1- into
hub.
– Counterhold on hexagon flats (30 mm) of puller and screw in
bolt -2- to pull off camshaft hub.
– Detach hub from taper of camshaft.
– Remove vacuum pump ⇒ Brake system; Rep. gr. 47 ; Vac‐
uum system; Removing and installing vacuum pump .
– Slacken retaining frame bolts in the sequence -24 ... 1-.

– Remove bolts and carefully release retaining frame from bon‐
ded joint.
– Mark fitting location of camshafts for re-installation and re‐
move.
Installing
Tightening torques
♦ ⇒ “3.1 Exploded view - valve gear”, page 122
Caution
Make sure axial bearings in retaining frame are not damaged.

♦ The camshafts MUST be installed using the camshaft fit‐
ting tool - T40094- as described in the following.
Caution
Protect lubrication system and bearings against contamina‐

tion.
♦ Cover exposed parts of the engine.
WARNING
Risk of eye injury.

– Remove remaining sealant from cylinder head and retaining

frame using rotating plastic brush or similar.
– Clean surfaces; they must be free of oil and grease.
– Oil running surfaces of both camshafts.
3. Valve gear 129

Set up camshaft fitting tool - T40094- as follows:

– Secure supports -T40094/9- and -T40094/10- (with -
T40094/11- ) to base plate, as shown in illustration. If neces‐
sary, remove any supports already attached at these posi‐
tions.
– Fit support -T40094/1- onto position -F- and support -

T40094/2- onto position -A-.
– Place inlet camshaft in supports -T40094/1- and -T40094/2- .

– Turn inlet camshaft in such a way that it can be locked in “TDC”
position using locking device -arrow 1-.
• Recess -arrow 2- for cylinder head bolt must face outwards.

– Place exhaust camshaft in supports -T40094/9- and -

T40094/10- .
– Lock exhaust camshaft with top section -T40094/11- .
• The lug -1- on the top section must engage in the slot -2- in
the camshaft,
– Place clamping tool -T40096/1- on teeth of exhaust camshaft
in such a way that the two arms of the tool engage on the two
halves of the gear (one in each half, as shown in illustration).
• The wider arm must engage in the wider half of the gear.
– Tighten the clamping tool using the knurled wheel so that the
faces of the gear teeth are in alignment.
– Slide inlet camshaft towards exhaust camshaft, until gear
teeth engage -arrows-.
– Fit retaining frame on camshafts.

• All camshaft bearings must be seated on the camshafts.
– Position camshaft fitting tool - T40095- and fix camshafts in
position in retaining frame, as shown in illustration.
– Detach top section -T40094/11- .
Note

2 mm).
3. Valve gear 131

Caution
Make sure excess sealant does not contaminate camshaft

bearings.
♦ The beads of sealant must not be thicker than specified.
– Apply beads of sealant onto clean sealing surfaces of cylinder

head as shown in illustration.
• Thickness of sealant beads: 2 ... 3 mm
Note
♦ The retaining frame should be fitted and secured without de‐

lay, as the sealant starts hardening immediately.
♦ After installing the retaining frame, wait about 30 minutes for
the sealant to dry.
– Take camshafts together with retaining frame, camshaft fitting

tool - T40095- and clamping tool -T40096/1- out of camshaft
fitting tool - T40094- and insert components carefully into cyl‐
inder head.
– Screw in retaining frame bolts in the sequence -1 ... 24- evenly

by hand until they make contact.
• The retaining frame should make contact with the cylinder
head over the full surface.
– Tighten bolts ⇒ page 123 .
– Remove camshaft fitting tool - T40095- and clamping tool -
T40096/1- .
note the following:
– Install camshaft oil seal ⇒ page 125 .
– Drive new sealing cap ⇒ Item 7 (page 122) into cylinder head
to a depth of approx. 1 ... 2 mm using suitable thrust piece.
– Install vacuum pump ⇒ Brake system; Rep. gr. 47 ; Vacuum
system; Removing and installing vacuum pump .
Caution
Risk of damage to valves and piston crowns after working on

valve gear.
♦ The hydraulic tappets have to settle; wait for approx. 30
minutes after installing camshafts before starting engine.
♦ Turn the crankshaft carefully at least 2 rotations to ensure
that none of the valves make contact when the starter is
operated.

3.6 Checking hydraulic compensation ele‐

ments
Note
♦ The hydraulic compensation elements cannot be serviced.

♦ Irregular valve noises when starting engine are normal.

♦ Feeler gauge
Procedure
– Start engine and run until radiator fan has started up once.
– Increase engine speed to approx. 2500 rpm for 2 minutes
(perform road test if necessary).
Note
If irregular valve noise disappears but repeatedly re-occurs when

travelling short distances, renew oil retention valve. The oil re‐
tention valve is located in the oil filter bracket
⇒ Item 10 (page 153) .
– If the compensation elements are still noisy, locate the defec‐

tive compensation element as follows:
– Rotate crankshaft by turning bolt for toothed belt sprocket until
cam of supporting element to be tested is facing upwards.
– Press roller rocker finger down -arrow- to determine clearance
between cam and roller rocker finger.
– If it is possible to insert a feeler gauge of 0.20 mm between
cam and roller rocker finger, renew hydraulic compensation
element
Additional steps required
3.7 Removing and installing valve stem oil

seals
⇒ “3.7.1 Removing and installing valve stem oil seals with cylinder
head installed”, page 133
⇒ “3.7.2 Removing and installing valve stem oil seals with cylinder
head removed”, page 137
3.7.1 Removing and installing valve stem oil

seals with cylinder head installed
3. Valve gear 133

♦ Valve stem seal puller - 3364-
♦ Valve stem seal fitting tool - 3365-
♦ Removal and installation device for valve cotters - VAS 5161-

with guide plate for 3.0 ltr. TDI engine - VAS 5161/23- and
sleeve -VAS 5161/23-1-
♦ Bolt M6x30 (2x)

Procedure
– Remove all glow plugs ⇒ page 321 .
– Remove camshafts ⇒ page 127 .
– Mark original positions of roller rocker fingers and hydraulic
compensation elements for re-installation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and put down on a clean surface.
– Set piston of appropriate cylinder to “bottom dead centre”.

– Fit guide plate for 3.0 ltr. TDI engine - VAS 5161/23- onto cyl‐
inder head.
– Secure guide plate on intake manifold side with knurled screw
-VAS 5161/12- and 2 M6x30 bolts -item 1- by hand until they
make contact.
– Screw sealing pin -VAS 5161/10- into guide plate.

– Screw adapter -VAS 5161/11- hand-tight into corresponding
glow plug thread.
– Insert drift -VAS 5161/3- into guide plate and use plastic-head‐
ed hammer to release sticking valve cotters.
– Screw snap-in device -VAS 5161/6- with engaging fork -

VAS 5161/5- into guide plate.
– Slide sleeve -VAS 5161/23-1- onto assembly cartridge -
VAS 5161/8- .
– Connect adapter to compressed air line using a commercially
available connection piece, and apply constant air pressure.
• Minimum pressure: 6 bar
– Attach pressure fork -VAS 5161/2- to snap-in device and push
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth slightly; the valve cotters
are thus forced apart and taken up by the assembly cartridge.
– Release pressure fork.
– Take off assembly cartridge with knurled spacer ring.
– Detach valve spring with valve spring plate.
3. Valve gear 135

– Pull off valve stem oil seal with valve stem seal puller - 3364- .
Caution
Make sure valve stem oil seals are not damaged when instal‐
ling.
♦ New valve stem oil seals -B- are supplied with plastic
sleeve; fit plastic sleeve -A- onto valve stem.
– Lightly oil sealing lip of valve stem oil seal.

– Slide valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Take off plastic sleeve.
If valve cotters have been removed from assembly cartridge, they

must first be inserted in insertion device -VAS 5161/18- .
• Larger diameter of valve cotters faces upwards.
– Insert valve spring and valve spring plate.
– Press assembly cartridge onto insertion device from above
and take up valve cotters.

– Insert assembly cartridge in guide plate for 3.0 ltr. TDI engine
- VAS 5161/23- again.
– Press down pressure fork and pull knurled screw upwards
while turning screw in both directions - this will insert the valve
cotters.
– Release pressure fork with knurled screw still in pulled posi‐
tion.
– Repeat procedure for each valve.
Assembling
– Ensure that all roller rocker fingers make contact with the ends
of the valve stems correctly and are clipped onto their respec‐
tive hydraulic compensation elements.
– Install camshafts ⇒ page 127 .
– Install glow plugs ⇒ page 321 .
3.7.2 Removing and installing valve stem oil seals with cylinder head removed

equipment required
♦ Valve stem seal puller -
3364-
♦ Valve stem seal fitting tool -
3365-
♦ Removal and installation
device for valve cotters -
VAS 5161- with guide plate
for 3.0 ltr. TDI engine - VAS
5161/23- and sleeve -VAS
5161/23-1-
♦ Engine and gearbox sup‐
port - VAS 6095-
♦ Cylinder head tensioning
device - VAS 6419-
♦ Bolt M6x30 (2x)
3. Valve gear 137

Procedure
– Remove camshafts ⇒ page 127 .
– Mark original positions of roller rocker fingers and hydraulic
compensation elements for re-installation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and put down on a clean surface.
– Insert cylinder head tensioning device - VAS 6419- into engine
and gearbox support - VAS 6095- .
– Secure cylinder head in cylinder head tensioning device, as
shown in illustration.
– Connect cylinder head tensioning device to compressed air
supply.
– Using lever -arrow-, slide air pad under combustion chamber
where valve stem oil seal is to be removed.
– Apply just enough compressed air to bring air pad into contact
with valve heads.
– Fit guide plate for 3.0 ltr. TDI engine - VAS 5161/23- onto cyl‐
inder head.
– Secure guide plate on intake manifold side with knurled screw
-VAS 5161/12- and 2 M6x30 bolts -item 1- by hand until they
make contact.
– Insert drift -VAS 5161/3- into guide plate and use plastic-head‐
ed hammer to release sticking valve cotters.

– Screw snap-in device -VAS 5161/6- with engaging fork -

VAS 5161/5- into guide plate.
– Slide sleeve -VAS 5161/23-1- onto assembly cartridge -
VAS 5161/8- .
– Attach pressure fork -VAS 5161/2- to snap-in device and push
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth slightly; the valve cotters
are thus forced apart and taken up by the assembly cartridge.
– Release pressure fork.
– Take off assembly cartridge with knurled spacer ring.
– Detach valve spring with valve spring plate.
– Pull off valve stem oil seal with valve stem seal puller - 3364- .
Caution
Make sure valve stem oil seals are not damaged when instal‐
ling.
♦ New valve stem oil seals -B- are supplied with plastic
sleeve; fit plastic sleeve -A- onto valve stem.
– Lightly oil sealing lip of valve stem oil seal.

– Slide valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Take off plastic sleeve.
If valve cotters have been removed from assembly cartridge, they

must first be inserted in insertion device -VAS 5161/18- .
• Larger diameter of valve cotters faces upwards.
– Insert valve spring and valve spring plate.
– Press assembly cartridge onto insertion device from above
and take up valve cotters.
3. Valve gear 139

– Insert assembly cartridge in guide plate for 3.0 ltr. TDI engine
- VAS 5161/23- again.
– Press down pressure fork and pull knurled screw upwards
while turning screw in both directions - this will insert the valve
cotters.
– Release pressure fork with knurled screw still in pulled posi‐
tion.
– Repeat procedure for each valve.
Assembling
– Ensure that all roller rocker fingers make contact with the ends
of the valve stems correctly and are clipped onto their respec‐
tive hydraulic compensation elements.
– Install camshafts ⇒ page 127 .

4 Inlet and exhaust valves

⇒ “4.1 Machining valve seats”, page 141
⇒ “4.2 Checking valve guides”, page 141
⇒ “4.3 Checking valves”, page 142
⇒ “4.4 Valve dimensions”, page 142
4.1 Machining valve seats
Note
Valve seats may not be machined due to the very small toleran‐
ces.
4.2 Checking valve guides

Procedure
Note
♦ If the valve has to be renewed as part of a repair, use a new

valve for the measurement.
♦ Only insert inlet valve into inlet valve guide and exhaust valve
into exhaust valve guide, as the stem diameters are different.
4. Inlet and exhaust valves 141

– Attach dial gauge - VAS 6079- with universal dial gauge brack‐
et - VW 387- to cylinder head.
– Insert valve into guide.
• End of valve stem must be flush with guide.
– Measure the amount of sideways play.
– If the wear limit is exceeded, repeat the measurement with
new valves.
– Renew cylinder head if wear limit is still exceeded.
Note
Valve guides cannot be renewed.
4.3 Checking valves

– Visually inspect for scoring on valve stems and valve seat sur‐
faces.
– Renew valve if scoring is clearly visible.
4.4 Valve dimensions
Note
Valves must not be machined. Only grinding-in is permitted.
Dimension Inlet valve Exhaust valve

∅a mm 28.10 26.00
∅b mm 5.975 5.965
c mm 99.30 99.10
α ∠° 45 45

17 – Lubrication
1 Sump/oil pump
⇒ “1.1 Exploded view - sump/oil pump”, page 143
⇒ “1.2 Engine oil”, page 147
⇒ “1.3 Checking oil level”, page 147
⇒ “1.4 Removing and installing sump”, page 147
⇒ “1.5 Removing and installing oil pump”, page 149
⇒ “1.6 Removing and installing oil level and oil temperature send‐
er G266 ”, page 151
1.1 Exploded view - sump/oil pump
Note
♦ If large quantities of metal shavings or abrasion are found

when performing engine repairs, this may be an indication of
damage to the crankshaft or conrod bearings. To prevent fur‐
ther damage, the following steps are required after completion
of repair work: clean the oil passages carefully and renew the
oil spray jets, engine oil cooler and oil filter.
♦ Refer to ⇒ Maintenance tables for engine oil capacity, oil
specifications and viscosity grades.
♦ Oil spray jet and pressure relief valve ⇒ page 87
1. Sump/oil pump 143

1 - Seal
❑ Renew
2 - Oil drain plug
❑ 30 Nm
3 - Sump
⇒ page 147
4 - O-ring
❑ Renew
5 - Suction pipe
❑ Clean strainer if dirty
6 - Bolt
❑ 9 Nm
7 - Oil pump
⇒ page 149
❑ Before installing, check
that the two dowel
sleeves for centring oil
pump are fitted onto bal‐
ance shaft assembly
8 - Drive shaft
❑ For oil pump
9 - Circlip
❑ Must fit securely in
groove
❑ Renew circlip if dam‐
aged or stretched
10 - Spur gear for balance
shaft
11 - Bolt
❑ Renew
❑ 20 Nm + 90°
12 - Thrust washer
❑ For idler gear
❑ Renew
❑ Installation position ⇒ page 147
❑ When installing idler gear, apply grease to hold washer on balance shaft assembly
13 - Idler gear
❑ Renew
❑ To achieve the correct backlash a suitably thick coating is already applied to the new idler gear; the
required clearance is achieved as the coating is worn down
❑ Installation position: Part No. must be visible.
❑ Make sure thrust washer is properly seated ⇒ page 147
14 - Bolt
❑ With washer
❑ Renew
❑ 90 Nm + 90°
15 - Hub
❑ For idler gear
144 Rep. gr.17 - Lubrication

❑ Renew
16 - Crankshaft gear
17 - Cover
❑ Installation position for cover of oil level and oil temperature sender - G266- ⇒ page 146
18 - Dowel sleeves
19 - Balance shaft assembly
❑ Removing ⇒ page 160
❑ Re-installing "old" balance shaft assembly ⇒ page 164
❑ Installing new balance shaft assembly ⇒ page 161
❑ Before installing, check that the two dowel sleeves for centring balance shaft assembly are fitted on
cylinder block
20 - Bolt
❑ Renew
21 - Dowel sleeves
22 - Bolt
❑ 9 Nm
23 - Oil intake pipe
24 - Bolt
❑ 9 Nm
25 - Seal
❑ Renew
26 - Oil level and oil temperature sender - G266-
⇒ “1.6 Removing and installing oil level and oil temperature sender G266 ”, page 151
27 - Cover
❑ For oil level and oil temperature sender - G266-
28 - Bolt
❑ Self-locking
❑ Renew
❑ 9 Nm
29 - Bolt

Installation position for cover of oil level and oil temperature send‐
er
– Clip in cover for oil level and oil temperature sender -arrow-,
as shown in illustration.
Note
For greater clarity, item -1- shows oil level and oil temperature
sender .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Sump - tightening torque and sequence
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Tighten bolts in stages:
1. -1 to 20- 5 Nm in diagonal sequence
2. -arrows- 15 Nm + turn 90° further (renew bolts)
3. -1 to 7-, Tighten in stages and in diagonal se‐
-9 and 10-, quence; final torque 13 Nm
-12 to 20-
4. -8 and 11- 23 Nm
Balance shaft assembly - tightening torque and sequence
Note
– Tighten bolts securing balance shaft assembly as follows:

1. -1 to 6- Screw in hand-tight in this sequence
2. -1 to 6- Pre-tighten bolts in this sequence to
6 Nm
3. -1 to 4- Tighten to 20 Nm
4. -5 and 6- Tighten to 13 Nm
5. -1 to 6- Use rigid wrench to turn 90° further in
this sequence

Installation position of thrust washer
Caution
Thrust washer can slip out of position behind idler gear.

♦ Make sure that thrust washer -A- does not slip out of the
recesses in the balance shaft assembly -arrows- when fit‐
ting the idler gear. If this is neglected, the thrust washer
can become trapped. If necessary, apply grease to hold
washer on balance shaft assembly.
1.2 Engine oil

Refer to ⇒ Maintenance tables for engine oil capacity, oil speci‐
fications and viscosity grades.
1.3 Checking oil level

Check oil level ⇒ Maintenance ; Booklet 811 or ⇒ Maintenance ;
Booklet 812 .
1.4 Removing and installing sump

♦ Socket - T10058-
Removing
• Engine oil drained ⇒ Maintenance ; Booklet 811 or ⇒ Mainte‐
– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Subframe .
– Unscrew nut -arrow- on longitudinal member (right-side) and
move earth cables clear.

– Unplug electrical connector -2- at oil level and oil temperature

sender - G266- .
Note
Disregard -item 1-.
– Remove torque reaction support ⇒ page 45 .

– Remove bolts securing sump to gearbox -arrows-.
– Unscrew bolts -1 to 20- in diagonal sequence and remove.
– Carefully release sump from bonded joint.
Installing
Tightening torques
♦ ⇒ Fig. ““Sump - tightening torque and sequence”“ , page 146
Caution
Protect lubrication system and bearings against contamina‐

tion.
♦ Cover exposed parts of the engine.
WARNING
Risk of eye injury.

– Remove sealant residue from sump and cylinder block using

rotating plastic brush or similar.
– Clean sealing surfaces; they must be free of oil and grease.

Note

2 mm).
Caution
Make sure lubrication system is not clogged by excess sealant.

♦ The bead of sealant must not be thicker than specified.
– Apply bead of sealant onto clean sealing surface of sump as

illustrated.
• Thickness of sealant bead: 2 ... 3 mm.
Note
♦ Take particular care when applying sealant bead in area of

rear sealing flange -arrows-.
♦ The sump must be installed within 5 minutes after applying the
sealant.
– Fit sump and tighten bolts ⇒ page 146 .
Note
♦ When installing sump with engine removed from vehicle, en‐

sure that sump is positioned flush with cylinder block at fly‐
wheel end.
♦ After fitting sump, sealant must dry for approx. 30 minutes.
Then (and only then) fill the engine with engine oil.
– Install subframe ⇒ Running gear, axles, steering; Rep. gr.

40 ; Subframe; Exploded view - subframe .
– Fill up with engine oil and check oil level ⇒ Maintenance ;
Booklet 811 or ⇒ Maintenance ; Booklet 812 .
1.5 Removing and installing oil pump

♦ Circlip pliers (commercially available)
♦ M3 bolt

Removing
– Remove bolt -arrow- and detach suction pipe from oil pump.
– Remove circlip -1- using circlip pliers.

– Pull drive shaft -2- out of oil pump using a magnet -arrow-.
– Remove bolts -3, 4, 5- and detach oil pump.
Caution
The bolt on the idler gear must NOT be loosened.
Installing
• Tightening torque
Note
♦ Fit new O-ring.

♦ Renew circlip if damaged or stretched.
♦ Circlip must fit securely in groove.
– Insert dowel sleeves -arrows- in oil pump, if not fitted.

– If no dowel sleeves for centring the oil pump are fitted in the
balance shaft assembly, install missing dowel sleeves.

1.6 Removing and installing oil level and oil

temperature sender - G266-
Removing
• Engine oil drained ⇒ Maintenance ; Booklet 811 or ⇒ Mainte‐
– Remove bolts -1- and detach oil level and oil temperature
sender - G266- -item 4-.
Installing
Note
Renew seal -2- and self-locking bolts -1-.
– Fill up with engine oil and check oil level ⇒ Maintenance ;

Booklet 811 or ⇒ Maintenance ; Booklet 812 .

2 Engine oil cooler

⇒ “2.1 Removing and installing engine oil cooler”, page 152
2.1 Removing and installing engine oil cool‐

er
Removing
– Drain coolant ⇒ page 171 .
Note
Place a cloth underneath to catch escaping coolant and engine

oil.
– Unscrew bolts -arrows- and detach engine oil cooler.

Installing
Tightening torques
♦ ⇒ “3.1 Exploded view - oil filter housing/oil pressure switch”,
page 153
– Fill up cooling system (or change coolant if the engine oil cool‐
er has been renewed) ⇒ page 173 .

3 Oil filter/oil pressure switch

⇒ “3.1 Exploded view - oil filter housing/oil pressure switch”, page
153
⇒ “3.2 Checking oil pressure”, page 154
⇒ “3.3 Checking oil pressure switch F1 ”, page 154
⇒ “3.4 Removing and installing oil pressure switch F1 ”,
page 156
⇒ “3.5 Removing and installing oil filter housing”, page 157
3.1 Exploded view - oil filter housing/oil pressure switch
1 - Sealing cap
❑ 25 Nm
2 - O-ring
❑ Renew
3 - O-ring
❑ Renew
4 - O-ring
❑ Renew
5 - Oil filter element
❑ See note ⇒ page 143
⇒ Maintenance ; Book‐
let 811 or ⇒ Mainte‐
nance ; Booklet 812
6 - Engine oil cooler
❑ See note ⇒ page 143
❑ Connection diagram -
coolant hoses
⇒ page 166
⇒ page 152
❑ If renewed, refill system
with fresh coolant
7 - Bolt
❑ 11 Nm
8 - Gaskets
❑ Renew
9 - Bolt
❑ Renew
❑ Tightening torque and
sequence ⇒ page 154
10 - Oil filter bracket
❑ With integrated oil retention valve
11 - Gaskets
❑ Renew
3. Oil filter/oil pressure switch 153

Oil filter bracket - tightening torque and sequence
Note
– Fit bolts at top left and bottom right first.

– Tighten bolts in 2 stages:
1. -arrows- 14 Nm in diagonal sequence
2. -arrows- Turn 90° further in diagonal sequence
3.2 Checking oil pressure

♦ Oil pressure tester - V.A.G 1342-
Procedure
• Oil level OK
– Remove oil pressure switch - F1- ⇒ page 156 .
– Connect oil pressure tester - V.A.G 1342- to bore for oil pres‐
sure switch.
– Screw a used oil pressure switch into threaded hole on oil
pressure tester - V.A.G 1342- to seal hole.
– Start engine.
• Oil pressure when starting and then at idling speed: at least
0.6 bar.
If specification is not obtained, switch off engine immediately and
check oil pump drive; renew oil pump if necessary
⇒ “1.5 Removing and installing oil pump”, page 149 .
If specification is obtained, let engine warm up.
• Oil pressure specification at operating temperature and 2000
rpm: at least 1.0 bar.
3.3 Checking oil pressure switch - F1-


♦ Oil pressure tester - V.A.G 1342-
♦ Voltage tester - V.A.G 1527B-
♦ Auxiliary measuring set - V.A.G 1594C-

Procedure
• Oil level OK
• Engine oil temperature approx. 80 °C
– Connect oil pressure tester - V.A.G 1342- to bore for oil pres‐
sure switch.
– Screw oil pressure switch - F1- -item 2- into threaded hole in
oil pressure tester.
– Connect brown wire -1- of oil pressure tester to earth (–).
– Connect voltage tester - V.A.G 1527B- with adapter leads from
auxiliary measuring set - V.A.G 1594C- to oil pressure switch
- F1- and battery positive (+).
• LED should not light up.
Note
Renew oil pressure switch - F1- if LED lights up at this stage.
Note
Observe oil pressure tester and LED while starting engine, as

switching point of oil pressure switch may already be exceeded
when starting.
• LED should light up at 0.3 ... 0.6 bar.

– Renew oil pressure switch - F1- if LED does not light up.
3.4 Removing and installing oil pressure

switch - F1-
♦ Articulated wrench, 24 mm - T40175-

Removing
– Remove bolts -2- and -3- and detach engine lifting eye -1-.
– Use articulated wrench, 24 mm - T40175- to unscrew oil pres‐
sure switch - F1- .
Installing
• Tightening torque ⇒ page 91
3.5 Removing and installing oil filter housing

♦ Used oil collection and extraction unit - V.A.G 1782-

Removing
– Remove oil filter element ⇒ Maintenance ; Booklet 811 or
⇒ Maintenance ; Booklet 812 .
– Remove coolant pipe (top left) ⇒ page 195 .
– Remove pump for exhaust gas recirculation cooler - V400-
⇒ page 189 .
– Pull oil dipstick out slightly and remove bolt -1-.
– Release clip -2- with removal lever - 80 - 200- .
– Pull guide tube for oil dipstick upwards out of cylinder block
and push to one side.

– Place drip tray for workshop hoist - VAS 6208- under connec‐
tion.
below engine.
– Unscrew bolts -arrows- and remove oil filter bracket with en‐
gine oil cooler.
Installing
Tightening torques
♦ ⇒ “3.1 Exploded view - oil filter housing/oil pressure switch”,
page 153
Note

♦ Renew gasket.

– Install pump for exhaust gas recirculation cooler - V400-
⇒ page 189 .
– Install coolant pipe (top left) ⇒ page 195 .
– Install oil filter element, fill up engine oil and check oil level
⇒ Maintenance ; Booklet 811 or ⇒ Maintenance ; Booklet
812 .
– Fill up with coolant ⇒ page 171 .

4 Balance shaft assembly

⇒ “4.1 Removing and installing balance shaft assembly”,
page 160
4.1 Removing and installing balance shaft

assembly
⇒ “4.1.1 Removing balance shaft assembly”, page 160
⇒ “4.1.2 Installing a new balance shaft assembly”, page 161
⇒ “4.1.3 Re-installing a used balance shaft assembly”,
page 164
4.1.1 Removing balance shaft assembly

♦ Diesel injection pump locking pin - 3359-
Procedure
– Pull out oil dipstick.
– Using angled ring spanner -1- at vibration damper, turn crank‐
shaft in normal direction of rotation -arrow- until crankshaft is
at “TDC”.

Caution


3359- .
Note
Disregard -arrows-.
– Loosen bolts in the sequence -6 ... 1-.

– Remove bolts and detach balance shaft assembly with oil
pump.
Note
♦ Installing a new balance shaft assembly ⇒ page 161 .

♦ Re-installing a used balance shaft assembly ⇒ page 164 .
4.1.2 Installing a new balance shaft assembly

♦ Bits - T10099-
4. Balance shaft assembly 161

♦ Insert tool, 14 mm - T10393-
Procedure
Tightening torques
♦ ⇒ “1.1 Exploded view - sump/oil pump”, page 143
• Camshaft locked with diesel injection pump locking pin -
3359- .
Note
♦ The spur gear drive of the balance shaft assembly must be

installed with a backlash of 0.038 ... 0.072 mm.
♦ To achieve the correct backlash, a suitably thick coating is al‐
ready applied to the new idler gear. The coating is applied to
the teeth on parts of the circumference.
♦ The coating is worn down rapidly and the backlash is then
correct.
♦ A new balance shaft assembly must always be installed in
conjunction with a new idler gear which has the correct coat‐
ing.
Caution
Thrust washer can slip out of position behind idler gear.

♦ Before positioning balance shaft assembly, slacken off
bolt for idler gear as specified below, but not further. In‐
stallation position of thrust washer ⇒ page 147

– Loosen bolt -1- for idler gear approx. 45° using e.g. bits -
T10099- and insert tool, 14 mm - T10393- .
– If not already fitted, fit dowel sleeves for centring balance shaft
assembly in cylinder block.
– Attach balance shaft assembly to cylinder block.
• Take care not to damage the coating of the idler gear.
– Tighten bolts securing balance shaft assembly ⇒ page 146 .
– Lock balance shaft with locking tool - T10255- , turning bal‐

ance shaft as required.
• The lug of the locking tool must engage in the groove of the
balance shaft.

– Carefully fit balance shaft gear onto balance shaft; to do so,

push idler gear slightly to one side.
• Take care not to damage the coating of the idler gear.
• The threaded holes in the balance shaft should be aligned as
centrally as possible with the elongated holes in the balance
shaft gear.
Note
If it is not possible to align the elongated holes in the balance shaft

gear with the threaded holes, you must turn the gear some teeth
further as required and then fit it again.
– Tighten bolts -arrows- for balance shaft gear.

– Remove locking tool - T10255- .
Note
The following three steps have to be performed simultaneously

(a second mechanic is therefore required):
– Push idler gear -3- firmly in direction of -arrow- into teeth on

spur gear -2- and balance shaft gear -1-. If necessary use a
wooden rod to do so.
– At the same time, turn balance shaft gear slightly anti-clock‐
wise.
– Tighten bolt securing idler gear.
– Remove diesel injection pump locking pin - 3359- .
Note
After installation the idler gear must have no backlash. This can
be checked by exerting light pressure by hand.

note the following:
4.1.3 Re-installing a used balance shaft as‐

sembly

Procedure
Tightening torques
♦ ⇒ “1.1 Exploded view - sump/oil pump”, page 143
• Camshaft locked with diesel injection pump locking pin -
3359- .
Note
♦ If re-installing the "old" balance shaft assembly and neither the

spur gear on the crankshaft nor the crankshaft itself have been
renewed, proceed as described in the following. It is also es‐
sential that the idler gear has NOT been slackened.
♦ If the bolt for the idler gear has been slackened or the spur
gear on the crankshaft or the crankshaft itself have been re‐
newed, you must install a new idler gear with the appropriate
coating. Procedure for installation
⇒ “4.1.2 Installing a new balance shaft assembly”, page 161 .
– Lock balance shaft with locking tool - T10255- , turning bal‐

ance shaft as required.
• The lug of the locking tool must engage in the groove of the
balance shaft.
– If not already fitted, fit dowel sleeves for centring balance shaft
assembly in cylinder block.
– Attach balance shaft assembly to cylinder block.
• With the balance shaft locked in position, the idler gear must
engage in the spur gear on the crankshaft.
• Idler gear must have noticeable backlash.
– Tighten bolts securing balance shaft assembly ⇒ page 146 .

– Remove diesel injection pump locking pin - 3359- .
note the following:

19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 166
⇒ “1.2 Checking cooling system for leaks”, page 169
⇒ “1.3 Draining and filling cooling system”, page 171
1.1 Connection diagram - coolant hoses

⇒ “1.1.1 Connection diagram - coolant hoses, vehicles without
auxiliary heater”, page 166
⇒ “1.1.2 Connection diagram - coolant hoses, vehicles with aux‐
iliary heater”, page 168
1.1.1 Connection diagram - coolant hoses, vehicles without auxiliary heater
Note
♦ Blue = Large coolant circuit.

♦ Red = Small coolant circuit.
♦ Brown = Heating circuit.
♦ Orange = Coolant circuit for exhaust gas recirculation.
166 Rep. gr.19 - Cooling

1 - Radiator
with fresh coolant
2 - Coolant pump
3 - Cylinder head/cylinder
block
with fresh coolant
4 - Exhaust gas recirculation
cooler
with fresh coolant
5 - Radiator outlet coolant tem‐
perature sender - G83-
6 - Coolant temperature send‐
er - G62-
7 - Coolant circulation pump -
V50-
❑ On vehicles with start/
stop system only
8 - Coolant shut-off valve
❑ Country-specific version
❑ Activated by Climatronic
coolant shut-off valve -
N422- (negative pres‐
sure)
⇒ Auxiliary heater, sup‐
plementary heater; Rep.
gr. 82 ; Coolant circuit
with auxiliary/supple‐
mentary heater; Re‐
moving and installing
heater coolant shut-off
valve
9 - Bleeder hole
10 - Heat exchanger for heater
❑ If renewed, refill system with fresh coolant
11 - Coolant valve for gearbox - N488-
❑ For vehicles with manual gearbox with gear oil cooling
12 - Gear oil cooler
13 - Thermostat
❑ For exhaust gas recirculation cooler
14 - Non-return valve
❑ Arrow points in direction of through-flow
15 - Filler cap
❑ For coolant expansion tank
16 - Coolant expansion tank
❑ Checking cooling system for leaks ⇒ page 169
1. Cooling system/coolant 167


18 - Pump for exhaust gas recirculation cooler - V400-
19 - 4/2-way valve with thermostat
1.1.2 Connection diagram - coolant hoses, vehicles with auxiliary heater
Note
♦ Blue = Large coolant circuit.

♦ Red = Small coolant circuit.
♦ Brown = Heating circuit.
♦ Orange = Coolant circuit for exhaust gas recirculation.
1 - Radiator
with fresh coolant
2 - Coolant pump
3 - Cylinder head/cylinder
block
with fresh coolant
cooler
with fresh coolant
5 - Radiator outlet coolant tem‐
perature sender - G83-
er - G62-
7 - Auxiliary heater
8 - Heater coolant shut-off
valve - N279-
❑ Connection diagram, re‐
moving and installing ⇒
Auxiliary heater, supple‐
mentary heater; Rep.
gr. 82 ; Coolant circuit
with auxiliary/supple‐
mentary heater; Re‐
moving and installing
heater coolant shut-off
valve
9 - Bleeder hole
10 - Heat exchanger for heater
with fresh coolant
11 - Coolant valve for gearbox - N488-

12 - Gear oil cooler

13 - Thermostat
❑ For exhaust gas recirculation cooler
❑ Arrow points in direction of through-flow
15 - Filler cap
❑ For coolant expansion tank
16 - Coolant expansion tank
❑ Checking cooling system for leaks ⇒ page 169
19 - 4/2-way valve with thermostat
1.2 Checking cooling system for leaks

♦ Cooling system tester - V.A.G 1274 B-
♦ Adapter for cooling system tester - V.A.G 1274/8-

♦ Adapter for cooling system tester - V.A.G 1274/9-
Checking cooling system for leaks

• Engine must be warm.
WARNING
The cooling system is under pressure when the engine is hot.

Danger of scalding skin and other parts of the body.
♦ Put on protective gloves.
♦ Release pressure (cover filler cap on coolant expansion
tank with a cloth and open carefully).

– Fit cooling system tester - V.A.G 1274 B- with adapter -V.A.G

1274/8- onto coolant expansion tank.
– Using hand pump on cooling system tester, build up a pres‐
sure of approx. 1.5 bar.
• The pressure should not drop more than 0.2 bar within 10 mi‐
nutes.
– If the pressure drops more than 0.2 bar, locate leak and elim‐
inate fault.
Note
The drop in pressure of 0.2 bar within 10 minutes is caused by

the decrease in coolant temperature. The colder the engine is,
the less the pressure will fall. If necessary, check again when the
engine is cold.
Checking pressure relief valve in filler cap

– Fit cooling system tester - V.A.G 1274 B- with adapter -
V.A.G 1274/9- onto filler cap.
– Build up pressure with hand pump on cooling system tester.
• The pressure relief valve should open at a pressure of
1.4 ... 1.6 bar.
– Renew filler cap if pressure relief valve does not open as de‐
scribed.
1.3 Draining and filling cooling system


equipment required
♦ Adapter for cooling system
tester - V.A.G 1274/8-
♦ Pipe for cooling system
tester - V.A.G 1274/10-
♦ Cooling system charge unit
- VAS 6096- with -
VAS 6096/1-
♦ Drip tray for workshop hoist
- VAS 6208-
♦ Hose clip pliers - VAS
6362-
♦ Refractometer - T10007 A-
Draining
WARNING

hot.

– Remove noise insulation ⇒ General body repairs, exterior;
tion .

gine.
– Remove drain plug -1- and drain off coolant.
Note
Disregard -item 2-.

– Release hose clips -1 and 2-, disconnect coolant hoses and
drain off coolant.
Filling
Caution
To ensure optimal corrosion protection, only distilled water

may be mixed with coolant additives.

Note
♦ The effectiveness of the coolant is greatly influenced by the

quality of the water with which it is mixed. Because water may
contain different substances depending on the country or even
the region, the water quality to be used for cooling systems
has been specified. Distilled water meets all the requirements
and is therefore recommended for use when topping up or fill‐
ing up with coolant.
♦ Use only coolant additives listed in the ⇒ Electronic parts
catalogue (ETKA) . If you use other coolant additives, this can
significantly impair in particular the corrosion protection effect.
The resulting damage could lead to loss of coolant and con‐
sequently to serious engine damage.
♦ Coolant with the recommended mixture ratio prevents frost
and corrosion damage and stops scaling. At the same time it
raises the boiling point of the fluid in the system. For this rea‐
son the cooling system must be filled all year round with the
correct coolant additive.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ The refractometer - T10007A- MUST be used to determine the
current level of frost protection.
♦ The mixture must guarantee frost protection down to at least
-25 ℃ (in countries with arctic climate: down to -36 ℃). The
amount of antifreeze should only be increased if greater frost
protection is required in very cold climates. This must only be
down to -48 ℃, however, as otherwise the cooling efficiency
of the coolant is impaired.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. Frost
protection must be provided to at least -25 ℃.
♦ Read off the level of frost protection on the scale for the rele‐
vant coolant additive.
♦ The temperature indicated on the refractometer - T10007A-
corresponds to the temperature at which the first ice crystals
can form in the coolant.
♦ Do not reuse coolant.
♦ Only use water/coolant additive as a lubricant for coolant ho‐
ses.
Recommended mixture ratio for coolant

• Coolant (40 %) and distilled water (60 %) for frost protection
to -25 °C
• Coolant (50 %) and distilled water (50 %) for frost protection
to -36 °C
• Coolant additive: ⇒ Electronic parts catalogue (ETKA)

Procedure
– Close drain plug -1-.

– Connect coolant hoses with hose clips -1 and 2-.

– Fill reservoir of -VAS 6096- with at least 8 litres of premixed
coolant (according to recommended ratio):
– Fit adapter for cooling system tester - V.A.G 1274/8- onto
coolant expansion tank.
– Attach cooling system charge unit - VAS 6096- to adapter -
V.A.G 1274/8- .
– Run vent hose -1- into a small container -2-.
Note
The vented air draws along a small amount of coolant, which

should be collected.
– Close both valves -A- and -B- (turn lever at right angles to di‐
rection of flow).
– Connect hose -3- to compressed air supply.
• Pressure: 7 ... 10 bar.

– Open valve -B- by setting lever in direction of flow.

• The suction jet pump generates a partial vacuum in the cooling
system; the needle on the gauge should move into the green
zone.
– Also briefly open valve -A- (turn lever in direction of flow) so
that hose on reservoir of -VAS 6096- can fill with coolant.
– Close valve -A- again.
– Leave valve -B- open for another 2 minutes.
• The suction jet pump continues to generate a partial vacuum
in the cooling system; the needle on the gauge should remain
in the green zone.
– Close valve -B-.
• The needle on the gauge should stop in the green zone. The
vacuum level in the cooling system is then sufficient for sub‐
sequent filling.
Note
♦ If the needle does not reach the green zone, repeat the proc‐
ess.
♦ Check cooling system for leaks if the vacuum is not main‐
tained.
– Detach compressed air hose.

– Open valve -A-.
• The vacuum in the cooling system causes the coolant to be
drawn out of the reservoir of -VAS 6096- ; the cooling system
is then filled.
– Detach cooling system charge unit - VAS 6096- from adapter
-V.A.G 1274/8- on coolant expansion tank.
– Fit pipe for cooling system tester - V.A.G 1274/10- onto adapt‐
er for cooling system tester - V.A.G 1274/8- .

– Remove plenum chamber cover ⇒ General body repairs, ex‐

terior; Rep. gr. 50 ; Bulkhead; Exploded view - plenum cham‐
ber partition panel .
– Fill up pipe for cooling system tester - V.A.G 1274/10- with
coolant.
– Release coolant hose going to heat exchanger for heater and

pull back hose until bleeder hole -arrow- in hose is no longer
blocked by connection.
– Fill up with coolant until it comes out at bleeder hole in coolant
hose.
– Push coolant hose back onto connection and secure with
spring-type hose clip.
– Detach pipe for cooling system tester - V.A.G 1274/10- and
close filler cap on coolant expansion tank.
– Start engine.
– Set temperature to “HI” in all zones.
Time period Engine speed Air conditioner / heater setting

3 minutes 2000 rpm • Air conditioning system “OFF”, LED in AC button
not lit
• Heating at “HI”, select lowest possible blower
speed (= 0)
Until both large coolant Idling speed • Air conditioning system “OFF”
hoses at radiator be‐
come warm • Heating at “HI”
1 minute 2000 rpm • Air conditioning system “OFF”

• Heating at “HI”
– Switch off ignition and allow engine to cool down.

tion .

WARNING

The cooling system is under pressure when the engine is hot.
Cover filler cap on coolant expansion tank with a cloth and
open carefully to dissipate pressure.
– Check coolant level.

• The coolant level must be between the “min” and “max” mark‐
ings when the engine is cold.
• The coolant level can be at the “max” marking when the engine
is warm.
– Top up with coolant again if necessary.

2 Coolant pump/thermostat assembly

⇒ “2.1 Exploded view - coolant pump/thermostat”, page 179
⇒ “2.2 Exploded view - pump for exhaust gas recirculation cooler
V400 ”, page 181
⇒ “2.3 Exploded view - continued coolant circulation pump V50 ”,
page 182
⇒ “2.4 Exploded view - coolant valve for gearbox”, page 183
⇒ “2.5 Removing and installing coolant pump”, page 184
⇒ “2.6 Checking thermostat”, page 184
⇒ “2.7 Removing and installing 4/2-way valve with thermostat”,
page 184
⇒ “2.8 Removing and installing coolant temperature sender G62
”, page 187
⇒ “2.9 Removing and installing radiator outlet coolant tempera‐
ture sender G83 ”, page 188
⇒ “2.10 Removing and installing pump for exhaust gas recircula‐
tion cooler V400 ”, page 189
⇒ “2.11 Removing and installing coolant circulation pump V50 ”,
page 191
⇒ “2.12 Removing and installing coolant valve for gearbox N488
”, page 192
2.1 Exploded view - coolant pump/thermostat
2. Coolant pump/thermostat assembly 179

1 - Coolant pump
⇒ page 184
2 - Bolt
❑ 15 Nm
3 - O-ring
❑ Renew
4 - O-ring
❑ Renew
5 - 4/2-way valve with thermo‐
stat
❑ The thermostat is loca‐
ted in the interior of the
4/2-way valve and can‐
not be renewed sepa‐
rately
⇒ page 184
6 - Bolt
❑ 15 Nm

2.2 Exploded view - pump for exhaust gas recirculation cooler - V400-
1 - Nut
❑ 9 Nm
2 - Bracket
❑ For pump for exhaust
gas recirculation cooler
- V400-
3 - Spacer bush
4 - Bolt
❑ 2.7 Nm
5 - Grommet
6 - Pump for exhaust gas re‐
circulation cooler - V400-
⇒ page 189

2.3 Exploded view - continued coolant circulation pump - V50-
1 - Bracket
2 - Mounting plate
3 - Coolant hoses
4 - Coolant circulation pump -
V50-
⇒ page 191
5 - Bolt
❑ 2.7 Nm
6 - Bolt
❑ Tightening torque
⇒ “1.3 Installing engine”,
page 32

2.4 Exploded view - coolant valve for gearbox
1 - Coolant valve for gearbox -

N488-
⇒ page 192
2 - Coolant hose
3 - Bolt
❑ 23 Nm
4 - Bracket
❑ For coolant valve for
gearbox - N488-
5 - Nut
❑ 9 Nm
6 - Coolant hose

2.5 Removing and installing coolant pump

Removing
– Unscrew bolts -1- and remove coolant pump -2-.
– Detach O-ring -3-.
Installing
⇒ “2.1 Exploded view - coolant pump/thermostat”, page 179
Note
Fit new O-ring.
– Clean and smoothen sealing surface for O-ring.

– Lightly lubricate O-ring -3- with coolant.
– Fit coolant pump -2-.
• Installation position: Sealing plug in housing faces down‐
wards.
2.6 Checking thermostat

– Remove thermostat and heat it in a water bath.
Starts to open Fully open Opening travel
approx. 92 °C approx. 107 °C1) at least 7 mm
• 1) Cannot be tested.
2.7 Removing and installing 4/2-way valve

with thermostat

♦ Articulated wrench, 10 mm - 3185-
♦ Socket - T10058-
Removing


wiring clear.

electrical wiring.
side.

– Move electrical connector -2- with bracket to one side.
– Pull oil dipstick out slightly and remove bolt -1-.

– Release clip -2- with removal lever - 80 - 200- .
– Pull guide tube for oil dipstick upwards out of cylinder block
and push to one side.

– Remove bolt -1- and pull coolant pipe (bottom left) off 4/2-way
valve.
– Remove bolts -2-.

– Release hose clips -3-, lift retaining clip -1- and detach coolant
hoses.
– Detach 4/2-way valve with thermostat.
Installing
Tightening torques
♦ ⇒ “2.1 Exploded view - coolant pump/thermostat”, page 179
Note
♦ Fit new O-ring.


– Install coolant pipe (bottom left) ⇒ page 196 .
– Connect coolant hose with plug-in connector ⇒ page 205 .
2.8 Removing and installing coolant temper‐

ature sender - G62-
Removing
• Engine cold.

– To relieve residual pressure in cooling system, open filler cap

on coolant expansion tank briefly and then close cap again (it
should click into place).

– Pull off retaining clip -1- and pull out coolant temperature
sender - G62- .
Installing
Note
♦ Fit new O-ring.

♦ Insert new coolant temperature sender - G62- immediately in‐
to connection to avoid loss of coolant.
– Install body brace ⇒ Running gear, axles, steering; Rep. gr.

40 ; Suspension strut, upper links; Removing and installing
body brace .
– Check coolant level ⇒ page 178 .
2.9 Removing and installing radiator outlet

coolant temperature sender - G83-
Removing
• Engine cold.
– To relieve residual pressure in cooling system, open filler cap
on coolant expansion tank briefly and then close cap again (it
should click into place).

Note
Place a cloth underneath to catch escaping coolant.
– Unscrew radiator outlet coolant temperature sender - G83-

-item 1-.
Installing
Note
♦ Fit new O-rings.

♦ Insert new radiator outlet coolant temperature sender - G83-
immediately into threaded hole to avoid loss of coolant.
2.10 Removing and installing pump for ex‐

haust gas recirculation cooler - V400-
♦ Hose clamps, up to 25 mm - 3094-

Removing

wiring clear.

electrical wiring.
side.


WARNING

hot.
♦ Cover filler cap on coolant expansion tank with a cloth and
open carefully to dissipate pressure.
– Remove nuts -2- and pull pump for exhaust gas recirculation
cooler - V400- off engine.
– Clamp off coolant hoses using hose clamps up to 25 mm -
3094- , release hose clips -1- and disconnect hoses.
– Remove bolts -3- and detach pump for exhaust gas recircula‐
tion cooler from bracket.
Installing
Tightening torques
♦ ⇒ “2.2 Exploded view - pump for exhaust gas recirculation
cooler V400 ”, page 181
2.11 Removing and installing coolant circula‐

tion pump - V50-

Removing

– Release fastener -arrow- and lift coolant circulation pump -
V50- off bracket.
Installing
Install in reverse sequence.
2.12 Removing and installing coolant valve

for gearbox - N488-

Removing
– Remove rear noise insulation -2- ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation; Exploded view - noise
insulation .

– Remove nuts -arrows- and detach coolant valve for gearbox -
N488- .
Installing
⇒ “2.4 Exploded view - coolant valve for gearbox”, page 183
Note
Secure all hose connections with the correct type of hose clips
– Install noise insulation (rear) ⇒ General body repairs, exterior;

tion .

3 Coolant pipes
⇒ “3.1 Exploded view - coolant pipes”, page 194
⇒ “3.2 Removing and installing coolant pipe (top left)”,
page 195
⇒ “3.3 Removing and installing coolant pipe (bottom left)”,
page 196
⇒ “3.4 Removing and installing coolant pipe (rear right)”,
page 198
⇒ “3.5 Removing and installing coolant pipe (rear)”, page 201
3.1 Exploded view - coolant pipes
1 - Bolt
❑ 9 Nm
2 - Coolant pipe (bottom left)
⇒ page 196
3 - O-ring
❑ Renew
4 - Thermostat
❑ For exhaust gas recircu‐
lation cooler
5 - Coolant pipe (rear right)
⇒ page 198
6 - Bolt
❑ 9 Nm
7 - Nut
❑ 9 Nm
8 - Retaining clip
er - G62-
⇒ page 187
10 - O-ring
❑ Renew
11 - Gasket
❑ Renew
12 - Bolt
❑ 9 Nm
13 - Connection
❑ For coolant hoses
14 - Radiator outlet coolant temperature sender - G83-
❑ 2 Nm
15 - O-rings
❑ Different diameters

❑ Renew
16 - Nut
❑ 9 Nm
17 - Coolant pipe (rear)
18 - Bolt
❑ 9 Nm
19 - Bolt
❑ 9 Nm
20 - Bolt
❑ 9 Nm
21 - Coolant pipe (top left)
3.2 Removing and installing coolant pipe

(top left)
Removing
3. Coolant pipes 195


wiring clear.

electrical wiring.
side.

– Remove bolts -1, 2-.
from coolant pipe (top left).
Installing
Tightening torques
♦ ⇒ page 194
Note


(bottom left)

Removing

wiring clear.

electrical wiring.
side.


– Release hose clip -3-, lift retaining clip -2- and detach coolant
hoses.
– Remove bolt -1- and pull coolant pipe (bottom left) off 4/2-way
valve.
Installing
Note


(rear right)
Removing


– Remove front exhaust pipe ⇒ page 296 .

Note
Disregard -item 1-.

Note
Disregard -item 1-.
– Remove front right wheel.
– Remove cover -1- for drive shaft in wheel housing (left-side).

– Remove exhaust gas temperature sender 4 - G648- -item 1-.
– Unplug electrical connector -4- and move clear.

– Remove Lambda probe -1- ⇒ page 286 .


– Move electrical wiring harness clear.

– Release hose clips -1, 2, 3- and disconnect coolant hoses from
coolant pipe (rear right).
Installing
Note


(rear)
Removing


- G505- .


Note
Disregard -item 1-.


– Release hose clips -1, 2, 3- and disconnect coolant hoses from
coolant pipe (rear right).
– Press coolant pipe (rear right) to one side.

from rear coolant pipe.
Note
Disregard -item 2-.
Installing
Note


4 Radiator/radiator fans
⇒ “4.1 Exploded view - radiator/radiator fans”, page 204
⇒ “4.2 Removing and installing radiator”, page 205
⇒ “4.3 Removing and installing radiator cowl with radiator fan”,
page 208
⇒ “4.4 Removing and installing radiator fan control unit J293 ”,
page 212
⇒ “4.5 Removing and installing radiator fans”, page 213
4.1 Exploded view - radiator/radiator fans
1 - Bolt
❑ 4.5 Nm
2 - Radiator fan control unit -
J293-
⇒ page 212
3 - Bolt
❑ 5 Nm
4 - Radiator cowl
⇒ page 208
5 - Radiator fan - V7-
⇒ page 213
6 - Bolt
❑ 3.5 Nm
7 - Washer
8 - Rubber bush
❑ For radiator
9 - Coolant hose
❑ Lift retaining clip to de‐
tach
❑ Connecting
⇒ page 205
10 - O-ring
❑ Renew
11 - Coolant hose
❑ Lift retaining clip to de‐
tach
❑ Connecting ⇒ page 205
12 - O-ring
❑ Renew
13 - Coolant hose
❑ To coolant expansion tank
❑ Connecting ⇒ page 205
14 - O-ring
❑ Renew

15 - Radiator
❑ Different versions available ⇒ Electronic parts catalogue
❑ Remove and install together with radiator cowl ⇒ page 205
16 - Retaining pin
❑ Use screwdriver to release and pull off
17 - Rubber buffer
18 - Radiator bracket
19 - Bolt
❑ 5.5 Nm
20 - Radiator fan 2 - V177-
❑ Depending on vehicle equipment
21 - Bolt
❑ 5 Nm
Connecting coolant hose with plug-in connector

– Remove old O-ring -2- from coolant hose -3-.
– Lightly lubricate new O-ring with coolant and fit O-ring in cool‐
ant hose.
– Press coolant hose onto connection -1- until it engages audi‐
bly.
– Press coolant hose in again and then pull to check that plug-
in connector is correctly engaged.
4.2 Removing and installing radiator
WARNING


4. Radiator/radiator fans 205

Removing
insulation .
– Remove bumper cover ⇒ General body repairs, exterior; Rep.
gr. 63 ; Bumper (front); Removing and installing bumper cov‐
er .
– Remove impact absorber ⇒ General body repairs, exterior;

Rep. gr. 63 ; Impact absorber (front) .
– Remove headlight (left-side) ⇒ Electrical system; Rep. gr. 94 ;
Headlights; Removing and installing headlights .
– Remove charge air cooler ⇒ page 226 .
– Remove condenser ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit; Removing and installing condenser .
gine.
– Remove drain plug -1- and drain off coolant.
– Then disconnect coolant hose -2- from radiator (pull out re‐
taining clip).
WARNING


– Detach connections -1- and -2- from radiator (lift retaining clip).
– Release retaining pins for radiator on both sides and pull out
upwards -arrows-.
– Remove bolt -1- on both sides and detach radiator bracket with
radiator from lock carrier -arrow-.
– Detach radiator.

– Press locking tabs on left and right sides of radiator cowl

-arrow- and at the same time lift radiator cowl off radiator.
Installing
Tightening torque
♦ ⇒ “4.1 Exploded view - radiator/radiator fans”, page 204
Note
If there are slight impressions on the fins, refer to ⇒ page 8 .
– Install condenser ⇒ Heating, air conditioning; Rep. gr. 87 ;

Refrigerant circuit; Removing and installing condenser .
– Install charge air cooler ⇒ page 226 .
– Install headlight (left-side) ⇒ Electrical system; Rep. gr. 94 ;
Headlights; Removing and installing headlights .
– Install impact absorber ⇒ General body repairs, exterior; Rep.
gr. 63 ; Impact absorber (front) .
– Install bumper cover ⇒ General body repairs, exterior; Rep.
er .
tion .
Note
The coolant in the entire system must be changed if the radiator

is renewed.
4.3 Removing and installing radiator cowl

with radiator fan

♦ Used oil collection and extraction unit - V.A.G 1782- for vehi‐
cles with multitronic/dual clutch gearbox
♦ Engine bung set - VAS 6122- for vehicles with multitronic/dual

clutch gearbox
Removing
insulation .
er .
– Remove bracket (left and right) for mounting for headlight

housing ⇒ General body repairs, exterior; Rep. gr. 50 ; Lock
carrier .


– Detach air duct -1- from intermediate flange -2- for air cleaner
housing.
Vehicles with multitronic/dual clutch gearbox:

below connection point.
– Unscrew bolts -arrows- and detach ATF lines from radiator.
Note
Tie ATF lines up onto longitudinal member to prevent fluid es‐

caping.
Continued for all vehicles
– Release catches -arrows A- and swivel air duct -1- on left and
right to centre of vehicle -arrow B-.

– Lift retaining clip -1- and detach connection from radiator.
– Release retaining pins for radiator on both sides and pull out
upwards -arrows-.
– Remove bolt -1- on both sides.

– Pull top of radiator to the front -arrows A and B-.
– Press locking tabs on left and right sides of radiator cowl si‐
multaneously -arrow-, lift radiator cowl off radiator and remove
from below.
Installing
Tightening torques
Note
– Attach air duct to intermediate flange for air cleaner housing

⇒ page 243 .
– Remove bracket (left and right) for mounting for headlight
housing ⇒ General body repairs, exterior; Rep. gr. 50 ; Lock
carrier .
– Install bumper cover ⇒ General body repairs, exterior; Rep.
er .
– Attach connection with plug-in connector ⇒ page 205 .
4.4 Removing and installing radiator fan

control unit - J293-
Removing
Note
Fit all cable ties in the original positions when installing.
– Remove front noise insulation ⇒ General body repairs, exte‐

insulation .

WARNING

– On vehicles with cross member -3-, remove bolts -1- for torque
reaction support.
– Remove bolts -2- from cross member -3- on both sides.
Note
♦ Due to the limited space available, the cross member cannot

be removed.
♦ Cross member must only be detached; leave it in installation
position.
– Move clear electrical wiring harness leading to radiator fan
control unit - J293- .
– Unplug electrical connectors -2- and -3-.

– Unscrew bolt -arrow- and remove radiator fan control unit -
J293- -1-.
Installing
– If previously fitted, re-install cross member ⇒ page 45 .
Tightening torques
tion .
4.5 Removing and installing radiator fans

Removing
Note
– Remove radiator cowl ⇒ page 208 .

Radiator fan - V7-

– Unscrew bolts -arrows- and remove radiator fan - V7- .
Radiator fan 2 - V177-

– Unscrew bolts -arrows- and remove radiator fan 2 - V177- .
Installing
Tightening torque
– Install radiator cowl ⇒ page 208 .

21 – Turbocharging/supercharging
1 Turbocharger
⇒ “1.1 Exploded view - turbocharger”, page 215
⇒ “1.2 Removing and installing turbocharger”, page 216
1.1 Exploded view - turbocharger
1 - Air hose
2 - Pulsation damper
3 - Oil return line
4 - Bolt
❑ 9 Nm
5 - Gasket
❑ Renew
6 - Threaded connection
❑ 40 Nm
7 - Gasket
❑ Renew
8 - Bolt
❑ 20 Nm
9 - Turbocharger
❑ Can only be renewed to‐
gether with vacuum unit
❑ Adaption must be per‐
formed after renewing
this component
❑ Select 01 - Engine
electronics, func-
tions and perform Gui‐
ded Function 01 -
Adaption after re-
placing positioner
⇒ page 216
10 - Gasket
❑ Renew
11 - Nut
❑ Renew
❑ Coat thread with high-temperature paste; for high-temperature paste refer to ⇒ Electronic parts catalogue
❑ 24 Nm
12 - Particulate filter
13 - Exhaust gas temperature sender 1 - G235-
❑ Exploded view ⇒ page 305
14 - Banjo bolt
❑ 30 Nm
1. Turbocharger 215
15 - Oil supply line

❑ Check for obstructions
❑ Before installing, fill turbocharger with engine oil at connection for oil supply line
❑ Tighten union nuts to 22 Nm
16 - Bolt
❑ 9 Nm
17 - Seals
❑ Renew
18 - Exhaust manifold
19 - Nut
❑ Renew
❑ 24 Nm
20 - Vacuum hose
21 - Hose
❑ For crankcase breather
❑ Optional equipment for countries with cold climates: with heater element for crankcase breather - N79-
22 - Air pipe
23 - Support
❑ For turbocharger
24 - Bolt
❑ 40 Nm
25 - Bolt
❑ 9 Nm
1.2 Removing and installing turbocharger

♦ Engine bung set - VAS 6122-
Removing
Note
Observe rules for cleanliness ⇒ page 6 .
216 Rep. gr.21 - Turbocharging/supercharging

Caution
If the turbocharger has suffered mechanical damage (e.g.

damaged compressor wheel), it is not sufficient merely to fit a
new turbocharger. The following work must be performed in
order to avoid further damage:
♦ Check air cleaner housing, air filter element and air hoses
for dirt and foreign particles.
♦ Check the entire charge air system (including the charge
air cooler) for foreign matter.
♦ If foreign matter is found in the charge air system, clean
all relevant ducts and hoses and renew charge air cooler
if necessary.

1. Turbocharger 217
– Press release tabs, disconnect crankcase breather hose -2-

and move clear.
– Remove cover -1- for drive shaft in wheel housing (right-side).
Note
Disregard -item 1-.

one side.

– Remove bolts -1- and -2- and take out support for turbocharg‐
er.
– Remove bolts -1-.

– Detach electrical connector -3- for exhaust gas temperature
sender 1 - G235- from bracket, unplug connector and move
electrical wiring clear.
1. Turbocharger 219

– Remove Lambda probe - G39- -1- ⇒ page 286 .

– Remove both nuts -bottom arrows-.
Note
Nut -top arrow- is removed later.
– Remove union nut -1-.

– Disconnect vacuum hose -2-.
– Unplug electrical connector -3- for position sender for charge
pressure positioner - G581- .
– Remove nut -4- securing turbocharger to exhaust manifold.

– Remove nuts -1-, pull turbocharger and particulate filter off

studs and swivel to side as far as possible.
1. Turbocharger 221
– Remove nut -top arrow- and disconnect turbocharger from

particulate filter.
Caution
Risk of damage to oil supply line.

♦ Do not attempt to bend oil supply line to a different shape.

Installing
Tightening torques
♦ ⇒ “1.1 Exploded view - turbocharger”, page 215
♦ ⇒ “1.1 Exploded view - silencers”, page 293
Note
♦ Renew gasket/seal, nuts and O-ring.

♦ Fill turbocharger with engine oil at connection for oil supply
line.
♦ After installing the turbocharger, allow the engine to idle for
approx. 1 minute without pressing the accelerator to ensure
that the turbocharger is supplied with oil.

tion .
– Adaption must be performed after renewing this component:
– Connect ⇒ Vehicle diagnostic tester.
– Select Diagnosis mode and then Start diagnosis .
– Choose Select own test tab and select following options
one after the other:
♦ Drive train
♦ Select engine code and engine
♦ 01 - Self-diagnosis compatible systems
♦ 01 - Engine electronics
♦ 01 - Engine electronics, functions
♦ 01 - Adaption after replacing positioner

2 Charge air system

⇒ “2.1 Overview - charge air system”, page 223
⇒ “2.2 Exploded view - charge air system”, page 224
⇒ “2.3 Removing and installing charge air cooler”, page 226
⇒ “2.4 Removing and installing charge pressure sender G31 / in‐
take air temperature sender G42 ”, page 228
⇒ “2.5 Checking charge air system for leaks”, page 229
2.1 Overview - charge air system
Caution
Risk of engine malfunctions

♦ When routing vacuum lines, make sure they are not
kinked, twisted or crushed.
1 - Vacuum unit
❑ On turbocharger
❑ With position sender for
charge pressure posi‐
tioner - G581-
2 - Charge pressure control
solenoid valve - N75-
3 - Noise insulation
4 - Air cleaner housing
5 - To brake servo
6 - Connection piece
❑ On vacuum pump
❑ Note installation posi‐
tion
cooler change-over valve -
N345-
9 - Cylinder head cover
10 - Vacuum unit
❑ For change-over func‐
tion for exhaust gas re‐
circulation cooler
2. Charge air system 223

2.2 Exploded view - charge air system

⇒ “2.2.1 Exploded view - charge air system, version 1”,
page 224
⇒ “2.2.2 Exploded view - charge air system, version 2”,
page 225
2.2.1 Exploded view - charge air system, version 1
1 - Charge air cooler

⇒ page 226
2 - Hose clip
3 - Air hose
❑ To turbocharger
4 - Hose clip
5 - Hose clip
6 - Air hose
❑ To intake manifold
7 - Hose clip
8 - O-ring
❑ Renew
9 - Charge pressure sender -
G31- / intake air temperature
sender - G42-
⇒ page 228
10 - Bolt
❑ 5 Nm
11 - Rubber grommet
12 - Bush
13 - Nut
❑ 9 Nm
14 - Rubber grommet
15 - Hose clip
16 - Air pipe
17 - Hose clip
18 - Air hose
❑ From charge air cooler
19 - Hose clip
20 - Bolt
❑ 7 Nm

21 - Resonator
22 - Rubber grommet
23 - Hose clip
24 - Air hose
❑ To resonator
2.2.2 Exploded view - charge air system, version 2
1 - Charge air cooler

⇒ page 226
2 - Hose clip
3 - Air hose
❑ To turbocharger
4 - Hose clip
5 - Hose clip
6 - O-ring
❑ Renew
7 - Charge pressure sender -
G31- / intake air temperature
sender - G42-
⇒ page 228
8 - Bolt
❑ 5 Nm
9 - Air hose
❑ To intake manifold
10 - Hose clip
11 - Bolt
❑ 7 Nm

Installing air hoses with screw-type clips
Note
♦ Hose connections and air pipes/hoses must be free of oil and

grease prior to fitting.
♦ The screw sections of used screw-type clips must be sprayed
with rust remover prior to fitting so that the air hoses can be
attached securely to the hose connections.
Tightening torque for

1- Hose clip with width -a- = 13 mm: 5.5 Nm
2- Hose clip with width -b- = 9 mm: 3 Nm
2.3 Removing and installing charge air cool‐

er
Removing
The following step is only required on allroad models:
er .
All vehicles except allroad models:
– Remove lock carrier cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Bumper (front); Exploded view - bumper cover .
– Lift lock carrier cover -4- -arrow- and detach from radiator
grille.

– Detach air duct -1- from intermediate flange -2- for air cleaner
housing.

– Loosen bolts -1- and -2- and detach noise insulation at front
bumper cover towards rear.
– Release retaining clips -arrows A- and detach air intake grille

-1- on left and right from bottom section of bumper cover
-arrow B-.
Note
For illustration purposes, the installation position is shown in the

following illustrations with the bumper removed.
All vehicles:
– Release catches -arrows A- and swivel air duct -1- on left and
right to centre of vehicle -arrow B-.
– Release hose clip -arrow- and detach air hose from charge air
cooler.

– Release hose clip -1- and detach air hose from charge air
cooler.
– Push catch down -arrow A- and move top of charge air cooler
slightly in direction of -arrow B-.
– Disengage charge air cooler upwards from radiator and de‐
tach.
Installing
Tightening torques
♦ ⇒ “2.2 Exploded view - charge air system”, page 224
Note
♦ If there are slight impressions on the fins, refer to note on

⇒ page 8 .

– Install lock carrier cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Bumper (front); Exploded view - bumper cover .
– On allroad models: Install bumper cover (front) ⇒ General
body repairs, exterior; Rep. gr. 63 ; Bumper (front); Removing
and installing bumper cover .
2.4 Removing and installing charge pres‐

sure sender - G31- / intake air tempera‐
ture sender - G42-
⇒ “2.4.1 Removing and installing charge pressure sender G31 /
intake air temperature sender G42 , version 1”, page 228
⇒ “2.4.2 Removing and installing charge pressure sender G31 /
intake air temperature sender G42 , version 2”, page 229
2.4.1 Removing and installing charge pres‐

ture sender - G42- , version 1
Removing
– Remove bolts -arrows- and pull charge pressure sender -
G31- / intake air temperature sender - G42- out of air pipe.
Installing
Note
Fit new O-ring.
Tightening torques

2.4.2 Removing and installing charge pres‐

ture sender - G42- , version 2
Removing
– Remove bolts -arrows- and pull charge pressure sender -
G31- / intake air temperature sender - G42- out of air pipe.
Installing
Note
Fit new O-ring.
Tightening torques
2.5 Checking charge air system for leaks

♦ Charge air system tester - V.A.G 1687-
Procedure
insulation .


one side.
– Insert adapter - 1687/12- into air hose -1- and secure with hose
clip.
– Connect charge air system tester - V.A.G 1687- as shown on
illustration.
Prepare charge air system tester - V.A.G 1687- as follows:

– Unscrew pressure control valve -2- completely and close
valves -3- and -4-.
Note
Make sure knob is pulled out before turning pressure control valve
-2-.

– Using a commercially available connection piece, connect

charge air system tester - V.A.G 1687- to compressed air -1-.
Note
If there is water in sight glass, remove drain plug -6- and drain
water.
– Open valve -3-.
Caution
Risk of damage if pressure is set too high.

♦ The pressure must not exceed 0.5 bar.
– Adjust pressure to 0.5 bar via pressure control valve -2-.

– Open valve -4- and wait until test system is pressurised. If
necessary, adjust pressure to 0.5 bar again.
– Check charge air system for audible leaks or leaks that can be
felt with the hand; apply commercially available leak detecting
spray or use ultrasonic tester - V.A.G 1842- .
Note
♦ A small amount of air escapes through the valves and enters

the engine. Therefore it is not possible to perform a pressure
retention test.
♦ For operation of ultrasonic tester -V.A.G 1842- , refer to ⇒
Operating instructions .
♦ Release pressure in test circuit by detaching hose coupling
from adapter before removing adapter.
Assembling
Note
Renew gasket and O-rings.

tion .

23 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Overview of fitting locations - injection system”,
page 232
⇒ “1.2 Overview - fuel system”, page 239
⇒ “1.3 Filling and bleeding fuel system”, page 240
⇒ “1.4 Checking fuel system for leaks”, page 241
1.1 Overview of fitting locations - injection system
1 - Air mass meter - G70-

⇒ page 285
2 - Air filter bypass flap valve -
N275-
❑ Country-specific version
3 - Electrical connectors
❑ For Lambda probe -
G39-
❑ For exhaust gas tem‐
perature sender 3 -
G495-
❑ Fitting location
⇒ page 237
4 - Lambda probe - G39- with
Lambda probe heater - Z19-
⇒ page 237
❑ Exploded view
⇒ page 286
control motor - V338- with ex‐
haust gas recirculation poten‐
tiometer - G212-
❑ Integrated into exhaust
gas recirculation cooler
exhaust gas recircula‐
tion cooler ⇒ page 314
6 - Exhaust gas temperature
sender 3 - G495-
⇒ page 237
7 - Radiator outlet coolant temperature sender - G83-
❑ Fitting location ⇒ page 236
8 - Pressure differential sender - G505-
232 Rep. gr.23 - Mixture preparation - injection

9 - Coolant circulation pump - V50-

❑ Vehicles with start/stop system only
11 - Coolant temperature sender - G62-
12 - Fuel pressure regulating valve - N276-
13 - Gearbox neutral position sender - G701-
❑ Vehicles with start/stop system only
14 - Brake servo pressure sensor - G294-
15 - Accelerator position sender - G79- and accelerator position sender 2 - G185-
16 - Brake light switch - F- and brake pedal switch - F47-
17 - Clutch position sender - G476-
❑ With clutch pedal switch for engine start - F194- and clutch pedal switch - F36-
❑ Only on vehicles with manual gearbox
18 - Engine control unit - J623-
19 - Engine speed sender - G28-
21 - Throttle valve module - J338- with throttle valve potentiometer - G69-
22 - Left electrohydraulic engine mounting solenoid valve - N144-
❑ On left side only
23 - Charge pressure sender - G31- / intake air temperature sender - G42-
24 - Fuel temperature sender - G81-
25 - Fuel metering valve - N290-
26 - Glow plugs
❑ Glow plug 1 - Q10-
1. Injection system 233


27 - Fuel pressure sender - G247-
29 - Injectors
❑ Injector, cylinder 1 - N30-
30 - Charge pressure control solenoid valve - N75-
31 - Exhaust gas recirculation cooler change-over valve - N345-
❑ Electrical connector ⇒ page 239
32 - Position sender for charge pressure positioner - G581-
Fitting location of engine control unit - J623-

♦ In electronics box in plenum chamber (left-side)
Removing and installing ⇒ page 289

Fitting location: accelerator position sender - G79- and accelera‐

tor position sender 2 - G185-
♦ In accelerator pedal module
Note
The accelerator position sender - G79- and accelerator position

sender 2 - G185- are integrated in the accelerator pedal module
and cannot be renewed individually.
Removing and installing ⇒ Fuel supply system; Rep. gr. 20 ;

Accelerator mechanism; Removing and installing accelerator
pedal module with accelerator position sender -G79- / -G185-
Fitting location of brake light switch - F- and brake pedal switch -

F47- / clutch position sender - G476-
1- Brake light switch - F- and brake pedal switch - F47-
2- Clutch position sender - G476- with clutch pedal switch for
engine start - F194- and clutch pedal switch - F36- (manual
gearbox only)
Fitting locations
2 - Fuel temperature sender - G81-
Fuel metering valve - N290- -arrow-

Fitting location of pump for exhaust gas recirculation cooler -

V400-
4 - Electrical connector for pump for exhaust gas recirculation
cooler - V400-
♦ At rear left of engine
Fitting location of coolant temperature sender - G62-

2 - Electrical connector for coolant temperature sender - G62-
♦ At rear of engine
Fitting location of radiator outlet coolant temperature sender -

G83-
♦ -Item 1- in coolant pipe (rear)
Fitting location of Hall sender - G40-

♦ At front of engine next to camshaft sprocket -arrow-

Fitting locations
1 - Lambda probe - G39-
3 - Electrical connector for Lambda probe - G39-
4 - Electrical connector for exhaust gas temperature sender 3 -
G495-
Exhaust gas temperature sender 4 - G648-

1 - Electrical connector for exhaust gas temperature sender 4 -
G648-
Fitting location of pressure differential sender - G505-

♦ At rear of engine
3 - Electrical connector for pressure differential sender - G505-
Fitting location of engine speed sender - G28-

1- Electrical connector for engine speed sender - G28-

Fitting location of charge pressure sender - G31- with intake air

temperature sender - G42-
♦ In engine compartment (front left)
1- Electrical connector for charge pressure sender - G31- with
intake air temperature sender - G42-
Fitting location of position sender for charge pressure positioner

- G581-
♦ On turbocharger on right side of engine
1- Electrical connector for position sender for charge pressure
positioner - G581-
Fitting location of charge pressure control solenoid valve - N75-

♦ At front right of engine -arrow-
Fitting location of gearbox neutral position sender - G701-

♦ On left of gearbox -arrow-
Only installed on vehicles with start/stop system

Electrical connectors
2 - Exhaust gas recirculation cooler change-over valve - N345-
Fitting location of left electrohydraulic engine mounting solenoid

valve - N144-
♦ On engine mounting (left-side) -arrow- (electrical connector)
Fitting location of brake servo pressure sensor - G294-

♦ In vacuum line leading to brake servo -arrow-
1.2 Overview - fuel system
Caution

fuel system must be bled ⇒ page 240 .
♦ If the high-pressure pump is removed or renewed, the first
fuel filling operation must be performed before the engine
is started for the first time ⇒ page 240 .

Note
The high-pressure pump will be damaged if the first fuel filling

operation is not performed.
1 - Fuel tank
❑ With fuel system pres‐
surisation pump - G6-
2 - Fuel filter
❑ Exploded view ⇒ Fuel
supply system; Rep. gr.
20 ; Fuel filter; Exploded
view - fuel filter
3 - Not fitted
4 - Filter strainer
5 - Fuel temperature sender -
G81-
6 - High-pressure pump
❑ After renewing high-
pressure pump or fuel
pressure regulating
valve - N276- , learnt
values must be re-adap‐
ted using ⇒ Vehicle di‐
agnostic tester
❑ Exploded view
⇒ page 272
7 - Fuel metering valve - N290-
❑ Do not unscrew
8 - Fuel pressure regulating
valve - N276-
❑ Exploded view
⇒ page 253
9 - Fuel rail
10 - Fuel pressure sender -
G247-
❑ Exploded view
⇒ page 253
11 - Restrictor
12 - Injector
1.3 Filling and bleeding fuel system

♦ Vehicle diagnostic tester
If components of the fuel system between the fuel tank and the
high-pressure pump are removed or renewed, the fuel system
must be bled.

Risk of irreparable damage to fuel pump

After working on the fuel system, the fuel pump may be irreparably
damaged if it is allowed to run while empty.
– Never allow fuel pump to run while it is empty.
– Fill/bleed fuel pump.
Proceed as follows to fill fuel system with fuel:

• Check fuel gauge in instrument cluster; fuel gauge needle
must indicate that fuel is above reserve level.
– Connect vehicle diagnostic tester .
– Switch on the ignition and select the following menu options
on the vehicle diagnostic tester :
♦ Systems with diagnostic capability
♦ Engine electronics
♦ Engine electronics functions
♦ Activate fuel pump
♦ Bleeding fuel system
– The fuel pump starts running.
– The fuel pump must run for approx. 3 minutes to ensure that
the fuel system is filled sufficiently with fuel.
– Start engine after filling fuel system.
– Run engine at moderate speed for several minutes and then
switch off.
– Check fuel system for leaks.
– Road-test vehicle and accelerate with full throttle at least once.
– Then inspect high-pressure section again for leaks.
1.4 Checking fuel system for leaks

– Allow engine to run for several minutes at moderate rpm.
– Switch off ignition.
– Check complete fuel system for leaks.
– If leaks are found although the connections have been tight‐
ened to the correct torque, the relevant component must be
renewed.
– Then inspect high-pressure section of fuel system again for
leaks.
Note
If there is any air left in the fuel system, the engine may switch to
the backup mode ('emergency running' mode) during the road
test. Switch off the engine and erase the event memory. Then
continue the road test.

2 Vacuum system
⇒ “2.1 Checking vacuum system”, page 242
2.1 Checking vacuum system

♦ Hand vacuum pump - VAS 6213-
Procedure
– Check all vacuum lines in the complete vacuum system for:
♦ Cracks
♦ Traces of animal bites
♦ Kinked or crushed lines
♦ Porous or leaking lines
– Check vacuum line to solenoid valve and from solenoid valve
to corresponding component.
– If a fault is stored in the event memory, check the vacuum lines
leading to the corresponding component and also check the
remaining vacuum lines in the system.
– If it is not possible to build up a vacuum with the hand vacuum
pump - VAS 6213- or if the vacuum pressure drops again im‐
mediately, check the hand vacuum pump and connecting
hoses for leaks.

3 Air cleaner
⇒ “3.1 Exploded view - air cleaner housing”, page 243
⇒ “3.2 Removing and installing air cleaner housing”, page 244
3.1 Exploded view - air cleaner housing
1 - Hose clip
❑ 3.5 Nm
2 - Air hose
3 - Hose clip
❑ 3.5 Nm
4 - Air duct
❑ Clipped into air cleaner
housing
❑ Remove any salt resi‐
due, dirt and leaves
5 - Air duct
6 - Air duct
❑ Secure to lock carrier
(2 Nm)
7 - Rubber grommet
8 - Water drain hose
❑ Clean any leaves and
dirt out of water drain
hose (important)
9 - Guide for water drain hose
10 - Hot air intake (countries
with cold climates only)
❑ Slide hot air intake into
air cleaner as far as
stop; then turn clock‐
wise until it engages no‐
ticeably
11 - Air cleaner (bottom section)
❑ Remove any salt residue, dirt and leaves
❑ Check for dirt in water drain and clean as required (important)
12 - Retainer for air cleaner (bottom section)
❑ Must engage positively
❑ Do not use any lubricants
13 - Air filter bypass flap valve - N275-
❑ With flap for variable intake manifold change-over
14 - Bolt
❑ For air filter bypass flap valve - N275-
15 - Air filter element
❑ Use genuine air filter element ⇒ Electronic parts catalogue
3. Air cleaner 243

❑ Change intervals ⇒ Maintenance tables

❑ Also clean snow screen (if fitted)
16 - Frame insert for air cleaner (bottom section)
17 - Air cleaner (top section)
❑ Remove any salt residue, dirt and leaves
18 - Bolt
❑ 1.5 Nm
19 - O-ring
❑ Renew if damaged
20 - Air mass meter - G70-
3.2 Removing and installing air cleaner

housing
⇒ “3.2.1 Removing and installing air cleaner (bottom section)”,
page 244
⇒ “3.2.2 Removing and installing air filter element”, page 246
3.2.1 Removing and installing air cleaner (bot‐

tom section)
Removing
– Open hose clip -2- on air hose leading to turbocharger and
disconnect hose at air mass meter - G70- .
– Remove air duct -3-.
– Detach vacuum hose -arrow- (if fitted).

– Release retainer -4- for bottom section of air cleaner (press in

rubber on left and right side and pull upwards).
Note
♦ The air filter bypass flap valve - N275- -item 1- is not installed
on all equipment versions / country-specific versions.
♦ Do not use lubricants when installing retainer.
– Unplug electrical connector at air filter bypass flap valve -

N275- (if fitted).
– Carefully take out complete air cleaner housing.
Installing
To ensure the proper function of the air mass meter - G70- it is
important to observe the following instructions.
Note
♦ The air cleaner housing must always be clean.

♦ To prevent malfunctions, cover critical parts of the engine air
intake (air mass meter, air pipes etc.) with a clean cloth when
blowing out the air cleaner housing with compressed air.
♦ Use a lubricant (silicone-free) when installing air hoses.
– If hot air intake is fitted (for countries with cold climates only),
make sure that air intake connection has engaged properly
-arrows- (pay attention to marking).
– Check water drain hose -1- in air cleaner (bottom section) for
dirt and other obstructions (clean if necessary).
– Clean salt residue, dirt and leaves out of air cleaner housing
(top and bottom sections); use a vacuum cleaner if necessary.
– Check for salt residue, dirt and leaves in air hose (engine in‐
take side).
– Check air duct leading from lock carrier to air cleaner housing
for dirt and leaves.
– Plug electrical connector at air filter bypass flap valve - N275-
in again (if fitted).
– Re-install air cleaner (bottom section).
Note
The water drain hose must be routed straight downwards; make

sure it is not kinked or twisted.
3. Air cleaner 245

– Slide vacuum hose -3- (if fitted) back onto connection of air
filter bypass flap valve - N275- -item 1-.
– Make sure that air hose is correctly seated at air mass meter
- G70- .
The remaining installation steps are carried out in the reverse se‐
quence.
3.2.2 Removing and installing air filter ele‐

ment
Removing
– Open hose clip -2- on air hose leading to turbocharger and
disconnect hose at air mass meter - G70- .
– Remove bolts -arrows- and detach air cleaner (top section).
– Take out old air filter element.
Installing
Tightening torques
♦ ⇒ “3.1 Exploded view - air cleaner housing”, page 243
To ensure that the air mass meter -G70- functions correctly, it is
important to observe the following notes and procedures.
Note
♦ If the air filter element is very dirty or wet, dirt particles or water
can reach the air mass meter and falsify the detected air mass
values. This will cause a loss of power, as the calculated in‐
jection quantities will be too low.
♦ Always use genuine air filter elements (same as original equip‐
ment).
♦ The air cleaner housing must always be clean.
♦ To prevent malfunctions, cover critical parts of the engine air
intake (air mass meter, air pipes etc.) with a clean cloth when
blowing out the air cleaner housing with compressed air.
♦ Observe environmental requirements for disposal.

– Clean salt residue, dirt and leaves out of air cleaner housing
(top and bottom sections) using a vacuum cleaner.
– Blow out water drain -arrow- with compressed air.
– Check air mass meter and air hose (engine intake side) for salt
residue, dirt and leaves.
– Check air duct leading from lock carrier to air cleaner housing
for dirt and leaves.
– When installing air filter element, check that it is properly cen‐
tred in retainer in air cleaner (bottom section).
– Carefully fit air cleaner (top section) on air cleaner (bottom
section) without applying any force. Make sure the top section
of the air cleaner is fitted straight on the air filter element (note
position of sealing lip on air filter element).
– Make sure that air hose is correctly seated at air mass meter
- G70- .
quence.
3. Air cleaner 247

4 Intake manifold
⇒ “4.1 Exploded view - intake manifold”, page 248
⇒ “4.2 Removing and installing intake manifold”, page 249
⇒ “4.3 Removing and installing throttle valve module J338 ”, page
252
4.1 Exploded view - intake manifold
1 - Guide tube
❑ For oil dipstick
2 - Seal
❑ Renew
3 - Gasket
❑ Renew
4 - Bolt
❑ 8 Nm
tion
6 - Bolt
❑ 9 Nm
7 - Intake manifold
⇒ page 249
8 - Not fitted
9 - Not fitted
10 - Not fitted
11 - Gasket
❑ Renew
12 - Bolt
❑ 9 Nm
13 - Connecting pipe
❑ To exhaust gas recircu‐
lation cooler
14 - Clamp
❑ Renew
❑ 5 Nm
15 - Connection
❑ For exhaust gas recirculation
16 - Bolt
❑ 9 Nm
17 - Seal
❑ Renew
18 - Throttle valve module - J338-
❑ With throttle valve potentiometer - G69-


19 - Bolt
❑ 8 Nm
20 - Bolt
❑ 9 Nm
21 - Clip
4.2 Removing and installing intake manifold

♦ Ratchet - V.A.G 1331/1-
♦ Socket - T40055-
♦ Socket Torx T30 - T10405-
4. Intake manifold 249

Removing
Caution
Risk of malfunctions caused by dirt.

♦ Observe ⇒ page 6 .
– Remove engine cover panel ⇒ page 48 .

– Unplug electrical connectors on glow plugs ⇒ page 321 .
– Remove bolt -2- and union nuts -1 and 3- and detach high-
pressure pipe.
– Unplug electrical connectors -2 and 3-.

– Remove bolt -arrow- and push wiring retainer to the side.
Note
Disregard -item 1-.
– Remove bolts -1 and 3-.
– Release hose clips -2 and 4- and detach fuel hoses.

– Unscrew bolt -2- and detach pressure differential sender -

G505- .
to one side.
Note
Do not bend fuel lines.
Caution
♦ Observe rules for cleanliness when working on the injec‐

tion system.
♦ Plug open connections with suitable sealing caps imme‐
diately.
– Open clamp -1- and detach.
Note
Disregard -item 2-.
– Release hose clip -2- and detach air hose.

– Unplug electrical connector -3- at throttle valve module -
J338- .
4. Intake manifold 251

– Unscrew intake manifold bolts -arrows- in diagonal sequence

starting from outside and working inwards using socket Torx
T30 - T10405- .
Installing
Tightening torques
♦ ⇒ “4.1 Exploded view - intake manifold”, page 248
Note
Renew seals and/or gaskets.
– Tighten intake manifold bolts in diagonal sequence, working

from inside to outside.
– Install high-pressure pipe ⇒ page 268 .
4.3 Removing and installing throttle valve

module - J338-
Removing
– Release hose clip -arrow- and detach air hose downwards.

– Remove bolts -arrows- and detach throttle valve module -
J338- .
Installing
Tightening torques
♦ ⇒ “4.1 Exploded view - intake manifold”, page 248
Note
Fit new O-ring.

5 Injectors/high-pressure reservoir
(rail)
⇒ “5.1 Exploded view - injectors”, page 253
⇒ “5.2 Checking injectors”, page 256
⇒ “5.4 Checking for injectors sticking open”, page 257
⇒ “5.5 Checking return flow rate of injectors with engine running”,
page 258
⇒ “5.6 Checking return flow rate of injectors at starter cranking
speed”, page 261
⇒ “5.7 Removing and installing injectors”, page 262
⇒ “5.8 Removing and installing high-pressure pipes”, page 268
⇒ “5.9 Removing and installing high-pressure reservoir (rail)”,
page 269
5.1 Exploded view - injectors

When installing a new base engine, you must check whether
there is a sticker on the cylinder head cover.
If a sticker is attached which states Spannpratzen auf vor-
geschriebenes Drehmoment angezogen (clamping pieces tight‐
ened to specified torque), the clamping pieces have already been
tightened to the specified final torque at the factory.
If no sticker is attached, it is essential that the clamping pieces for
the injectors are tightened to the specified torque
⇒ Item 7 (page 254) after installing the high-pressure pipes. If
these instructions are not observed, the engine could be dam‐
aged.
5. Injectors/high-pressure reservoir (rail) 253

1 - Seal
❑ In cylinder head cover
❑ Renew if leaking
⇒ page 108
2 - Copper seal
❑ Always renew copper
seal when removing and
installing
3 - O-ring
❑ Renew
4 - Injector
❑ Use a coloured pen to
mark allocation of injec‐
tors to corresponding
clamping piece and
high-pressure pipe, and
to corresponding cylin‐
der for re-installation;
pay attention to mark‐
ings when installing
❑ Always renew copper
seal when removing and
installing
❑ To remove carbon de‐
posits from the injector
sealing surface, clean
the injector bore in the
cylinder head with
cleaning kit - VAS 6811-
(it is important to do this
to avoid leaks)
⇒ page 262
5 - O-ring
❑ Renew
❑ To fuel tank
❑ With restrictor
❑ Must not be kinked, damaged or clogged
❑ Do not dismantle
❑ The restrictor maintains a constant residual pressure in the fuel return lines
❑ This residual pressure is required for the control function of the injectors
❑ After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system; then
check fuel return line for leaks
7 - Bolt
❑ Renew
❑ Tighten initially to 2 Nm, then screw on union nuts for high-pressure pipes hand-tight and align injectors
❑ 8 Nm + 270° (3x 90° further)
8 - Clamping piece
❑ Use a coloured pen to mark injectors and corresponding clamping piece and cylinder for re-installation;
pay attention to markings when installing
❑ The clamping pieces can be re-used when installing new injectors
❑ Each clamping piece secures two injectors
9 - High-pressure pipe
❑ Between fuel rail and injectors

Note
♦ The high-pressure pipe can be

re-used after performing the fol‐
lowing checks:
♦ Check taper seat for deformation
and cracks.
♦ The bore of the pipe must not be
distorted, restricted or otherwise
damaged.
♦ Corroded pipes must not be
used again.
❑ Install free of stress
❑ Lubricate threads of union nuts with clean engine oil
❑ 25 Nm
10 - Bolt
❑ 22 Nm
11 - Fuel rail
12 - Fuel return hose
❑ Always renew after removing
❑ Use open-end spanner insert, 30 mm - T10553-
❑ 80 Nm
❑ After renewing high-pressure pump or fuel pressure regulating valve - N276- , learnt values must be re-
adapted; see “Guided Functions” in ⇒ Vehicle diagnostic tester
14 - O-ring
❑ Renew
❑ Between high-pressure pump and fuel rail
Note
♦ Note identification marks for cyl‐

inder allocation when re-instal‐
ling high-pressure pipes.
♦ The high-pressure pipes can be
lowing checks:
♦ Check taper seats of high-pres‐
sure pipes for deformation and
cracks.
damaged.
used again.
❑ 25 Nm

16 - Bolt
❑ 8 Nm
❑ Always renew after removing
❑ 100 Nm
18 - Grommet
❑ In cylinder head cover
5.2 Checking injectors

There are four different tests for checking the operation of the
injectors.
• ⇒ “5.3 Performing adaption of correction values for injectors”,
page 256 .
• ⇒ “5.4 Checking for injectors sticking open”, page 257 .
• ⇒ “5.5 Checking return flow rate of injectors with engine run‐
ning”, page 258 .
• ⇒ “5.6 Checking return flow rate of injectors at starter cranking
speed”, page 261 .
Perform the following tests first if the engine does not start at all:
♦ ⇒ “5.4 Checking for injectors sticking open”, page 257 .
♦ ⇒ “5.6 Checking return flow rate of injectors at starter cranking
speed”, page 261 .
♦ ⇒ “7.2 Checking fuel pressure regulating valve N276 ”,
page 279 .
5.3 Performing adaption of correction val‐

ues for injectors
The “Injector delivery calibration values” function serves to correct
the injection rates for each cylinder of a common rail system in‐
dividually across the entire operating range.
The 7-digit adaption values -1- (details in illustration are only an
example) are marked separately on each injector. The values
may consist of letters and/or numbers.
Injector (view from above)
1 - Checksum
2 - Data matrix code
3 - Part number
When a new injector is installed, the adaption value must be writ‐
ten into the engine control unit.
When a new engine control unit is installed, the “Adaption values
for injectors” must be written into the new control unit.
Additionally, check that the “injector delivery calibration values”
are correctly entered for all the other injectors. Do NOT attempt
to re-enter these values if the correct values are already stored in
the engine control unit.
The adaption procedure is described in the Guided Fault Finding.
(The procedure is described in Guided Functions.)

5.4 Checking for injectors sticking open

♦ Use a return line to make an -adapter-.
Caution


– Clean all connections (with commercial cleaning solution or
similar) before removing.
Note
♦ Make sure all parts are clean; no dirt must be allowed to enter
the fuel system.
♦ Check all cylinders in turn.
– Dry all components after cleaning.

Start with cylinder No. 1.

– Pull return line connections off injectors; to do so, press tabs

-1- and -2- down and at the same time pull release pin upwards
-arrow-.
– Connect adapter to return line connection of injector to be tes‐
ted after adapter has been cleaned and blown out.
– Generate a vacuum of -500 mbar using the hand vacuum
pump - VAS 6213- .
If the vacuum reading remains the same for 30 seconds, the in‐
jector is OK.
If the injector is faulty, the vacuum reading will fall back to 0 bar
within 2 to 3 seconds.
Repeat test if necessary; note drop in vacuum reading on hand
vacuum pump - VAS 6213- .
– Renew faulty injectors ⇒ page 262 .
Installing fuel return lines
– Check O-ring for fuel return line connection for damage and
deformation.
If O-ring is damaged or deformed, renew O-ring.
Note
Lubricate all seals with engine oil or assembly oil before installing.
– Push return line connections carefully over seals and onto in‐
jectors. The catch should engage audibly. Then press release
pin down carefully.
Checking fuel system for leaks
– Run engine at idling speed for several minutes (do not press
accelerator) and then switch off. Fuel system will bleed itself
automatically.
– Check the entire fuel system for leaks.
Renew the affected component if leakage occurs.
– After completing the repair, road-test the vehicle. Accelerate
with full throttle at least once. Then check the high-pressure
section of the fuel system again for leaks.
5.5 Checking return flow rate of injectors

with engine running
Checking return flow rate of all injectors
Caution


– Disconnect hose connection at fuel line.

– Seal off open return line connection with a clean plug -2-.
– Hold end of fuel return hose -1- (lengthen if necessary) in a
measuring container to measure the total return flow rate.
– Start engine and let it idle for 2 minutes.
• Specification for 2 minutes: 0 ml to 50 ml
– If specification is attained, increase engine speed to 2000 ...
2500 rpm for approx. 2 minutes and then check return flow rate
again.
• Specification for 2 minutes: less than 250 ml
Note
1000 ml = 1 litre
If specification is exceeded, this indicates that one or more injec‐

tors are defective. Check return flow rate from each injector
individually.
Checking return flow rate of individual injectors

♦ Return flow meter - VAS 6684-
Each injector normally has a relatively low fuel return flow rate. If
the return flow rate at one injector is relatively high compared to
the other injectors, that injector is probably defective.
– Clean all return line connections (e.g. with commercial clean‐
ing solution etc.) before removing.

– Clamp off fuel return hose -arrow- using hose clamp up to

25 mm - 3094- .

-arrow-.
– Connect hoses of return flow meter - VAS 6684- to return line
connections of all four injectors.
Caution
Risk of damage to injectors when return lines are disconnec‐

ted.
♦ Do NOT press the accelerator during this test; the engine
must only run at idling speed.
– Start engine and let it idle for several minutes.

– When the engine is warm and running at idling speed, the re‐
turn flow rates at each of the 4 return lines must not differ by
more than a small amount.
– If one injector has a significantly higher return flow rate than
the others (example -2-), it must be renewed ⇒ page 262 .
deformation.
Note
– Push return line connections carefully onto injectors. The

catch should engage audibly. Then press release pin down
carefully.
automatically.
5.6 Checking return flow rate of injectors at

starter cranking speed
Only perform this test if the engine does not start at all.
♦ Return flow meter - VAS 6684-
Caution


Procedure
Each injector normally has a relatively low fuel return flow rate. If
the return flow rate at one injector is relatively high compared to
the other injectors, that injector is probably defective.
– Clean all return line connections (e.g. with commercial clean‐
ing solution etc.) before removing.
-arrow-.
– Connect hoses of return flow meter - VAS 6684- to return line
connections of all four injectors.
– Operate starter three times (wait approx. 20 seconds each
time after operating starter to prevent it from overheating).
• Specification of return flow rate: 0 ml
– If fuel comes out of an injector, that injector must be renewed.
deformation.
Note
– Push return line connections carefully onto injectors. The

catch should engage audibly. Then press release pin down
carefully.
automatically.
5.7 Removing and installing injectors

♦ Cleaning kit - VAS 6811-

♦ Puller - T10055-
♦ Assembly sleeve - T10377-
♦ Puller -T10415-
Removing
Caution

Caution
♦ Mark cylinder numbers on injector units. They must al‐

ways be re-installed on the same cylinders.
♦ Observe rules for cleanliness when working on the injec‐
tion system.
♦ Plug open connections with suitable sealing caps imme‐
diately.


-arrow-.
– Unplug electrical connectors -arrows- at injectors.

– Loosen union nuts of high-pressure pipes -1 to 4-.

– Unscrew bolt -1- for clamping piece.
Note
Leave clamping piece in position until adjacent injector is detach‐

ed.
Caution
Risk of damage to injector if clamping piece is not kept straight.

♦ First detach injectors for cylinders 2 and 4; then detach
injectors for cylinders 1 and 3, and at the same time detach
clamping piece.
– Apply puller - T10055- with puller -T10415- as shown in illus‐

tration, and pull out injector upwards.
Note
To avoid damaging the sealing lip, rotate the injector while pulling
it out.
– After removal, lay injectors on a clean cloth.

Important instructions for installing injectors:
When installing injectors, the following components must be re‐
newed:
♦ Bolt for clamping piece
♦ Copper seal
♦ O-ring for injector bore
♦ O-ring for fuel return line connection
Note
♦ Note identification marks for cylinder allocation when re-in‐

stalling high-pressure pipes.
♦ The high-pressure pipes can be re-used after performing the
following checks:
♦ Check taper seats of high-pressure pipes for deformation and
cracks.
♦ The bore of the pipe must not be distorted, restricted or oth‐
erwise damaged.
♦ Corroded pipes must not be used again.
If a used injector is being re-installed:

– Spray tip of injector nozzle with rust-releasing spray. Wait ap‐
prox. 5 minutes and wipe off soot particles and oil with a cloth.
– To remove the old copper seal from the injector, clamp the seal
carefully in a vice so that it is just held between the jaws without
turning. Then carefully pull and twist the injector out of the
copper seal by hand.
– Clean off deposits under the copper seal using a suitable scra‐
per.

– Fit new copper seal.

– Lubricate all O-rings with engine oil or assembly oil before in‐
stalling.

– Renew O-ring for injector bore using assembly sleeve -

T10377- .
Continued (same procedure for used and new injectors):
Note
♦ If injector seals in cylinder head cover are damaged, they must

be renewed ⇒ page 108 .
♦ Lubricate all O-rings with assembly oil, engine oil or diesel fuel
before installing.
Caution
Risk of damage to injector sealing surface.

♦ To remove carbon deposits from the injector sealing sur‐
face, clean the injector bore in the cylinder head with
cleaning kit - VAS 6811- .
– Install injectors.
– Slide clamping piece onto injectors; observe installation posi‐
tion.
– Always insert 2 injectors with clamping piece carefully into
bores in cylinder head.
– Hand-tighten union nuts on high-pressure pipes. Make sure
that connections are not under tension.
– Tighten clamping piece to specified torque.
Tightening torques
♦ ⇒ “5.1 Exploded view - injectors”, page 253
– Press return line connections carefully over seals and onto in‐
jectors (check seal for damage before connecting return line).
The catch should engage audibly. Then press release pin
down carefully.
After renewing one or more injectors, the “injector delivery cali‐
bration values” and “injector voltage calibration values” for the
new injectors must be written into the engine control unit.
Additionally, check that the “injector delivery calibration values”
and “injector voltage calibration values” are correctly entered for
all the other injectors. Do NOT attempt to re-enter these calibra‐
tion values if the correct values are already stored in the engine
control unit.
Bleeding fuel system and checking for leaks
Note
The fuel system is self-bleeding; do not open the high-pressure

connections.
– Run engine at idling speed for several minutes and then switch
off.
– Check the complete fuel system including all 4 return line con‐
nections for leaks.

Renew affected component if leakage still occurs after tightening

to correct torque.
Note
5.8 Removing and installing high-pressure

pipes
♦ Open end spanner insert, AF 17 - V.A.G 1331/6-
Procedure
Note

following checks:
cracks.
erwise damaged.
– Use vacuum cleaner to remove dirt from taper seat at fuel rail.
– Clean fuel pipe and end of pipe using cleaning solution and
dry with compressed air.
– Lubricate threads of union nuts with fuel.
– Hand-tighten union nuts on high-pressure pipes (ensure that
pipes are not under tension).
Tightening torques

– To tighten unions of high-pressure pipes to fuel rail and injec‐

tors, use torque wrench - V.A.G 1331- with open end spanner
insert, AF 17 - V.A.G 1331/6- .
– Check fuel system for leaks ⇒ page 241 .

reservoir (rail)
♦ Ratchet - V.A.G 1331/1-
♦ Socket - T40055-
Removing
Caution


– Unplug electrical connector -arrow- at fuel pressure regulating

valve - N276- .
pressure pipe.
– Release hose clip -arrow- and detach fuel return hose from
fuel rail.
– Seal off open fuel return hose with a clean plug.
Note
– Unplug electrical connectors on glow plugs ⇒ page 321 .

– Unplug electrical connectors -1, 2, 3-.

– Remove bolt -arrow- and move wiring retainer with electrical
wiring harness clear and press to one side.
– Loosen union nuts for high-pressure pipes using socket -
T40055- .
– Remove union nuts -1- and bolts -arrows- and detach fuel rail.
– Set removed fuel rail (with high-pressure pipes attached)
down on a clean cloth.
– Seal off openings in fuel rail with clean plugs.
Installing
– Install high-pressure pipes so they are free of stress.
Note

following checks:
cracks.
erwise damaged.
Tightening torques

6 High-pressure pump
⇒ “6.1 Exploded view - high-pressure pump”, page 272
⇒ “6.2 Removing and installing high-pressure pump”, page 273
6.1 Exploded view - high-pressure pump
1 - Bracket for ancillaries

⇒ page 59
2 - Bolt
❑ 2x
❑ Renew
❑ 20 Nm + 180°
3 - Hub
❑ Use counterhold tool -
T10051- when loosen‐
ing and tightening
❑ To remove, use puller -
T40064-
sprocket
5 - Bolt
❑ 20 Nm
6 - Nut
❑ 95 Nm
7 - Bolt
❑ Renew
❑ 20 Nm + 45°
❑ With fuel metering valve
- N290- (do not open)
❑ After renewing, first fuel
filling operation MUST
be performed (it is im‐
portant not to allow
pump to run while it is
still empty) ⇒ page 275
❑ After renewing high-pressure pump or fuel pressure regulating valve - N276- , learnt values must be re-
adapted; see “Guided Functions” in ⇒ Vehicle diagnostic tester
9 - Fuel supply hose
10 - Fuel return hose
❑ Between high-pressure pump and fuel rail
Note
♦ The high-pressure pipes can be

lowing checks:

♦ Check taper seat for deformation

and cracks.
damaged.
used again.
❑ 25 Nm

pump
Caution

Removing
– Set service position ⇒ General body repairs, exterior; Rep.
gr. 50 ; Lock carrier; Setting service position and returning to
normal position .
– Remove toothed belt
⇒ “2.2 Removing and installing toothed belt”, page 113 .
pressure pipe.
– Remove bolts -1 and 3-.

– Release hose clips -2- and detach fuel hoses.
to one side.
Note
Disregard -item 4-.
6. High-pressure pump 273

– Unplug electrical connector -arrow- at fuel metering valve -

N290- .
– Using an M10 bit, remove bolts -arrows- for toothed belt

sprocket on high-pressure pump.
– Counterhold using counterhold tool - T10051- and remove nut

-1- at hub of high-pressure pump.
– Apply puller - T40064- with thrust piece - T40064/1- and pin -

T40064/2- as shown in illustration and pull hub off high-pres‐
sure pump. If necessary, counterhold using an open-end
spanner (24 mm).

– Unscrew securing bolts -arrows- for high-pressure pump.

– Carefully take out high-pressure pump.
Installing
Tightening torques
♦ Exploded view - high-pressure pump
⇒ “6.1 Exploded view - high-pressure pump”, page 272
– Install toothed belt for high-pressure pump ⇒ page 113 .
– Install high-pressure pipe ⇒ page 268 .
– Return to normal position ⇒ General body repairs, exterior;
Rep. gr. 50 ; Lock carrier; Setting service position and return‐
ing to normal position .
Caution
Running when dry causes irreparable damage to high-pres‐

sure pump.
♦ The high-pressure pump must first be filled with fuel before
the engine is started. The high-pressure pump must not
be allowed to run while still empty. First fuel filling
⇒ page 275 .
– Reset learnt values after renewing high pressure pump ⇒ Ve‐

hicle diagnostic tester, Guided Functions , 01 - Reset
learnt values .
6.3 Performing first fuel filling operation af‐

ter installing high-pressure pump
If components of the fuel system between the fuel tank and the
high-pressure pump are removed or renewed, the fuel system
must be bled.
Risk of irreparable damage to fuel pump
After working on the fuel system, the fuel pump may be irreparably
damaged if it is allowed to run while empty.
– Never allow fuel pump to run while it is empty.
– Fill/bleed fuel pump.
Proceed as follows to fill fuel system with fuel:

• Check fuel gauge in instrument cluster; fuel gauge needle
must indicate that fuel is above reserve level.
– Connect vehicle diagnostic tester .
– Switch on the ignition and select the following menu options
on the vehicle diagnostic tester :
♦ Systems with diagnostic capability
6. High-pressure pump 275

♦ Engine electronics
♦ Engine electronics functions
♦ Activate fuel pump
♦ Bleeding fuel system
– The fuel pump starts running.
– The fuel pump must run for approx. 3 minutes to ensure that
the fuel system is filled sufficiently with fuel.
– Start engine after filling fuel system.
– Run engine at moderate speed for several minutes and then
switch off.
– Then inspect high-pressure section again for leaks.
– Interrogate event memory.

7 Senders and sensors

⇒ “7.1 Checking fuel pressure (low pressure)”, page 277
⇒ “7.2 Checking fuel pressure regulating valve N276 ”,
page 279
⇒ “7.3 Removing and installing fuel pressure regulating valve
N276 ”, page 280
⇒ “7.4 Removing and installing fuel pressure sender G247 ”, page
282
⇒ “7.5 Removing and installing air mass meter G70 ”, page 285
7.1 Checking fuel pressure (low pressure)

♦ K-Jetronic pressure tester - V.A.G 1318-
Test conditions:
• Battery voltage at least 12.5 V
• Fuel filter OK.
• Fuel tank at least 1/2 full.
• Ignition switched off.
Checking residual pressure
Caution

♦ To reduce the pressure in the fuel system, wrap a clean
cloth around the connection and carefully loosen the con‐
nection.
7. Senders and sensors 277

– Release hose clip and detach fuel supply line -arrow- from
high-pressure pump.
– Connect K-Jetronic pressure tester - V.A.G 1318- to fuel sup‐

ply line -2- with suitable adapter -3-.
– Connect second hose -1- (from -V.A.G 1318- ) to open con‐
nection on high-pressure pump, as shown in illustration below.
Note
In this way the K-Jetronic pressure tester - V.A.G 1318- is con‐

nected into the fuel supply line.
– Connect a ⇒ Vehicle diagnostic tester.

– Switch on ignition.
– Select “Engine electronics” in vehicle self-diagnosis.
– Then select “Basic setting”.
– Select “Checking fuel system pressurisation pump” from the
list.
– Let fuel pump run until maximum fuel pressure has built up.
• Specification: at least 3.5 bar
If specification is not obtained:
♦ Leak in union between pressure tester and fuel line.
♦ Leak in pressure tester.
♦ Leak in fuel lines and their connections.
♦ Fuel filter is blocked.
– Check delivery rate of fuel pump ⇒ Fuel supply system; Rep.
gr. 20 ; Fuel pump; Checking fuel system pressurisation pump
- G6- .
Note
Check fuel system for leaks.

7.2 Checking fuel pressure regulating valve

- N276-
♦ Fuel-resistant measuring container
Caution

♦ To reduce the pressure in the fuel system, wrap a clean
cloth around the connection and carefully loosen the con‐
nection.

– Release hose clip -arrow- and detach fuel return hose from
fuel rail.
– Seal off open fuel return hose with a clean plug.

– Connect test hose -2- to return line connection of fuel rail -3-.
– Seal off open fuel return hose -1- with a clean plug.
– Hold end of test hose into measuring container -4- to measure
return flow rate.
1) Checking while engine is running
– Start the engine and run at idling speed.
• Specification: more than 75 ml in 30 seconds
If specification is not obtained, fuel pressure regulating valve -
N276- is defective.
2) Checking while engine is running
If condition for 1) is met, start engine and increase engine speed
to ≥ 2000 rpm.
• Fuel is still discharged in the first few seconds after the engine
is started
• Specification after a few seconds: return flow rate = 0 ml
• Drip leaks are permissible
If specification is not obtained, fuel pressure regulating valve -
N276- is defective.
3) If engine can no longer be started
Perform check at cranking speed.
• Specification of return flow rate: 0 ml
• Drip leaks are permissible
• If specification is not obtained, fuel pressure regulating valve
- N 276- is defective.
7.3 Removing and installing fuel pressure

regulating valve - N276-
♦ Open-end spanner insert, 30 mm - T10553-
♦ Torque wrench

The fuel pressure regulating valve - N276- -arrow- is located in

the fuel rail. It maintains a constant pressure in the fuel rail and
the injector pipes (high-pressure fuel circuit).
If the pressure in the high-pressure fuel circuit is too high, the
regulating valve opens to allow some of the fuel to flow back from
the fuel rail to the fuel tank via a return line.
If the pressure in the high-pressure fuel circuit is too low, the fuel
pressure regulating valve - N276- closes and seals off the high-
pressure section of the system from the low-pressure section.
Note
Fuel pressure regulating valve - N276- must always be renewed

after it has been removed.
Removing
Caution

– Remove fuel rail ⇒ page 269 .

– Before removal, clean area around thread for fuel pressure
regulating valve - N276- using commercial cleaning solution
or similar (no dirt must enter opening in fuel rail).
Note
Clean carefully; cleaning solution must not enter the electrical

connector.
– Dry off fuel pressure regulating valve - N276- .

– Loosen union nut using open-end spanner insert, 30 mm -
T10553- (at the same time, counterhold at hexagon flats on
housing). Then unscrew and remove by hand.
– Extract dirt from opening in fuel rail (thread and sealing sur‐
face) using a vacuum cleaner. Do not use metal tools, etc.
– Seal off opening in fuel rail with a clean plug.

Installing
Tightening torques
Note
♦ The fuel pressure regulating valve - N276- has a deformable

sealing lip and no separate seal; it can therefore be used only
once.
♦ Check that sealing surfaces (deformable sealing lip) and
threads on new fuel pressure regulating valve - N276- are not
damaged.
♦ Check sealing surface at opening in fuel rail.
♦ The beginning of the thread, the deformable sealing lip and
the O-ring of the fuel pressure regulating valve - N276- must
be coated with diesel fuel.
– Screw on union nut by hand.

– Align new regulating valve so that connecting wire is free of
tension after connector is attached.
– Hold regulating valve in this position by holding hexagon flats
on housing of regulating valve with open-end spanner or pliers
(water pump pliers or similar).
– Tighten union nut using open-end spanner insert, 30 mm -
T10553- (at the same time, counterhold at hexagon flats on
housing).
– Install fuel rail ⇒ page 269 .
After renewing high-pressure pump or fuel pressure regulating
valve - N276- , learnt values must be re-adapted; see “Guided
Functions” in ⇒ Vehicle diagnostic tester
– After installation, run engine at moderate speed for several
minutes and then switch off.
– Interrogate event memory.
– Interrogate event memory again.
7.4 Removing and installing fuel pressure

sender - G247-

♦ Bit (27 mm) - T40218- or commercially available socket

(27 mm)
♦ Torque wrench
Note
♦ The fuel pressure sender - G247- continuously measures the

fuel pressure in the high-pressure system. It transmits a cor‐
responding voltage signal to the engine control unit - J623- .
♦ Should the fuel pressure sender fail, the engine control unit
will control the fuel pressure via a mapped open-loop backup
function. Maximum engine speed in this mode is restricted.
♦ The fuel pressure sender - G247- has a deformable sealing lip
and no separate seal; it can therefore be used only once.
Removing
Caution


– Before removal, clean area around thread for fuel pressure
sender - G247- using e.g. commercial cleaning solution.
• Make sure no dirt gets into opening in high-pressure reservoir.
• Clean carefully; cleaning solution must not enter the electrical
connector.
– Dry off fuel pressure sender - G247- .

– Unplug electrical connector -1- at fuel pressure sender -

G247- .
– Unscrew fuel pressure sender - G247- using socket, 27 mm -
T40218- .
Note
An open-end spanner must not be used for loosening or tighten‐

ing.
– Extract dirt from opening in high-pressure reservoir (thread

and sealing surface) using a vacuum cleaner. Do not use met‐
al tools, etc.
– Seal off opening in high-pressure reservoir with a plug.
Installing
Note
♦ Fuel pressure sender - G247- must always be renewed after

it has been removed.
♦ Also check sealing surface at opening in high-pressure reser‐
voir.
♦ Check that the deformable sealing lip and the thread on the
new fuel pressure sender - G247- are not damaged.
♦ The beginning of the thread and the deformable sealing lip of
the fuel pressure sender - G247- must be coated with diesel
fuel.
– Screw in fuel pressure sender - G247- by hand.

– Then tighten fuel pressure sender - G247- to specified torque.
Tightening torques
– After installing fuel pressure sender - G247- , leave engine
running at moderate speed for a few minutes when bleeding
fuel system and then switch off again.
Note
The fuel system is “self-bleeding”; do NOT open the high-pres‐

sure connections.

– Carefully check the entire fuel system for leaks.
– Renew affected component if leakage still occurs after tight‐
ening to correct torque.

Note
– After road test, interrogate event memory again.
7.5 Removing and installing air mass meter

- G70-
Removing
– Unplug electrical connector -1- at air mas meter - G70- –
Release hose clip securing air hose (coming from turbocharg‐
er) and disconnect hose from air mass meter - G70- .
– Unscrew both bolts from air mass meter - G70- .
– Then carefully pull air mass meter - G70- out of guide on air
cleaner housing.
Installin
To ensure that the air mass meter -G70- functions correctly, it is
important to observe the following notes and procedures.
Note
♦ If the air filter element is very dirty or wet, dirt particles or water
can reach the air mass meter and falsify the detected air mass
values. This will cause a loss of power, as the calculated in‐
jection quantities will be too low.
– Check air mass meter and air hose (engine intake side) for salt
residue, dirt and leaves.
– Check intake duct as far as air filter element for dirt. If neces‐
sary, clean salt residue, dirt and leaves out of air cleaner
housing (top and bottom sections); wash out or use a vacuum
cleaner as required. Removing and installing air cleaner
⇒ page 244 .
quence.

8 Lambda probe
⇒ “8.1 Exploded view - Lambda probe”, page 286
⇒ “8.2 Removing and installing Lambda probe”, page 286
8.1 Exploded view - Lambda probe
1 - Turbocharger
❑ With position sender for
charge pressure posi‐
tioner - G581-
❑ May be fitted depending
on emission standard
❑ New Lambda probes
are coated with an as‐
sembly paste
❑ If you are re-using
Lambda probe, coat on‐
ly thread with high-tem‐
perature paste; refer to
⇒ Electronic parts cata‐
logue for high-tempera‐
ture paste
❑ The assembly paste/
high-temperature paste
must not get into the
slots on the Lambda
probe body
⇒ page 286
❑ 55 Nm
sender 3 - G495-
⇒ page 308
4 - Pressure differential sender
- G505-
❑ Pressure pipes to partic‐
ulate filter: 45 Nm
❑ Tighten bolt to 4.5 Nm
❑ Adaption must be performed after renewing particulate filter. Use ⇒ Vehicle diagnostic tester
8.2 Removing and installing Lambda probe


♦ Lambda probe open ring spanner set - 3337-
Removing
WARNING
When working on all parts of the exhaust system:

♦ Observe safety precautions when working on the exhaust
system
⇒ “2.6 Safety precautions when working on the exhaust
system”, page 5 .

– Unplug electrical connector -3- for Lambda probe - G39- and
move electrical wiring clear.
– Unscrew Lambda probe - G39- -item 1- using a tool from
Lambda probe open ring spanner set - 3337- .
Note
Installing
Tightening torques
♦ ⇒ “8.1 Exploded view - Lambda probe”, page 286
Note
♦ Threads of new Lambda probes are already coated with as‐

sembly paste; the paste must not get into the slots on the probe
body.
♦ In the case of a used Lambda probe grease only the thread
with high-temperature paste. The paste must not get into the
slots on the Lambda probe body. For high-temperature paste
refer to ⇒ Electronic parts catalogue
♦ When installing, the Lambda probe wiring must always be re‐
attached at the same locations to prevent it from coming into
contact with the exhaust pipe.
8. Lambda probe 287

9 Engine control unit

⇒ “9.1 Wiring and component check with test box V.A.G 1598/42
”, page 288
⇒ “9.2 Removing and installing engine control unit J623 ”,
page 289
9.1 Wiring and component check with test

box - V.A.G 1598/42-
♦ Adapter cable - V.A.G 1598/39-1-
♦ Adapter cable - V.A.G 1598/39-2-
♦ Test box - V.A.G 1598/42-

Note
♦ The test box has 105 sockets. The connecting cable can be
disconnected from the test box. This means that only the cable
(and not the test box) has to be purchased for future engine
control units with different types of connectors.
♦ The smaller of the two connectors on the engine control unit
has the contacts 1 to 60. The larger of the two connectors has
the contacts 1 to 94.
♦ To carry out tests on the 60-pin wiring harness connector, the
adapter cable - V.A.G 1598/39-1- is connected to connector
“A” on the test box. For components connected to 60-pin wiring
harness connector ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
♦ To carry out tests on the 94-pin wiring harness connector, the
adapter cable - V.A.G 1598/39-2- must be connected to con‐
nectors -A- and -B- on the test box. For components connec‐
ted to 94-pin wiring harness connector ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
♦ The test box - V.A.G 1598/42- is designed so it can be con‐
nected both to the wiring harness for the engine control unit
and to the engine control unit itself at the same time.
♦ The advantage of this is that the electronic engine control sys‐
tem remains fully functional when the test box is connected
(for example, for measuring signals when the engine is run‐
ning).
♦ The relevant test procedure will state whether it is necessary
to also connect the engine control unit to the test box.
WARNING
To prevent irreparable damage to the electronic components,

select appropriate measuring range before connecting the
measuring cables and observe the test requirements.
– Remove engine control unit ⇒ page 289 .

– Connect the test box - V.A.G 1598/42- to wiring harness with
adapter cable - V.A.G 1598/39-1- or adapter cable - V.A.G
1598/39-2- . Connect earth clip of test box to negative terminal
of battery. The instructions for performing the individual tests
indicate whether or not the engine control unit itself also needs
to be connected to the test box.
– Carry out test as described in appropriate repair procedures.
Installing engine control unit
Installation is performed in the reverse sequence; the engine con‐
trol unit must be installed with the protective housing. New shear
bolts must be used.
Perform the following after reconnecting engine control unit:
– Interrogate event memory and erase if necessary.
9.2 Removing and installing engine control

unit - J623-
9. Engine control unit 289

♦ Hot air blower - VAS 1978/14A- -item 1- with nozzle attach‐

ment -2- from wiring harness repair set - VAS 1978 B-
♦ Small, commercially available mole grips -3-
Note
♦ Not every engine control unit is bolted to a protective housing.

Whether a protective housing is fitted depends on the engine/
gearbox combination.
♦ The engine control unit -1- is bolted to the protective housing
-5-. To make it more difficult to unscrew the shear bolts -4- for
locking plate -2-, their threads have been coated with locking
fluid.
♦ The protective housing has to be removed before the connec‐
tors can be unplugged from the engine control unit (e.g. to
connect the test box or renew the engine control unit).
Removing
– Before removing the engine control unit - J623- , the adaption
values of the injectors and the ash deposit mass must be read
out. Use ⇒ Vehicle diagnostic tester.
– Store adaption values as electronic file.
– Switch off ignition and remove ignition key after storing elec‐
tronic file containing adaption values.
Note
If the adaption values of the injectors cannot be read out of the

old (defective) engine control unit, they must be entered into the
new engine control unit manually and the adaption procedure
must be performed accordingly.
– Remove nut -3- and bolt -2-.

– Pull filler neck -1- with filler pipe out of washer fluid reservoir
and through opening in body -arrow-.

– Unscrew bolts -arrows- and take off lid for electronics box.
Note
Disregard -item 1-.
– Release retainers -arrows A- and pull out engine control unit

- J623- -arrow B-.
Note
Cover painted surfaces with a cloth to prevent scratching.
The threads of the two shear bolts -4- which are not screwed into
the engine control unit are secured with locking fluid. To unscrew
these two bolts, the threads must therefore be heated with the hot
air blower.
The threads of the two shear bolts -3- which are screwed into the
engine control unit are not secured with locking fluid. Do not apply
heat to the threads in the control unit housing; this is not neces‐
sary and would cause overheating of the control unit.
– Select settings on hot air blower as shown in illustration, i.e.

set temperature potentiometer -2- to maximum heat output
and two-stage air flow switch -3- to position 3.
WARNING
Heating the thread of the locking plate also heats up the shear
bolts and parts of the metal housing. Take care to avoid burns.
It is also important to ensure that only the thread is heated and
none of the surrounding components if at all possible. These
should be covered if necessary.
9. Engine control unit 291

Switch on the hot air blower and heat the bolt for approximately
20 ... 30 seconds.
– Unscrew shear bolts using suitable vice-grip pliers (see arrow

in illustration).
– The two shear bolts screwed into the engine control unit do
not need to be heated. They should be removed without being
heated.
– Detach protective housing from control unit connectors.
– Release connectors on engine control unit and unplug con‐
nectors.
– Take out old engine control unit - J623- and install new engine
control unit - J623- .
Installing
Installation is performed in the reverse sequence.
– After installation, the protective housing must be re-fitted on
the engine control unit - J623- .
– Clean threaded holes for shear bolts to remove any residue
from locking fluid. This can be done using a thread tap.
– Always use new shear bolts.
After installing a new engine control unit, the following operation
must be performed:
– Activate engine control unit using ⇒ Vehicle diagnostic tester
in “Guided Functions” mode, “Replace engine control unit”.

26 – Exhaust system
1 Exhaust pipes/silencers
⇒ “1.1 Exploded view - silencers”, page 293
⇒ “1.2 Removing and installing front exhaust pipe”, page 296
⇒ “1.3 Separating exhaust pipes/silencers”, page 297
⇒ “1.4 Renewing tailpipes”, page 298
⇒ “1.5 Stress-free alignment of exhaust system”, page 299
⇒ “1.6 Checking exhaust system for leaks”, page 300
1.1 Exploded view - silencers
1 - Gasket
❑ Renew
❑ With catalytic converter
❑ With pressure line for
exhaust gas pressure
sensor 1 - G450-
⇒ page 302
❑ Mounting components
⇒ page 295
❑ After renewing, perform
Adaption in Guided
Functions ⇒ Vehicle
diagnostic tester
3 - Seal
❑ Renew
4 - Nut
❑ Renew
❑ 23 Nm
5 - Front exhaust pipe
❑ With flexible joint; do not
bend flexible joint more
than 10° – otherwise it
can be damaged
❑ Protect against knocks
and impact
⇒ page 296
❑ Align exhaust system so
it is free of stress
⇒ page 299
6 - Clamp (front)
❑ Before tightening, align exhaust system so it is free of stress ⇒ page 299
❑ Tighten bolted connections evenly
7 - Nut
❑ 23 Nm
1. Exhaust pipes/silencers 293

8 - Rear silencer
❑ Combined as one unit with centre silencer and tailpipes as original equipment Can be renewed individ‐
ually for repair purposes
❑ Cutting point: centre silencer / rear silencer ⇒ page 297
❑ Renewing tailpipes ⇒ page 298
❑ Align exhaust system so it is free of stress ⇒ page 299
9 - Mounting
❑ Check preload ⇒ “1.5 Stress-free alignment of exhaust system”, page 299
10 - Bolt
❑ 20 Nm
11 - Rubber mounting
12 - Bracket
13 - Bolt
❑ 23 Nm
14 - Tailpipe
❑ Can be renewed separately for repair purposes ⇒ page 298
15 - Clamp
16 - Nut
❑ 23 Nm
17 - Clamp (rear)
❑ For separate replacement of centre and rear silencers
❑ Before tightening, align exhaust system so it is free of stress ⇒ page 299
❑ Tighten bolted connections evenly
18 - Centre silencer
❑ Combined in one unit with rear silencers as original equipment. Can be renewed individually for repair
purposes
❑ Cutting point: centre silencer / rear silencer ⇒ page 297
❑ Align exhaust system so it is free of stress ⇒ page 299
19 - Mounting
❑ Check preload ⇒ “1.5 Stress-free alignment of exhaust system”, page 299
20 - Bolt
❑ 23 Nm
21 - Nut
❑ 23 Nm
22 - Retainer
23 - Bolt
24 - Nut
❑ Renew
❑ 23 Nm
294 Rep. gr.26 - Exhaust system

Installation position of front clamp

– Install clamp so that ends of bolts do not protrude beyond bot‐
tom of clamp.
• Bolted connection faces to left.
Installation position of rear clamps

– Install clamps so that the bolt ends do not protrude beyond
bottom of clamp.
Components of mountings for particulate filter

1- Spacer sleeve
2- Compression spring
3- Washer
4- Bolt, 23 Nm
5- Bolt, 23 Nm
6- Spacer sleeve
7- Buffer
8- Bracket
9- Bolt, 23 Nm
10 - Retainer
11 - Nut

1.2 Removing and installing front exhaust

pipe
Removing
insulation .
WARNING

system
system”, page 5 .
– Remove nuts -arrows-.

Caution
Risk of damage to flexible joints in front exhaust pipe

♦ Do not bend flexible joints in front exhaust pipe more than
10°.
– Loosen bolts -arrows-, push back clamp and detach front ex‐
haust pipe.
Installing
• Tightening torques
⇒ “1.1 Exploded view - silencers”, page 293
Note
Renew gasket and nuts.
– Align the exhaust system so it is free of stress ⇒ page 299 .

tion .
1.3 Separating exhaust pipes/silencers

♦ The connecting pipe can be cut through at the cutting location
in order to renew the centre and rear silencers separately.
♦ The cutting point is marked by an indentation on the circum‐
ference of the exhaust pipe.
♦ Chain pipe cutter - VAS 6254-

Procedure
– Cut through exhaust pipe at right angles at the position marked
-arrow- using chain pipe cutter - VAS 6254-
– Position centre of clamps -arrow- over cutting location.
– Install clamp so that ends of bolts do not protrude beyond bot‐

tom of clamp.

1.4 Renewing tailpipes

♦ The tailpipes can be cut through at the point marked so that
the tailpipes can be renewed separately.
♦ The cutting point is marked by an indentation on the circum‐
ference of the tailpipe.

♦ Chain pipe cutter - VAS 6254-
Procedure
– Cut through tailpipe at right angle at the position marked by
-arrows- using chain pipe cutter - VAS 6254- .
– Fit tailpipes.
– Check clearance between tailpipes and bumper:

• Dimension -x- (left-side) = dimension -x- (right-side)
– Tighten bolt connections on clamps.
1.5 Stress-free alignment of exhaust system

Procedure
• The exhaust system must be aligned when it is cool.
• Tightening torques ⇒ page 293
Vehicles without clamps between centre silencer and rear silenc‐
er
– Loosen bolted connections on front clamp.
– Push exhaust system towards front of vehicle -arrow- so that
rear mountings for rear silencer are preloaded by -a- =
11 ... 15 mm.
– Align rear silencer so it is horizontal.


– Tighten bolt connections on clamp evenly.
Vehicles with clamps between centre silencer and rear silencer

– Loosen bolted connections on front and rear clamps.
– Push centre silencer towards front of vehicle -arrow- until
mounting for centre silencer is preloaded by -a- = 6 ... 10 mm.
– Tighten bolt connections on front clamp evenly.
– Push rear silencer towards front of vehicle -arrow- so that rear

mounting for rear silencer is preloaded by -a- = 11 ... 15 mm.
– Align rear silencer so it is horizontal.

– Tighten bolted connections on rear clamps evenly.
1.6 Checking exhaust system for leaks

– Start the engine and run at idling speed.
– Plug tailpipes during leak test (e.g. with cloth or plug).
– Listen for noise at connection points of cylinder head/exhaust
manifold, turbocharger/exhaust manifold, turbocharger/partic‐
ulate filter etc. to locate any leaks.

– Rectify any leaks that are found.

2 Emission control system

⇒ “2.1 Removing and installing particulate filter”, page 302
⇒ “2.2 Removing and installing pressure differential sender G505
”, page 303
2.1 Removing and installing particulate filter

♦ Tool set, 17 mm - T10395-
Removing
Note
WARNING

system
system”, page 5 .

– Remove coolant pipe (rear right) ⇒ page 198 .
– Remove exhaust gas recirculation cooler ⇒ page 314 .
– Remove turbocharger ⇒ page 216 .

– Remove bolts -2- and detach exhaust gas recirculation pipe.
Note
Disregard -item 1-.

– Remove bolt -1- and nut -2- and push rear coolant pipe clear
to one side.
Note
Disregard -arrows-.
– Remove particulate filter forwards.

Installing
Tightening torques
• ⇒ “1.1 Exploded view - silencers”, page 293 .
• ⇒ “3.1 Exploded view - exhaust gas temperature control”, page
305 .
Note
Renew gaskets and nuts.
– Secure coolant pipe (rear) ⇒ page 201 .

– Install exhaust gas recirculation pipe ⇒ page 313 .
– Install oil pressure switch - F1- ⇒ page 156 .
– Install exhaust gas recirculation cooler ⇒ page 314 .
– After renewing particulate filter, perform Adaption in Guided
Functions ⇒ Vehicle diagnostic tester.
2.2 Removing and installing pressure differ‐

ential sender - G505-
Note
The pressure differential sender - G505- detects the amount of

deposits in the particulate filter.
2. Emission control system 303


Removing
– Unscrew bolt -2- and detach pressure differential sender -
G505- .
– Before disconnecting, spray hoses coming from exhaust gas
pressure sensor 1 - G450- with suitable release agent.
– Carefully disconnect the hoses from their connections (take
care to keep the hoses straight: the connections on pressure
sensor can break off easily).
Installing
Tightening torques
♦ ⇒ page 286
Note
♦ Before installing, blow out pressure pipes from pressure dif‐

ferential sender - G505- to particulate filter towards particulate
filter with compressed air (pipes can become obstructed or
may ice up due to condensation).
♦ Make sure that hoses are securely fitted and that there are no
leaks.
♦ If pressure pipes were loosened on particulate filter, tighten
pressure pipe connections ⇒ page 302 .
After renewing pressure differential sender - G505- and/or par‐

ticulate filter, adaption must be performed in order to reset learnt
values. The adaption procedure is described in the Guided Fault
Finding or Guided Functions.
Use ⇒ Vehicle diagnostic tester.

3 Exhaust gas temperature control

⇒ “3.1 Exploded view - exhaust gas temperature control”,
page 305
⇒ “3.2 Removing and installing exhaust gas temperature sender 1
G235 ”, page 306
G495 ”, page 308
G648 ”, page 310
3.1 Exploded view - exhaust gas temperature control
1 - Turbocharger
⇒ page 286
❑ 55 Nm
sender 3 - G495-
⇒ page 308
❑ The thread of the ex‐
haust gas temperature
sender is coated; it must
not additionally be
greased with high-tem‐
perature paste
❑ 60 Nm
4 - Exhaust gas pressure sen‐
sor 1 - G450-
⇒ page 303
❑ Pressure pipes to partic‐
ulate filter: 45 Nm
❑ Coat thread with high-
temperature paste; for
refer to ⇒ Electronic
parts catalogue
❑ May be fitted depending on emission standard
❑ The thread of the exhaust gas temperature sender is coated; it must not additionally be greased with
❑ 60 Nm
❑ May be fitted depending on emission standard
3. Exhaust gas temperature control 305


❑ Adaption must be performed after renewing particulate filter. Use ⇒ Vehicle diagnostic tester
❑ 45 Nm
3.2 Removing and installing exhaust gas

temperature sender 1 - G235-
♦ Tool set, 17 mm - T10395-
Removing
Note
WARNING

system
system”, page 5 .

- G505- .

– Remove cover -1- for drive shaft in wheel housing (right-side).

Note
Disregard -item 1-.

– Remove Lambda probe -1- ⇒ page 286 .

– Unplug electrical connector -3- for exhaust gas temperature

sender 1 - G235- and unclip at bottom.
Note
– Unscrew exhaust gas temperature sender 1 - G235- -item 1-

and unclip electrical wiring -arrow-.
Installing
⇒ “3.1 Exploded view - exhaust gas temperature control”, page
305


♦ Tool set, 17 mm - T10395-
Removing
Note
WARNING

system
system”, page 5 .
– Detach electrical connector -3- from bracket.

Note
Disregard -item 1-.
Installing
⇒ “3.1 Exploded view - exhaust gas temperature control”, page
305
Caution
Risk of malfunctions caused by improperly secured exhaust

gas temperature senders.
♦ The threads of the exhaust gas temperature senders -
G495- and -G648- are coated. It is important that you do
NOT grease them additionally with high-temperature
paste and that you tighten them to the specified torque.


♦ Tool set, 17 mm - T10395-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Gearbox support - T10337-

Removing
insulation .
WARNING

system
system”, page 5 .

– Remove torque reaction support ⇒ page 45 .
– Support gearbox using engine and gearbox jack - V.A.G 1383

A- with gearbox support - T10337- attached.
– Remove bolts -arrows- for tunnel cross member.
– Lower engine and gearbox jack - V.A.G 1383 A- as far as dis‐

tance -a-.
• Dimension -a- = 80 mm (maximum).
WARNING
Risk of accident.
♦ Engine and gearbox jack - V.A.G 1383 A- must remain in
position when work is being carried out and must not be
left unattended.

– Unclip electrical wiring -A- from gearbox and unplug electrical

connector -C-.
– Unclip bracket -B- for exhaust gas temperature sender 4 -
G648- from gearbox.

Installing
Tightening torques
• ⇒ “1.1 Exploded view - silencers”, page 293 .
• ⇒ “3.1 Exploded view - exhaust gas temperature control”, page
305 .
– Secure tunnel cross-piece ⇒ Rep. gr. 34 ; Assembly mount‐
ings; Exploded view - assembly mountings .
– Install torque reaction support ⇒ page 45 .
– Install front exhaust pipe ⇒ page 296 .
tion .

4 Exhaust gas recirculation

⇒ “4.1 Exploded view - exhaust gas recirculation system”,
page 313
⇒ “4.2 Removing and installing exhaust gas recirculation cooler”,
page 314
⇒ “4.3 Checking exhaust gas recirculation cooler change-over”,
page 316
4.1 Exploded view - exhaust gas recirculation system
1 - Gasket
❑ Renew
2 - Bolt
❑ 9 Nm
3 - Pipe for exhaust gas recir‐
culation
4 - Bolt
❑ 9 Nm
5 - Gasket
❑ Renew
6 - Bolt
❑ 9 Nm
7 - Coolant hose
cooler
❑ With integrated exhaust
gas recirculation control
motor - V338- with ex‐
haust gas recirculation
potentiometer - G212-
❑ After renewing exhaust
gas recirculation control
motor - V338- , learnt
values must be re-adap‐
ted; see “Guided Func‐
tions” of ⇒ Vehicle diag‐
nostic tester, 01 -
Adaption elec. ad-
juster with check-
back
❑ Checking change-over
function ⇒ page 316
9 - Coolant hose
10 - Bolt
❑ 9 Nm
11 - Bolt
❑ 23 Nm
12 - Gaskets
❑ Renew
4. Exhaust gas recirculation 313

13 - Pipe for exhaust gas recirculation

14 - Bolt
❑ 23 Nm
4.2 Removing and installing exhaust gas re‐

circulation cooler
Removing



– Remove bolts -2- for exhaust gas recirculation pipe.
– Remove bolts -1- for exhaust gas recirculation pipe.

– Unplug electrical connectors -2, 3, 4- and move electrical wir‐

ing clear.

– Remove bolts -1, 3- and detach exhaust gas recirculation
cooler.
Installing
Tightening torques
♦ ⇒ “4.1 Exploded view - exhaust gas recirculation system”,
page 313
♦ ⇒ “3.1 Exploded view - coolant pipes”, page 194
Note
♦ Renew gaskets and O-ring.


– After renewing exhaust gas recirculation control motor -
V338- , learnt values must be re-adapted; see Guided Func-
tions of ⇒ Vehicle diagnostic tester, 01 - Adaption elec.
adjuster with checkback .
4.3 Checking exhaust gas recirculation

cooler change-over

Procedure
– Disconnect vacuum hose from vacuum unit and connect hand

vacuum pump - VAS 6213- in its place.
– Operate hand vacuum pump to produce a vacuum.
• The linkage of the exhaust gas recirculation cooler change-
over should move -arrows-.
If the linkage does not move or only moves jerkily:
♦ The vacuum unit is defective.
♦ The change-over flap for exhaust gas recirculation is sticking.

5 Exhaust manifold
⇒ “5.1 Exploded view - exhaust manifold”, page 318
⇒ “5.2 Removing and installing exhaust manifold”, page 319
5.1 Exploded view - exhaust manifold
1 - Gasket
❑ Renew
2 - Exhaust manifold
⇒ page 319
3 - Nut
❑ 25 Nm
❑ Renew
❑ Coat thread with high-
temperature paste; for
refer to ⇒ Electronic
parts catalogue
4 - Heat shield
5 - Nut
❑ 25 Nm

5.2 Removing and installing exhaust mani‐

fold
Removing
– Remove turbocharger ⇒ page 216 .
- G505- .
– Detach electrical connectors from bracket and unplug.

3 - For Lambda probe - G39-
4 - For exhaust gas temperature sender 3 - G495-
– Move particulate filter to rear.
Note
– Remove bolt -1- at retaining clamp for oil supply line.
Note
Disregard -item 2-.
– Remove bolts -1, 2- and detach exhaust gas recirculation pipe.
5. Exhaust manifold 319

– Remove nuts -arrows- and detach heat shield.
– Remove nuts -arrows-.
Caution
Risk of damage to oil supply line.

♦ Do not attempt to bend oil supply line to a different shape.
– Detach exhaust manifold.

Installing
Tightening torques
♦ ⇒ “5.1 Exploded view - exhaust manifold”, page 318
♦ ⇒ “4.1 Exploded view - exhaust gas recirculation system”,
page 313
Note
Renew gaskets and nuts.


28 – Glow plug system

1 Glow plug system
⇒ “1.1 Exploded view - glow plug system”, page 321
⇒ “1.2 Removing and installing glow plug”, page 321
⇒ “1.3 Checking glow plug”, page 323
⇒ “1.4 Removing and installing Hall sender G40 ”, page 324
⇒ “1.5 Removing and installing engine speed sender G28 ”, page
325
1.1 Exploded view - glow plug system

⇒ page 324
2 - Bolt
❑ 9 Nm
3 - Glow plug
❑ Glow plug 1 - Q10- ,
glow plug 2 - Q11- , glow
plug 3 - Q12- , glow
plug 4 - Q13-
⇒ page 321
❑ 17 Nm
4 - Electrical connector
❑ For glow plug
5 - Bolt
❑ 4.5 Nm
6 - Engine speed sender -
G28-
⇒ page 325
7 - Sealing flange (gearbox
end)
❑ With oil seal
8 - Sender wheel
❑ For engine speed send‐
er - G28-
⇒ page 69
1.2 Removing and installing glow plug

1. Glow plug system 321

♦ Articulated wrench, 10 mm - 3220-
♦ Pliers - 3314-
Removing
– Clean glow plug openings in cylinder head; make sure no dirt
gets into cylinder.
Note
♦ Cleaning procedure:
♦ Use a vacuum cleaner to remove coarse dirt.
♦ Spray brake cleaner or suitable cleaning agent into glow plug
openings, let it work in briefly, and blow out with compressed
air.
♦ Then clean the glow plug openings using a cloth moistened
with oil.
– Release retaining clips at wiring harness and detach electrical

connectors from glow plugs.
322 Rep. gr.28 - Glow plug system

– Apply groove -arrow A- of pliers - 3314- to collar of support

sleeve -arrow B- and pull glow plug connectors off glow plugs.
Caution
Make sure that no wire connection is damaged when unplug‐

ging the glow plug connectors; otherwise the entire wiring
harness must be renewed. When unplugging the glow plug
connectors, do not compress the pliers - 3314- with too much
force so that the support sleeve is not damaged.
– To slacken glow plugs use special tool articulated wrench,

10 mm - 3220- .
Installing
Tightening torques
♦ ⇒ “1.1 Exploded view - glow plug system”, page 321
– Fit glow plug connectors -1- back onto glow plugs -arrow-.
Note
Check that glow plug connectors are securely seated.
1.3 Checking glow plug

Automatic glow period control unit - J179- is located in relay and
fuse holder in electronics box in plenum chamber.
A - Automatic glow period control unit - J179-
The glow plug system is activated via the automatic glow period
control unit - J179- . The automatic glow period control unit - J179-
is capable of self-diagnosis.
A fault is stored in the engine control unit if a fault occurs in the
glow plug system.
The procedure for checking the glow plug system is described in
the “Guided Fault Finding”.
For faster starting, the vehicle is equipped with electronically con‐
trolled glow plugs and a separate glow period control unit.
Each glow plug is activated and diagnosed separately.

1.4 Removing and installing Hall sender -

G40-
Removing
– Detach toothed belt from idler roller and high-pressure pump
⇒ page 113 .
– Detach electrical connector -2- from bracket and unplug.
Note
Disregard -item 1-.
– Unbolt Hall sender - G40- -arrow-.
– Using a screwdriver, remove projections and take out cover

for repair opening -arrows-.
– Take Hall sender - G40- off cylinder head and guide its con‐
nector through repair opening in toothed belt cover.
Installing
Tightening torques
– Seal repair opening in toothed belt cover with rubber plug; for
rubber plug refer to ⇒ Electronic parts catalogue .
– Fit toothed belt and adjust valve timing ⇒ page 113 .
324 Rep. gr.28 - Glow plug system

1.5 Removing and installing engine speed

sender - G28-
Removing
– Remove pump for exhaust gas recirculation cooler - V400-
⇒ page 189 .
– Unplug electrical connector -1- at engine speed sender - G28-
using assembly tool - T10118- .
– Move wiring clear.
– Remove bolt from engine speed sender - G28- .
Installing
– Install pump for exhaust gas recirculation cooler - V400-
⇒ page 189 .
Tightening torques

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4-cylinder TDI engine (2.0 ltr. 4-valve common rail -

Service Department. Technical Information

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Copyright © 2016 Audi AG, Ingolstadt D3E8033D040

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

2 Coolant pump/thermostat assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

5.2 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

1.4 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324

1.1 Engine identification number/engine da‐

♦ The four-letter engine code is found on the type plate (country

For engine data refer to:

2.1 Safety precautions when working on the

Fuel under pressure - risk of injuries!

2 Rep. gr.00 - Technical data

The high-pressure pump has very close tolerances and must

Observe the following points to prevent personal injuries and

To prevent irreparable damage to the electronic components

Escaping fuel can cause a risk.

2.2 Safety precautions when working on ve‐

Risk of injury due to automatic engine start on vehicles with

2.3 Safety precautions when using testers

Accidents can be caused if the driver is distracted by test

2.4 Safety precautions when working on the

Hot steam/hot coolant can escape - risk of scalding.

4 Rep. gr.00 - Technical data

Overheating can occur if the filler cap is not fitted properly.

2.5 Safety precautions when working on the

Risk of damage to running gear components.

2.6 Safety precautions when working on the

Please note the following warnings when working on all parts

Risk of damage to flexible joint.

3.1 Rules for cleanliness

3.2 General notes

6 Rep. gr.00 - Technical data

♦ The vehicles are fitted with a crash/fuel shut-off system. This

3.3 General repair instructions

The high-pressure pump has very close tolerances and must

♦ Clean tools and workbench etc. before working on the injection

♦ Fuel hoses in engine compartment must only be secured with

3.4 Foreign particles in engine

3.5 Contact corrosion

3.6 Routing and attachment of pipes, hoses

3.7 Installing radiators and condensers

8 Rep. gr.00 - Technical data

10 – Removing and installing engine

1.1 Removing engine

When installing a new base engine, it is essential that the

Special tools and workshop

1. Removing and installing engine 9

♦ Drip tray for workshop hoist - VAS 6208-

♦ Hose clip pliers - VAS 6362-

♦ Lifting tackle - T40013- for vehicles with dual clutch gearbox

♦ Locking tool - T40098-