Anda di halaman 1dari 317

Volkswagen Touareg 2003->

(7L)

Technical data
Engine identification
Engine data

00-1, Engine identification

00-1, Engine specifications

Engine identification

The engine number ( "engine code" and "serial number" )


is located on cylinder block, below the cylinder head of
cylinder bank 2.
The engine number consists of up to nine characters
(alphanumeric). The first part (maximum 3 letters)
represents the "engine code" , the second (six digit) is the
"serial number" . If more than 999,999 engines with the
same engine code are produced, the first of the six
characters is replaced with a letter.
In addition, a sticker with "engine code" and "serial
number" is affixed to acoustic cover of cylinder head at
cylinder bank 1.
The engine code is also included on the vehicle data plate.

Numbering of cylinders begins on right side - A - as seen


in direction of travel (cylinder bank 1) opposite the power

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru


Volkswagen, Skoda, Seat, Audi

transfer side - C - . Cylinders are counted on each side in


sequence.
Engine specifications

Engine code

BKW
12.03

Production

02.06

Tier 1

Emission values in accordance with


Displacement

10.04

BWF

ltr.

4.9

4.9

Output

kW at 1/rpm

230/3750

230/3750

Torque

Nm at rpm

750/2000

750/2000

Dia. mm

81.0

81.0

mm

95.5

95.5

18.5

18.5

51

51

Bore
Stroke
Compression ratio
CN
Ignition sequence

min.

1-6-5-10-2-7-3-8-4-9 1-6-5-10-2-7-3-8-4-9

Catalytic converter

yes

yes

Particle filter

no

yes

Exhaust gas recirculation

yes

yes

Charging

yes

yes

Charge air cooler

yes

yes

Engine, removing and installing

Page 1 / 21

10 - 1

Engine, removing and installing


Engine, removing

10-1, Engine, removing

Removing engine from Scissor Lift Table VAS 6131


10-1, Removing engine from Scissor Lift Table VAS 6131
Notes on installing

10-1, Notes on installation

Engine, removing

Special tools, testers and auxiliary items


required

Scissor lift table VAS 6131

Drip tray V.A.G 1306

Frame support T10191

Engine, removing and installing

Spring-type clip pliers VAS 5024


A

Torque wrench (40 to 200 Nm)


V.A.G 1332

Tensioner Hooks (2) VW 552

Not illustrated:

Standard set for Touareg VAS 6131/6

Support F/Vas6131 For V6/V10/V8 VAS6131/8

Container for removed components V.A.G 1698

Engine bung set VAS 6122

Cable tie

The engine with transmission is removed downward.


- Before removing engine, check DTC memories of all
control modules Vehicle Diagnosis, Testing and
Information System VAS 5051 or VAS 5052 "Guided
functions"
Note:

To allow free rotation of the driveshaft, move the


selector lever to the "N" position.

Leave the key in the ignition lock to prevent the


steering wheel lock from engaging.

It is advisable to remove the front wheels before the


disassembly. The vehicle can be lowered on the
hoist until the cover plates of the brake discs are just
above the floor. This ensures the greatest ability to
perform work at body-level regarding accessibility of
components in the engine compartment.

Page 2 / 21

Engine, removing and installing

When the engine is installed in the engine


compartment some components cannot be removed
or can only be removed with great difficulty.
Determine which components are faulty before
removing engine.

To prevent damage to removed components, use


the container for removed components V.A.G 1698
for storage.

All cable ties which are opened or cut open when


removing engine, must be replaced in the same
position when installing engine.

Caution!
Always observe the exact procedure for disconnecting
the battery!
- Switch off ignition and all electrical consumers.
- First, disconnect batter under drivers seat.
- Then disconnect the auxiliary battery, in luggage
compartment in spare wheel well.

Repair Manual, Electrical Equipment, Repair Group 27,


Battery, disconnecting and connecting
- Remove left and right windshield wiper arms

Repair Manual, Electrical Equipment, Repair Group 92,


Windshield wiper system
- Remove engine compartment cover seal off bulkhead.

Page 3 / 21

Engine, removing and installing

- Remove covers - A - , - B - (if equipped) and - C - in


engine compartment and - D - for plenum chamber.

- Disconnect smaller connector - A - from Engine Control


Modules (ECM) and remove Ground (GND) connection arrow - for wiring harness.

- Open fuse box cover on left in plenum chamber and


disconnect connectors - A - , - B - and - C - .
- Remove wiring harness from plenum chamber and place
it on engine.
- Remove intake line on both sides between air filter and
intake manifold.
Note:

With connector couplings, follow the installation


instructions closely 21-1, Hose connections with
connector couplings, installing .

Vehicles with engine code BKW

Page 4 / 21

Engine, removing and installing

- Disconnect vacuum lines - arrows - for Exhaust Gas


Recirculation (EGR) valve and brake booster as well as
harness connector - A - for Heated Oxygen Sensor
(HO2S) G39 of cylinder bank 1.

- Disconnect vacuum line - arrow - for Exhaust Gas


Recirculation (EGR) valve as well as harness connector A - for Heated Oxygen Sensor (HO2S) 2 G108 of cylinder
bank 2.
Vehicles with engine code BWF

- Disconnect vacuum lines - 1 - for the bypass flap


vacuum actuators (mark lines before separating) and brake
booster - 2 - .

Page 5 / 21

Engine, removing and installing

- Disconnect the following connections and free up wiring


harness to components:
1 - 6-pin harness connector, black: For Heated Oxygen
Sensor (HO2S) G39
2 - 6-pin harness connector, brown: For Heated Oxygen
Sensor (HO2S) 2 G108
3 - 2-pin harness connector, black: For Turbocharger
intake temperature sensor G507
4 - 2-pin harness connector, brown: For Turbocharger
intake temperature sensor 2 G499
Continuation for all vehicles

- Disconnect harness connectors - arrows - for glow


plugs in cylinder bank 1 and cylinder bank 2.

Page 6 / 21

Engine, removing and installing

- Secure suspension struts using spring compressor VW


552. as shown.
- Remove upper suspension struts

Repair Manual, Suspension, Wheels, Steering, Repair


Group 40, II - Assembly overview: Front suspension
.
- Remove noise insulation

Repair Manual, Body Exterior, Repair Group 50, Noise


insulation
.
- Extract refrigerant from air conditioning system

Repair Manual, Heating Air Conditioning, Repair Group


87,
- Drain coolant
filling .

19-1, Cooling system, draining and

Page 7 / 21

Engine, removing and installing

- Disconnect line - arrow - from transmission oil cooler


below on right. Catch fluid which runs out.

- Disconnect line - A - from servo oil cooler at lower left.


Catch fluid which runs out.
- Remove charge air connecting pipe - B - for cylinder
bank 1 and cylinder bank 2.

- Loosen clamp - arrow - from connecting pipe to air filter


for cylinder bank 1 and cylinder bank 2 and remove it.

Page 8 / 21

Engine, removing and installing

- Disconnect coolant hoses - arrows - and place them so


that they cannot be pinched when removing and installing
engine.

- Disconnect starter wire - A - and generator wire - B and place them on engine.

- Unclip transmission ventilation line - arrows - .

Page 9 / 21

Engine, removing and installing

- Disconnect connector from Intake Air Temperature (IAT)


sensor G42 - A - and from Mass Air Flow (MAF) sensor
G70 - B - for cylinder bank 1.

- Disconnect connector from Mass Air Flow (MAF) sensor


2 G246 - A - and from Intake Air Temperature (IAT)
sensor 2 G299 - B - for cylinder bank 2.

- Remove wire connection - arrow - of air suspension


compressor on air filter housing 23-1, Line connection to
compressor for air suspension
- Remove both top sections of air filter upward.

Page 10 / 21

Engine, removing and installing

- Open clamp and pull off servo-line - A - . Catch fluid


which runs out. Remove A/C lines - B - from A/C
compressor.
Vehicles with engine code BKW

- Disconnect fuel lines - arrows - from fuel filter.


- Separate connection of catalytic converter/center muffler
and remove exhaust system 26-1, Muffler with
mountings (vehicles with engine code BKW), assembly
overview .
Vehicles with engine code BWF

- Disconnect fuel lines - arrows - from fuel filter.

Page 11 / 21

Engine, removing and installing

- Separate connection of particle filter/exhaust pipe and


remove exhaust system 26-1, Muffler with mountings
(vehicles with engine code BWF), assembly overview .
Continuation for all vehicles
- Remove heat shield on steering box and loosen universal
joint

Repair Manual, Suspension, Wheels, Steering, Repair


Group 48, Steering column
.
- Disconnect connectors on transmission as well as
transfer case and loosen selector lever cable

Repair Manual, 6 Spd. Automatic Transmission 09D All


Wheel Drive, Repair Group 37, Shift mechanism, servicing
- Remove rear driveshaft

Repair Manual, Rear Final Drive, Repair Group 39,


Driveshafts, removing and installing

- Remove transmission transverse support - A - .

Page 12 / 21

Engine, removing and installing

- Disconnect brake lines at points indicated - arrow - .


Catch escaping brake fluid.
- Disconnect all harness connectors between chassis and
front axle in wheel housings.
Preparing Scissor lift table VAS 6131 for further
steps:
Note:

The basic set for Touareg VAS 6131/6 consists of


supports supports VAS 6131/6-1 to VAS 6131/6-7 .
To describe the following work sequence more
clearly, they are called support 1 (for VAS 6131/6-1)
to support 7 (for VAS 6131/6-7).

- Install support - 1 - on left and support - 2 - on right


(arrows point in direction of travel) on the Scissor lift table
VAS 6131 and secure bolts at the following positions:

Left support - 1 - : A5, B4 and B5

Page 13 / 21

Engine, removing and installing

Right support - 2 - : G4, H4 and H5

- Tighten support 3 and support 4 on Scissor lift table VAS


6131 in the following positions:

Left support - 3 - : A6 and C6

Right support - 4 - : F6 and H6

- Screw down turntables of supports - 3 - and - 4 - .


- Place supports - 5 - for subframe and - 6 - for
transmission console in corresponding positions on lift
table.
Engine and transmission are separated after removal:
- Remove insulation mat under lower section of oil pan.
- Loosen clamp for starter cable.

- Loosen and remove transmission bolts - A - .


- Remove six bolts for torque converter through hole in
upper section of oil pan - arrow - . To do so, rotate engine
at vibration damper using Counterhold Tool Touareg V10
T10172 and associated pin T10172/2 .

Page 14 / 21

Engine, removing and installing

- Install support - 7 - for transmission support in


corresponding positions on Scissor lift table VAS 6131 and
tighten down turntables completely.

- Before moving up Scissor lift table VAS 6131 , always


engage Support F/Vas6131 For V6/V10/V8 VAS6131/8 ,
which was completely tightened down earlier, into hole of
transmission flange - arrow - as shown.
Continued:

Page 15 / 21

Engine, removing and installing

- Position horizontally adjusted Scissor lift table VAS


6131 under engine/transmission assembly. The supports 1 - and - 2 - must be guided into corresponding mount arrows - at right and left.

- At the same time, guide support - 6 - for transmission


cross bar into corresponding holes - arrows - at right and
left.
When all four supports are in the appropriate receptacle
holes without pressure:
- If installed, check support height of support for V10, V8
and V6 assembly, Touareg VAS 6131/8 at knurled nut and
secure support in position D7 on Scissor lift table VAS
6131 .

Page 16 / 21

Engine, removing and installing

- Using light pressure beneath control arm, screw both


turning knobs of supports 3 and 4 until securing device can
be removed using Tensioner Hooks (2) VW 552 .

- Guide support - 5 - into corresponding mount in


subframe, if necessary check support height on knurled
nut.
- Locate subframe to body

Repair Manual, Suspension, Wheels, Steering, Repair


Group 40, I - Assembly overview: Subframe, stabilizer bar,
lower control arms

- Loosen subframe bolts - 2 - and - 3 - , as well as


transmission transverse support - 4 - .
If subframe was not located:
- Loosen subframe bolts - 1 - .

Page 17 / 21

Engine, removing and installing

Note:

If the subframe was not located, it is necessary to


perform a vehicle alignment

Repair Manual, Suspension, Wheels, Steering, Repair


Group 44, Vehicle alignment
.
- Slowly lower assembly, constantly observing clearances.
Removing engine from Scissor Lift Table VAS 6131

Special tools, testers and auxiliary items required

Shop crane VAS 6100

Transportation plate T10126

Transportation plate T10126/1

Frame support T10191

Work procedure
- Disconnect transmission from engine

Repair Manual, 6 Spd. Automatic Transmission 09D All


Wheel Drive, Repair Group 37, Transmission, removing
and installing

- Loosen threaded connection - A - of engine mount on

Page 18 / 21

Engine, removing and installing

both sides of engine.


- Loosen support for V10, V8 and V6 assembly, Touareg
VAS 6131/8 from scissor lift platform and remove it.

- Install transportation plates T10126 and transportation


plates T10126/1 on cylinder heads as shown - arrows - .
- Hook lifting tackle 3033 into workshop crane VAS 6100
and into transportation plate .
- Lift engine from Scissor Lift Table VAS 6131 .
- Set engine in frame support T10191 .
Notes on installation

Caution!
When doing any repair work, especially in the engine
compartment, pay attention to the following due to
clearance issues:

Route lines of all types (e.g. for fuel, hydraulic,


additive, coolant and refrigerant, brake fluid,
vacuum) and electrical wiring so that the original
path is followed.

To prevent damages to the lines, make sure


there is sufficient clearance to all moving or hot
components.

Installation is performed in reverse order. When doing


this note the following:

Page 19 / 21

Engine, removing and installing

Page 20 / 21

- Make sure centering sleeves for engine to transmission


are installed in cylinder block. Install if necessary.
- Reconnect all lines, hoses and connections that were
disconnected for removal sequence.
- Electrical connections and routing Electrical Wiring
Diagrams, Troubleshooting and Component Locations
binder .
- Connect air conditioning lines

Repair Manual, Heating Air Conditioning, Repair Group


87,
.
- Top off oil level for power steering system
Repair Manual, Maintenance
.
- Fill with coolant
filling .

19-1, Cooling system, draining and

- Check headlight adjustment, correct if necessary


Repair Manual, Maintenance
:
- Perform test drive and check all DTC memories Vehicle
Diagnosis, Testing and Information System VAS 5051 or
VAS 5052 "Guided Fault Finding" .
Torque specifications
Bolted connections

Torque specifications

Engine to transmission

M10

45 Nm

(except starter)

M12

80 Nm

Engine support to cylinder block

50 Nm

Engine support to engine mount

75 Nm

Engine mount to engine carrier


Engine carrier to body
Transmission carrier to body
Subframe to body

60 Nm
100 Nm plus an additional 1 / 2 turn (180
50 Nm plus an additional 1 / 4 turn (90

Engine, removing and installing

Page 21 / 21

Repair Manual, Suspension, Wheels, Steering, Repair Group 40, I - Assembly overview:
Subframe, stabilizer bar, lower control arms

Engine, disassembling and assembling

Page 1 / 17

13 - 1

Engine, disassembling and assembling


Caution!

Upper section of bearing bracket is bolted to the


cylinder with two multi-point socket bolts M8,
which are found in the valley between the
cylinder heads. These bolts must not be
loosened under any circumstances, because it
causes a deformation of the cylinder block which
is no longer reparable.

Crankshaft, piston, and connecting rods must


not be replaced! Only removal and installation of
these components is permitted.

Note:

If large quantities of metal particles or other deposits


(caused, for example, by partial seizure of the
crankshaft or connecting rod damage) are found in
the engine oil, the oil passages must be cleaned
thoroughly and the oil cooler replaced in order to
prevent further damage from re-occurring.

The engine must not be set down on the oil pan


otherwise the liquid gasket between the upper and
lower oil pan will be damaged. To set down the
engine, use frame T10191 .

Secure engine using engine and transmission holder


VAS 6095 when working on the engine.

Components in engine valley, assembly overview


13-1, Components in engine valley, assembly overview
Engine timing module, assembly overview
Engine timing module, assembly overview

13-1,

Engine timing module (wheel cassette), removing and


installing 13-1, Engine timing module (wheel cassette),
removing and installing
Engine mounts and engine supports (right and left),
removing and installing 13-1, Engine mounts and
engine supports (right and left), removing and installing
Drive plate, removing and installing

13-1, Drive plate,

Engine, disassembling and assembling

Page 2 / 17

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru


Volkswagen, Skoda, Seat, Audi

removing and installing


Components in engine valley, assembly overview

Input hub

8 Nm

Clutch

Phased in introduction of a
torsion elastic clutch

Repair Manual, Electrical Equipment,


Repair Group 27, Generator

50 Nm plus an additional 1 / 4
turn (90

Engine, disassembling and assembling

Replace

20 Nm

Generator

Removing and installing

Repair Manual, Electrical Equipment,


Repair Group 27, Generator

Oil filter housing, upper section

Coolant connection

With Engine Coolant


Temperature (ECT) Sensor
G62

Removing and installing


19-1, Coolant connection,
removing and installing

Gasket

Seal

Replace

Replace

20 Nm plus an additional 1 / 4
turn (90

Replace

Oil filter housing, lower section

Oil filter housing, assembly


overview 17-3, Oil filter
housing, assembly
overview

With coolant thermostat


housing: Assembly overview
19-1, Coolant thermostat
housing, assembly

Page 3 / 17

Engine, disassembling and assembling

overview

Cover

Noise insulation

Installation not necessary

Bypass flap with cooler for


Exhaust Gas Recirculation
(EGR)

On vehicles with engine


code BWF

Assembly overview 26-2,


Bypass flap with cooler for
Exhaust Gas Recirculation
(EGR) (vehicles with engine
code BWF), assembly
overview

Fuel filter

For vehicles with engine


code BKW

Assembly overview 20-1,


Fuel filter (vehicles with
engine code BKW),
assembly overview

Alignment bushing

Secure with commercially


available grease, if
necessary, before
installation

Engine timing module, assembly overview

Page 4 / 17

Engine, disassembling and assembling

Sleeve

For linkage mounting


components

Replace with compensation


linkage in case of noticeable
formation of deposits

Compensation linkage

Camshaft gear

For cylinder bank 1: with


sensor wheel for camshaft
position

Removing and installing


15-1, Camshaft
compensation wheel and
input gear, removing and
installing

Page 5 / 17

Engine, disassembling and assembling

Compensation wheel

Removing and installing


15-1, Camshaft
compensation wheel and
input gear, removing and
installing

150 Nm plus an additional 1 / 4


turn (90

Full-floating axle

Compensating piston

20 Nm

Observe tightening
sequence 13-5,
Tightening sequence of bolts
for control housing

Seal

Do not oil or grease sealing


lip of sealing ring

Before installing, remove oil


residue from crankshaft
journal with a clean cloth

Replace 13-4, Crankshaft


seal (engine timing side),
replacing

Control housing

Replace

Assembly overview 13-5,


Control housing, assembly
overview

Cylinder bolt

Tighten to 60 Nm, then to


150 Nm plus an additional 1 /
4

turn (90

Page 6 / 17

Engine, disassembling and assembling

Oil pan, upper section

Assembly overview 17-2,


Oil pan (upper section),
assembly overview

Hex bolt

Tighten to 60 Nm, then to


150 Nm plus an additional 1 /
4

turn (90

Engine timing module

Removing and installing


13-1, Engine timing module
(wheel cassette), removing
and installing

Engine timing module (wheel cassette), removing and


installing

Page 7 / 17

Engine, disassembling and assembling

Special tools, testers and auxiliary items


required

Engine and transmission holder


VAS 6095

Guide pins T10200

Assembly tool T10208/3

Not illustrated:

Torque wrench (40 to 200 Nm) V.A.G 1332

Requirements:

Engine and transmission removed

Page 8 / 17

Engine, disassembling and assembling

Page 9 / 17

Engine secured to engine and transmission holder


VAS 6095

Removing

- Drain engine oil


Repair Manual, Maintenance
.
- Set crankshaft to TDC Cylinder 1
checking , check valve timing.
- Remove cylinder heads

15-1, Valve timing,

15-1, Cylinder head .

- Disconnect transmission from engine

Repair Manual, 6 Spd. Automatic Transmission 09D All


Wheel Drive, Repair Group 37, Transmission, removing
and installing
.
- Remove all required hoses, lines and pipes from the
engine management side.
- Remove lower and upper sections of oil pan
pan, assembly overview .

17-2, Oil

- Loosen bolts for engine timing module.


Caution!
Make sure that the input shafts for oil- and coolant
pumps do not fall off cylinder block.
- Carefully pull engine timing module off inclined splines.
Installing

Engine, disassembling and assembling

- Screw guide pins T10200 into threaded holes of upper


section of bearing bracket as shown.
- Place engine timing module on guide pins.
Note:

Observe the following adjustment marks and


requirements and note the inclined splines while
doing so (wheels turn slightly when sliding on the
module):

Page 10 / 17

Engine, disassembling and assembling

- Holes on splines of crankshaft gear and input gear for oil


pump must align as shown.

- Input shaft fits only in one position. Rotate shaft so that


the wide cut-out in the hole aligns to the broad tooth on the
pin.

- The hole on the drive wheel of cylinder bank 1 must align


with cast tab on inside of engine timing module as shown.
- Carefully slide engine timing module on guide pins in its
seat, note the mentioned adjustment markings while doing
so.

Page 11 / 17

Engine, disassembling and assembling

- Center engine timing module by placing pressure piece


of assembly tool T10208/3 on generator shaft end - A - .
Pressure piece must be able to be set into countersink
without force.
- Replace individual guide pins with bolts and tighten bolts
to 60 Nm.
- Tighten bolts to 150 Nm plus an additional 1 / 4 turn. (90
) turn.
Engine mounts and engine supports (right and left),
removing and installing

Special tools, testers and auxiliary items required

Torque wrench (40 to 200 Nm) V.A.G 1332

Page 12 / 17

Engine, disassembling and assembling

Engine/transmission jack V.A.G 1383 A

Assembly support T10296

Removing
- Remove front sound insulation

Repair Manual, Body Exterior, Repair Group 50, Sound


insulation
- Remove front wheelhousing liners

Repair Manual, Body Exterior, Repair Group 66,


Wheelhousing liners
- Remove lower part of air filter for cylinder bank 1 and 2
23-1, Air filter, assembly overview , Air filter - Assembly
overview.

- Remove nut - 2 - on engine mount at left and right


engine supports.

Page 13 / 17

Engine, disassembling and assembling

- Align mounting pins of assembly support T10296


centrally at the mountings of the cylinder block - arrows to assembly support . Tighten mounting pins.
- Insert assembly support T10296 into
engine/transmission jack V.A.G 1383 A and support
assembly (engine and transmission) at mountings of
cylinder block - arrows - with slight pretension.

- Remove right and left bolts - 1 - for engine mount.

- Carefully lift assembly with assembly support T10296


and remove engine mount.
Caution!

Page 14 / 17

Engine, disassembling and assembling

Page 15 / 17

Be aware of the available clearance between the


cylinder heads and the bulkhead.
- If necessary, unfasten engine supports at cylinder block
and remove engine mounts together with engine supports.
Installing
- Make sure the alignment pin of engine mount is correctly
positioned in engine carrier.
- Start all bolts and nuts by hand and then tighten to torque
specification.

Torque specifications
Bolted connections

Torque specifications

Engine support to cylinder block

50 Nm

Engine mount to engine carrier - 1 -

60 Nm

Engine support to engine mount - 2 -

75 Nm

The rest of assembly is basically a reverse of the


disassembling sequence.
Drive plate, removing and installing

Special tools, testers and auxiliary items required

Engine, disassembling and assembling

Flywheel lock adapter VW 558

Torque wrench (40 to 200 Nm) V.A.G 1332

Not illustrated:

Caliper gauge

Hex bolt M850 and three M12-hex nuts

Drive plate, loosening and tightening

- Secure flywheel lock adapter VW 558 with hex bolt

Page 16 / 17

Engine, disassembling and assembling

Page 17 / 17

M8x50 to drive plate. Insert three M12 hex nuts between


flywheel lock adapter and drive plate. Installed location of
flywheel retainer: - A - to loosen; - B - to tighten
Installing drive plate.
- Install drive plate using a washer

Item - 8 - .

- Install new bolts and tighten to 30 Nm.

- Using caliper gauge, check distance between drive plate


and cylinder block. Specified dimension - a - : 19.0 to 20.6
mm.
If specification is not obtained:
- Remove drive plate again and insert shim between
crankshaft and drive plate. Tighten bolts again to 30 Nm.
- Tighten bolts to 50 Nm and turn an additional 1 / 4 turn
(90

), (additional rotation may occur in several stages).

Differential shaft

Page 1 / 2

13 - 2

Differential shaft
Note:

Secure engine in engine and transmission holder


VAS 6095 when working on engine.

Balance shaft, assembly overview


shaft, assembly overview

13-2, Balance

Balance shaft, assembly overview

Note:

It is only possible to remove the balancing shaft


when the engine timing module has been removed
beforehand 13-1, Engine timing module (wheel
cassette), removing and installing .

Differential shaft

Thrust washer

Main bearing bolt

Page 2 / 2

Note tightening sequence


and torque Topic 13-3 ,
Main bearing bolts,
tightening.

Bearing cap bolt

For differential shaft bearing

Note tightening sequence


and torque Topic 13-3 ,
Main bearing bolts,
tightening.

Bearing cap

With eye for securing oil


pump

Bearing shell

Balancing shaft

Positioning

Bearing shell

Thrust washer

Bearing cap

Topic 13-1

Bearing cap with grooves for


thrust washers

Crankshaft

Page 1 / 6

13 - 3

Crankshaft
Caution!

Upper section of bearing bracket is bolted to


cylinder with two multi-point socket bolts M8,
which are found in the valley between the
cylinder heads. These bolts must not be
loosened under any circumstances, because it
causes a deformation of the cylinder block which
is no longer reparable.

Crankshaft, piston, and connecting rods must


not be replaced! Only removal and installation of
these components is permitted.

Note:

Secure engine on engine and transmission holder


VAS 6095 when working on engine.

Crankshaft, assembly overview


assembly overview

13-3, Crankshaft,

Bearing bracket for crankshaft, removing and


installing 13-3, Bearing bracket for crankshaft,
removing and installing
Crankshaft dimensions

13-3, Crankshaft dimensions

Crankshaft, assembly overview

Crankshaft

Page 2 / 6

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru


Volkswagen, Skoda, Seat, Audi

Bearing bracket

Installed in tensioned state

Removing and installing


13-3, Bearing bracket for
crankshaft, removing and
installing

Thrust washer

For lower section of bearing


bracket

Main bearing bolt

Note tightening sequence


and torque Topic 13-3 ,
Main bearing bolts,
tightening.

Crankshaft

Page 3 / 6

Bearing shell

Crankshaft

Axial play new: 0.07 to 00.17


mm, Wear limit: 0.37 mm

Check radial clearance with


Plastigage 0.03 to 00.08
mm, Wear limit: 0.17 mm

Do not turn crankshaft when


measuring radial play

Crankshaft dimensions
13-3, Crankshaft
dimensions

8 Nm

Oil spray jet

For piston cooling

Bearing shell

Cylinder block

With upper section of


bearing bracket

Cylinder bore, checking


13-6, Checking cylinder
bores

Piston and cylinder


dimensions 13-6, Piston
and cylinder dimensions

Engine Speed (RPM) Sensor


G28

10 Nm

Thrust washer

For upper section of bearing


bracket

Bearing bracket for crankshaft, removing and installing

Crankshaft

Page 4 / 6

Caution!
Upper section of bearing bracket is bolted to cylinder
with two multi-point socket bolts M8, which are found
in valley between the cylinder heads. These bolts must
not be loosened under any circumstances, because it
causes a deformation of the cylinder block which is no
longer reparable.
Note:

Secure engine in engine and transmission holder


VAS 6095 when working on engine.

Special tools, testers and auxiliary items required

Tensioning element T10201

Torque wrench (5 to 50 Nm) V.A.G 1331

Not illustrated:

Removing

Torque wrench (40 to 200 Nm) V.A.G 1332

Crankshaft

Page 5 / 6

- Remove bolts for lower section of bearing bracket.

- Install engine support bridge T10201 on lower section of


bearing bracket as shown.
- Tighten bolts of tensioning device T10201 to 20 Nm.
- Remove lower section of bearing bracket.
Installing
- Place tensioning device T10201 on lower section of
bearing bracket and tighten bolts to 20 Nm.
- Check whether all bearing shells are lying properly in
bearing supports Item - 4 - . Pay attention to thrust
washers Item - 2 - .
- Carefully place lower section of bearing bracket into
cylinder block.
Tightening main bearing bolts

Topic 13-3 .

Tightening main bearing bolts

- Tighten main bearing bolts in three stages in the


tightening sequence shown as follows ( - arrow - points in
driving direction).

Tighten using torque wrench:

Crankshaft

Page 6 / 6

Step I = 35 Nm
Step II = 65 Nm

Tighten further using a solid wrench:


Stage III = 1 / 2 additional turn (180

Crankshaft dimensions

(Dimensions in mm)
Reconditioning
dimension, dimensions in mm

Crankshaft bearing
pins-diameter
-0.032

Basic dimension

Connecting rod bearing


pins-diameter
-0.022
58.00

65.00
-0.047

-0.042

-0.032

-0.022

1st oversize

57.75

64.75
-0.047

-0.042

-0.032

-0.022

2nd oversize

57.50

64.50
-0.047

-0.042

Sealing flanges, seals and vibration damper

Page 1 / 11

13 - 4

Sealing flanges, seals and vibration damper


Note:

Secure engine on engine and transmission holder


VAS 6095 when working on engine.

Front sealing flange and vibration damper, assembly


overview 13-4, Front sealing flange and vibration
damper, assembly overview
Sealing ring for crankshaft, vibration damper side,
replacing 13-4, Crankshaft seal (vibration damper side),
replacing
Crankshaft seal (engine timing side), replacing
Crankshaft seal (engine timing side), replacing
Generator shaft seal, replacing
seal, replacing

13-4,

13-4, Generator shaft

Front sealing flange and vibration damper, assembly


overview

Sealing flanges, seals and vibration damper

Sealing flange, front

Must be located on dowel


sleeves

8 Nm

Observe tightening
sequence 13-4,
Tightening sequence of bolts
for front sealing flange and
coolant pump cover

Coolant pump cover

Vibration damper

50 Nm plus an additional 1 / 4
turn (90

Page 2 / 11

Sealing flanges, seals and vibration damper

Washer

Seal

Do not additionally oil or


grease sealing lip of sealing
ring

Before installing, remove oil


remains from crankshaft
journal with a clean cloth

Replace 13-4, Crankshaft


seal (vibration damper side),
replacing

13 Nm

Tightening sequence of bolts for front sealing flange and


coolant pump cover

- Tighten bolts in the shown tightening sequence to 8 Nm.


Crankshaft seal (vibration damper side), replacing

Special tools, testers and auxiliary items required

Page 3 / 11

Sealing flanges, seals and vibration damper

Counter-holder tool T10172

Extractor hook T20143/2

Not illustrated:

Assembly tool T10196

Work procedure
- Bring lock carrier into service position

Repair Manual, Body Exterior, Repair Group 50, Lock


carrier
.
- Remove vibration damper

Item - 4 - .

Note:

Be careful not to damage sealing surface when


removing sealing ring.

Page 4 / 11

Sealing flanges, seals and vibration damper

- Carefully remove old sealing ring from its seat using hook
T20143/2 .
- Before installing, remove oil remains from end of
crankshaft with a clean cloth.
Note:

Only remove protective ring from seal immediately


prior to assembly.

- Join assembly sleeve T10196/1 and assembly sleeve


T10196/2 . Slide sealing ring - A - to stop on assembly
sleeve T10196/2 .
- Separate both assembly sleeves.

Page 5 / 11

Sealing flanges, seals and vibration damper

- Place assembly sleeve T10196/2 together with sealing


ring on crankshaft flange and tighten knurled bolts - A hand-tight.
- Press in seal up to stop using pressure sleeve
T1096/3 .
The rest of the assembly is a reverse of the disassembling
sequence.
Crankshaft seal (engine timing side), replacing

Special tools, testers and auxiliary items required

Pulling hook T20143/2

Not illustrated:

Assembly tool T10207

Requirement:

Page 6 / 11

Sealing flanges, seals and vibration damper

Engine removed

Transmission separated from engine

Work procedure
Note:

Make sure the sealing surface is not damaged when


removing the seal.

- Carefully remove old sealing ring from its seat using hook
T20143/2 .
- Before installing, remove oil remains from end of
crankshaft with a clean cloth.

- Join assembly sleeve T10207/1 and assembly sleeve


T10207/2 . Slide sealing ring - A - to stop on assembly
sleeve T10207/2 .

Page 7 / 11

Sealing flanges, seals and vibration damper

- Separate both assembly sleeves.

- Place assembly sleeve T10207/2 together with sealing


ring on crankshaft flange and tighten knurled bolts - A hand-tight.
- Press in seal up to stop using pressure sleeve
T1207/3 .
The rest of the installation follows the reverse of the
removal procedures.
Generator shaft seal, replacing

Special tools, testers and auxiliary items required

Pulling hook T20143/1

Not illustrated:

Assembly tool T10208

Page 8 / 11

Sealing flanges, seals and vibration damper

Work procedure
Vehicles with engine code BKW
- Remove fuel filter 20-1, Fuel filter (vehicles with engine
code BKW), removing and installing .
Vehicles with engine codes BWF
- Remove bypass flap with cooler for Exhaust Gas
Recirculation (EGR) 26-2, Bypass flap with cooler for
Exhaust Gas Recirculation (EGR) (vehicles with engine
code BWF), assembly overview .
Continuation for all vehicles
- Remove generator

Repair Manual, Electrical Equipment, Repair Group 27,


Generator
.
Note:

Make sure the sealing surface is not damaged when


removing the seal.

- Carefully remove old sealing ring from its seat using hook
T20143/1 .
- Remove oil residue on input shaft for generator using a
clean cloth.

Page 9 / 11

Sealing flanges, seals and vibration damper

- Press inner part of sealing ring toward outside as shown.

- Screw guide sleeve T10208/1 hand-tight onto input shaft


for generator and carefully slide sealing ring - A - on up to
stop.

Page 10 / 11

Sealing flanges, seals and vibration damper

- Position pressure piece T10208/2 and press in inner part


of sealing ring up to stop.
- Position pressure piece T10208/3 and press in outer part
of sealing ring up to stop.
The rest of the assembly is basically a reverse of the
disassembling sequence.

Page 11 / 11

Control housing

Page 1 / 3

13 - 5

Control housing
Note:

Secure engine on engine and transmission holder


VAS 6095 when working on engine.

Control housing, assembly overview


housing, assembly overview
Control housing, assembly overview

Engine timing module

Removing and installing


13-1, Engine timing module
(wheel cassette), removing
and installing

13-5, Control

Control housing

Control housing

Insert with silicone sealant D


176 501 A1
13-5, Sealant
bead on control housing

20 Nm

Observe tightening
sequence 13-5,
Tightening sequence of bolts
for control housing

20 Nm

Seal

Do not additionally oil or


grease sealing lip of sealing
ring

Before installing, remove oil


remains from crankshaft
journal with a clean cloth

Replace 13-4, Crankshaft


seal (engine timing side),
replacing

Drive plate

Page 2 / 3

Removing and installing


13-1, Drive plate, removing
and installing

50 Nm plus an additional 1 / 4
turn (90

Replace

Washer

13 Nm

Control housing

Sealant bead on control housing

- Apply sealant bead onto clean sealing surface of the


control housing as shown.

Tightening sequence of bolts for control housing

- Tighten bolts in the illustrated tightening sequence to 20


Nm.

Page 3 / 3

Piston and connecting rod

Page 1 / 7

13 - 6

Piston and connecting rod


Caution!
Crankshaft, piston, and connecting rods must not be
replaced! Only removal and installation of these
components is permitted.
Note:

Secure engine on engine and transmission holder


VAS 6095 when working on engine.

Piston and connecting rod, assembly overview


Piston and connecting rod, assembly overview
Checking piston position at TDC
at TDC, checking
Piston and cylinder dimensions
cylinder dimensions

13-6,

13-6, Piston position


13-6, Piston and

Piston rings, cylinder bores and piston positioning


13-6, Piston rings, cylinder bores and piston positioning
Piston and connecting rod, assembly overview

Piston and connecting rod

Connecting rod bolt, 30 Nm plus


an additional 1 / 4 turn (90 )

Replace

Lubricate threads and


contact surface

Use old bolt to measure


radial play

Connecting rod bearing cap

Note installation position

Bearing shell

Note installation position

Note version: Upper bearing


shell (to piston) made of

Page 2 / 7

Piston and connecting rod

wear-resistant material,
identification: Black line on
contact surface in area of
separating point

Do not interchange used


bearing shells

Insert bearing shells in


center

Check for secure seating

Axial play wear limit: 0.37


mm

Measure radial clearance


with Plastigage: Wear limit:
0.08 mm. Do not turn
crankshaft when checking
radial clearance

Connecting rod

Mark matching cylinder arrow A -

Location: Markings - arrows


B - point to vibration damper
side

Circlip

Piston

With combustion chamber

Mark installed position and


cylinder allocation

Installed position and


allocation, piston/cylinder
Topic 13-6

Directional arrow on piston


head points to intake side

Install with piston ring


compressor

Checking piston position at


TDC 13-6, Piston position
at TDC, checking

Piston and cylinder

Page 3 / 7

Piston and connecting rod

dimensions 13-6, Piston


and cylinder dimensions

Cylinder bore, checking


13-6, Checking cylinder
bores

Piston pin

If difficult to move, heat


piston to 60 C

Removing and installing


using a drift VW 222 A

Piston rings

Offset gaps by 120

Use piston ring pliers for


removal and installation

"TOP" faces toward piston


crown

Checking ring gap


13-6,
Checking piston ring gap

Check piston ring groove


clearance 13-6, Checking
ring to groove clearance

Piston position at TDC, checking

It is not possible to measure piston projection position


using workshop equipment. Due to the connecting rod
principle for cylinder head bolts in conjunction with the
aluminum cylinder block results in a compression of the
cylinder block which cannot be reproduced when cylinder
head is removed. For this reason, a new cylinder head
gasket with the same index number ( 15-1, Tightening
sequence of bolts for cylinder head cover ) must be
installed when replacing the cylinder head gasket.
Piston and cylinder dimensions

Note:

No repair sizes are provided!

Page 4 / 7

Piston and connecting rod

Page 5 / 7

Honing dimension
Basic dimension

mm

Piston diameter

Cylinder bore diameter

80.97

81.01

Piston rings, cylinder bores and piston positioning

Checking piston ring gap

Special tools, testers and auxiliary items required

Feeler gauge

Test sequence
- Push piston ring squarely from above down to approx. 15
mm from bottom end of cylinder.
Piston ring
dimensions in mm

New

Wear limit

1. Compression ring

0.20 to 0.40

1.0

2. Compression ring

0.30 to 0.50

1.0

Oil scraping ring

0.25 to 0.50

1.0

Checking ring to groove clearance

Piston and connecting rod

Page 6 / 7

Special tools, testers and auxiliary items required

Feeler gauge

Test sequence
- Clean ring groove before checking.
Piston ring
dimensions in mm

New

Wear limit

1. Compression ring

0.08 to 0.10

0.25

2. Compression ring

0.03 to 0.05

0.25

Oil scraping ring

0.02 to 0.05

0.15

Checking cylinder bores

Special tools, testers and auxiliary items required

Internal dial gauge 50 - 100 mm

Test sequence
- Measure bores at 3 locations in both directions - A across engine and - B - in line with crankshaft.
Deviations from nominal dimension: max. 0.05 mm.
Piston: Installed position and allocation,
piston/cylinder

Piston and connecting rod

Pistons are identified on piston head:

Pistons 1 through 5: for cylinder bank 1

Pistons 6 through 10: for cylinder bank 2

Positioning:

Directional arrow on piston head points to intake


side

Page 7 / 7

Cylinder head

Page 1 / 28

15 - 1

Cylinder head
Caution!
Because of the threaded connection of cylinder head
through the aluminum cylinder block into crankshaft
bearing bracket (connecting rod), both cylinder heads
must always be removed. If cylinder head bolts are
loosened or tightened on one side, cylinder block is
warped.
Note:

Secure engine on engine and transmission holder


VAS 6095 when working on engine.

When installing a replacement cylinder head with


camshaft installed, the contact surfaces between the
lifters and cam lobes must be lubricated before
installing the cylinder head cover.

The plastic protectors installed to protect the open


valves must only be removed immediately before
fitting the cylinder head.

When cylinder heads are replaced, all coolant must


also be replaced.

Cylinder head, assembly overview


head, assembly overview

15-1, Cylinder

Removing input gear for camshaft 15-1, Camshaft


compensation wheel and input gear, removing and
installing
Valve timing, checking

15-1, Valve timing, checking

Valve timing, adjusting

15-1, Valve timing, adjusting

Cylinder heads, removing and installing


Cylinder heads, removing and installing
Checking compression pressure
pressures, checking
Cylinder head, assembly overview

Note:

15-1,

15-1, Compression

Cylinder head

Page 2 / 28

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru


Volkswagen, Skoda, Seat, Audi

Components depicted here correspond to cylinder


bank 1. They are different only as a mirror image of
components for cylinder bank 2.

Connecting hose

On vehicles with engine


code BWF

To crankcase ventilation
valve

Ensure seated tightly

Sealing sleeve

On vehicles with engine


code BWF

Replace if damaged

Cylinder head

Bracket

On vehicles with engine


code BWF

For intake hose between air


filter and intake manifold flap

Acoustic cover

For vehicles with engine


code BWF

Cylinder head cover

On vehicles with engine


code BWF

Always clean sealing


surfaces of cylinder head
cover with a clean cloth
before setting in place

Replace seal together with


cylinder head cover if
damaged or leaking

Observe tightening
sequence of bolts 15-1,
Tightening sequence of bolts
for cylinder head cover

Acoustic cover

Ensure seated tightly

For vehicles with engine


code BKW

Cylinder head cover

For vehicles with engine


code BKW

Always clean sealing


surfaces of cylinder head
cover with a clean cloth
before setting in place

Replace seal together with


cylinder head cover if

Page 3 / 28

Cylinder head

damaged or leaking

20 Nm

Between control housing and


cylinder head

Cylinder head gasket

Replace

Install new seal of the same


strength 15-1,
Identification of cylinder
head gasket

Imprint of replacement part


numbers - A - must be
readable

After replacing replace entire


amount of coolant

Cylinder head

Observe tightening
sequence of bolts 15-1,
Tightening sequence of bolts
for cylinder head cover

Removing and installing


15-1, Cylinder heads,
removing and installing

Cylinder head bolt

Replace

Observe sequence for


loosening and tightening
15-1, Cylinder heads,
removing and installing ,
Cylinder head, removing and
installing

Sealing sleeve

For vehicles with engine


code BKW

Replace if damaged

Page 4 / 28

Cylinder head

Check for secure seating

Connection piece

For vehicles with engine


code BKW

To crankcase ventilation
valve

Check for secure seating

Tightening sequence of bolts for cylinder head cover

- Tighten bolts in the shown tightening sequence to 10


Nm.

Identification of cylinder head gasket

Number of holes (specifies thickness of gasket) )

Page 5 / 28

Cylinder head

Control code (disregard)


Replacement part number

) Cylinder

head gasket is available in three different


strengths, whereby the number of holes indicates the
corresponding strength ETKA (Electronic Parts
Catalog) Always install a new gasket of the same strength
when replacing.
Camshaft compensation wheel and input gear, removing
and installing

Note:

After each separation of the gear drive, the position


of the pump pistons in the pump injector units must
be checked after completing assembly and adjusted
if necessary 23-1, Position of pump pistons in
pump injector units, checking and adjusting

Special tools, testers and auxiliary items

Page 6 / 28

Cylinder head

Page 7 / 28

required

Torque wrench (5 to 50 Nm) V.A.G


1331

Torque wrench (40 to 200 Nm)


V.A.G 1332

Puller T10055

Multi-point socket T10198

Clamping device T10199

Wrench T10211

Note:

Work sequence described and components depicted


here apply to cylinder bank 1. The difference for
cylinder bank 2 is minimal and is not described
separately for this reason.

Removing
- Remove engine and transmission
removing and installing .

10-1, Engine,

- Remove intake manifold flap and crankcase ventilation


line from respective cylinder.
- Remove acoustic cover and cylinder head cover of the
applicable cylinder head.
- Check rocker arm shaft running surfaces for wear.
- Remove coolant pipe below tandem and fuel pump.
- Remove vibration damper Item - 4 - . For this, use
counterholder T10172 with threading pins T10172/1 .

Cylinder head

- Screw crankshaft locator bar T10195 onto crankshaft


stub. Observe alignment pin while doing so.
- Now carefully rotate crankshaft until the pin of crankshaft
locator bar T10195 inserts into alignment bore.
- Remove corresponding pump 20-1, Tandem pump
and Fuel Pump (FP), removing and installing , Tandem
and fuel pump, removing and installing.

Cylinder bank 1: Tandem pump

Cylinder bank 2: Fuel Pump (FP)

- Remove oil supply line to exhaust turbocharger.

- Position Wrench T10211 as shown and loosen adapter


ring on pump injection unit central connector.

Page 8 / 28

Cylinder head

- Remove Camshaft Position (CMP) Sensor G40 - C (only on cylinder bank 1).
- Remove outer bearing cap - A - , place clamping device
T10199 on camshaft gear and tighten its bolt to 40 Nm.
- Loosen mounting bolt - B - for camshaft gear using
socket insert T10198 and remove together with tandem
pump drive.
- Loosen bolts on Clamping Device T10199 and remove
it.

- Remove compensating piston - B - for full-floating axle


of compensation linkage.
- Unscrew pull-off head for pump-injector unit from puller
T10055 .

Page 9 / 28

Cylinder head

- Screw puller T10055 into full-floating axle as shown and


pull full-floating axle out of its seat in direction of - arrow , using careful knocking motions.

- Pull out the outer compensation linkage on transmission


side, including its sleeve. If necessary, loosen by hitting
lightly with a plastic hammer.
- Remove camshaft gear.
- Now remove compensation wheel and inner
compensation linkage on engine side.

- Remove diamond disc from camshaft stub.


Installing

Page 10 / 28

Cylinder head

- Clean bearing cap contact surfaces of any sealant


residue.
- Oil compensation linkage sleeve guide surfaces.
Note:

If there is marked crimping or deposits on


compensation linkage sleeve guide surfaces, these
must be replaced.

- First engage inner, engine-side compensation linkage A - at bottom (if necessary, guide through compensating
piston hole with finger) and then slide top onto sleeve.
- Place a new diamond disc on camshaft stub.

- Bring lower, transmission-side compensation linkage into


position 15-1, Compensation linkage position and insert
compensation wheel with phase - arrow - in direction of
transmission.

Page 11 / 28

Cylinder head

- When inserting, turn the camshaft gear so marking arrow - on sensor wheel aligns with upper edge of sealing
surface.
- Secure construction by carefully sliding full-floating axle
on by hand with force as even as possible.
Caution!
There is the risk that a linkage may pivot to the side
out of the wheel cassette and will not engage when
full-floating axle is inserted, or it may be distorted
when inserting the full-floating axle.
- Insert guide sleeve in transmission-side compensation
linkage.
- Carefully pull full-floating axle back out of its seat. When
doing so, ensure compensation linkages which have
already been positioned remain in correct location.
- Install transmission-side compensation linkage with
writing toward transmission. When doing so, support if
necessary with light tapping on guide sleeve with a plastic
hammer.
- Control correct seating of compensation linkage with
finger through compensating piston hole.
- Compensation wheel must be aligned so that the holes in
the four linkages and in sprocket are positioned flush
behind one another 15-1, Compensation linkage
position .

Page 12 / 28

Cylinder head

Page 13 / 28

Compensation linkage position

- Lubricate free-floating axle with oil, then carefully slide in


by hand and with as even a force as possible. Correct seat
of full-floating axle faces toward a clear gap to cylinder
head bore - arrow - .

- Before fastening, turn the camshaft gear so that the


marking - arrow - on the sensor wheel aligns with upper
edge of sealing surface.
- Remove tandem or fuel pump drive.
- Position bearing cap flush with cylinder head edge using
Sealant AMV 176 501 and tighten. Tightening torque
Topic 15-1 .
- Install new compensating pistons. Tightening torque
Topic 15-1 .
- Positing Clamping Device T10199 and tighten camshaft
gear bolt. Tightening torque Topic 15-1 .
Torque specifications
Bolted connections
Bolts, nuts

Torque specifications

Cylinder head

Page 14 / 28

M6

10 Nm

M8

20 Nm

M10

45 Nm

M12

60 Nm

Exceptions:
Compensating piston
Bolt for camshaft gear

110 Nm
1st oversize

60 Nm

2nd oversize

150 Nm

Stage III
Bolt for bearing cap

Valve timing, checking

Special tools, testers and auxiliary items


required

/ 4 additional turn (90

8 Nm plus and additional 1 / 4 turn (90

Cylinder head

Counter-holder tool T10172

Camshaft locator bar T10193 for


cylinder bank 1

Camshaft locator bar T10194 for


cylinder bank 2

Work procedure
- Remove noise insulation ( Item - 14 - ) and covers (
Item - 13 - ) from cylinder heads.

- Rotate crankshaft slowly in direction of engine rotation


using counterholder T10172 until camshaft locator bar
T10193 for camshaft for cylinder bank 1 and camshaft
locator bar T10194 for camshaft for cylinder bank 2 can be
inserted into fitting holes as shown.
- Raise vehicle on vehicle platform.

- Check whether marking - arrow A - on vibration damper


aligns with alignment pin - arrow B - .
If markings do not align:

Page 15 / 28

Cylinder head

- Adjust valve timing

Page 16 / 28

15-1, Valve timing, adjusting .

Valve timing, adjusting

Special tools, testers and auxiliary items


required

Counter-holder tool T10172

Camshaft locator bar T10193 for


cylinder bank 1

Camshaft locator bar T10194 for


cylinder bank 2

Crankshaft anchor T10195

Multi-point socket T10198

Cylinder head

Page 17 / 28

Clamping device T10199

Work procedure
- Remove engine and transmission
removing and installing .

10-1, Engine,

- Remove tandem and fuel pumps from cylinder heads


20-1, Tandem pump and Fuel Pump (FP), removing and
installing .
- Remove noise insulation ( Item - 14 - ) and covers (
Item - 13 - ) from cylinder heads.
- Remove acoustic covers and cylinder head cover.

- Turn engine using counterholder T10172 until at least


one camshaft locator bar can be inserted.
- Place clamping device T10199 onto wheel of secured
camshaft and loosen camshaft wheel bolt. Wheel can now
be turned freely on camshaft.
If only one camshaft locator bar could be inserted:
- Turn engine using counterholder T10172 until camshaft
locator bar for other cylinder bank can be inserted.
- Place clamping device T10199 on camshaft gear and
loosen its bolt. Wheel can also now be turned freely on
camshaft.
- Remove vibration damper Item - 4 - . For this, use
counterholder T10172 with threading pins T10172/1 .

Cylinder head

- Screw crankshaft locator bar T10195 onto crankshaft


stub. While doing so, observe alignment pin.
- Carefully rotate crankshaft until pin of crankshaft locator
bar T10195 inserts into alignment bore.

- Place clamping device T10199/1 as shown and tighten


its clamping bolts to 70 Nm.
- Place a torque wrench (40 to 200 Nm) V.A.G 1332 into
square of clamping device and push with 80 Nm in
opposite direction of engine rotation direction to eliminate
play from gear drive.

Cylinder bank 1: in direction of - arrow -

Cylinder bank 2: against direction of - arrow -

- Maintain specified force and tighten mounting bolt of


camshaft gear to a tightening torque of 50 Nm using socket
T10198 .
- Remove clamping device T10199/1 .

Page 18 / 28

Cylinder head

- Place clamping device T10199 on camshaft gear.


Note:

Make sure that clamping device T10199 makes


contact flush on cylinder head.

- Tighten clamping device T10199 bolts to 40 Nm.


- Then tighten camshaft gear using socket T10198 .
Torque specification: 150 Nm plus an additional 1 / 4 turn
(90

).

- Remove clamping device T10199 .


- Remove anchors from camshafts and crankshaft.
- Continue turning crankshaft two rotations in direction of
engine rotation until the crankshaft is again at TDC for
cylinder 1.

- Check whether anchors for camshafts as well as for


crankshaft can be inserted simultaneously.
Cylinder heads, removing and installing

Caution!

Page 19 / 28

Cylinder head

Because of the threaded connection of cylinder head


through the aluminum cylinder block into crankshaft
bearing bracket (connecting rod), both cylinder heads
must always be removed. If cylinder head bolts are
loosened or tightened on one side, cylinder block is
warped.
Special tools, testers and auxiliary items required

Counter-holder tool T10172

Torque wrench (5 to 50 Nm) V.A.G 1331

Not illustrated:

Torque wrench (40 to 200 Nm) V.A.G 1332

Container for removed components V.A.G 1698

Engine bung set VAS 6122

Cable tie

Page 20 / 28

Cylinder head

Page 21 / 28

Removing
- Remove engine and transmission
removing and installing .

10-1, Engine,

- Remove acoustic covers as well as cylinder head covers


from cylinder heads.
- Remove tandem and fuel pumps from cylinder heads
20-1, Tandem pump and Fuel Pump (FP), removing and
installing .
- Set crankshaft to TDC Cylinder 1
checking , check valve timing.

15-1, Valve timing,

- Remove drive gears for camshafts 15-1, Camshaft


compensation wheel and input gear, removing and
installing .
- Remove bolts ( Item - 8 - ) between control housing
and cylinder head of cylinder bank 1 and 2.

- Loosen and remove cylinder head bolts in specified


sequence ( - arrow - points in driving direction).
- Carefully remove cylinder heads with assistance of a
second technician.
Note:

The cylinder heads must be carefully guided to


prevent damages.

- Place clean rags into cylinders so that no dirt or emery


cloth particles can get in between cylinder wall and piston.
- Do not allow dirt or abrasive powder to get into coolant
either.
- Carefully clean cylinder head and cylinder block sealing
surfaces. Avoid introducing scratches or scoring (do not
use sandpaper with grit below 100).

Cylinder head

Installing
Note:

Always replace cylinder head bolts.

Only unpack new cylinder head gasket immediately


prior to installation.

Install cylinder head gasket with the same


"thickness" index as the one removed.

Handle gasket carefully. Damages to the silicone


layer and in areas of recesses may result in leaks.

- Before installing cylinder heads, position crankshaft to


TDC for cylinder 1.
- Turn back crankshaft in opposite direction of engine
rotation direction until all pistons stand almost evenly below
TDC.
- Set cylinder head gasket in place.

- Install cylinder head according to position of


compensation linkage - arrow - , insert cylinder head bolts
with associated washers and tighten hand-tight.
Caution!
All cylinder head bolts, except number - 1 - , - 2 - , 17 - and - 19 - in tightening sequence must be
installed with notched washers ETKA (Electronic
Parts Catalog)

Page 22 / 28

Cylinder head

Page 23 / 28

- Tighten cylinder heads in sequence indicated, in four


stages as follows ( - arrow - points in driving direction).

Tighten using torque wrench:


Step I = 30 Nm
Step II = 60 Nm

Tighten further using a solid wrench:


Stage III = 1 / 2 additional turn (180
Step IV = 1 / 2 turn (180

- Install drive gears for camshafts 15-1, Camshaft


compensation wheel and input gear, removing and
installing .
- Adjust valve timing

15-1, Valve timing, adjusting .

Compression pressures, checking

Note:

With this engine, the static compression test requires


a significant amount of work. Therefore it is
recommended to check idle stabilization control
before disassembly Vehicle Diagnosis, Testing
and Information System VAS 5051 or VAS 5052
"Guided Fault Finding; Repair Group 15; partial
systems, boundary conditions" . Only if one or more
cylinder(s) is/are noticeable at this point is the
compression test warranted.

Cylinder head

Special tools, testers and auxiliary items


required

Torque wrench (5 to 50 Nm) V.A.G


1331

Adapter V.A.G 1381/12

Compression tester V.A.G 1763

Not illustrated:

Sealing plate T10247

Connecting hose VAS 6278

Requirements:

Page 24 / 28

Cylinder head

Page 25 / 28

Engine oil temperature min. 30

Ignition switched off

Work sequence
- Drain coolant
filling .

19-1, Cooling system, draining and

Vehicles with engine code BKW


- Remove fuel filter 20-1, Fuel filter (vehicles with engine
code BKW), removing and installing .

- Seal connection for fuel hoses using sealing plate


T10247 .

- Connect fuel supply line - A - using connecting hose


VAS 6278 to fuel return line - B - .
Vehicles with engine code BWF
- Remove bypass flap with cooler for Exhaust Gas
Recirculation (EGR) 26-2, Bypass flap with cooler for
Exhaust Gas Recirculation (EGR) (vehicles with engine
code BWF), assembly overview .
Continuation for all vehicles

Cylinder head

- Remove upper part of oil filter housing 17-3, Oil filter


housing, assembly overview , Oil filter housing, assembly
overview.
- Remove glow plugs :

Vehicles with engine codes BKW and BWF 28-1,


Glow plugs vehicles with engine code BKW, BWF)
removing and installing, checking

- Remove right plenum chamber cover - D - .


- Disconnect small connectors from Engine Control
Modules (ECM).
Note:

By disconnecting the small harness connectors for


Engine Control Modules (ECM) the engine is
prevented from starting up even though the starter is
turning. If any DTCs are stored in DTC memory
during start procedure, it is necessary to check and
erase (if required) the DTC memory.

After the compression test, check the DTC memory


23-2, Diagnostic Trouble Code (DTC) memory of
Engine control modules (ECM) , checking and
erasing , DTC memory of engine control module
(ECM) , checking and erasing.

Page 26 / 28

Cylinder head

Page 27 / 28

- Screw in adapter V.A.G 1381/12 in place of glow plug at


cylinder to be tested.
- Re-install upper part of oil filter housing 17-3, Oil filter
housing, assembly overview , Oil filter housing,
disassembling and assembling.
- Check compression pressure using compression tester
V.A.G 1763 .
Note:

Using the compression tester


instructions .

Operating

- Operate starter until tester shows no further pressure


increase.
Compression pressure:

New: 25 to 0.31 bar pressure

Wear limit: 19 bar pressure

Permissible difference between all cylinders: 5 bar

- Install glow plugs 28-1, Glow plugs vehicles with


engine code BKW, BWF) removing and installing,
checking :
Vehicles with engine codes BKW 28-1, Glow plugs
vehicles with engine code BKW, BWF) removing and
installing, checking
- Fill with coolant
filling .

19-1, Cooling system, draining and

- After all cylinders have been checked and engine has


been completely re-assembled, check DTC memory and

Cylinder head

erase it if necessary 23-2, Diagnostic Trouble Code


(DTC) memory of Engine control modules (ECM) ,
checking and erasing , DTC memory of engine control
module (ECM) , checking and erasing.

Page 28 / 28

Valvetrain

Page 1 / 16

15 - 2

Valvetrain
Note:

Secure engine on engine and transmission holder


VAS 6095 when working on engine.

Cylinder heads with tears between the valve seats


can continue to be used without reducing service
life, as long as the tears have a width of max. 0.5
mm.

Valve gear, assembly overview


assembly overview

15-2, Valvetrain,

Rework valve seats

15-2, Valve seats, refacing

Check valve guides

15-2, Valve guides, checking

Replacing valve stem oil seals


seals, replacing

15-2, Valve stem

Camshaft, removing and installing


removing and installing
Valvetrain, assembly overview

15-2, Camshaft,

Valvetrain

Page 2 / 16

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru


Volkswagen, Skoda, Seat, Audi

20 Nm plus an additional 1 / 4
turn (90

Replace

Observe sequence for


loosening and tightening
15-2, Camshaft, removing
and installing , removing and
installing camshaft

Rocker arm axle

Do not interchange

Bearing cap

To install, seal joint surfaces


of outer bearing cap with
sealant AMV 176 501
15-

Valvetrain

Page 3 / 16

2, Seal joint surfaces of


outer bearing caps

Valve lifter

Do not interchange

With hydraulic valve


clearance compensation

Place on running surface


when setting down

Before installing, check axial


play of camshafts 15-2,
Camshaft, checking axial
play

Lubricate contact surface

Before removing, remove


bearing caps for camshaft

Valve keepers

Valve spring plate

Outer valve spring

Inner valve spring

Replace 15-2, Valve stem


seals, replacing

Diamond disc

Removing and installing


15-2, Valve stem seals,
replacing , Valve stem seals,
replacing

Valve stem seal

Removing and installing


15-2, Valve stem seals,
replacing , Valve stem seals,
replacing

Replace

Sleeve

Valvetrain

Read "Notes"

Reface valve seats 15-2,


Valve seats, refacing

Topic 15-2

Valves
Valve dimensions
Valve dimensions

15-2,

Pump-Injector Unit

For linkage mounting


components

Cylinder head

Page 4 / 16

Removing and installing


23-1, Pump-Injector Unit,
removing and installing

Washer

For cylinder head bolts

Insert into cylinder head


before assembling bearing
caps

Observe "Precautions"
Topic 15-1

Bearing shell

Do not interchange used


bearings (mark)

Make sure retaining tabs are


engaged properly in bearing
caps and cylinder head

Camshaft

Checking axial play 15-2,


Camshaft, checking axial
play

Identification, valve timing


15-2, Camshaft
identification, valve timing

Valvetrain

Page 5 / 16

Removing and installing


15-2, Camshaft, removing
and installing

Checking radial clearance


with Plastigage, Wear limit:
0.11 mm

Run-out: max. 0.01 mm

Bearing shell

Do not interchange used


bearings (mark)

Make sure retaining tabs are


engaged properly in bearing
caps and cylinder head

Cylinder head bolt

Replace

Observe sequence for


loosening and tightening
15-1, Cylinder heads,
removing and installing ,
Cylinder heads, removing
and installing

Before installing, insert


shims Item - 15 - into
cylinder head

8 Nm plus an additional 1 / 4 turn


(90

Replace

Valvetrain

Camshaft, checking axial play

Special tools, testers and auxiliary items required

Dial gauge holder VW 387

Dial gauge

Test sequence
Measurement with valve lifters removed and bearing caps
installed:
Cylinder bank 1:

Bearing caps 2, 4 and 6 installed

Cylinder bank 2:

Bearing caps 9, 11 and 13 installed

Wear limit: max. 0.15 mm

Seal joint surfaces of outer bearing caps

Page 6 / 16

Valvetrain

Page 7 / 16

Special tools, testers and auxiliary items required

Sealant AMV 176 501

Work procedure
- Apply sealant AMV 176 501 thinly and evenly on surface
- 1- .
Cylinder bank 1:

Seal bearing caps 1 and 7 with sealant AMV 176


501

Cylinder bank 2:

Seal bearing caps 8 and 14 with sealant AMV 176


501

Valve dimensions

Note:

Valves must not be refaced. Only lapping is


permitted.

Dimension

Intake valve

Exhaust valve

Diameter a

mm

35.950

31.450

Diameter b

mm

6.980

6.956

mm

89.950

89.950

45

45

Valvetrain

Page 8 / 16

Camshaft identification, valve timing

Identification

Base circle of valve cams: a = diameter 52.8 mm

Identification by numbers and letters stamped on


face surface of camshaft drive side.

Drive side - arrow Cylinder bank 1


Cylinder bank 2

07Z G
07Z H

Valve timing at 1 mm valve lift


Intake valve opens after TDC

12.0

Intake valve closes after BDC

21.5

Exhaust valve opens before BDC

30.0

Exhaust valve closes before TDC

20.5

Valve seats, refacing

Special tools, testers and auxiliary items required

Depth gauge

Valve seat refacing tool

Note:

When repairing engines with leaking valves, it is not


sufficient to reface or replace valve seats and
valves. It is particularly important to check valve

Valvetrain

Page 9 / 16

guides for wear on engines with longer running


times.

Only reface valve seats enough until a perfect


contact pattern is obtained. The maximum
permissible reworking dimension must be calculated
before work is carried out. If the reworking
dimension is exceeded, the function of the hydraulic
lifters can no longer be guaranteed and therefore the
cylinder head should be replaced.

The maximum permissible reworking dimension is


calculated as follows:
- Insert valve and press firmly against seat.
Note:

If a valve is to be replaced as part of a repair, use a


new valve for the calculation.

- Measure distance - a - between end of valve stem and


upper edge of cylinder head.
- Calculate max. permissible reworking dimension from
measured distance - a - and minimum dimension.
Minimum dimensions:

Intake valve 43.4 mm

Exhaust valve 43.2 mm

Measured distance minus minimum dimension = max.


permissible reworking dimension.
Example:

Valvetrain

Page 10 / 16

Measured distance

44.1 mm

Minimum dimension

43.4 mm

Max. permissible reworking dimension*

Refacing intake valve seat


a - Diameter 35.7 mm
b - 1.6 mm
45 - Valve seat angle
Note:

The 30 relief milling of the valve seat is always


necessary due to flow ratios in the intake canal.

Refacing exhaust valve seat


a - Diameter 31.4 mm
b - 2.7 mm
45 - Valve seat angle
Valve guides, checking

Special tools, testers and auxiliary items required

0.7 mm

Valvetrain

Page 11 / 16

Dial gauge holder VW 387

Not illustrated:

Dial gauge

Work sequence

- Insert a new valve into guide. The end of the valve stem
must be flush with the guide. Due to the slight difference in
stem dimensions, make sure that only an intake valve is
used in the intake guide and an exhaust valve in the
exhaust guide.
- Determine tilt clearance. Wear limit: max. 1.3 mm
- If tilt clearance exceeds wear limit, the cylinder head
must be replaced.
Valve stem seals, replacing

Valvetrain

Special tools, testers and auxiliary items


required

Valve assembly tool 2036

Removal tool 3047 A

Valve stem seal driver 3129

Valve lever VW 541/1 A

Pressure piece VW 541/5

Removing
(With cylinder head installed)

Page 12 / 16

Valvetrain

- Remove camshaft
installing .

Page 13 / 16

15-2, Camshaft, removing and

- Remove valve lifters and place on running surface when


setting down. Be careful not to switch valve lifters.
- Move piston for respective cylinder to Top Dead Center
(TDC) position.

- Insert valve assembly tool 2036 and adjust mounting to


stud height.
- Remove valve springs with valve lever VW 541/1 A and
pressure piece VW 541/5 .
Note:

Support valves on piston head while doing this.

- Pull off valve stem seals with valve seal removal tool
3047 A .
Installing

Valvetrain

Page 14 / 16

- Attach plastic sleeves provided - A - to the respective


valve stem. This will help avoid damage to new valve stem
oil seal - B - .
- Insert new valve stem oil seal into valve stem seal driver
3129 .
- Grease lip of valve stem oil seal and carefully slide onto
valve guide.
- Install camshaft
installing .

15-2, Camshaft, removing and

Camshaft, removing and installing

Special tools, testers and auxiliary items required

Torque wrench (5 to 50 Nm) V.A.G 1331

Sealant AMV 176 501

Removing
- Remove engine and transmission
removing and installing .
- Remove drive gear for camshaft

10-1, Engine,
15-1, Camshaft

Valvetrain

Page 15 / 16

compensation wheel and input gear, removing and


installing .
- Remove rocker arm axles

Item - 2 - .

- Loosen camshaft bearing cap starting from outside


working inward, whereby the bolts of last two bearing caps
must be loosened alternating in diagonal sequence.
Installing
Note:

Make sure that no valve is pressed onto piston when


installing the camshaft. Bring pistons evenly to just
below Top Dead Center (TDC) position.

Do not interchange run-in connecting rod bearing


shells (mark).

When installing camshaft, make sure bearing shell


retaining tabs are seated properly in bearing caps
and cylinder head.

Before installing bearing cap, make sure that


washers for cylinder head bolts are inserted in
cylinder head.

- Oil bearing cap contact surfaces.


- Tighten inner two bearing caps alternating in diagonal
sequence and tighten to 8 Nm plus an additional 1 / 4 turn
(90

) (replace bolts).

- Install remaining bearing caps and also tighten to 8 Nm


plus an additional 1 / 4 turn. (90 ) (replace bolts).
Note:

Seal joint surfaces of outer bearing caps with sealant


AMV 176 501
15-2, Seal joint surfaces of outer
bearing caps .

- Install rocker arm axles and tighten first the inner and
then outer mounting bolts evenly in diagonal sequence to
tightening torque: 20 Nm plus an additional 1 / 4 turn (90
) turn (replace bolts).
- Re-install drive gear for camshaft

15-1, Camshaft

Valvetrain

Page 16 / 16

compensation wheel and input gear, removing and


installing .
- Adjust valve timing

15-1, Valve timing, adjusting .

- Install acoustic cover as well as cylinder head cover of


respective cylinder.
- Install engine and transmission
removing and installing .

10-1, Engine,

Note:

After installing new valve lifters, the engine may not


be started for approx. 30 minutes. The hydraulic
valve lifters have to settle (otherwise valves will
strike the pistons).

Engine oil

Page 1 / 2

17 - 1

Engine oil
Caution!
The oil level must not be above the max. mark - danger
of damage to catalytic converter! Markings on oil
dipstick 17-1, Engine oil level, checking .
Engine oil, draining
Repair Manual, Maintenance
Engine oil specifications
Repair Manual, Maintenance
Oil filling quantities

17-1, Oil filling quantities

Engine oil level, checking


checking

17-1, Engine oil level,

Oil filling quantities

Without oil filter 11.2 L


With oil filter 11.5 L
Engine oil level, checking

Markings on oil dipstick

1 - Max. mark
2 - Min. mark
a - Area above hatched field up to Max. mark: Do not
replenish with engine oil!
b - Oil level within hatched field: Can be replenished with

Engine oil

engine oil
c - Area from Min. mark up to hatched field: Replenish with
max. 0.5 ltr. of engine oil!

Page 2 / 2

Oil pan

Page 1 / 6

17 - 2

Oil pan
Caution!
The oil level must not be above the max. mark - danger
of damage to catalytic converter! Markings on oil
dipstick 17-1, Engine oil level, checking .
Note:

If large quantities of metal particles or other deposits


(caused, for example, by partial seizure of the
crankshaft or connecting rod damage) are found in
the engine oil, the oil passages must be cleaned
thoroughly and the oil cooler replaced in order to
prevent further damage from re-occurring.

The engine must not be set down on the oil pan


otherwise the liquid gasket between the upper and
lower oil pan will be damaged. To set down the
engine, use frame support T10191 .

Secure engine in engine and transmission holder


VAS 6095 when working on engine.

Oil pan, assembly overview


overview
Sealant , applying

17-2, Oil pan, assembly

17-2, Sealant , applying

Oil pan, assembly overview

Lower part of oil pan, assembly overview


pan (lower section), assembly overview

17-2, Oil

Upper part of oil pan, assembly overview


pan (upper section), assembly overview

17-2, Oil

Oil pan (lower section), assembly overview

Oil pan

Page 2 / 6

8 Nm

8 Nm

Oil Level Thermal Sensor G266

Seal

Checking Electrical Wiring


Diagrams, Troubleshooting
and Component Locations
binder

Replace

Oil drain plug, 30 Nm

If sealing ring is leaking cut


open and replace.

Oil pan

Page 3 / 6

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru


Volkswagen, Skoda, Seat, Audi

Oil pan, lower section

Clean sealing surface before


installing

Insert with sealant AMV 176


501
17-2, Sealant ,
applying

Oil tube

8 Nm

O-ring

Replace

Oil pan (upper section), assembly overview

Oil pan

Page 4 / 6

8 Nm

8 Nm

Oil tube

Oil pan (upper section)

Clean sealing surface before


installing

Insert with sealant AMV 176


501
17-2, Sealant ,
applying

Note internal oil lines 172, Oil lines in upper section


of oil pan

10 Nm

Baffle

Cylinder block

Engine, disassembling and


assembling 13-1, Engine,
disassembling and
assembling

Oil lines in upper section of oil pan

Oil pan

- Insert oil lines - A - as shown in illustration and tighten


bolts - B - to 8 Nm.
Sealant , applying

Special tools, testers and auxiliary items required

Sealant AMV 176 501

Work procedure

- Remove sealant residue from pan with a rotating brush,


e.g. a hand drill with a plastic brush attachment (wear eye
protection).
- Clean sealing surfaces. Sealing surfaces must be free of
oil and grease.
Note:

Note the expiration date of the sealant .

The oil pan must be installed within 5 minutes of


applying sealant .

Page 5 / 6

Oil pan

Page 6 / 6

- Cut tube nozzle at front marking (nozzle diameter approx.


3 mm).
- Apply silicone sealing compound , as shown, to clean oil
pan sealing surface. Sealing compound bead must be:

2 to 3 mm thick

and run on inside of bolt holes - arrows -

Seal contour for oil pan, lower section

- Apply sealant , as shown, to clean sealing surface of


lower section of oil pan.

Seal contour for oil pan, upper section

- Apply sealant , as shown, to clean sealing surface of


upper section of oil pan.

Oil pump, oil filter housing and oil pressure

Page 1 / 9

17 - 3

Oil pump, oil filter housing and oil pressure


Caution!
The oil level must not be above the max. mark - danger
of damage to catalytic converter! Markings on oil
dipstick 17-1, Engine oil level, checking .
Note:

If large quantities of metal particles or other deposits


(caused, for example, by partial seizure of the
crankshaft or connecting rod damage) are found in
the engine oil, the oil passages must be cleaned
thoroughly and the oil cooler replaced in order to
prevent further damage from re-occurring.

The engine must not be set down on the oil pan


otherwise the liquid gasket between the upper and
lower oil pan will be damaged. To set down the
engine, use frame support T10191 .

Secure engine in engine and transmission holder


VAS 6095 when working on engine.

Oil pump, assembly overview


assembly overview

17-3, Oil pump,

Oil filter housing, assembly overview


housing, assembly overview

17-3, Oil filter

Oil pressure and oil pressure switch, checking


Oil pressure and oil pressure switch, checking
Checking oil pressure at engine face
pressure, checking at front of engine
Oil pump, assembly overview

17-3, Oil

17-3,

Oil pump, oil filter housing and oil pressure

8 Nm plus an additional 1 / 4 turn


(90

Oil return line

Gasket

Replace if damaged

Oil pump

Loosening return
connections 17-3,
Loosening return
connections of oil pump

To remove, slide slightly in


direction of engine
management side after
loosening all mounts and
remove

Page 2 / 9

Oil pump, oil filter housing and oil pressure

10 Nm

Baffle plate

Slide block

Baffle plate

20 Nm plus an additional 1 / 4
turn (90

Loosening return connections of oil pump

- Pull out securing clamps - A - in direction of - arrow and slide connecting pieces in direction of - arrow B - .
Oil filter housing, assembly overview

Page 3 / 9

Oil pump, oil filter housing and oil pressure

Oil filter cover, 25 Nm

With bypass valve for oil


filter

Loosen and tighten with oil


filter wrench T10192
173, Loosening and tightening
oil filter cover

Oil filter element

Cap

Replace gaskets if damaged

Housing upper section

8 Nm

10 Nm

Page 4 / 9

Oil pump, oil filter housing and oil pressure

Gasket

Replace if damaged

Filler tube

Oil cooler

Housing lower section

Loosening and tightening oil filter cover

Special tools, testers and auxiliary items required

Oil filter wrench T10192

Work procedure
- Loosen and tighten oil filter cover with oil filter wrench
T10192 .

Torque specification 25 Nm

Oil pressure and oil pressure switch, checking

Page 5 / 9

Oil pump, oil filter housing and oil pressure

Special tools, testers and auxiliary items


required

Oil pressure gauge V.A.G 1342

Voltage tester V.A.G 1527 B

Connector test set V.A.G 1594 C

Note:

Function test and service of visual and acoustic oil


pressure indicator Electrical Wiring Diagrams,
Troubleshooting and Component Locations binder
and Vehicle Diagnosis, Testing and Information
System VAS 5051 or VAS 5052 "Guided Fault
Finding"

Page 6 / 9

Oil pump, oil filter housing and oil pressure

Work sequence
Vehicles with engine codes BKW
- Remove fuel filter 20-1, Fuel filter (vehicles with engine
code BKW), removing and installing .
Vehicles with engine coded BWF
- Remove bypass flap with cooler for Exhaust Gas
Recirculation (EGR) 26-2, Bypass flap with cooler for
Exhaust Gas Recirculation (EGR) (vehicles with engine
code BWF), assembly overview .
Continuation for all vehicles
Note:

When removing oil pressure switch, counterhold


banjo bolt so that leaks in the vicinity of the oil line
are prevented.

- Remove oil pressure switch F1 and screw it into oil


pressure gauge V.A.G 1342 .
- Screw oil pressure gauge into banjo fitting in place of oil
pressure switch F1 .
- Connect brown wire of oil pressure gauge to Ground (-).
- Connect diode test lamp of voltage tester V.A.G 1527 B
to B+ and oil pressure switch using adapter cables from
connector test set V.A.G 1594 C . LED must not light up.
Vehicles with engine code BKW
- Install fuel filter 20-1, Fuel filter (vehicles with engine
code BKW), removing and installing .
Vehicles with engine code BWF
- Install bypass flap with cooler for Exhaust Gas

Page 7 / 9

Oil pump, oil filter housing and oil pressure

Recirculation (EGR) 26-2, Bypass flap with cooler for


Exhaust Gas Recirculation (EGR) (vehicles with engine
code BWF), assembly overview .
Continuation for all vehicles
- Start engine and slowly increase engine speed.
- LED must light up at 0.55 to 0.85 bar positive pressure,
otherwise replace oil pressure switch F1 .
- Increase engine speed (RPM) further. At 2000 RPM and
an oil temperature of 80 C, oil pressure must be at least
2.0 bar.
Oil positive pressure must not exceed 7.0 bar at higher
engine speeds.
Oil pressure, checking at front of engine

Special tools, testers and auxiliary items required

Oil pressure gauge V.A.G 1342

Adapter V.A.G 1342/19

Work sequence
- Remove covers in engine compartment.
- Remove noise insulation (
heads.

Item - 14 - ) from cylinder

Page 8 / 9

Oil pump, oil filter housing and oil pressure

- Remove oil channel sealing plug - A - from cylinder bank


to be tested.
Caution!
The oil channel hole indicates a very low thread depth.
the Adapter VAG1342/19 V.A.G 1342/19 should not be
installed too tightly due to the danger of damaging the
threads.
- Connect oil pressure tester V.A.G 1342 with adapter
V.A.G 1342/19 to oil channel hole.
- Seal test hole for oil pressure switch on oil pressure
tester V.A.G 1342 using engine sealing plug.
- Start engine.
Oil pressure must not reach below a value of 1.4 bar at
1000 RPM and 80 C oil temperature.

Page 9 / 9

Cooling system components

Page 1 / 30

19 - 1

Cooling system components


Caution!
When doing any repair work, especially in the engine
compartment, pay attention to the following due to
clearance issues:

Route lines of all types (e.g. for fuel, hydraulic,


additive, coolant and refrigerant, brake fluid,
vacuum) and electrical wiring so that the original
path is followed.

To prevent damages to the lines, make sure


there is sufficient clearance to all moving or hot
components.

Note:

When the engine is warm the cooling system is


under pressure. If necessary release pressure
before commencing repair work.

Hoses are secured with spring-type clips. In cases of


repair only use spring-type clips.

The spring-type clip pliers VAS 5024 A are


recommended for installing spring-type clips.

When installing coolant hoses, make sure they are


free of stress and do not come into contact with
other components (observe markings on coolant
connections and hoses).

Cooling system components

Page 2 / 30

Perform leak test of cooling system using cooling


system tester V.A.G 1274 , adapter V.A.G 1274/8
as well as adapter V.A.G 1274/9 .

Radiator, assembly overview


assembly overview

19-1, Radiator,

Coolant fan, assembly overview


assembly overview

19-1, Coolant fan,

Cooling system components, body side


Cooling system components, body side

19-1,

Cooling system components, on engine and at top


19-1, Cooling system components, on engine and at top
Components of fuel and generator cooling
and generator cooling system components

19-1, Fuel

Component location of After-Run Coolant Pump V51


and Pump for fuel cooler 19-1, After-Run Coolant
Pump V51 and Fuel Cooler Pump V166 , component
location
Coolant thermostat housing, assembly overview
1, Coolant thermostat housing, assembly overview
Coolant pump - assembly overview
pump, assembly overview

19-

19-1, Coolant

Coolant hose connection diagram 19-1, Coolant hose


connection diagram (Vehicles with engine codes BKW)

Vehicles with engine code BKW 19-1, Coolant


hose connection diagram (Vehicles with engine
codes BKW)

Vehicles with engine code BWF


19-1, Coolant
hose connection diagram, vehicles with engine code
BWF

Cooling system, draining and filling


system, draining and filling

19-1, Cooling

Coolant mixture ratios 19-1, Cooling system, draining


and filling , Coolant, draining and filling
Coolant fan mount, removing and installing
Coolant fan mount, removing and installing
Radiator, removing and installing
removing and installing

19-1,

19-1, Radiator,

Cooling system components

Page 3 / 30

Coolant connection, removing and installing


Coolant connection, removing and installing
Coolant pump, removing and installing
pump, removing and installing
Radiator, assembly overview

Upper coolant hose

Secured to radiator with a


retaining clip

Check for secure seating

Radiator

Removing and installing


19-1, Radiator, removing
and installing

After replacing replace entire

19-1,

19-1, Coolant

Cooling system components

amount of coolant

Condenser

ATF oil cooler

For air conditioning system

For transmission oil

Oil cooler

For power steering oil

Lock carrier

Bolts, 10 Nm

Radiator
Vehicles with engine code
BKW:

For generator and fuel


cooling

Vehicles with engine code BWF

For fuel cooling

Bolts, 10 Nm

Rubber bushing

Retaining clip

Check for secure seat

Rubber bushing

Engine Coolant Temperature


(ECT) Sensor (on Radiator) G83

If necessary release
pressure in cooling system
before removing

Lower coolant hose

Secured to radiator with a


retaining clip

Page 4 / 30

Cooling system components

Check for secure seating

Junction piece

For coolant hose from


expansion tank

Coolant fan, assembly overview

Coolant fan V7

Coolant fan mount

Removing and installing


19-1, Coolant fan mount,
removing and installing

Bolts, 10 Nm

Page 5 / 30

Cooling system components

Bolts, 10 Nm

Coolant Fan 2 V177

Coolant Fan Control (FC) control


module J293

Bolts, 10 Nm

Cooling system components, body side

Cap

Check using cooling system


tester V.A.G 1274 and
adapter V.A.G 1274/9

Test pressure 1.4 to 1.6 bar

Reservoir

Page 6 / 30

Cooling system components

Perform leak test of cooling


system with cooling system
tester V.A.G 1274 and
adapter V.A.G 1274/8

Depending on optional
equipment, connection may
be sealed with a blanking
plug.

Y-piece

Note installation position

Coolant hose

Fastened to lock carrier

Bracket

Radiator
Vehicles with engine code
BKW:

For generator and fuel


cooling

Vehicles with engine code


BWF:

For fuel cooling

Cooling system components, on engine and at top

Page 7 / 30

Cooling system components

Cap

Check using cooling system


tester V.A.G 1274 and
adapter V.A.G 1274/9

Test pressure 1.4 to 1.6 bar

Reservoir

Perform leak test of cooling


system with cooling system
tester V.A.G 1274 and
adapter V.A.G 1274/8

Depending on optional
equipment, connection may
be sealed with a blanking
plug.

Coolant pipe

Page 8 / 30

Cooling system components

To thermostat housing

Coolant pipe
Vehicles with engine code
BKW:

To auxiliary water heater

Vehicles with engine code


BWF:

Coolant hose

To auxiliary water heater

Coolant hose

To cooler for exhaust gas


recirculation

From heat exchanger

Upper coolant hose

Secured to radiator with a


retaining clip

Check for secure seating

Lower coolant hose

Secured to radiator with a


retaining clip

Check for secure seating

Fuel and generator cooling system components

Page 9 / 30

Cooling system components

Reservoir

Perform leak test of cooling


system with cooling system
tester V.A.G 1274 and
adapter V.A.G 1274/8

Depending on optional
equipment, connection may
be sealed with a blanking
plug.

Cap

Check using cooling system


tester V.A.G 1274 and
adapter V.A.G 1274/9

Test pressure 1.4 to 1.6 bar

Coolant pipe

Page 10 / 30

Cooling system components

To Fuel Cooler Pump V166

Coolant pipe
Vehicles with engine code
BKW:

To cooler for generator and


fuel cooling Item - 6 -

Vehicles with engine code


BWF:

To cooler for fuel cooling


Item - 6 -

Coolant hose
Vehicles with engine code
BKW:

From cooler for generator


and fuel cooling Item - 6 -

Vehicles with engine code


BWF:

From cooler for fuel cooling


Item - 6 -

Radiator
Vehicles with engine code
BKW:

For generator and fuel


cooling

Vehicles with engine code


BWF:

For fuel cooling

Coolant hose

From fuel cooler pump V166


to radiator Item - 6 -

After-Run Coolant Pump V51 and Fuel Cooler Pump

Page 11 / 30

Cooling system components

V166 , component location

After-run coolant pump V51

Bolted to engine on right

Fuel Cooler Pump V166

Bolted to engine on right

To Fuel Cooler Pump V166

From Fuel Cooler Pump V166

Check valve

Note installation position

From After-run coolant pump


V51

Page 12 / 30

Cooling system components

To After-run coolant pump V51

Coolant thermostat housing, assembly overview

Note:

The coolant thermostat housing is located in the


lower part of oil filter housing.

Routing of coolant hoses to thermostat housing


19-1, Cooling system components, on engine and at
top , Cooling system components - engine side and
top.

Oil filter housing - lower section

With coolant thermostat


housing

Oil filter housing, assembly

Page 13 / 30

Cooling system components

Page 14 / 30

overview 17-3, Oil filter


housing, assembly
overview

20 Nm plus an additional 1 / 4
turn (90

Replace

Hex bolt, 10 Nm

Bracket

Socket head bolt, 10 Nm

Map Controlled Engine Cooling


Thermostat F265

Connecting piece

Gasket

Replace

Coolant thermostat

Note installation position

Checking: Heat up
thermostat in water

Opening begins approx. 80


C

Ends approx. 105

Opening lift min. 7 mm

20 Nm plus an additional 1 / 4
turn (90

Replace

Coolant pump, assembly overview

Cooling system components

Page 15 / 30

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru


Volkswagen, Skoda, Seat, Audi

Seal

Replace

Coolant drain plug, 40 Nm

Coolant pump

Removing and installing


19-1, Coolant pump,
removing and installing

20 Nm plus an additional 1 / 4
turn (90

Coolant pump cover

8 Nm

Observe tightening
sequence 19-1, Coolant

Cooling system components

pump, removing and


installing , Coolant pump,
removing and installing

Seal

Replace

O-ring

Replace

Coolant hose connection diagram (Vehicles with engine


codes BKW)

Heater unit heat exchanger

Auxiliary water heater (auxiliary


heater)

Page 16 / 30

Cooling system components

Recirculation Pump V55

Fuel cooler

Generator

Cylinder head/cylinder block

Coolant thermostat housing

Valve body

Radiator

Radiator

For generator and fuel


cooling

Pump for fuel cooler V166

After-run coolant pump V51

Check valve

Note installation position

Expansion tank

Coolant hose connection diagram, vehicles with engine


code BWF

Page 17 / 30

Cooling system components

Heat exchanger

For heater

Cylinder head/cylinder block

Fuel cooler

Radiator

For Exhaust Gas


Recirculation (EGR) system

Coolant thermostat housing

Valve body

Pump for fuel cooler V166

Radiator

Page 18 / 30

Cooling system components

Radiator

For fuel cooling

After-run coolant pump V51

Check valve

Note installation position

Expansion tank

Cooling system, draining and filling

Special tools, testers and auxiliary items


required

Refractometer T10007

Page 19 / 30

Cooling system components

Drip tray V.A.G 1306

Torque wrench (5 to 50 Nm) V.A.G


1331

Spring-type clip pliers VAS 5024


A

Adapter V.A.G 1274/8

Cooling system charge unit VAS


6096

Draining

Warning!
Hot steam may escape when opening expansion tank.
Wear protective goggles and protective clothing to
prevent damage to eyes and scalding. Cover the cap
with a rag and open very carefully.
- Open cap on coolant expansion tank.
- Remove sound insulation

Repair Manual, Body Exterior, Repair Group 50, Sound


insulation
.
- Remove crossmember

Repair Manual, Body Exterior, Repair Group 63, Front


bumper; Bumper cover, removing and installing; Bumper
carrier - Assembly overview

Page 20 / 30

Cooling system components

- Remove sealing plug - arrow - from radiator.


Note:

Observe disposal regulations for coolant!

- Disconnect coolant hoses at coolant regulator housing arrows - to drain coolant from engine.
Filling

Note:

Only coolant additive G 12 can be used, in


compliance with TL VW 774 F . Distinguishing
feature: colored violet

G 12 and coolant additives marked in accordance


with TL VW 774 F prevent frost and corrosion
damage, scaling and also raise boiling point of
coolant. For this reason the system must be filled all
year round with frost and corrosion protection
additives.

Because of its high boiling point, the coolant


improves engine reliability under heavy loads,

Page 21 / 30

Cooling system components

Page 22 / 30

particularly in countries with tropical climates.

Protection against frost must be assured to about 25 C (in arctic climatic countries to about -35
C).

The coolant concentration must not be reduced by


adding water even in warmer seasons and in
warmer countries. The coolant additive portion must
be at least 40%.

If for climatic reasons a greater frost protection is


required, the amount of G 12 can be increased, but
only up to 60% (frost protection to about -40 C), as
otherwise frost protection is reduced again and
cooling effectiveness is also reduced.

If radiator, heat exchanger, cylinder head or cylinder


head gasket is replaced, do not reuse old coolant.

The refractometer T10007 is recommended for


determining the current anti-freeze density.

Recommended mixture ratios:


Frost protection to

Anti-freeze amount

G 12 1)

Water 1)

-25

40%

5.0 l

8.0 l

-35

50%

6.5 l

6.5 l

1) The

quantity of coolant can vary depending upon the


vehicle equipment.
Work procedure

Cooling system components

- Install coolant hoses and secure.


- Thread adapter V.A.G 1274/8 on expansion tank.
- Fill coolant circuit using cooling system charge unit VAS
6096
Operating instructions for cooling system charge
unit VAS 6096
Coolant fan mount, removing and installing

Special tools, testers and auxiliary items required

Torque wrench (5 to 50 Nm) V.A.G 1331

Removing
- Drain coolant
filling .

19-1, Cooling system, draining and

- Pull off retaining clamps for upper coolant hose, remove


bolt - 1 - .
- Disconnect upper coolant hose from radiator.
- Remove front bumper

Page 23 / 30

Cooling system components

Repair Manual, Body Exterior, Repair Group 63, Front


bumper
- Bring lock carrier into service position

Repair Manual, Body Exterior, Repair Group 50, Lock


carrier
.
- Disconnect harness connectors for radiator fan.
- Disengage retainer - arrows - and remove fan mount
upward.
Installing
Installation is in reverse order of removal. Note the
following:
- The coolant fan mount must engage into mounting points
intended for it.
- Fill with coolant
filling .

19-1, Cooling system, draining and

Radiator, removing and installing

Special tools, testers and auxiliary items required

Drip tray V.A.G 1306

Page 24 / 30

Cooling system components

Torque wrench (5 to 50 Nm) V.A.G 1331

Removing
- Remove fan mount
and installing .

19-1, Coolant fan mount, removing

- Remove retaining clips on bumper carrier

Repair Manual, Body Exterior, Repair Group 63, Front


bumper; Bumper cover, removing and installing; Bumper
carrier - Assembly overview

- Disengage securing clamps for A/C system condenser


and ATF oil cooler - arrow - .
- Remove upper radiator securing bolts and remove
radiator upward.
Installing
Installation is in reverse order of removal. Note the
following:
- Fill with coolant
filling .

19-1, Cooling system, draining and

Page 25 / 30

Cooling system components

- Electrical connections and routing Electrical Wiring


Diagrams, Troubleshooting and Component Locations
binder
- Install front bumper

Repair Manual, Body Exterior, Repair Group 63, Front


bumper
- Check headlight adjustment and correct, if necessary
Repair Manual, Maintenance
Coolant connection, removing and installing

Special tools, testers and auxiliary items required

Drip tray V.A.G 1306

Torque wrench (5 to 50 Nm) V.A.G 1331

Removing
- Drain coolant
filling .

19-1, Cooling system, draining and

Page 26 / 30

Cooling system components

- Pull off coolant hoses from coolant connection.


- Disconnect connector from Engine Coolant Temperature
(ECT) Sensor G62 .
- Remove bolts from coolant connection.

- Slide cylinder connecting pieces in direction of - arrow into coolant housing - 1 - .


Installing
Installation is in reverse order of removal. Note the
following:

- Always replace seals - 2 - and gaskets.


- Tighten bolts of coolant housing - 1 - to 8 Nm.
- Fill with coolant
filling .

19-1, Cooling system, draining and

Coolant pump, removing and installing

Special tools, testers and auxiliary items required

Page 27 / 30

Cooling system components

Page 28 / 30

Drip tray V.A.G 1306

Torque wrench (5 to 50 Nm) V.A.G 1331

Removing
- Remove front bumper

Repair Manual, Body Exterior, Repair Group 63, Front


bumper
- Bring lock carrier into service position

Repair Manual, Body Exterior, Repair Group 50, Lock


carrier
.
- Set crankshaft to TDC Cylinder 1
checking , check valve timing.
- Remove vibration damper

15-1, Valve timing,

Item - 4 - .

Cooling system components

- Drain coolant
filling .

Page 29 / 30

19-1, Cooling system, draining and

- Disconnect coolant hose - 3 - from coolant pipe.


Unscrew mounting bolts - 1 - and - 2 - and fold coolant
pipe toward front.
- Remove coolant drain plugs
- Remove coolant pump cover

Item - 2 - .
Item - 5 - .

- Remove mounting bolts for coolant pump - arrows - and


remove coolant pump.
Note:

If coolant pump bolts are not accessibly, attach


vibration damper and turn crankshaft using
counterholder T10172 and threaded pins T10172/1
until bolts are accessible.

Installing
Installation is in reverse order of removal. Note the
following:
- Coat new O-ring with coolant, do not use any other
lubricants.

Cooling system components

- Install coolant pump.

- Tighten coolant pump bolts - arrows - to 20 Nm plus an


additional 1 / - 4 - turn (90 ).

- Tighten coolant pump cover bolts in the shown tightening


sequence to 8 Nm.
- Fill with coolant
filling .

19-1, Cooling system, draining and

Page 30 / 30

Fuel supply system components

Page 1 / 48

20 - 1

Fuel supply system components


Note:

Hose connections are secured with couplings or


spring-type or clamp-type clips.

Always replace clamp-type clips with spring-type


clips.

Fuel hoses at engine must only be secured with


spring-type clips. The use of clamp or screw type
clips is not permitted.

The spring-type clip pliers VAS 5024A are


recommended for installing spring-type clips.

Observe safety precautions when working on fuel


supply system 20-1, Safety precautions when working
on fuel supply system
Note rules of cleanliness

20-1, Rules for cleanliness

Fuel tank with attachments, assembly overview


1, Fuel tank with attachments, assembly overview

20-

Fuel filter, assembly overview 20-1, Fuel filter


(vehicles with engine code BKW), assembly overview

Vehicles with engine code BKW 20-1, Fuel filter


(vehicles with engine code BKW), assembly
overview

Vehicles with engine code BWF


20-1, Fuel filter,
(vehicles with engine code BWF), assembly

Fuel supply system components

Page 2 / 48

overview
Connection diagram of fuel lines and components in
fuel tank 20-1, Connection diagram for fuel lines and
fuel tank components
Connection diagram for fuel hoses in engine
compartment 20-1, Connection diagram for fuel hoses
in engine compartment (vehicles with engine code BKW)

Vehicles with engine code BKW 20-1, Connection


diagram for fuel hoses in engine compartment
(vehicles with engine code BKW)

Vehicles with engine code BWF


20-1, Fuel hoses
in engine compartment, vehicles with engine code
BKW, connection diagram

Fuel tank, emptying

20-1, Fuel tank, emptying

Fuel delivery unit, fuel gauge sender and suction jet


pump, removing and installing 20-1, Fuel delivery
unit, fuel gauge sensor and suction jet pump, removing and
installing
Fuel tank with attachments, removing and installing
20-1, Fuel tank with attachments, removing and installing
Fuel filter, removing and installing (Vehicles with
engine code BKW) 20-1, Fuel filter (vehicles with
engine code BKW), removing and installing
Check fuel pumps

20-1, Fuel pumps, checking

Tandem and fuel pump, checking


pump and Fuel Pump (FP), checking

20-1, Tandem

Tandem and fuel pump, removing and installing 201, Tandem pump and Fuel Pump (FP), removing and
installing
Accelerator pedal mechanism, assembly overview
20-1, Accelerator pedal mechanism, assembly overview
Safety precautions when working on fuel supply system

Warning!
When doing any repair work, especially in the engine
compartment, pay attention to the following due to
clearance issues:

Route lines of all types (e.g. for fuel, hydraulic,

Fuel supply system components

additive, coolant and refrigerant, brake fluid,


vacuum) and electrical wiring so that the original
path is followed.

Ensure sufficient clearance to all moving or hot


components.

The fuel or fuel lines in fuel system can become


very hot (danger of scalding)!

In addition, the fuel system is under pressure!


Before opening the system, place rags around
the connection area and release pressure by
carefully loosening the connection!

Wear protective goggles and protective gloves


when working on the fuel system!

Always observe the following when removing and installing


the sender for fuel gauge or the fuel delivery unit from full
or partially filled fuel tanks:
When removing and installing sender for fuel gauge from
full or partially full fuel tanks, the following must be
observed:

Before starting work, switch on exhaust extraction


system and place an extraction hose close to the
installation opening of fuel tank to extract escaping
fuel fumes. If no exhaust extraction system is
available, a radial fan (as long as motor is not in air
flow) with a displacement greater than 15 m 3 /h can
be used.

Prevent fuel from contacting skin! Wear fuelresistant gloves!

Rules for cleanliness

When working on the fuel supply/injection system, pay


careful attention to the following "7 rules" of cleanliness:

Thoroughly clean all connections and the


surrounding area before disconnecting.

Place parts that have been removed on a clean

Page 3 / 48

Fuel supply system components

surface and cover them. Do not use fluffy cloths!

Carefully cover over opened components or seal, if


repairs are not performed immediately.

Only install clean components: Only unpack


replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in
tool boxes etc.).

Supplied transport and protective packaging and


sealing caps should only be removed immediately
before installing.

When the system is open: Avoid working with


compressed air if possible. Do not move vehicle
unless absolutely necessary.

In addition, do not let diesel fuel flow onto coolant


hoses. If necessary, the hoses must be cleaned
again immediately. Replace corroded hoses.

Fuel tank with attachments, assembly overview

Page 4 / 48

Fuel supply system components

Page 5 / 48

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru


Volkswagen, Skoda, Seat, Audi

Fuel filler tube

Metering line

Only for vehicles with engine


code BLE (Not available)

Fuel tank

Connection diagram of fuel


lines and components in fuel
tank 20-1, Connection
diagram for fuel lines and
fuel tank components

Draining
emptying

Removing and installing


20-1, Fuel tank with
attachments, removing and
installing

20-1, Fuel tank,

Fuel supply system components

Flange

Left side

Note installed position on


fuel tank 20-1, Installation
position of fuel delivery unit
flange

Locking ring, 145 Nm

Use wrench T10202 for


removal and installation

Check for secure seating

Fuel delivery unit

Left side

Removing and installing


20-1, Fuel delivery unit, fuel
gauge sensor and suction jet
pump, removing and
installing , Fuel delivery unit,
fuel gauge sender and
suction jet pump, removing
and installing

Check fuel pumps 20-1,


Fuel pumps, checking

Fuel Level Sensor 3 G237

Left side

Clipped into bottom of tank

Removing and installing


20-1, Fuel delivery unit, fuel
gauge sensor and suction jet
pump, removing and
installing , Fuel delivery unit,
fuel gauge sender and
suction jet pump, removing
and installing

Checking Electrical Wiring


Diagrams, Troubleshooting
and Component Locations
binder

Page 6 / 48

Fuel supply system components

Suction jet pump

Left side

At fuel delivery unit

Removing and installing


20-1, Fuel delivery unit, fuel
gauge sensor and suction jet
pump, removing and
installing , Fuel delivery unit,
fuel gauge sender and
suction jet pump, removing
and installing

Protective cover

For bottom of fuel tank

Securing strap

Note installation position

Check for secure seating

20 Nm plus an additional 1 / 4
turn (90

Protective cover

For top of fuel tank

Suction jet pump

Left side

Clipped into bottom of tank

Removing and installing


20-1, Fuel delivery unit, fuel
gauge sensor and suction jet
pump, removing and
installing , Fuel delivery unit,
fuel gauge sender and
suction jet pump, removing
and installing

Metering line

Only for vehicles with engine

Page 7 / 48

Fuel supply system components

code BLE (Not available)

Suction jet pump

Right side

Removing and installing


20-1, Fuel delivery unit, fuel
gauge sensor and suction jet
pump, removing and
installing , Fuel delivery unit,
fuel gauge sender and
suction jet pump, removing
and installing

Fuel delivery unit

Right side

Removing and installing


20-1, Fuel delivery unit, fuel
gauge sensor and suction jet
pump, removing and
installing , Fuel delivery unit,
fuel gauge sender and
suction jet pump, removing
and installing

Check fuel pumps 20-1,


Fuel pumps, checking

Fuel Level Sensor G

Right side

Removing and installing


20-1, Fuel delivery unit, fuel
gauge sensor and suction jet
pump, removing and
installing , Fuel delivery unit,
fuel gauge sender and
suction jet pump, removing
and installing

Checking Electrical Wiring


Diagrams, Troubleshooting
and Component Locations
binder

Flange

Right side

Page 8 / 48

Fuel supply system components

Note installed position on


fuel tank 20-1, Installation
position of fuel delivery unit
flange

Bracket

Only for vehicles with engine


code BLE (Not available)

Installation position of fuel delivery unit flange

Insert sender flange with marking in direction of travel arrow - .


Fuel filter (vehicles with engine code BKW), assembly
overview

Connection diagram for fuel hoses in engine


compartment 20-1, Connection diagram for fuel hoses
in engine compartment (vehicles with engine code BKW)
Coolant hose connection diagram 19-1, Coolant
hose connection diagram (Vehicles with engine codes
BKW)

Page 9 / 48

Fuel supply system components

8 Nm

Fuel filter cover

Seal

Connections for fuel hoses


20-1, Fuel hose
connection

Replace

Fuel filter insert

Observe change intervals


Repair Manual, Maintenance

Water drain connection

Page 10 / 48

Fuel supply system components

To drain water, extract


approx. 100 cm 3 using
suction pump VAS 5226 .

Tighten sealing plug to 3 Nm

Return tube

To fuel tank

Blue or with blue marking

Check for secure seating

Supply tube

From fuel tank

White or with white markings

Check for secure seating

Coolant return line

Coolant supply line

8 Nm

3 Nm

Flexible Fuel (FF) Sensor G133

O-ring, replace

Fuel cooler

Fuel filter housing

Removing and installing


20-1, Fuel filter (vehicles
with engine code BKW),
removing and installing

Page 11 / 48

Fuel supply system components

Fuel hose connection

- Replace seal between connection and fuel filter cover.


- Tighten mounting bolts - arrows - to 8 Nm.
Fuel filter, (vehicles with engine code BWF), assembly
overview

Connection diagram for fuel hoses in engine


compartment 20-1, Fuel hoses in engine compartment,
vehicles with engine code BKW, connection diagram
Coolant hose connection diagram 19-1, Coolant
hose connection diagram, vehicles with engine code
BWF

Page 12 / 48

Fuel supply system components

Fuel line

Between fuel filter cover


Item - 6 - (identification on
connection - RT - ) and fuel
cooler Item - 16 -

Blue or with blue marking

Ensure seated tightly

Fuel supply line

From fuel tank to fuel filter


cover Item - 6 (identification on connection
- VF - )

White or with white markings

Ensure seated tightly

Page 13 / 48

Fuel supply system components

Locking bolt, 5 Nm

Seal

To drain water, extract


approx. 100 cm 3 using
suction pump VAS 5226 .

Fuel filter cover

Note installation position

Only possible to install in


one position

Seal

Replace

Water drain connection

Page 14 / 48

Replace

Fuel filter insert

Observe change intervals


Repair Manual, Maintenance

8 Nm

Seal

Note installation position

Replace

Fuel filter

Item -

Bracket

Secured to bracket
12 -

For fuel filter Item - 11 and fuel cooler Item - 16 -

50 Nm plus an additional 1 / 4

Fuel supply system components

turn (90

Replace

Ensure seated tightly

Fuel return line

Blue or with blue marking

Ensure seated tightly

Fuel cooler

Coolant hose

Page 15 / 48

Secured to bracket
12 -

Item -

Fuel return line

From connection at fuel line


Item - 3 - to fuel filter
cover Item - 6 (identification on connection
- RF - )

Blue or with blue marking

Ensure seated tightly

Fuel supply line

From fuel filter cover Item


- 6 - (identification on
connection - VM - ) to
connection at fuel line
Item - 2 -

White or with white markings

Ensure seated tightly

Connection diagram for fuel lines and fuel tank


components

- A - : Left half of tank


- arrow - : Direction of travel

Fuel supply system components

- B - : Right half of tank

Supply line for suction jet pump

Left side

Supply line
Vehicles with engine code
BKW:

To fuel filter

Item - 7 -

Vehicles with engine code


BWF:

To fuel filter

Item - 2 -

Return line
Vehicles with engine code,

Page 16 / 48

Fuel supply system components

Page 17 / 48

BKW:

From fuel filter

Item - 6 -

Flange

Right side

Supply line for auxiliary heater

Supply line for suction jet pump

Suction jet pump

Right side

Delivery line

Black

To fuel delivery unit on left


side

Delivery line

Black

To fuel delivery unit on right


side

Suction jet pump

Right side

Suction jet pump

To fuel delivery unit, right


side

Fuel delivery unit

Right side

Left side

Fuel delivery unit

Left side

Fuel supply system components

Suction jet pump

To fuel delivery unit, left side

Connection diagram for fuel hoses in engine


compartment (vehicles with engine code BKW)

Caution!
When installing fuel lines and hoses, ensure there is
clearance to other components or to body. Contact
can cause leaks.

Return line

To fuel tank

Blue or with blue marking

Check for secure seating

Page 18 / 48

Fuel supply system components

Supply line

From fuel tank

White or with white markings

Check for secure seating

Fuel rail

For cylinder bank 2

Fuel cooler

Test connection

For cylinder bank 1

Tighten sealing plug to 27


Nm

Not available on all vehicles

Fuel rail

Tandem pump

For cylinder bank 1

With vacuum pump

Tandem and fuel pump,


checking 20-1, Tandem
pump and Fuel Pump (FP),
checking

Tandem and fuel pump,


removing and installing
20-1, Tandem pump and
Fuel Pump (FP), removing
and installing

Fuel Temperature Sensor G81

For cylinder bank 1

For cylinder bank 1

Fuel filter

Page 19 / 48

Fuel supply system components

Fuel Pump (FP)

For cylinder bank 2

Tandem and fuel pump,


checking 20-1, Tandem
pump and Fuel Pump (FP),
checking

Tandem and fuel pump,


removing and installing
20-1, Tandem pump and
Fuel Pump (FP), removing
and installing

Fuel Temperature Sensor 2 G248

Removing and installing


20-1, Fuel filter (vehicles
with engine code BKW),
removing and installing

For cylinder bank 2

Test connection

For cylinder bank 2

Tighten sealing plug to 27


Nm

Not available on all vehicles

Fuel hoses in engine compartment, vehicles with engine


code BKW, connection diagram

Warning!
When installing fuel lines and hoses, ensure there is
clearance to other components or to body. Contact
can cause leaks.

Page 20 / 48

Fuel supply system components

Test connection

For cylinder bank 2

Tighten sealing plug to 27


Nm

Not available on all vehicles

Fuel supply line

From connection at fuel filter


cover Item - 18 -

White or with white markings

Ensure seated tightly

Fuel return line

To connection at fuel filter

Page 21 / 48

Fuel supply system components

cover

Blue or with blue marking

Ensure seated tightly

Fuel line

For cylinder bank 1

Tighten sealing plug to 27


Nm

Fuel rail
For cylinder bank 1

Tandem pump

For cylinder bank 1

With vacuum pump

Tandem and fuel pump,


checking 20-1, Tandem
pump and Fuel Pump (FP),
checking

Tandem and fuel pump,


removing and installing
20-1, Tandem pump and
Fuel Pump (FP), removing
and installing

Must not be disassembled

Fuel Temperature Sensor G81

For cylinder bank 2

Test connection

Secured to intake manifold


of cylinder bank 2

Fuel rail

Item - 17 -

For cylinder bank 1 and 2

Fuel Pump (FP)

Page 22 / 48

Fuel supply system components

For cylinder bank 2

Tandem and fuel pump,


checking 20-1, Tandem
pump and Fuel Pump (FP),
checking

Tandem and fuel pump,


removing and installing
20-1, Tandem pump and
Fuel Pump (FP), removing
and installing

Must not be disassembled

Fuel tank, emptying

Special tools, testers and auxiliary items required

Fuel siphoning unit VAS 5190

Wrench T10202

Not illustrated:

Page 23 / 48

Fuel supply system components

Torque wrench (40 to 200 Nm) V.A.G 1332

Work procedure
- Read safety precautions before beginning work 20-1,
Safety precautions when working on fuel supply system .
- Open fuel tank flap and remove fuel tank cap.
Note:

Secure Ground (GND) wire of fuel extraction unit


VAS 5190 to a bare area of the chassis.

- Slide extraction hose - arrow - of fuel extraction unit


VAS 5190 approx. 170 to 180 cm into fuel filler tube and
extract fuel.
Note:

When no more fuel can be extracted, the tank is


emptied only enough for the sender flange to be
opened without danger. The tank may be removed
while containing the remaining fuel. If work must be
performed on the fuel pumps or fuel tank senders,
proceed as follows:

- Fold rear seat bench forward.

Page 24 / 48

Fuel supply system components

- Cut open carpet from point - A - to point - B - in pre-cut


area - arrows - .

- Remove nuts - 1 - for cover. If necessary, remove


anchor plate - 2 - .

- Disconnect harness connector for fuel pump and tank


sensor - 4 - .
- Disconnect return line - 1 - , supply line - 2 - as well as
supply line for auxiliary heater - 3 - from right sensor
flange.
Note:

Press in securing ring to disengage the fuel lines.

Page 25 / 48

Fuel supply system components

- Remove locking ring from sensor flange using wrench


T10202 .
- Carefully pry out sensor flange and raise it slightly.
- Insert extraction hose of fuel extraction unit VAS 5190 as
deeply as possible into right or left side of fuel tank and
extract fuel.
- For work on left side of fuel tank, proceed as described
above.
- When disconnecting fuel lines, it is possible that the
securing rings on the hose connections cannot be pressed
in. To do this, insert assembly tool T10118 .
For additional work on components inside of fuel tank,
sensor flanges may remain removed.
If fuel tank needed only to be emptied, install sensor
flanges again.
- Check that sensor flange seals are properly seated.
Note:

If seals are swollen with fuel, always replace.

Page 26 / 48

Fuel supply system components

- Insert sensor flange with marking in direction of travel arrow - .


- Tighten left and right locking rings using wrench T10202
to 145 Nm.
Note:

Do not interchange supply and return lines (return


line blue - 1 - , supply line black - 2 - ).

Ensure fuel hoses are seated securely.

Fuel delivery unit, fuel gauge sensor and suction jet


pump, removing and installing

Special tools, testers and auxiliary items required

Torque wrench (40 to 200 Nm) V.A.G 1332

Page 27 / 48

Fuel supply system components

Page 28 / 48

Wrench T10202

Requirements

The fuel tank must be drained


emptying , emptying fuel tank

20-1, Fuel tank,

Connectors and lines for left and right sender


flanges are disconnected

Locking rings for left and right sender flanges are


removed

Removing
- Observe safety precautions before performing repair
work 20-1, Safety precautions when working on fuel
supply system .

- Disconnect harness connectors - 1 - and - 2 - , as well


as hose couplings - 3 - , - 4 - and - 5 - below right sensor
flange.
Note:

Press in securing ring to disengage the fuel lines.

Fuel supply system components

- Remove sensor flange.

- Unclip black filler hose - arrow - from fuel delivery unit


housing on left and right sides of fuel tank.

- Disconnect fuel supply line from fuel delivery unit - arrow


- on left and right sides of fuel tank to suction jet pumps.
- Disconnect supply and return lines between both fuel
delivery units on left side of fuel tank.
- Unscrew Fuel Pump (FP) unit in bottom of fuel tank by
turning approx. 90 to left.
Note:

The fuel pump (FP) unit housing is filled with fuel.


Fuel may run out if the housing is tipped.

- Unclip fuel level sensors on both sides of fuel tank and


pull them out.
- Unclip suction jet pumps from bottom on each side and
remove with a slight turn.
- Pull out hose ends through left and right sender
openings.

Page 29 / 48

Fuel supply system components

Installing
Installation is in reverse order of removal. Note the
following:

Connections for fuel lines must engage audibly when


joined.

Route fuel hoses kink-free.

Make sure fuel hoses are seated securely.

Fuel tank with attachments, removing and installing

Special tools, testers and auxiliary items


required

Fuel extraction unit VAS 5190

Page 30 / 48

Fuel supply system components

Page 31 / 48

Polydrive key T10202

Torque wrench (5 to 50 Nm) V.A.G


1331

Torque wrench (40 to 200 Nm)


V.A.G 1332

Engine/transmission jack V.A.G


1383 A

Removing
Note:

Read safety precautions before beginning work


20-1, Safety precautions when working on fuel
supply system .

The fuel tank must be drained


emptying , emptying fuel tank.

20-1, Fuel tank,

Vehicles with engine code BKW


- Remove middle and rear mufflers of exhaust system
26-1, Muffler with mountings (vehicles with engine code
BKW), assembly overview .
Vehicles with engine code BWF
- Remove rear muffler of exhaust system 26-1, Muffler
with mountings (vehicles with engine code BWF),
assembly overview .
Continuation for all vehicles
- Remove rear driveshaft

Repair Manual, Rear Final Drive, Repair Group 39,


Driveshafts, removing and installing
- Remove rear subframe

Repair Manual, Suspension, Wheels, Steering, Repair

Fuel supply system components

Group 42, I - Assembly overview: Subframe, stabilizer bar,


stone impact protection
- Open fuel tank flap and remove fuel tank cap.
- Pull rubber gasket off filler neck.

- Remove securing bolts - 1 - on filler neck and pull off


Ground (GND) wire - 2 - .
- Remove right rear wheelhousing liner

Repair Manual, Body Exterior, Repair Group 66,


Wheelhousing liners

- Unbolt cover plate - arrow - .

Page 32 / 48

Fuel supply system components

- Unclip fuel tank breather lines at securing clip attached


on longitudinal member.

- Remove mounting nut for filling pipe - arrow - in wheel


housing.

- Disconnect fuel pump connectors, on left next to fuel


tank.
- Remove securing straps with covers on left and right
below fuel tank.
- Support fuel tank using engine/transmission jack V.A.G
1383 A and remove tension strap at center of fuel tank.
- Carefully lower fuel tank about 30 cm.

Page 33 / 48

Fuel supply system components

- Grab between fuel tank and vehicle floor and disconnect


fuel lines from sensor flange. When pulling off fuel supply
line, hold a cloth around fuel supply line.
Note:

This step eliminates having to cut open the carpeting


in the vehicle interior in the vicinity of sender flange
cover.

- Lower and remove fuel tank.


Installing
Installation is in reverse order of removal. Note the
following:

Line connections for metering, ventilation and fuel


lines must engage audibly when joined.

Do not interchange supply and return lines (return


line blue or with blue marking - 1 - , supply line
black - 2 - ).

Clip in the metering and fuel lines at the fuel tank.

Make sure metering, ventilation and fuel hoses are


not kinked when installed.

Make sure metering and fuel lines are securely


positioned.

If necessary, fill up additive for additive tank


Repair Manual, Maintenance

Page 34 / 48

Fuel supply system components

Fuel filter (vehicles with engine code BKW), removing


and installing

Special tools, testers and auxiliary items


required

Hose clamps up to 25 mm dia.


3094

Torque wrench (5 to 50 Nm) V.A.G


1331

Spring-type clip pliers VAS 5024


A

Suction pump VAS 5226

Removing

Page 35 / 48

Fuel supply system components

- Disconnect supply hose - 3 - (white marking) and return


hose - 2 - (blue marking) from fuel filter.

- Connect suction pump VAS 5226 to water drain


connection - arrow - of fuel filter.
- Operate suction pump VAS 5226 until fuel no longer
flows out.

- Remove both mounting bolts - 1 - and remove


connection with fuel lines.
- Open cap on coolant expansion tank.
- Clamp off both coolant hoses - 4 - using hose clamps up
to dia. 25 mm 3094 .

Page 36 / 48

Fuel supply system components

- Disconnect coolant hoses and catch escaping coolant


using a rag.

- Remove both mounting bolts - arrows - and pull fuel


filter slightly toward front.
Note:

Be careful not to lose the rubber mount bushing on


the top and bottom of the fuel filter mounting holes.

- Unclip lines at rear side of fuel filter.


- Disconnect harness connector for Flexible Fuel (FF)
Sensor G133 and remove fuel filter.
Installing
Installation is in reverse order of removal. Note the
following:
- Replace seal between connection and fuel filter cover.
- Tighten sealing plug of water drain connection to 3 Nm.
- Fill with coolant
filling .

19-1, Cooling system, draining and

Fuel pumps, checking

Special tools, testers and auxiliary items required

Page 37 / 48

Fuel supply system components

Voltage tester V.A.G 1527 B

Hand multimeter V.A.G 1526 C or Multimeter V.A.G


1715

Not illustrated:

Connector test set V.A.G 1594 C

Requirements

The fuses must be OK

Battery voltage must be at least 11.5 Volts

All electrical consumers such as, lights and rear


window defroster must be switched off

Function and voltage supply, checking


- Fold rear seat bench forward.
- Briefly operate starter. Fuel Pumps (FP) must run
audibly.

Page 38 / 48

Fuel supply system components

- Switch off ignition.


If Fuel Pumps (FP) do not start up:

- Cut floor carpet in pre-cut area - arrows - from points A - to - B - on left and right vehicle sides.

- Remove nuts - 1 - for cover. If necessary, unscrew


anchor plate - 2 - .
Check voltage supply of each individual Fuel Pump (FP) as
follows:
- Disconnect 4-pin harness connector from right flange of
fuel delivery unit.

- Connect diode test lamp V.A.G 1527 B using adapter

Page 39 / 48

Fuel supply system components

cables from connector test kit V.A.G 1594 C to outer


terminals of connector.
- Switch on ignition, LED must light up for approx. 2
seconds.
If LED does not light up:
- Check activation of fuel pump relay and check wires for
open circuit and short circuit Vehicle Diagnosis, Testing
and Information System VAS 5051
LED lights up (voltage supply OK):
- Remove right Fuel Pump (FP) unit 20-1, Fuel delivery
unit, fuel gauge sensor and suction jet pump, removing and
installing .
- Check if electrical wiring between flange and fuel pump is
connected and has continuity.
If no open circuits are found:
- Right fuel pump is faulty. Replace fuel delivery unit 201, Fuel delivery unit, fuel gauge sensor and suction jet
pump, removing and installing .
- Repeat test on left fuel delivery unit.
Current pick-up of fuel pumps, checking
- Check current consumption of each fuel pump separately
as follows:

- Connect current clamp of multimeter V.A.G 1715 to the


wire of the 4-pin connector contact - 1 - - arrow - from
wiring harness to right fuel delivery unit.
- Start engine and let run at idle speed.
- Measure Fuel Pump (FP) current draw: Specification:
max. 8 amperes.

Page 40 / 48

Fuel supply system components

If current draw is exceeded:


- Right fuel pump is faulty. Replace fuel delivery unit 201, Fuel delivery unit, fuel gauge sensor and suction jet
pump, removing and installing .
- Repeat test on left fuel delivery unit.
Tandem pump and Fuel Pump (FP), checking

Note:

The tandem pump delivers fuel for cylinder bank 1


and Fuel Pump (FP) delivers fuel for cylinder bank
2.

Special tools, testers and auxiliary items required

Torque wrench (5 to 50 Nm) V.A.G 1331

Pressure Gauge VAS 5187 with Adapter Set VAS


5187/6

Not illustrated:

Vehicle Diagnostic, Testing and Information System

Page 41 / 48

Fuel supply system components

Page 42 / 48

VAS 5051 A with diagnostic cable

Adapter Set VAS5187/6

Requirements

Coolant temperature must be at least 85

C.

Pump-injector units OK

Fuel filter and fuel lines must not be blocked

Work sequence
Vehicles with test connections (engine code BKW)

- Connect pressure gauge VAS 5187 to test connection


for cylinder bank 1 - 1 - or to test connection for cylinder
bank 2 - 2 - .
Vehicles with test connections (engine code BWF)

- Connect test unit for tandem pump VAS 5187 to test


connection for cylinder bank 1 - 1 - or to test connection
for cylinder bank 2 - 2 - .

Fuel supply system components

Vehicles without test connections (engine code BKW)


- Remove fuel filter 20-1, Fuel filter (vehicles with engine
code BKW), removing and installing .

- Connect test unit for tandem pump VAS 5187 to supply


line for cylinder bank 1 - 1 - or to supply line for cylinder
bank 2.
- Install fuel filter 20-1, Fuel filter (vehicles with engine
code BKW), removing and installing .
Continuation for all vehicles
Connect vehicle diagnosis, testing and information system
VAS 5051 as follows:

- Open cover - 1 - (if equipped) and connect the connector


of the diagnostic cable to the Data Link Connector (DLC).
- Start engine and run at idle speed.
- On Vehicle diagnostic, testing, and information system ,
select operating mode "Vehicle Self Diagnosis" . Then, go
into engine control module (ECM) J623 with address word
"01 - Engine electronics" .
- Press diagnostic function "08 - Read measuring value
blocks" .

Page 43 / 48

Fuel supply system components

- Enter "display group 1" via number keypad and confirm


input by pressing Q button.
- Read idle RPM in "display field 1" .
- Increase engine speed to 1500 RPM.
- Observe pressure displayed on pressure gauge.
Specification: at least 7.5 bar.
- Press

key twice.

- Press function "06 - End output" .


If specification is not obtained:
- Replace tandem pump or Fuel Pump (FP) 20-1,
Tandem pump and Fuel Pump (FP), removing and
installing .
Note:

After removing pressure gauge for tandem pump ,


tighten supply line and sealing plug to 27 Nm.

Tandem pump and Fuel Pump (FP), removing and


installing

Caution!
The tandem pump must not be disassembled under
any circumstances because it can cause the vacuum
part to malfunction. The result would be brake booster
failure.
Special tools, testers and auxiliary items required

Torque wrench (5 to 50 Nm) V.A.G 1331

Page 44 / 48

Fuel supply system components

Page 45 / 48

Spring-type clip pliers VAS 5024 A

Removing
Note:

Work sequence for removing and installing tandem


pump is described. Work sequence for Fuel Pump
(FP) is identical up to disconnecting the vacuum
line.

Vehicles with engine code BKW


- Remove fuel filter 20-1, Fuel filter (vehicles with engine
code BKW), removing and installing .
Vehicles with engine code BWF
- Remove bypass flap with cooler for Exhaust Gas
Recirculation (EGR) 26-2, Bypass flap with cooler for
Exhaust Gas Recirculation (EGR) (vehicles with engine
code BWF), assembly overview .
Continuation for all vehicles
- Remove intake manifold
removing and installing .

23-1, Intake manifold,

Fuel supply system components

- Disconnect vacuum line - 1 - from brake booster of


tandem pump - 5 - .
- Disconnect central connector for Pump-Injector Units - 3
- .
- Disconnect fuel hose - 2 - at tandem pump - 5 - .
- Remove mounting bolts - arrows - .
- Remove tandem pump - 5 - from cylinder head.
- Pull tandem pump - 5 - slightly upward, unscrew fuel
hose - 4 - and remove tandem pump.
Installing
Installation is in reverse order of removal. Note the
following:
Note:

Make sure that the tandem pump coupling has


proper seating in camshaft.

Tandem pump seals must always be replaced.

- Connect fuel line - 4 - with new sealing rings to tandem


pump - 5 - and tighten banjo bolt to 25 Nm.
- Install tandem pump and tighten mounting bolts - arrows
- .
Torque specification:

M6: 8 Nm

M8: 20 Nm

Page 46 / 48

Fuel supply system components

- Connect fuel hose - 2 - and vacuum line - 1 - to tandem


pump.
- Connect central connector for Pump-Injector Units.
Vehicles with engine code BKW
- Install fuel filter 20-1, Fuel filter (vehicles with engine
code BKW), removing and installing .
Vehicles with engine code BWF
- Install bypass flap with cooler for Exhaust Gas
Recirculation (EGR) 26-2, Bypass flap with cooler for
Exhaust Gas Recirculation (EGR) (vehicles with engine
code BWF), assembly overview .
Continuation for all vehicles
- Install intake manifold
and installing .

23-1, Intake manifold, removing

- Perform test drive and check DTC memory 23-2,


Diagnostic Trouble Code (DTC) memory of Engine control
modules (ECM) , checking and erasing , DTC memory of
Engine Control Module (ECM) , checking and erasing.
Note:

By disconnecting the central connection for the


pump-injector unit, DTCs will be stored. Check the
DTC memory and erase, if necessary.

Accelerator pedal mechanism, assembly overview

Page 47 / 48

Fuel supply system components

Bracket

Connector

Black, 6-pin

10 Nm

Throttle position (TP) sensor


G79

Not adjustable

Remove footwell cover to


remove sensor

Page 48 / 48

Charge air system with turbocharger

Page 1 / 9

21 - 1

Charge air system with turbocharger


Observe safety precautions
precautions .
Note rules of cleanliness

21-1, Safety
21-1, Rules for cleanliness

Observe installation of hose connections with


connector couplings 21-1, Hose connections with
connector couplings, installing
Turbocharger, assembly overview
Turbocharger, assembly overview

21-1,

Charge air cooler, assembly overview 21-1, Charge


air cooler components, assembly overview
Safety precautions

Caution!
When doing any repair work, especially in the engine
compartment, pay attention to the following due to
clearance issues:

Route lines of all types (e.g. for fuel, hydraulic,


additive, coolant and refrigerant, brake fluid,
vacuum) and electrical wiring so that the original
path is followed.

To prevent damages to the lines, make sure


there is sufficient clearance to all moving or hot
components.

Observe the following if test and measuring instruments


are required during a test drive:

Test and measuring instruments must be secured to


rear seat and operated by a 2nd person from this
location.

If test and measuring instruments are operated from the


front passengers seat and the vehicle is involved in an
accident, there is a possibility that the person sitting in this
seat may receive serious injuries when the airbag is
triggered.
Warning!
Secure Scan Tool (ST) on the rear seat and operate it

Charge air system with turbocharger

from there by second technician.


Rules for cleanliness

When working on turbocharger, carefully observe the


following "7 rules" of cleanliness:

Thoroughly clean all connections and surrounding


area before disconnecting.

Place parts that have been removed on a clean


surface and cover them. Do not use fluffy cloths!

Carefully cover over opened components or seal, if


repairs are not performed immediately.

Only install clean components: Only unpack


replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in
tool boxes etc.).

Supplied transport and protective packaging and


sealing caps should only be removed immediately
before installing.

During repair, clean oil from connections and hose


ends.

When the system is open: Avoid working with


compressed air if possible. Do not move vehicle
unless absolutely necessary.

Hose connections with connector couplings, installing

Caution!
Connector coupling sealing ring can be damaged if
securing clamp is in locked position when installing.
This would result in a leak. Follow assembly
instructions.
Removing

Page 2 / 9

Charge air system with turbocharger

- Release connection coupling by pulling securing clip arrow - . Separate hose/tube without assistance from
tools.
Installing
- When replacing sealing ring, lay ring in charge air hose
groove. Ensure gasket is completely seated in groove all
the way around.
- Oil sealing surfaces and sealing ring.
- Bring securing clip into release position - 1 - .
- Slide charge air hose into clutch as far as stop.

- Bring securing clip into lock position - 2 - and then press


charge air hose back again.
- Check for correct seating and proper locking of connector
by pulling on hose.

Page 3 / 9

Charge air system with turbocharger

Page 4 / 9

Turbocharger, assembly overview

Note:

Various hose connections are secured.

Charge air system must be properly sealed.

Replace self-locking nuts.

Before screwing on oil supply line, fill turbocharger


with engine oil at connecting tube.

After installing turbocharger, let engine run at idle for


approx. 1 minute and without increasing engine
speed. This ensures that Turbocharger is
lubricated.

Components depicted here correspond to cylinder


bank 2. They are different only as a mirror image of
components for cylinder bank 1.

Observe safety precautions


precautions .
Observe rules for cleanliness
cleanliness .

21-1, Safety
21-1, Rules for

Charge air system with turbocharger

Page 5 / 9

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru


Volkswagen, Skoda, Seat, Audi

To connecting pipe

Vehicles with engine code


BKW Item - 12 -

Vehicles with engine code


BWF Item - 11 -

Exhaust manifold

Exhaust manifold, assembly


overview 26-1, Exhaust
manifold, assembly
overview

Turbocharger Intake
Temperature Sensor , 45 Nm

Only on vehicles with engine


code BWF

Charge air system with turbocharger

Cylinder bank 1:

Turbocharger (TC) Intake


Temperature Sensor G507

Cylinder bank 2:

Turbocharger (TC) Intake


Temperature Sensor 2
G499

Securing clamp, 8 Nm

Turbocharger

Can only be replaced when


engine is removed from
engine compartment 10-1,
Engine, removing and
installing , Engine, removing
and installing

Tighten oil supply line to 23


Nm

To front exhaust pipe with


catalytic converter

Vehicles with engine code


BKW Item - 7 -

Vehicles with engine code


BWF Item - 11 -

40 Nm

Servo motor for turbocharger

Component of the
turbocharger cannot be
replaced

Cylinder bank 1:

Turbocharger (TC) 1 Servomotor V280

Cylinder bank 2:

Turbocharger (TC) 2 Servomotor V281

Page 6 / 9

Charge air system with turbocharger

Seal

Replace

Before installing, check


sealing surfaces for
contamination and clean if
necessary

8 Nm

Connecting pipe

To charge air tube

Item - 8 -

Sealing sleeve

Replace if damaged

Check for secure seating

Connecting pipe

From crankcase ventilation


valve

Charge air cooler components, assembly overview

Note:

Various hose connections are secured.

If necessary, use lubricant (water without additive) to


assist assembly. Do not use lubricants containing
oil.

Charge air system must be properly sealed.

With connector couplings, follow the installation


instructions closely 21-1, Hose connections with
connector couplings, installing .

Components depicted here correspond to cylinder


bank 2. They are different only as a mirror image of

Page 7 / 9

Charge air system with turbocharger

Page 8 / 9

components for cylinder bank 1.


Observe safety precautions
precautions .
Note rules of cleanliness

Air duct

8 Nm

Spacer bushing

Air charge cooler

21-1, Safety
21-1, Rules for cleanliness

To remove, remove bumper


cover

Repair Manual, Body Exterior, Repair


Group 63, Front bumper

Charge air system with turbocharger

O-ring

Replace if damaged

3 Nm

Charge Air Pressure Sensor G31


with Intake Air Temperature (IAT)
Sensor G42
Cylinder bank 1:

Charge Air Pressure Sensor


G31 with Intake Air
Temperature (IAT) Sensor
G42

Cylinder bank 2:

Charge Air Pressure Sensor


2 G447 with Intake Air
Temperature (IAT) Sensor 2
G299

Charge air pipe

Retaining clip

Check for secure seat

To intake manifold

Vehicles with engine code


BKW Item - 1 -

Vehicles with engine code


BWF Item - 15 -

Connecting hose

8 Nm

From connecting pipe

Item - 11 -

Page 9 / 9

Diesel-Direct Fuel Injection System, servicing

Page 1 / 28

23 - 1

Diesel-Direct Fuel Injection System, servicing


Note:

Engine control modules for Diesel-Direct fuel


injection system are equipped with a DTC memory.
Before and after repairs or adjustment work, DTC
memory must be checked 23-2, Diagnostic
Trouble Code (DTC) memory of Engine control
modules (ECM) , checking and erasing ; DTC
memory of Engine Control Modules (ECM) ,
checking and erasing.
23-1, Safety

Observe safety precautions


precautions .
Note rules of cleanliness

23-1, Rules for cleanliness

Intake manifold, removing and installing


manifold, removing and installing

23-1, Intake

Intake connection, assembly overview 23-1, Intake


connection (vehicles with engine code BKW), assembly
overview

Vehicles with engine code BKW 23-1, Intake


connection (vehicles with engine code BKW),
assembly overview

Vehicles with engine code BWF


23-1, Intake
connection (vehicles with engine code BWF),
assembly overview

Air filter, assembly overview


overview

23-1, Air filter, assembly

Pump-injector unit, assembly overview


injector unit, assembly overview

23-1, Pump-

Pump-injector unit, removing and installing


Pump-Injector Unit, removing and installing
O-rings for pump-injector unit, replacing
rings for pump-injector unit, replacing

23-1,
23-1, O-

Safety precautions

Caution!
When doing any repair work, especially in the engine

Diesel-Direct Fuel Injection System, servicing

compartment, pay attention to the following due to


clearance issues:

Route lines of all types (e.g. for fuel, hydraulic,


additive, coolant and refrigerant, brake fluid,
vacuum) and electrical wiring so that the original
path is followed.

To prevent damages to the lines, make sure


there is sufficient clearance to all moving or hot
components.

Observe the following if test and measuring instruments


are required during a test drive:

Test and measuring instruments must be secured to


rear seat and operated by a 2nd person from this
location.

If test and measuring instruments are operated from the


front passengers seat and the vehicle is involved in an
accident, there is a possibility that the person sitting in this
seat may receive serious injuries when the airbag is
triggered.
Warning!
Secure Scan Tool (ST) on the rear seat and operate it
from there by second technician.
To reduce the risk of personal injury and/or damage to the
fuel injection and glow plug system, always observe the
following:

Only disconnect and reconnect wires for glow plug


and fuel injection systems, including test leads,
when ignition is turned off.

Obtain radio code for radios with anti-theft coding


before disconnecting battery.

The battery must only be disconnected and


connected with the ignition switched off, otherwise
the Engine Control Modules (ECM) could be
damaged.

Rules for cleanliness

Page 2 / 28

Diesel-Direct Fuel Injection System, servicing

When working on the fuel supply/injection system, pay


careful attention to the following "7 rules" of cleanliness:

Thoroughly clean all connections and the


surrounding area before disconnecting.

Place parts that have been removed on a clean


surface and cover them. Do not use fluffy cloths!

Carefully cover over opened components or seal, if


repairs are not performed immediately.

Only install clean components: Only unpack


replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in
tool boxes etc.).

Supplied transport and protective packaging and


sealing caps should only be removed immediately
before installing.

When the system is open: Avoid working with


compressed air if possible. Do not move vehicle
unless absolutely necessary.

In addition, do not let diesel fuel flow onto coolant


hoses. If necessary, the hoses must be cleaned
again immediately. Replace corroded hoses.

Intake manifold, removing and installing

Requirements:
Vehicles with engine code BKW

Fuel filter unit removed 20-1, Fuel filter (vehicles


with engine code BKW), removing and installing

Vehicles with engine code BWF

Bypass flap with cooler for Exhaust Gas


Recirculation (EGR) removed 26-2, Bypass flap
with cooler for Exhaust Gas Recirculation (EGR)
(vehicles with engine code BWF), assembly
overview

Page 3 / 28

Diesel-Direct Fuel Injection System, servicing

Continuation for all vehicles

Upper part of oil filter housing removed 17-3, Oil


filter housing, assembly overview , Oil filter housing Assembly overview

Note:

Components depicted here correspond to cylinder


bank 2. They are different only as a mirror image of
components for cylinder bank 1.

In order to be able to remove intake manifold without


disassembling the fuel rail, intake manifold bolts
must be completely removed.

Cylinder head

Removing and installing


15-1, Cylinder heads,

Page 4 / 28

Diesel-Direct Fuel Injection System, servicing

removing and installing ,


Cylinder heads, removing
and installing

Gasket

Replace

Intake manifold
Intake connection - Assembly
overview:

Vehicles with engine code


BKW 23-1, Intake
connection (vehicles with
engine code BKW),
assembly overview

Vehicles with engine code


BWF 23-1, Intake
connection (vehicles with
engine code BWF),
assembly overview

20 Nm

Fuel rail

8 Nm plus an additional 1 / 4 turn


(90

Seal

Replace

Replace

Connecting piece

Long

For supply

Remove and install using


pliers VAS 6275

Connecting piece

Short

Page 5 / 28

Diesel-Direct Fuel Injection System, servicing

For return

Remove and install using


pliers VAS 6275

Glow plug , 15 Nm
Cylinder bank 1

Glow plugs 1 through 5 Q10


to Q14

Cylinder bank 2

Glow plugs 6 through 10


Q15 to Q19

Removing and installing,


checking:

Vehicles with engine codes


BKW and BWF 28-1,
Glow plugs vehicles with
engine code BKW, BWF)
removing and installing,
checking

Intake connection (vehicles with engine code BKW),


assembly overview

Note:

When engine is switched off, the intake connection


is closed for approx. 3 seconds and then opens
again. This reduces the stop jolt.

Components depicted here correspond to cylinder


bank 2. They are different only as a mirror image of
components for cylinder bank 1.

Page 6 / 28

Diesel-Direct Fuel Injection System, servicing

Intake connection with intake


flap motor
Cylinder bank 1:

Intake Flap Motor V157

Cylinder bank 2:

8 Nm

Seal

Intake Flap Motor 2 V275

Replace

Before installing, check


sealing surfaces for
contamination and clean if
necessary

Page 7 / 28

Diesel-Direct Fuel Injection System, servicing

EGR Vacuum Regulator


Solenoid Valve N18

Intake manifold

Checking mechanically
26-2, Exhaust Gas
Recirculation (EGR) valve
(vehicles with engine code
BKW), checking

Removing and installing


23-1, Intake manifold,
removing and installing

Gasket

Replace

Note installation position

20 Nm

From exhaust manifold

Item - 2 -

Connecting pipe

Bracket
For connecting pipe

Item - 9 -

Intake connection (vehicles with engine code BWF),


assembly overview

Note:

When engine is switched off, the intake connection


is closed for approx. 3 seconds and then opens
again. This reduces the stop jolt.

Components depicted here correspond to cylinder


bank 2. They are different only as a mirror image of
components for cylinder bank 1.

Page 8 / 28

Diesel-Direct Fuel Injection System, servicing

Test connection bracket

Cylinder bank 1

Item - 6 -

Cylinder bank 2

Item - 1 -

8 Nm

Seal

Replace

Before installing, check the


sealing surfaces for
contamination and clean if
necessary

Gasket

Replace

Page 9 / 28

Diesel-Direct Fuel Injection System, servicing

Note installation position

To the bypass flap


Item - 16 -

Connecting pipe

20 Nm

From the bypass flap


Item - 17 -

Bracket
For connecting pipe
-

Connecting pipe

Connecting pipe

8 Nm

From exhaust manifold

Item - 10

Item - 2 -

Intake connection with intake


flap motor
Cylinder bank 1:

Intake Flap Motor V157

Cylinder bank 2:

Intake Flap Motor 2 V275

EGR Vacuum Regulator


Solenoid Valve with EGR
Potentiometer
Cylinder bank 1:

EGR Vacuum Regulator


Solenoid Valve N18 with
EGR Potentiometer G212

Cylinder bank 2:

Page 10 / 28

Diesel-Direct Fuel Injection System, servicing

Exhaust Gas Recirculation


(EGR) valve 2 N213 with
Exhaust Gas Recirculation
(EGR) Position Sensor
G466

If the Exhaust Gas


Recirculation (EGR) valve with
EGR Potentiometer is replaced,
then do the following:
- Switch ignition on and off.
- Then wait for one minute
for the control module
after-run.
- Start engine and let run at
idle for at least 1 minute.
- Then, check the DTC
memory of the engine
control module (ECM)
23-2, Diagnostic Trouble
Code (DTC) memory of
Engine control modules
(ECM) , checking and
erasing , DTC memory of
engine control module
(ECM) , checking and
erasing.
If a fault is stored in DTC
memory:
- Repeat work procedure.

Intake manifold

Removing and installing


23-1, Intake manifold,
removing and installing

Air filter, assembly overview

Note:

Page 11 / 28

Diesel-Direct Fuel Injection System, servicing

The spring-type clip pliers VAS 5024 A are


recommended for installing spring-type clips.

Components depicted here correspond to cylinder


bank 2. They are different only as a mirror image of
components for cylinder bank 1.

Line connection to compressor for air suspension


23-1, Line connection to compressor for air
suspension

Page 12 / 28

Diesel-Direct Fuel Injection System, servicing

Lower section of air filter

Filter element

Upper section of air filter

Securing pins

Removing and installing


23-1, Removing and
installing securing pins

O-ring

Replace if damaged

Intake manifold

Mass air flow (MAF) sensor


Cylinder bank 1:

Page 13 / 28

Diesel-Direct Fuel Injection System, servicing

Mass air flow (MAF) sensor


G70

Cylinder bank 2:

Mass Air Flow (MAF) Sensor


2 G246

6 Nm

Spring-type clip

Use pliers for spring-type


clamps VAS 5024 A to
remove and install

Transition piece

Connecting pipe

Connecting hose

To turbocharger

Removing and installing securing pins

Removing
- Using an appropriate socket, turn securing pins until
markings - A - on pins and - B - on housing align.
- Remove pins upward.
Installing
- Press pins into holes up to stop and twist them approx.
180 using an appropriate socket.

Page 14 / 28

Diesel-Direct Fuel Injection System, servicing

Line connection to compressor for air suspension

- Using a screwdriver - C - , pry off green sealing ring - 1


- from line flange - 3 - .
- Press securing sleeve - 2 - in direction of - arrow - and
disconnect line - B - from air filter connection - A - .
Pump-injector unit, assembly overview

Note rules of cleanliness

23-1, Rules for cleanliness

Note:

Always replace seals and O-rings.

Page 15 / 28

Diesel-Direct Fuel Injection System, servicing

20 Nm plus an additional 1 / 4
turn (90

Replace

Lock nut, 30 Nm

Adjustment screw

Replace with each


separation from ball pin

Rocker arm axle

With rocker arm

Removing and installing


23-1, Pump-Injector Unit,
removing and installing ,
removing and installing

Page 16 / 28

Diesel-Direct Fuel Injection System, servicing

Pump-Injector Unit

Tension block

12 Nm plus an additional 3 / 4
turn (270

Removing and installing


23-1, Pump-Injector Unit,
removing and installing

Replace ball pins when


separating from adjusting
screw

O-ring
Replace 23-1, O-rings for
pump-injector unit,
replacing

Heat protection seal

Replace

Pump-Injector Unit

Replace

Circlip

Pump-Injector Unit, removing and installing

Page 17 / 28

Diesel-Direct Fuel Injection System, servicing

Special tools, testers and auxiliary items


required

Dial gauge holder VW 387

Multi-point socket 3410

Multi-point socket T10054

Puller T10055

Torque wrench (5 to 50 Nm) V.A.G


1331

Not illustrated:

Gauge T10210

Page 18 / 28

Diesel-Direct Fuel Injection System, servicing

Dial gauge

Removing

- Remove acoustic cover and cylinder head cover of the


applicable cylinder head.
- Rotate crankshaft until cam pair of respective PumpInjector Unit to be installed and removed face upward
simultaneously.

- Loosen lock nuts of adjustment bolts - 1 - and unscrew


adjustment bolts as far until respective rocker arm makes
contact at plunger spring of Pump-Injector Unit.
- Loosen bolts - 2 - for rocker lever shaft from the outside
toward the inside, using the socket insert 3410 and
remove the rocker lever shaft.
- Loosen mounting bolt - 3 - for tension block using socket
insert T10054 and remove tension block.
- Pry out connector from Pump-Injector Unit using a
screwdriver. In order to avoid canting, support opposite
side of connector with light finger pressure.

Page 19 / 28

Diesel-Direct Fuel Injection System, servicing

- Insert puller T10055 in place of tension block into side


slit of pump-injector unit.
- Using careful knocking motions, pull Pump-Injector Unit
upward out of its cylinder head seat.
Installing

Note:

Install a new pump-injector unit, and also replace the


corresponding adjustment bolt in rocker arm.

For every procedure that requires adjustment of the


pump-injector unit, the adjustment screw in the
rocker lever and the ball pin of the pump-injector unit
must be replaced.

New Pump-Injector Units are shipped with O-rings


and heat protection seal.

- Install pump-injector unit again, replace O-rings and heat


protection seal 23-1, O-rings for pump-injector unit,
replacing .
- Before installing Pump-Injector Unit, check that the three
sealing rings, heat protection seal and securing ring are
seated properly.
Note:

Sealing rings must not be twisted on themselves.

Page 20 / 28

Diesel-Direct Fuel Injection System, servicing

- Oil sealing rings and insert Pump-Injector Unit with great


care into cylinder head seat.
- Drive Pump-Injector Unit in using uniform pressure into
cylinder head seat until stop.
- Insert tension block into lateral slot of Pump-Injector Unit.
Note:

If Pump-Injector Unit does not stand at right angle to


tension block, securing bolt can loosen and thereby
cause damage to Pump-Injector Unit / cylinder head.

Align pump-injector unit as follows:


- Screw new bolt into tension block so far that the pumpinjector unit can still be lightly turned.

- Insert gauge T10210 between thrust bearing and PumpInjector Unit as shown.
- Turn pump-injector unit against gauge by hand.
- Re-align pump-injector unit if necessary and tighten
securing bolt as follows: 12 Nm plus an additional 3 / 4 turn
(270 ) further (additional rotation can occur in several
stages).
- Install rocker arm axle and tighten new mounting bolts as
follows.
- Tighten first inner and then both outer bolts by hand.
Then, in the same sequence to 20 Nm plus an additional
1 / turn (90
) further.
4

Page 21 / 28

Diesel-Direct Fuel Injection System, servicing

- Place a dial gauge as shown onto adjustment screw of


pump-injector unit.
- Rotate crankshaft in direction of engine rotation until
rocker arm roller stands at camshaft point.

Roller side - arrow A - is positioned at highest


point

Dial gauge - arrow B - is positioned at lowest point

- Remove dial gauge .


- Thread adjusting screw into rocker arm against spring
force of pump-injector unit until significant resistance is
detected (pump-injector unit is positioned at stop).

- Turn back adjustment bolt from stop approx. 180


- Hold adjustment bolt in this position and tighten lock nut
to 30 Nm.
- Connect connector of the pump-injector unit and install
cylinder head cover and acoustic cover.
Position of pump pistons in pump injector units,
checking and adjusting

Page 22 / 28

Diesel-Direct Fuel Injection System, servicing

Special tools, testers and auxiliary items


required

Clamping device T10199

Socket XZN16 T10198

Crankshaft anchor T10195

Multi-point socket T10336

Dial gauge holder VW 387

Dial Gauge Set, 4-part VAS 6341

Requirement:

Page 23 / 28

Diesel-Direct Fuel Injection System, servicing

Engine removed

Work procedure
- Remove acoustic cover and cylinder head cover of the
applicable cylinder head.
- Remove fuel or tandem pump from respective cylinder
head 20-1, Tandem pump and Fuel Pump (FP),
removing and installing .
- Rotate engine with Counterhold Tool Touareg V10
T10172 to TDC 15-1, Valve timing, checking and
remove vibration damper
13-4, Front sealing flange and
vibration damper, assembly overview .
- Install Camshaft Tool T10195 .

- Position dial gauge from Dial Gauge Set, 4-part VAS


6341 using Dial Gauge Holder VW 387 and approx. 1 mm
pre-tension as shown on pump injector unit spring seat.
- Remove Camshaft Tool T10195 pin and rotate engine
opposite engine rotation direction until dial gauge needle
no longer moves.

- Set dial gauge to "0" .


- Now turn motor again in direction of rotation to TDC and

Page 24 / 28

Diesel-Direct Fuel Injection System, servicing

Page 25 / 28

insert camshaft tool securing pin.


- Read out value on dial gauge.
Specified values

Engine code BKW: 5.18 mm

0.1 mm

Engine code BWF: 4.95 mm

0.1 mm

If specified value is not achieved:


- Complete engine.
If specification is not obtained:
- Remove outer bearing cap - A - , place clamping device
T10199 on camshaft gear and tighten its bolt to 40 Nm.

- Loosen camshaft gear bolt - B - using Socket XZN16


T10198 .
- Rotate camshaft with Socket T10336 until specified
value is reached.
- Tighten camshaft to 150 Nm and repeat measurement.
- If specified value is now reached, tighten camshaft gear
threaded connection an additional 90 .
- Reinstall cylinder head cover
15-1, Tightening
sequence of bolts for cylinder head cover as well as
acoustic cover.
O-rings for pump-injector unit, replacing

Special tools, testers and auxiliary items required

Diesel-Direct Fuel Injection System, servicing

Assembly sleeve T10056

Removing
- Remove pump-injector unit
removing and installing .

23-1, Pump-Injector Unit,

- Pry off old O-rings from Pump-Injector Unit extremely


carefully.
- Above all, make sure that no burrs develop at O-ring
seat.
Installing
Note:

Always use assembly sleeves T10056 for installing


O-rings. Not using them may cause the O-rings to be
damaged during installation.

O-rings without distinguishing color markings are


gradually introduced. Ensure the correct allocation of
O-rings to grooves: ring strength decreases in
direction toward injector.

Avoid rolling movements when sliding on O-rings. Orings must not be twisted on itself in the seat of
Pump-Injector Unit.

- Pull off heat protection seal together with securing ring.


- Clean seating surfaces for O-rings on Pump-Injector Unit
very carefully.

Page 26 / 28

Diesel-Direct Fuel Injection System, servicing

Page 27 / 28

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru


Volkswagen, Skoda, Seat, Audi

- Insert assembly sleeve T10056/1 up to stop on PumpInjector Unit.


- Slide upper, thicker O-ring carefully on assembly sleeve
and into seat of Pump-Injector Unit.
- Remove assembly sleeve.

- Insert assembly sleeve T10056/2 up to stop on PumpInjector Unit.


- Slide center, thinner O-ring carefully onto assembly
sleeve and into seat of pump-injector unit.
- Remove assembly sleeve.

- Insert assembly sleeve T10056/3 up to stop on Pump-

Diesel-Direct Fuel Injection System, servicing

Injector Unit.
- Slide lower O-ring carefully on assembly sleeve and into
seat of Pump-Injector Unit.
- Remove assembly sleeve.
- Slide on a new heat protection seal together with
securing ring.
- Install pump-injector unit
removing and installing .

23-1, Pump-Injector Unit,

Page 28 / 28

Engine Control Modules (ECM)

Page 1 / 5

23 - 2

Engine Control Modules (ECM)


Note:

Engine control modules for Diesel-Direct fuel


injection system are equipped with a DTC memory.
Before and after repairs or adjustment work, DTC
memory must be checked 23-2, Diagnostic
Trouble Code (DTC) memory of Engine control
modules (ECM) , checking and erasing ; DTC
memory of Engine Control Modules (ECM) ,
checking and erasing.

Observe safety precautions


precautions .

23-1, Safety

DTC memory of Engine control modules (ECM) ,


checking and erasing 23-2, Diagnostic Trouble Code
(DTC) memory of Engine control modules (ECM) ,
checking and erasing
Adapting functions and components
and adapting components

23-2, Functions

Engine Control Modules (ECM) , removing and


installing 23-2, Engine Control Modules (ECM) ,
removing and installing
Diagnostic Trouble Code (DTC) memory of Engine
control modules (ECM) , checking and erasing

Special tools, testers and auxiliary items required

Vehicle Diagnostic, Testing and Information System


VAS 5051 A with diagnostic cable

Work procedure

Engine Control Modules (ECM)

Connect vehicle diagnosis, testing and information system


VAS 5051 A as follows:

- Open cover - 1 - (if equipped) and connect connector of


diagnostic cable to the Data Link Connector (DLC).
- Start engine and run at idle speed.
Only when engine does not start:
- Switch ignition on.
Selecting operating mode:
- Press button on display for "Vehicle Self-Diagnosis" .
Selecting vehicle system:
- Press "01 - Engine electronics" on display to check
Engine Control Module (ECM) J623 for cylinder bank 1, or
"11 - Engine electronics 2" on display to check Engine
Control Module (ECM) 2 J624 for cylinder bank 2.

The control module identification with code - 2 - of engine


control module , as well as chassis number and
immobilizer identification number will be indicated on the
display.
Note:

Page 2 / 5

Engine Control Modules (ECM)

A print-out is available. Press Print button if


required.

Selecting diagnosis function:


- Press button "02 - Check DTC memory" on display.
- If no DTC is stored in engine control module "0
malfunction(s) detected" is displayed.
- If DTCs are stored in engine control module , these are
shown one below the other on the display.
- Press

key.

- Press button "05 - Erase DTC memory" on display.


- Press function "06 - End output" .
Functions and adapting components

Special tools, testers and auxiliary items required

Vehicle Diagnostic, Testing and Information System


VAS 5051 A with diagnostic cable

Work procedure
Connect vehicle diagnosis, testing and information system
VAS 5051 A as follows:

Page 3 / 5

Engine Control Modules (ECM)

- Open cover - 1 - (if equipped) and connect connector of


diagnostic cable to the Data Link Connector (DLC).
On Vehicle diagnostic, testing, and information system
VAS 5051 A , select "Guided Fault Finding" .
After all control modules have been checked:
- Press "Go to" button.
- Select "Function/component selection" .
- Select "powertrain" .
- Select "engine code" .
- Select "01-Systems capable of self-diagnosis" .
- Select "engine management system" .
- Select "Functions" .
- Select "Function or component" .
Engine Control Modules (ECM) , removing and installing

Caution!
This vehicle is equipped with two Engine Control
Modules (ECM) which cannot be visually distinguished
from each other. If engine control modules are
installed interchanged, the DTC memories are not
detected. Therefore it is recommended to mark the
engine control modules , as well as their
corresponding harness connectors, before removing
in order to prevent interchanging the engine control
modules .
- Before removing Engine Control Modules (ECM) , the
control module identification and with it also the coding of
the previous control module must be checked 23-2,
Diagnostic Trouble Code (DTC) memory of Engine control

Page 4 / 5

Engine Control Modules (ECM)

modules (ECM) , checking and erasing ; DTC memory of


Engine Control Module (ECM), checking and erasing.
Work procedure
- Switch off ignition.

- Remove right plenum chamber cover - D - .

- Release and disconnect connector of engine control


module - 1 - and/or - 2 - .
- Remove old control module and install new control
module.
- Verify old coding and code new control module 23-2,
Functions and adapting components ; Adapting functions
and components.
- Check DTC memory of new Engine Control Module
(ECM) and erase if necessary 23-2, Functions and
adapting components ; DTC memory of Engine Control
Module (ECM) , checking and erasing.
- Perform test drive.
- Again, check engine control module DTC memory.

Page 5 / 5

Exhaust system components, removing and installing

Page 1 / 18

26 - 1

Exhaust system components, removing and


installing
Special tools, testers and auxiliary items required

Ring spanner 7-piece set 3337

Caution!
When doing any repair work, especially in the engine
compartment, pay attention to the following due to
clearance issues:

Route lines of all types (e.g. for fuel, hydraulic,


additive, coolant and refrigerant, brake fluid,
vacuum) and electrical wiring so that the original
path is followed.

To prevent damages to the lines, make sure


there is sufficient clearance to all moving or hot
components.

Note:

After exhaust system repairs, make sure exhaust


system is not under stress and that it has sufficient
clearance from the body. If necessary, loosen
double clamps and clamp and align exhaust pipe so
that sufficient clearance is maintained to the body
and support rings carry uniform loads.

Always replace self-locking nuts.

Do not use sealants containing silicone. Particles of


silicone drawn into the engine, will not be burned in

Exhaust system components, removing and installing

the engine and damage the oxygen sensor .


Exhaust manifold, assembly overview
manifold, assembly overview

26-1, Exhaust

Front exhaust pipe with catalytic converter and


attachments, assembly overview 26-1, Front exhaust
pipe with catalytic converter and attachments (vehicles with
engine code BKW), assembly overview
Muffler with mountings, assembly overview:

Vehicles with engine code BKW 26-1, Muffler with


mountings (vehicles with engine code BKW),
assembly overview

Vehicles with engine code BWF


26-1, Muffler with
mountings (vehicles with engine code BWF),
assembly overview

Exhaust manifold, assembly overview

Note:

Components depicted here correspond to cylinder


bank 2. They are different only as a mirror image of
components for cylinder bank 1.

Page 2 / 18

Exhaust system components, removing and installing

Cylinder head

Exhaust manifold

Can only be replaced when


engine is removed from
engine compartment 10-1,
Engine, removing and
installing , Engine, removing
and installing

Turbocharger (TC) Intake


Temperature Sensor , 45 Nm

Only on vehicles with engine


code BWF

Cylinder bank 1:

Turbocharger (TC) Intake


Temperature Sensor G507

Page 3 / 18

Exhaust system components, removing and installing

Cylinder bank 2:

Turbocharger (TC) Intake


Temperature Sensor 2
G499

To turbocharger
Item - 5 -

Spacer piece

23 Nm

Replace

Observe tightening
sequence 26-1,
Tightening sequence of nuts
for exhaust manifold

4.5 Nm

Heat shield

To connecting pipe

Vehicles with engine code


BKW Item - 12 -

Vehicles with engine code


BWF Item - 11 -

Gasket

Replace

Note installation position

Page 4 / 18

Exhaust system components, removing and installing

Tightening sequence of nuts for exhaust manifold

- Tighten nuts in the tightening sequence shown as


follows:

Pre-tighten all nuts to 5 Nm

Then tighten all nuts to 23 Nm

Front exhaust pipe with catalytic converter and


attachments (vehicles with engine code BKW), assembly
overview

Note:

Components depicted here correspond to cylinder


bank 2. They are different only as a mirror image of
components for cylinder bank 1.

Page 5 / 18

Exhaust system components, removing and installing

Turbocharger

Turbocharger, Assembly
overview 21-1,
Turbocharger, assembly
overview

Gasket

Replace

25 Nm

25 Nm

Connector

For Heated oxygen sensor


(HO2S) and Oxygen sensor
(O2S) heater

Page 6 / 18

Exhaust system components, removing and installing

Cylinder bank 1:

Connector (black)

Cylinder bank 2:

Connector (brown)

Heated Oxygen Sensor (HO2S) ,


50 Nm

Can only be replaced with


the engine removed 10-1,
Engine, removing and
installing

Grease only threads with


High-temperature lubricant G
052 112 A3 (anti-seize
compound). Hightemperature lubricant G 052
112 A3 must not get into
slots on sensor body.

To remove, use ring wrench


for oxygen sensor 3337

Cylinder bank 1:

Oxygen sensor G39

Cylinder bank 2:

Heated Oxygen Sensor


(HO2S) 2 G108

Front exhaust pipe with catalytic


converter

Can only be replaced with


the engine removed 10-1,
Engine, removing and
installing

Catalytic converter

Suspended mount

Bracket

Front exhaust pipe with catalytic converter, particle filter


and attachments, vehicles with engine code BLE and

Page 7 / 18

Exhaust system components, removing and installing

BWF, Assembly overview

Note:

Components depicted here correspond to cylinder


bank 2. They are different only as a mirror image of
components for cylinder bank 1.

Turbocharger

Gasket

Turbocharger - Assembly
overview 21-1,
Turbocharger, assembly
overview

Replace

25 Nm

Page 8 / 18

Exhaust system components, removing and installing

Heated Oxygen Sensor (HO2S) ,


50 Nm

Can only be replaced with


the engine removed 10-1,
Engine, removing and
installing

Grease only threads with hot


bolt paste G 052 112 A3
(anti-seize compound). Hot
bolt paste G 052 112 A3
must not get into slots on
sensor body.

To remove, use ring wrench


for oxygen sensor 3337

Cylinder bank 1:

Oxygen sensor G39

Cylinder bank 2:

Heated Oxygen Sensor


(HO2S) 2 G108

Pre-Particle Filter Temperature


Sensor , 45 Nm
Cylinder bank 1:

Pre-Particle Filter
Temperature Sensor G506

Cylinder bank 2:

Particle Filter Intake


Temperature Sensor 2
G498

Pressure line

Ensure seated tightly

Cylinder bank 1:

To exhaust pressure sensor


1 G450

Cylinder bank 2:

To exhaust pressure sensor


2 G451

Page 9 / 18

Exhaust system components, removing and installing

To rear muffler
Item - 9 -

Transmission crossmember

Suspended mount

Particle filter

after replacing, the


adaptation of the soot load
measurement must be set to
"0" Vehicle Diagnosis,
Testing and Information
System VAS 5051

Front exhaust pipe with catalytic


converter

Can only be replaced when


engine is removed from
engine compartment 10-1,
Engine, removing and
installing , Engine, removing
and installing

with engine code BWF with


metering pump connecting
pieces at catalytic converter
26-1, Post-injection
metering pump, engine code
BWF

Bracket

Post-injection metering pump, engine code BWF

Metering pumps are secured on subframe and inject diesel


fuel behind catalytic converters. The goal is to increase the
exhaust temperature in order to burn the particle filter.
- 1 - : Bank 2 Particle Filter Post-Injection Metering
Pump V337

Page 10 / 18

Exhaust system components, removing and installing

Page 11 / 18

- 2 - : Bank 1 Particle Filter Post-Injection Metering


Pump V336
Metering pumps, securing

- A - : Bolts, tightening torque 9 Nm

- B - : To cylinder bank 2 catalytic converter


Metering pumps, connecting line

- C - : From fuel tank

- D - : To cylinder bank 1 catalytic converter


Metering pumps, connecting line

Metering Pumps for Post-injection in Particle Filter

Metering pumps, connecting line

26-1,

26-1,

Exhaust system components, removing and installing

The metering pump fuel line is secured directly behind the


catalytic converter in order to utilize its exhaust
temperature.
Muffler with mountings (vehicles with engine code BKW),
assembly overview

Double clamp

Page 12 / 18

Exhaust system components, removing and installing

Threads M8:

Fasten evenly to 25 Nm

Threads M10:

Fasten evenly to 40 Nm

Center muffler

Suspended mount

25 Nm

Rear muffler

As standard, center and rear


mufflers are installed as a
single component. In cases
of repair, the center and rear
muffler are supplied
individually and with a
double clamp for connecting.

Cut through connecting pipe


with body repair saw V.A.G
1523A at right angles at
separating point 26-1,
Separating points between
center muffler and rear
muffler

End pipe

Align in bumper cutout

Clamp

Fasten to 60 Nm

Note installation position

Dimension - a - = approx. 10 mm

Exhaust system must be


cold

Arrow points in direction of


travel

Repair double clamp

Page 13 / 18

Exhaust system components, removing and installing

Double clamp viewed in


direction of travel

Note installation position

Repair double clamp

Double clamp viewed in


direction of travel

Note installation position

Dimension - a - = approx. 4 mm

Exhaust system must be


cold

Arrow points in direction of


travel

Double clamp

Bolt heads must point toward


transmission

Note installation position

Suspended mount

Separating points between center muffler and rear muffler

Special tools, testers and auxiliary items required

Body repair saw V.A.G 1523A

Page 14 / 18

Exhaust system components, removing and installing

Work procedure
- Separate connecting pipes at a right angle between
center muffler and rear muffler at the locations marked with
a groove:

Dimension - a - approx. 510 mm

Dimension - b - approx. 535 mm

Muffler with mountings (vehicles with engine code BWF),


assembly overview

Suspended mount

Right, in driving direction

Particle filter

Right, in driving direction

Page 15 / 18

Exhaust system components, removing and installing

Item - 10

Double clamp

Right, in driving direction

Threads M8:

Fasten evenly to 25 Nm

Threads M10:

Particle filter

Fasten evenly to 40 Nm

Left, in driving direction


Item - 10 -

Double clamp

Left, in driving direction

Threads M8:

Fasten evenly to 25 Nm

Threads M10:

Fasten evenly to 40 Nm

25 Nm

Suspended mount

Left, in driving direction

Repair double clamp

Left, in driving direction

Threads M8:

Fasten evenly to 25 Nm

Threads M10:

Fasten evenly to 40 Nm

Rear muffler

Suspended mount

Page 16 / 18

Exhaust system components, removing and installing

Left, in driving direction

End pipe

Left, in driving direction

Align in bumper cutout

Dimension - a - = approx. 10 mm

Exhaust system must be


cold

Arrow points in direction of


travel

Clamp

Fasten to 60 Nm

Note installation position

Dimension - a - = approx. 4 mm

Exhaust system must be


cold

Arrow points in direction of


travel

End pipe

Right, in driving direction

Align in bumper cutout

Repair double clamp

Double clamp viewed in


direction of travel

Note installation position

Repair double clamp

Double clamp viewed in


direction of travel

Note installation position

Page 17 / 18

Exhaust system components, removing and installing

Double clamp

Bolt heads must point toward


transmission

Note installation position

Suspended mount

Right, in driving direction

Repair double clamp

Right, in driving direction

Threads M8:

Fasten evenly to 25 Nm

Threads M10:

Fasten evenly to 40 Nm

Separating point

For repairs

Marked by two grooves


around circumference of
respective exhaust pipe

At factory, exhaust pipe and


rear mufflers are installed as
a single component.
Replacement exhaust pipe
and rear muffler are supplied
separately, with replacement
double clamp for connecting
joint

Cut through exhaust pipes


with body repair saw V.A.G
1523A at right angles at
separating point

Page 18 / 18

Exhaust Gas Recirculation (EGR) system

Page 1 / 18

26 - 2

Exhaust Gas Recirculation (EGR) system


Observe safety precautions
precautions .
Note rules of cleanliness

26-2, Safety
26-2, Rules for cleanliness

Exhaust Gas Recirculation (EGR), assembly overview:

Vehicles with engine code BKW 26-2, Exhaust


Gas Recirculation (EGR) (vehicles with engine code
BKW), assembly overview

Vehicles with engine code BWF


26-2, Exhaust
Gas Recirculation (EGR) (vehicles with engine code
BWF), assembly overview

Bypass flap with cooler for Exhaust Gas Recirculation


(EGR) - Assembly overview (Vehicles with engine code
BWF) 26-2, Bypass flap with cooler for Exhaust Gas
Recirculation (EGR) (vehicles with engine code BWF),
assembly overview
Connection diagram for vacuum hoses:

Vehicles with engine code BKW 26-2, Vacuum


hose connection diagram (vehicles with engine code
BKW)

Vehicles with engine code BWF


26-2, Vacuum
hose connection diagram (vehicles with engine
codes BWF)

Exhaust Gas Recirculation (EGR) valve (vehicles with


engine code BKW) , checking 26-2, Exhaust Gas
Recirculation (EGR) valve (vehicles with engine code
BKW), checking
Safety precautions

Caution!
When doing any repair work, especially in the engine
compartment, pay attention to the following due to
clearance issues:

Route lines of all types (e.g. for fuel, hydraulic,


additive, coolant and refrigerant, brake fluid,
vacuum) and electrical wiring so that the original

Exhaust Gas Recirculation (EGR) system

path is followed.

To prevent damages to the lines, make sure


there is sufficient clearance to all moving or hot
components.

Rules for cleanliness

When working on the exhaust gas recirculation (EGR)


system, pay careful attention to the following "7 rules" of
cleanliness:

Thoroughly clean all connections and the


surrounding area before disconnecting.

Place parts that have been removed on a clean


surface and cover them. Do not use fluffy cloths!

Carefully cover over opened components or seal, if


repairs are not performed immediately.

Only install clean components: Only unpack


replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in
tool boxes etc.).

Supplied transport and protective packaging and


sealing caps should only be removed immediately
before installing.

During repair, clean oil from connections and hose


ends.

When the system is open: Avoid working with


compressed air if possible. Do not move vehicle
unless absolutely necessary.

Exhaust Gas Recirculation (EGR) (vehicles with engine


code BKW), assembly overview

Note:

Exhaust gas recirculation is controlled by Engine


Control Module (ECM) J623 and Engine Control

Page 2 / 18

Exhaust Gas Recirculation (EGR) system

Page 3 / 18

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru


Volkswagen, Skoda, Seat, Audi

Module (ECM) 2 J624 via EGR Vacuum Regulator


Solenoid Valve N18 (electro-pneumatic) and EGR
Valve 2 N213 (electro-pneumatic) to the mechanical
exhaust gas recirculation valves.

The mechanical EGR valve with cone-shaped valve


plunger makes different opening diameters possible
at different valve lift.

Components depicted here correspond to cylinder


bank 2. They are different only as a mirror image of
components for cylinder bank 1.

Intake connection with intake


flap motor
Cylinder bank 1:

Intake Flap Motor V157

Exhaust Gas Recirculation (EGR) system

Cylinder bank 2:

8 Nm

Seal

Replace

Before installing, check the


sealing surfaces for
contamination and clean if
necessary

EGR Vacuum Regulator


Solenoid Valve

Intake Flap Motor 2 V275

Checking mechanically
26-2, Exhaust Gas
Recirculation (EGR) valve
(vehicles with engine code
BKW), checking

Intake manifold

Removing and installing


23-1, Intake manifold,
removing and installing

20 Nm

Gasket

Replace

Note installation position

8 Nm

Exhaust manifold

Exhaust manifold, assembly


overview 26-1, Exhaust
manifold, assembly
overview

8 Nm

20 Nm

Page 4 / 18

Exhaust Gas Recirculation (EGR) system

Connecting pipe

Exhaust Gas Recirculation (EGR) (vehicles with engine


code BWF), assembly overview

Note:

Activation of the Exhaust Gas Recirculation (EGR)


system occurs from Engine Control Module (ECM)
J623 and Engine Control Module 2 J624 via the
EGR Potentiometer G212 and the EGR Position
Sensor G466 .

Components depicted here correspond to cylinder


bank 2. They are different only as a mirror image of
components for cylinder bank 1.

Bypass flap with cooler for Exhaust Gas


Recirculation (EGR), assembly overview 26-2,
Bypass flap with cooler for Exhaust Gas
Recirculation (EGR) (vehicles with engine code
BWF), assembly overview .

Page 5 / 18

Exhaust Gas Recirculation (EGR) system

Test connection bracket

Cylinder bank 1:

Item - 6 -

Cylinder bank 2:

Item - 1 -

8 Nm

Seal

Replace

Before installing, check the


sealing surfaces for
contamination and clean if
necessary

Gasket

Replace

Page 6 / 18

Exhaust Gas Recirculation (EGR) system

Note installation position

To the bypass flap


Item - 16 -

Connecting pipe

20 Nm

From the bypass flap


Item - 17 -

Bracket
For connecting pipe
-

Connecting pipe

Connecting pipe

8 Nm

To turbocharger

Item - 5 -

Exhaust manifold

Item - 10

Exhaust manifold, assembly


overview 26-1, Exhaust
manifold, assembly
overview

Intake connection with intake


flap motor
Cylinder bank 1:

Intake Flap Motor V157

Cylinder bank 2:

Intake Flap Motor 2 V275

EGR Vacuum Regulator


Solenoid Valve with EGR
Potentiometer

Page 7 / 18

Exhaust Gas Recirculation (EGR) system

Cylinder bank 1:

EGR Vacuum Regulator


Solenoid Valve N18 (electropneumatic) with EGR
Potentiometer G212

Cylinder bank 2:

EGR Valve 2 N213 (electropneumatic) with Exhaust


Gas Recirculation (EGR)
Position Sensor G466

If EGR Vacuum Regulator


Solenoid Valve is replaced with
EGR Potentiometer , you must
then:
- Switch ignition on and off.
- Then wait for one minute
for the control module
after-run.
- Start engine and let run at
idle for at least 1 minute.
- Then, check the DTC
memory of the engine
control module (ECM)
23-2, Diagnostic Trouble
Code (DTC) memory of
Engine control modules
(ECM) , checking and
erasing , DTC memory of
engine control module
(ECM) , checking and
erasing.
If a DTC is stored in DTC
memory:
- Repeat work procedure.

Intake manifold

Removing and installing


23-1, Intake manifold,
removing and installing

Page 8 / 18

Exhaust Gas Recirculation (EGR) system

Bypass flap with cooler for Exhaust Gas Recirculation


(EGR) (vehicles with engine code BWF), assembly
overview

Note:

Hose connections are secured with either springtype or clamp-type clips.

Always replace clamps.

The spring-type clip pliers VAS 5024 A are


recommended for installing spring-type clips.

Exhaust Gas Recirculation (EGR), assembly


overview 26-2, Exhaust Gas Recirculation (EGR)
(vehicles with engine code BWF), assembly
overview .

Page 9 / 18

Exhaust Gas Recirculation (EGR) system

8 Nm

Vacuum tube

Vacuum line

For cylinder bank 2

Ensure seated tightly

To Exhaust Gas
Recirculation (EGR) Cooler
Switch-Over Valve 2 N381

Connection diagram for


vacuum hoses 26-2,
Vacuum hose connection
diagram (vehicles with
engine codes BWF)

Vacuum hose

Page 10 / 18

Exhaust Gas Recirculation (EGR) system

For cylinder bank 1

Ensure seated tightly

To Exhaust Gas
Recirculation (EGR) Cooler
Switch-Over Valve N345

Connection diagram for


vacuum hoses 26-2,
Vacuum hose connection
diagram (vehicles with
engine codes BWF)

Coolant hose

Between cooler for Exhaust


Gas Recirculation (EGR)
and bypass flap

Ensure seated tightly

40 Nm

Coolant hose

Ensure seated tightly

Use pliers for spring-type


clamps VAS 5024 A to
remove and install

5 Nm

Coolant line

Bracket

For coolant pipe

20 Nm

Coolant hose

Item - 9 -

Ensure seated tightly

Use pliers for spring-type


clamps VAS 5024 A to
remove and install

To heat exchanger for heater


unit

Page 11 / 18

Exhaust Gas Recirculation (EGR) system

Vacuum actuator

For cylinder bank 1

Check operation with hand


vacuum pump V.A.G 1390
at vacuum connection

Connecting pipe

For cylinder bank 1

from EGR Vacuum


Regulator Solenoid Valve
N18 (electro-pneumatic) with
EGR Potentiometer G212
Item - 16 -

Connecting pipe

For cylinder bank 1

To connecting pipe of
exhaust manifold Item 11 -

Connecting pipe

For cylinder bank 2

From EGR Valve 2 N213


(electro-pneumatic) with
Exhaust Gas Recirculation
(EGR) Position Sensor
G466
Item - 16 -

Connecting pipe

For cylinder bank 2

To connecting pipe of
exhaust manifold Item 11 -

Gasket

Replace

Note installation position

Page 12 / 18

Exhaust Gas Recirculation (EGR) system

Bracket

For bypass-flap
-

Fastened to cylinder block

Bypass-flap

Remove and install together


with cooler for exhaust gas
recirculation ( Item - 25 )

Vacuum actuator

For cylinder bank 2

Check operation with hand


vacuum pump V.A.G 1390
at vacuum connection

Ball pin, 3 Nm

Fastened to flange of
generator

Rubber bushing

Bracket

For cooler for Exhaust Gas


Recirculation (EGR) Item
- 25 -

Cooler for Exhaust Gas


Recirculation (EGR)

Item - 20

Remove and install together


with bypass flap ( Item 20 - )

Coolant hose

Ensure seated tightly

Use pliers for spring-type


clamps VAS 5024 A to
remove and install

Page 13 / 18

Exhaust Gas Recirculation (EGR) system

From coolant pipe

Vacuum hose connection diagram (vehicles with engine


code BKW)

EGR Vacuum Regulator


Solenoid Valve N18 (electropneumatic)

EGR Vacuum Regulator


Solenoid Valve (mechanical)

For cylinder bank 1

For cylinder bank 1

EGR Vacuum Regulator


Solenoid Valve (mechanical)

Page 14 / 18

Exhaust Gas Recirculation (EGR) system

For cylinder bank 2

EGR Valve 2 N213

For cylinder bank 2

Filter

Vacuum line

Between tandem pump and


brake booster

Check for secure seating

Tandem pump

Component location:
Cylinder bank 1

For fuel and vacuum supply

Must not be disassembled

Vacuum hose connection diagram (vehicles with engine


codes BWF)

Page 15 / 18

Exhaust Gas Recirculation (EGR) system

Vacuum actuator

For cylinder bank 1

Vacuum actuator

For cylinder bank 2

Vacuum tube

Exhaust Gas Recirculation


(EGR) Cooler Switch-Over Valve
N345

For cylinder bank 1

Component location: at right


rear wheelhousing

Exhaust Gas Recirculation

Page 16 / 18

Exhaust Gas Recirculation (EGR) system

(EGR) Cooler Switch-Over Valve


2 N381

For cylinder bank 2

Component location: at right


front wheelhousing

Tandem pump

Component location:
Cylinder bank 1

For fuel and vacuum supply

Must not be disassembled

From brake booster

Exhaust Gas Recirculation (EGR) valve (vehicles with


engine code BKW), checking

Special tools, testers and auxiliary items required

Hand vacuum pump V.A.G 1390

Work sequence
- Remove connecting hose charge air pipe/intake
manifold.
Note:

With connector couplings, follow the installation


instructions closely 21-1, Hose connections with
connector couplings, installing .

- Disconnect vacuum hose at EGR vacuum regulator


solenoid valve.

Page 17 / 18

Exhaust Gas Recirculation (EGR) system

- Connect hand vacuum pump with additional equipment


V.A.G 1390 to valve.

- Operate hand vacuum pump and observe diaphragm rod.


Diaphragm rod must move in direction of - arrow - .
- Disconnect hose of hand vacuum pump from EGR valve.
Diaphragm rod must move back in opposite direction of arrow - into output position.

Page 18 / 18

Glow plugs

Page 1 / 4

28 - 1

Glow plugs
Glow plugs , removing and installing, checking:

Vehicles with engine codes BKW and BWF 28-1,


Glow plugs vehicles with engine code BKW, BWF)
removing and installing, checking

Glow plugs vehicles with engine code BKW, BWF)


removing and installing, checking
Visual characteristics of ceramic sheathed element glow plugs

Caution!
Ceramic sheathed element glow plugs are susceptible
to shock and bending. For this reason, do not use
sheathed element glow plugs which have dropped
(even from a height of approx. 2 cm) under any
circumstances, even if no visible damage can be
detected. Installation instructions must be performed
in sequence, otherwise there is a danger the plug
breaks and will cause damage to engine.

Visual characteristics of ceramic sheathed element glow


plugs

A - Ceramic sheathed element glow plugs, phased


stepping on tip (see magnified area), white color coding
arrow
B - Metal glow plugs, green color coding arrow
Ceramic sheathed element glow plugs, removing, installing
and checking 28-1, Ceramic sheathed element glow
plugs, removing, installing and checking .

Glow plugs

Ceramic sheathed element glow plugs, removing,


installing and checking

Special tools, testers and auxiliary items


required

Flex wrench 3220


Torque wrench (5 to 50 Nm) V.A.G
1331
Portable multimeter V.A.G 1526
A
Connector test set V.A.G 1594 C

Not illustrated:

Page 2 / 4

Glow plugs

Page 3 / 4

Pliers 6275

Requirements

Engine is cold

Ignition is switched off

Work procedure
Note:

Observe visual characteristics of ceramic sheathed


element glow plugs 28-1, Visual characteristics of
ceramic sheathed element glow plugs .

When removing and installing, do not cant ceramic


sheathed element glow plugs. Remove components
which hinder installation.

- Remove intake manifolds 23-1, Intake manifold,


removing and installing , Intake manifold, removing and
installing.
- Disconnect connectors from ceramic sheathed element
glow plugs using pliers 6275 .
- Remove ceramic sheathed element glow plugs using flex
wrench 3220 .
Installation is in reverse order of removal. Note the
following:
- Clean deposits from cylinder head bore and threads
completely before installing.
Note:

Never oil or grease thread of bore in cylinder head


and ceramic sheathed element glow plugs.

- Screw ceramic sheathed element glow plugs into cylinder


head by hand using flex wrench 3220 .
- Tighten ceramic sheathed element glow plugs. Torque
specification: 15 Nm
Caution!
After installing and before first engine start with a cold

Glow plugs

Page 4 / 4

engine, always perform a resistance test at all ceramic


sheathed element glow plugs.

Specification: max. 1.0

- If specified value is exceeded, replace malfunctioning


ceramic sheathed element glow plug.
Note:

If the malfunctioning ceramic sheathed element glow


plug is broken, remove all broken pieces from
engine, otherwise they can cause damage to
engine.

Electrical components of transmission control, removing and installing, checking

Page 1 / 27

38-1

Electrical components of
transmission control,
removing and installing,
checking
Safety precautions
WARNING!
Observe the following for all installations,
especially in engine compartment due to lack
of room:
Route lines of all types (e.g. for fuel,
hydraulic, EVAP canister system, coolant
and refrigerant, brake fluid, vacuum) and
electrical wiring so that the original path is
followed.
Watch for sufficient clearance to all moving
or hot components.
Shift selector lever into position -P- and
engage parking brake before working with
the engine running.
If special testing equipment is required during
road test, note the following:
Test equipment must always be secured to the
rear seat and operated from there by a second
person.

Electrical components of transmission control, removing and installing, checking

Page 2 / 27

38-2

If test and measuring equipment is operated


from the passenger seat, the person seated
there could be injured in the event of an accident
involving deployment of the passenger-side
airbag.
Notes:
For the electric components to work properly, a
voltage of at least 11.5 V is required.
Transmission Control Module (TCM) is
equipped with On Board Diagnostic (OBD).
It is possible that the control module will
recognize a malfunction and store a DTC during
some tests. Therefore the following work steps
must be performed in the mentioned sequence
after ending all tests and repairs.
- - Check DTC memory Page ST-23 ,
Diagnostic mode 3: Check DTC Memory,
- - Erase DTC memory
Page ST-28 ,
Diagnostic mode 4: Reset/erase diagnostic
data
- - For completion, generate readiness code
Page ST-50 .

Electrical components of transmission control, removing and installing, checking

Page 3 / 27

38-3

Multi-Function Transmission
Range (TR) Switch, removing
and installing, adjusting
Recommended special tools and
equipment
V.A.G 1331 torque wrench (5 to 50
Nm)

T10173 adjustment tool

Electrical components of transmission control, removing and installing, checking

Page 4 / 27

38-4

Note:
For the sake of illustration, work procedure
shown with transmission removed.
Removing
- Place selector lever in position "P".
- Remove noise insulation panel below
transmission.
- Remove cap nut -4-.
- Remove cover -3- from shift rod.
- Carefully bend hooks of locking washer using a screwdriver.
Note:
If a hook breaks off, replace locking washer
- Now remove nut -2- and locking washer shift rod.
- Disconnect harness connector from Multi
Function Transmission Range (TR) Switc
F125- (arrow -A-).
- Unscrew mounting bolts (arrows -B-) and
remove Multi-Function Transmission Ran
Switch -F125- (arrow -A-) from shift rod.

Electrical components of transmission control, removing and installing, checking

Page 5 / 27

38-5

Installing and adjusting


- Shift the lever/switch rod at the transmiss
N- position.
- Connect Multi-Function Transmission Ra
(TR) Switch -F125- (arrow -A-) on shift ro
- Hand-tighten mounting bolts (arrows -B-)
Multi-Function Transmission Range (TR)

- Place adjustment tool (T10173) on shift ro


- Disengage selector lever cable.
- Rotate Multi-Function Transmission Rang
Switch until tab on connector -arrow 1- en
in groove of adjustment tool.

Electrical components of transmission control, removing and installing, checking

Page 6 / 27

38-6

- Tighten mounting bolts -arrows Bof Multi-Function Transmission


Range (TR) Switch.
Tightening torque: 6 Nm
- Remove adjustment tool (T10173)
from shift rod.
- Hook in selector lever cable.
Rest of installation is performed in
the reverse order of removal.
- Check adjustment of selector
lever cable:
Repair Manual, 6 Spd. Automatic
Transmission 09D All Wheel Drive,
Repair Group 37; servicing shift
mechanism

Electrical components of transmission control, removing and installing, checking

Page 7 / 27

38-7

Multi-Function Transmission Range (TR)


Switch, checking
Recommended special tools and equipment
V.A.G 1526 multimeter or V.A.G 1715
multimeter
V.A.G 1594 connector test kit
Wiring diagram
Test requirements
Respective fuses in fuse box (instrument
panel, right) must be OK:
Electrical Wiring Diagrams and Component
Locations
Control Module with indicator unit in
instrument panel insert -J285- must be OK.
Battery voltage must be at least 11.5 volts.
All electrical consumers such as, for
example, lights and rear window defroster
must be switched off.
Parking brake must be engaged or else
daylight driving lights will be switched on.
Selector lever must be in -P- position.
Ground (GND) connections to transmission
must be OK.

Electrical components of transmission control, removing and installing, checking

Page 8 / 27

38-8

Function test
- Switch ignition on.
- Depress brake pedal and maintain depressed.
- Shift into all selector lever positions.
Selector lever position must correspond to
display of Control Module with indicator unit
in instrument panel insert -J285-.
- Switch ignition off.
If selector lever position does not correspond to
display of Control Module with indicator unit in
instrument panel insert -J285- Check wires according to wiring diagram
Page 38-9 .

Electrical components of transmission control, removing and installing, checking

Page 9 / 27

38-9

Checking wiring
- Connect test box to control module wiring
harness Page ST-10 , connect test box
wiring test.
- Disconnect 10-pin harness connector -ar
to Multi-Function Transmission Range (T
Switch -F125-.

Electrical components of transmission control, removing and installing, checking

Page 10 / 27

38-10

- Check wires between test box


and 10-pin connector to
Transmission Control Module
(TCM) for open circuit according
to wiring diagram.
Terminal 1+socket 47
Terminal 3 + socket 1
Terminal 4 + socket 2
Terminal 5 + socket 22
Terminal 7 + socket 10
Terminal 9 + socket 36
Terminal 10 + socket 21
Wire resistance: max. 1.5
- Also check wires for short circuit
to each other.
Specified value:
If no malfunctions are found in
wires:
- Check adjustment of MultiFunction Transmission Range
(TR) Switch -F125- Page 38-3 ,
Multi-Function Transmission
Range (TR) Switch, removing and
installing, adjusting.
- Check adjustment of selector
lever cable:
Repair Manual, 6 Spd. Automatic
Transmission 09D All Wheel Drive,
Repair Group 37; servicing shift
mechanism

Electrical components of transmission control, removing and installing, checking

Page 11 / 27

38-11

- Erase DTC memory of Transmission Control


Module (TCM) Page ST-28 , Diagnostic mode
4: Reset/erase diagnostic data.
- Generate readiness code

Page ST-50 .

If no malfunctions are detected in wires and


adjustments of selector lever cable and MultiFunction Transmission Range (TR) Switch are
OK:
- Replace Multi-Function Transmission Range
(TR) Switch -F125- Page 38-3 , MultiFunction Transmission Range (TR) Switch,
removing and installing, adjusting.
- Erase DTC memory of Transmission Control
Module (TCM) Page ST-28 , Diagnostic mode
4: Reset/erase diagnostic data.
- Generate readiness code

Page ST-50 .

Electrical components of transmission control, removing and installing, checking

Page 12 / 27

38-12

Sensor for transmission RPM, checking


Recommended special tools and equipment
V.A.G 1526 multimeter or V.A.G 1715
multimeter
V.A.G 1594 connector test kit
Wiring diagram
Test requirements
Respective fuses in fuse box (instrument
panel, right) must be OK:
Electrical Wiring Diagrams and Component
Locations
Battery voltage must be at least 11.5 volts.
Ground (GND) connections to transmission
must be OK.
Selector lever must be in -P- position.
Ignition switched off.

Electrical components of transmission control, removing and installing, checking

Page 13 / 27

38-13

Checking wiring
- Connect test box to control module wiring
harness Page ST-10 , connect test box
wiring test.
- Disconnect 8-pin harness connector -arro

- Check wires between test box and 8-pin


connector to Transmission Control Modu
(TCM) for open circuit according to wiring
diagram.
Terminal 3 + socket 51
Terminal 4 + socket 39
Wire resistance: max. 1.5
- Also check wires for short circuit to each
Specified value:

Electrical components of transmission control, removing and installing, checking

Page 14 / 27

38-14

If no malfunctions are found in wires:


- Replace Sensor for transmission RPM -G182-.
- Erase DTC memory of Transmission Control
Module (TCM) Page ST-28 , Diagnostic mode
4: Reset/erase diagnostic data.
- Generate readiness code

Page ST-50 .

Electrical components of transmission control, removing and installing, checking

Page 15 / 27

38-15

Sender for transmission output RPM


checking
Recommended special tools and equipm
V.A.G 1526 multimeter or V.A.G 1715
multimeter
V.A.G 1594 connector test kit
Wiring diagram
Test requirements
Respective fuses in fuse box (instrumen
panel, right) must be OK:
Electrical Wiring Diagrams and Component
Locations
Battery voltage must be at least 11.5 vo
Ground (GND) connections to transmiss
must be OK.
Selector lever must be in -P- position.
Ignition switched off.
Checking wiring
- Connect test box to control module wiring
harness Page ST-10 , connect test box
wiring test.
- Disconnect 8-pin harness connector -arro

Electrical components of transmission control, removing and installing, checking

Page 16 / 27

38-16

- Check wires between test box


and 8-pin connector to
Transmission Control Module
(TCM) for open circuit according
to wiring diagram.
Terminal 5 + socket 38
Terminal 6 + socket 50
Wire resistance: max. 1.5
- Also check wires for short circuit
to each other.
Specified value:
If no malfunctions are found in
wires:
- Replace Sender for transmission
output RPM -G195-.
- Erase DTC memory of
Transmission Control Module
(TCM) Page ST-28 , Diagnostic
mode 4: Reset/erase diagnostic
data.
- Generate readiness code
ST-50 .

Page

Electrical components of transmission control, removing and installing, checking

Page 17 / 27

38-17

Transmission Fluid Temperature


Sensor, checking
Recommended special tools and equipment
V.A.G 1526 multimeter or V.A.G 1715
multimeter
V.A.G 1594 connector test kit
Wiring diagram
Test requirements
Respective fuses in fuse box (instrument
panel, right) must be OK:
Electrical Wiring Diagrams and Component
Locations
Battery voltage must be at least 11.5 volts.
Ground (GND) connections to transmission
must be OK.
Selector lever must be in -P- position.
Ignition switched off.

Electrical components of transmission control, removing and installing, checking

Page 18 / 27

38-18

Test sequence
- Disconnect 8-pin harness
connector -arrow 3-.
Checking resistance
- Measure resistance of
Transmission Fluid Temperature
Sensor-G93- between terminals 1
+ 2 at connector to sensor:
ATF
temperature

Specified
value
37.0 to 51.0
K

approx. -30

approx. 10

5.0 to 8.0 K

approx. 25

3.0 to 5.0 K

approx. 110

230.0 to 265.0

approx. 145

100.0 to 120.0

If one of the specified values is not


obtained:
- Replace Transmission Fluid
Temperature Sensor -G93-.
- Erase DTC memory of
Transmission Control Module
(TCM) Page ST-28 , Diagnostic
mode 4: Reset/erase diagnostic
data.
- Generate readiness code
ST-50 .

Page

Electrical components of transmission control, removing and installing, checking

Page 19 / 27

38-19

If specified values are obtained:


- Check wires according to wiring diagram
Page 38-19 .
Checking wiring
- Connect test box to control module wiring
harness Page ST-10 , connect test box
wiring test.
- Check wires between test box and 8-pin
connector to Transmission Control Modu
(TCM) for open circuit according to wiring
diagram.
Terminal 1+socket 45
Terminal 2+socket 8
Wire resistance: max. 1.5
- Also check wires for short circuit to each
Specified value:
If no malfunctions are found in wires:
- Replace Transmission Control Module (T
J217- Page 38-29 .

Electrical components of transmission control, removing and installing, checking

Page 20 / 27

38-20

Solenoid valves in valve body, checking


Recommended special tools and equipment
V.A.G 1526 multimeter or V.A.G 1715
multimeter
V.A.G 1594 connector test kit
Wiring diagram
Test requirements
Respective fuses in fuse box (instrument
panel, right) must be OK:
Electrical Wiring Diagrams and Component
Locations
Selector lever must be in -P- position.
Ground (GND) connections to transmission
must be OK.
Ignition switched off.

Electrical components of transmission control, removing and installing, checking

Page 21 / 27

38-21

Test sequence
- Disconnect 14-pin harness
connector -arrow 2- to solenoid
valves (Solenoid Valve 1 -N88- to
Solenoid Valve 6 -N93-, Solenoid
Valve 9-N282-, Solenoid Valve 10
-N283-).

Electrical components of transmission control, removing and installing, checking

Page 22 / 27

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru


Volkswagen, Skoda, Seat, Audi

38-22

Checking resistance
- Check resistances of solenoid valves
at connector to the solenoid valves:
Component

Connector

Specified
value

Terminal
Solenoid
Valve 1 N88-

1+Ground
(GND)
transmission

10.0 to
16.0

Solenoid
Valve 2 N89-

2+Ground
(GND)
transmission

10.0 to
16.0

Solenoid
Valve 3 N90-

7+8

4.0 to 8.0

Solenoid
Valve 4 N91-

11+12

4.0 to 8.0

Solenoid
Valve 5 N92-

3+4

4.0 to 8.0

Solenoid
Valve 6 N93-

13+14

4.0 to 8.0

Solenoid
Valve 9 N282-

5+6

4.0 to 8.0

Solenoid
Valve 10 N283-

9+10

4.0 to 8.0

Note:
Resistance value is valid at approx. 20
C. At higher temperatures, resistance
value increases.

Electrical components of transmission control, removing and installing, checking

Page 23 / 27

38-23

If one of the specified values is not obtained:


- Replace the respective solenoid valve.
- Erase DTC memory of Transmission Control
Module (TCM) Page ST-28 , Diagnostic mode
4: Reset/erase diagnostic data.
- Generate readiness code

Page ST-50 .

If specified values are obtained:


- Check wires according to wiring diagram
Page 38-23 .
Checking wiring
- Connect test box to control module wiring
harness Page ST-10 , connect test box for
wiring test.
- Check wires between test box and 14-pin
connector to Transmission Control Module
(TCM) for open circuit according to wiring
diagram.
Wire resistance: max. 1.5
Component

Connector

Test box

Solenoid Valve 1 N88-

Terminal 1

Socket
41

Solenoid Valve 2 N89-

Terminal 2

Socket
15

Solenoid Valve 3 N90-

Terminal 7

Socket
30

Terminal 8

Socket
18

Electrical components of transmission control, removing and installing, checking

Page 24 / 27

38-24

Component

Connector

Test box

Solenoid Valve 4 -N91-

Terminal
11

Socket 5

Terminal
12

Socket
43

Terminal 3

Socket
42

Terminal 4

Socket 6

Terminal
13

Socket
31

Terminal
14

Socket
17

Terminal 5

Socket
16

Terminal 6

Socket
32

Terminal 9

Socket 4

Terminal
10

Socket
44

Solenoid Valve 5 -N92-

Solenoid Valve 6 -N93-

Solenoid Valve 9 N282-

Solenoid Valve 10 N283-

- Also check wires for short circuit to each


other.
Specified value:
If no malfunctions are found in wires:
- Replace Transmission Control Module (TCM) J217- Page 38-29 .

Electrical components of transmission control, removing and installing, checking

Page 25 / 27

38-25

Sender for hydraulic pressure, checking


Recommended special tools and equipment
V.A.G 1526 multimeter or V.A.G 1715
multimeter
V.A.G 1594 connector test kit
Wiring diagram
Test requirements
Respective fuses in fuse box (instrument
panel, right) must be OK:
Electrical Wiring Diagrams and Component
Locations
Battery voltage must be at least 11.5 volts.
Ground (GND) connections to transmission
must be OK.
Selector lever must be in -P- position.
Ignition switched off.

Electrical components of transmission control, removing and installing, checking

Page 26 / 27

38-26

Checking wiring
- Connect test box to control module wiring
harness Page ST-10 , connect test box
wiring test.
- Disconnect 8-pin harness connector -arro

Electrical components of transmission control, removing and installing, checking

Page 27 / 27

38-27

- Check wires between test box


and 8-pin connector to
Transmission Control Module
(TCM) for open circuit according
to wiring diagram.
Wire resistance: max. 1.5
Component

Connector

Test
box

Sender 1 for
hydraulic
pressure,
automatic
transmission
-G193-

Terminal 7

Socket
24

Sender 2 for
hydraulic
pressure,
automatic
transmission
-G194-

Terminal 8

Socket
25

- Also check wires for short circuit


to each other.
Specified value:
If no malfunctions are found in
wires:
- Replace the respective sender for
hydraulic pressure:
Repair Manual, 6 Spd. Automatic
Transmission 09D All Wheel Drive,
Repair Group 38
- Erase DTC memory of
Transmission Control Module
(TCM) Page ST-28 , Diagnostic
mode 4: Reset/erase diagnostic
data.
- Generate readiness code
ST-50 .

Page