Amk Bam Engine
266
set'vlce SEF-T I I ' Workshop Manual 1 Toledo 1999 ), Le6n Booklet 4-cyl. injection egine, (5-valve). Edition 06.02 Customer Service. Technical lnformation
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Transcript of Amk Bam Engine
set'vlceSEF-T
II
' Workshop Manual1 Toledo 1999 ), Le6n
Booklet 4-cyl. injection egine,(5-valve).
Edition 06.02
Customer Service. Technical lnformation
serviGe
List of Workshop Manual Repair GroupsToledo 1999 ), Le6n
K]AMI t
lBOOklet 4-cyl. injection engine, (S-vatve), edition 06.02 |
when fiIng a Technicai Bufletrn enter the Bu etin No. in the adjacent corumn.when. using the work.lo jNlanualyou can then see at a glance whether Techn ca gutteinshavebipanicutar Cepiir-ci".ip i. *r-' iZn v", are rookrng.
:en puor sned n respect c Tl e'
Repair Grou p
00 Technical Data
15 Cylinder head, Valve gear
Tech nical Bul let ins 1jIll0 Remov ng and instal l ing enqrne
13 Crankshaft group
17 Lubr icat ion19 Coo ng
Injection26 Exhaust system
eLhtCd' r lorTal o ' ' s l o- lo al ,voys Oe o/d ab- ro d oten e. ' ) o-o TeLno r 'S hor: .^ol id^ e
^ " 5o -15., . .1.o ' r rgver 5es>o,.d roe . o Ja rL e odo,^o , .otr . " . r . l j j , , ) i . ' . ]^n ' ,
"the nofn.ra saletypfecautonstobeobservedwhenworkingonmotcrvehic lesar* i ia" ' j " " i . "0 i" .
All riqhts resefvedNo reproduct on withoLrt p. of aqfeement fromO 2OO, SEAT S'A
DBt24Bo702c lc
p u blishe r'
Contents
Technical dataTechn;caldata
|- temovtno anct tnstal l rno enotne
Engine: removing and instal l ing . . . . . . . . . . . . .
00
10
Page
00-100 100,2
Page10-l10 31A-231A-241A 21
10-2810 30
Paget3-1
13-1013-11
73-2513 29
13-371341
Rerrova notes . .engrne 10 assembly stand
T ghlening tofques
Eng ne secur nglfs lat ,ng nl tes
Engine brackets- Fn..a hr: .1!1< A
^n.^
13 C.ankshaft groupEngine: dismantl ing and assemblingRibbed bett . . . . . . . . . . .
P fho,r h6lr .^, i ^^
R bbed be t : remov ng and nsta I ng . . . . . .- Be I pul eylvibrat on dampert remov ng and insta I ng . . .- Add t ona sLrbjrarne b|acket: rernov ng and nstal ing . . .Toothedbel t . . . . . . . . .- Toothed be t : removtng and instal tngSealing tlanges and engine tlywheel: removing and instal l ing
C|ankshaf l oi l seal -be t puley end: replace
' Front seal ing f lange: removing ard- Fywhee rremovrng and insta Ing
nslaI ng 13-44t3 4913,51
13,5813-67
Page15-r
15-22
15-4115 4815,5115-5415 5715-6815-12
17-111-317 9
Piston and conrod: dismant l ing and assemb| ing.. . . . . . . . . . . . . . . . .- P ston and cylnder dlanens ons
15 Cylinder head, Valve gearCylinder head: removing and installing' nlake rnanifoldt remov ng and insta ng . . . . . .
Cy nder head cover: removing and rnstal t ing- Cy nder head: remov ng and instal l ing- Compression rat io: check . . . .Valve gear: repairing
Crankshaft : removing and installing- Cranlshaft d mens ons
- Camshait or sea s: rep aceExhausl camsha{t o I sea replace
Va ve guides: check ng\,'a ve slem sea iep ace
In et camshaJt oi l seal: replaceHydraul c cam fol owers check ngCanrshafts: removing anci r .sta l ing
Variable valve timing: checking . . .- So enoid va v€ of ihe caf ishaf l adl !stment syslem check nl l
17 LubricationLubricat ion system components: removing and instal l ing . . . . . . . . . . . .
ParlO er 'e ci eck
:1, r ' r : : ' : : l : ra l! f - r , , : r : , . . : : : r ,1. : : . t , ) . i )F : : : ! i ! Jr , l : . ; , : : : r ! i . - : r t t1r I r r . i , t i
19 Cooling systemCool ing system components: removing and insra ing . . . . . . . . . . . . . .
' 'a- t l 2:'t i l'/
Page
19,1t9 319 61.2-12
l ! ,1519 2213 21r9-2919 33
t9 40
Page
20-12432D 1220-1320-152A-1e2A 222A-232A-28
2A-2920-3020-4320 4420'4120-5420-5520-58
Page21-121-121 2
2i-41,
21 aA
Page24-12!-1:r ' l . l
- coa rg system aompoi3nis, boaty srceCoc ng sysle i l compcnents, eng ne s. leCcafa"i hose connecl oi l d agram
' C.o art dr i rn rg and f l fgA:o.1or reanoving ani l nsla lngCoo ar l pump: remlvrng anC |sial rng
- coo ant theff f ostat: femovtng and insta Ing'oo o . .
^de.05n6. . r 'g
Cor 1 nued coo ant c fculal on pump ,V51 I check ng
20
Fad elor lans V7-and V35 checklng
Fuel supply systemFuelsupply system componentsi removing and instat l ing- Fuel lank w th accessory paf is and f i ]e l f t ter removrng and
Safely precautrons when work ng on the fLre supply system
FLre de rvery uni l rernov Ng and nstal ngFLre evei sender remov ng and nsta ing
21 ChargingSupercharging system with exhaust gas turbocompressor
Mixture preparation, Iniection
i fs ta l inq . .
E.6 Ot . oo, .e c
Genera assenrb y diagram of th-a fue detvery Lrnrt and fuel gauge sendel
Fuei tankr rernovrng and instal ng
Crash tuel shut off- Fue pump ard fuel syslem: checkingElectronic power control {EPC} . . . . . . . . . . . . . .
Acce;eralor peda posi l on senders check rrgAct ivated charcoalf i l ter system . . . . . . . . . . . . .- Servic ng pafts of the act vated charcoa ii ter systern repairing . .- F ra 1: .1 h 'a) i l_ ior .ha. t n^
Connection diagram for the regulation of the supercharging pressureand vacuum control , . . . . . 21-2,1- Tesi ng condrt cns fof exhausl gas supercharg ng syslern . . . . . .21-32
Effects oi pcss b e eaks n the superch:rg no sysrem Zt 33
- FLr es for c ean rness- Tufbocompressor refaov ng and nstal ing- lnleraocier systear parts rgmovngand nsial ing-
q:1!r , r '6. . i ^" .
' SirDeraharg ng pfess!re contro check ng- llecha:r ca al: fec .culat on va ve check ng
A r rec rcLJ aton salenc i va ve for tu.bocompressor -N2:19 : c ireck ngSoieno d va ve 10 jrm t s:percharg ng press!re ,N75- checl NgD.1- l_ a:r i . .D-. . ,o .06. .no.g. gp. | . . .
J
Injection system: repairingF t t n! ocat ons overv ewA' l ief C s| Iar : ;ng aialEssenb ng
Fiu es for cieanlness . . 24-24
FL,!r ie f i t rJealrr5. j , . i r : i a|rg; a ia;s:mbing- Gelar ir l nal i : an . l - -a!ar. q;1:n, . ' . . - i
^^-
Technicaldala. . . .
Checking componentsComponenls and fLrnct ons. addpt ng
nleclors chec(rng ... . .
- qafan, nra.r r
^ . ., r ) r uo o, Jpd . Piuq)
- Voltage supply relay to contro unit -J- Hall sender'G40-: checking ...
27 J choct ing
24 ia24,2024-21
24-26
24-2724 2824-3624-3924-4024-44244424 5224-59
28)52834
- Eng ne control unrt fault rnemory: consu trng and clear ngCheck ng cables and cor.ponents with test box VA.G 1598/31Procedure aiter interr!ption in voltage supply
Control unit voltage supply: checkingCheck intake a r system for leaks lunmetered a r) . . .
' Eng ne speed sender -G28't checking . . . .
Iniectors: checking the injectors {or leaks and amount injectedCheck the pressure n the fuelsuppy system and the holding pressure. . . . . . . . . .
Exhaust system pageExhaust system components: removing and instal l ing . . . . . . . . . . . . . . . . . . . . . . . _. . . . . . . . , . . . . . . . 26-1' Exhaust manifoldr removing and instal l ing . . . . . . . . . . . . .26tO- Front exhaust pipe: removngand nstaihng ... . . . . . . . . . . . . . . 26-11
Exhaust gas temperature sender -G235-: removing and inst6 | ng . . 26 ZAExhalst system:checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . 26-28
- Exhaust system: lnstaLl and adlust wl thout s lbtect ing to stress . . . . . . . . . . . . . . . . . . 26-26
lgnition system pagelgni t ion system: repahing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-1- Genera information: ignition system . . . 2B-1
lgntonsystem com ponents: remov ng and nstal ing . . . . . . . . . . . . . . . . . . . . . . . 2A3
28$28-828,928-14
gnit ion coils with output stages -N-, -N128 , Nl58- and -N]63- checklng ... . .kno't qelso's -C6 -and G66 . "Ltrq
Technical data
Engine number
The eng fe nul]rber.ofslsts o1 LJ; j to r ne cfrar6ciers (a pnan!nief lct .Ine trrst part (ntaximurn 3 chatacters) f ral iesupthe,enginecode,, ,19 l l "^ -" ro"r . ,6 ro. . . , e co.c .qt 6. r , ro e rLa.y"9,q-9e10 o
^ t ' - !6,d. 6a)gto.od.- .poouLoo,, tef . .oJ
Ine sr ' cnaracter: s repaced wit l a let te.
Theengrnenrmber("Codelefters and, 'Seria nunrber, , lcanbefoundon ine lo nt between engine/gearbox.
Theengine code is ona labe placed ontheroolnecioettcoveroron thecy Inoer neao -arTows .
-heongi , lecooe . d,oonlhauel{ e oaia p ot . lould i , t .ec_sro reTve1r. a ser l tce sa' led- le d1d a ,o dr the .Far or rhe , /eh . . . . . L r . sp. tewheel housing or the f loor of the boot_
o0-1_
-.. l. {.
Engine data
3u[ t
F-
Engine code AMKExhaLrst em ss on
Disp acement
Torque
Diameter
Stroke
Compression rat o
OCT
nlect on
lgnitron
Knock contfo
limits accord ng to
cm3
kWmin
Nm/min
Omm
mm
Variable d str ibl t on
Varrab e ntake nanifo d
EU3 Standard
1781
154/5800
210/2140 .. .5A0A
86,4
Motronrc ME75
Motronic ME75
r l Except ional ly, mtnim!m octane95 OCl, but wth some power oss
. a T\a'!l L\€14
r
AMI(
Exhaust gaa fitcirculstlon r
Super.flarging
Secondary 6ir syslgJn
SelfiAcdiagnpsis
taqldea iF6rratiooCatalytic convener
yes
no
no
Engine: removing and in-stal l ing
Special tools. workshop systems, testers,measuring instruments and auxil iaryitems required
I Engine brackel AF 22044
a Bracket T10012
I S!pport toolT20082
a Ho ding tool T20127
1 Workshop crane VA.G 12024
a VA.G 1306 Dr p tray
10-1-
r Hydrau ic co umn jack SAT 1040
a Torque spanners SAT 8010
t T20029 p iers
a Guid ng centrahser T20070
a Compression tool U-30042
a Step ladder
I Cabe clamps
a G 000 100 grease
I Bolt lvl l0 X 25 / 8.8
sAT801o
q0m!E-{8"_*
(Gdn{+-€ "*.
@0!!:}
f2@29 120070
u-30042
Ti;-;1
- "t'i- a; {v\, - ae=
Removal: notes
a The engine is renoved d.y,nr€rds iogeiher r,,itl th_. Ee:rbc!.) All cable ties wh ich are opened ar cut opert wtten renjovng engne
must be repleced in Lhe same position wheD re tnstallitlg.a AII thermal prctectian sleeves rcmoved must be re ffted in the
same place on teassembly.a The remaved coalent shauld be put nIo a clean receptacle to be rc
used ar dtspased ()f.
Femoving r ibbed belt -
page 13 11
Drain coolant -
page 19 15
- With igni t ion switched off , disconnect battery earth strap and thentfre pos trve terminal.
- Remove secur ng bolts -arrows- and remove coveT -1
10-3 _
Unc|p the fuseholder suppcrl frame arrows-.
Open and remove the proteclive battery cover
Remove bolt -2-, supoort plate -3 End remove
Remove the battery ho der nrrows-
1, .
tie lrattery.
Locser c anr! . i - rer- | ! !e n;er r . ,se-5.6rd
Fernove bo ls - l anC 3 :nd rerrove the arr
Re ease the coo ant pipe f ange 1- andtube.
D sconnect the vacLrum hose -a(ow-.
coni eal t I i ro l - th€
remove t irom the meta
D sconnect pressure regu atorvalve l of the eng ne breather fromthe arr in let hose 4-.
Fernove the a r recirculatLon va ve ,2- f rom the air rnlet hose ,6,.
Remove connector -3 of the sLrpercharglng press!fe soJenold valve
Femove hoses -4 and 5 from the supercharglng pressure so eno dvalve'N75-
FeLease the tube -arrow-and remove the a r in ethose S reeasrngthe fange that secures i t to the exhaust gas turbocompressor
< ' Uernove thr airo ar i l tose5 ioi i i r€ l reai €xchaoger -erfou"rs-
10_7 _
< ' Remove the earth cable -1- l fom the eng ne/gearbox
- Fernove cab es -3 and -4- from the braner moror
Sepa€te the connector -2 and remove i t f rom the bracket.
Remove the cab es from the cl ip on the starter motor and piace onone s de; unbo t the cl ip.
a screwdriver a(ows and loosen th€ hexagon nuts a few turns.
- Loosen the w ndscreen w per aTms l- f rom the shalt .
- UnscTewand Temove the hexagon nuts and remove the windscreenw per arms.
Remove the rubber gasket 2 from the p enum chamber cover.
Remove the p enlm chamber cover -3 and place in thed recton ofIne wrnoscleen.
< - Se@ratethe e{t-ha nd con nector f rom the con tro Lrntbymovtngthecatch €rrow-
-1r=-==1,i
Open e11 iar d . , de . :abie
D sc n rect ihe a.r n, .cror
cfarrr le n i ie er qtre t r :y : rc\a-s-
' i t f re cei l le channel .
Femove the conneclor from the bracket and re ease rl ,arrow-
Uncover the w nng harness of the contro Ltni l to eng ne.
10-9 _
Femove the gearbox contro cab es on gearbox as iolows:
- Removethecrrcip-4-secur ngthe connect ion cable to t he connectron rod l
- Remove the c rcl ip -3- securing the select ion cable to the selectorle\ /et 2.
- Remove the select on cable and the connect ion cab e from the pl-vots -aTTows-.
fows and p ace t on one s de.
Clamp tn€ hose f . i i r :
Pl l the caich u pi . ! : fcs
. . r i . l_ P!rnp,.^. ' r i 13ol ! 3 l ! !2.
-arrow , remove tne pressure ptpe - ' l -
Waming!
Do not prcss the clutch pedal altet refiovingthe ctutch pump.
Removetheconneclorforthesupercharg ngpressuresender G7l-ano re ease the a r hose arrows-
Remove the alr hose frorn the thrott e va ve contro un t .
_ 10-11 _
an1c rculai ton p!mp -v51-.
- Unbolt the contLnued coolant crcuatton pump -V51 fromthearcondurt - lef t-hand arrows-; the coo ant hoses remain connected
- , lo-12 _
Remove the connectof -arTow ofsender -G235 .
the exhaust g:s lemperature
_ 10_13 _
Aftention!The fuel system is under prcssurc. Before opening the systemplace a cloth arcund the connection, Then release Drcssure bvcarefully Ioos ening the connection.
- Remove the vacuum hose -2- from the ntake manifold
Remove the coolant hose -1- lrom the expansion tank
Release the coolant expans on tank and lay 10 srde.
- Re ease the vacLrum tLtbe for the charcoal f l ter system
Remove power steer ng tank and lay 10 s de.
so, press the unlock ng keys
I
- -_ f e@$t
- '10-14 .-
t l rbe connectrno the two ntercoolers _2_
_ 10_15 _
- Br ino ock carr er into service posit onl+ Gefera Body Repairs, instal lat ion work, exter ior; Repa r group 50;
Genera body reparrs, i ront; Lock carr ier Leon CLtpra R: service pos!t ion
Bemove r ighthand drve shaft and dlsconnect lef t hand dr ive shaj lat gearbox:
+ Runninggear,axles,steering,frontwhee andfourwheeldrve; Re-pa r group 40; Drve shaft : removing and instal |ng
Remove front exhaust pipe + page 26t1
It ts not necessary to remove the sub-f?me, just push the front ex-haust pipe to one side so tt does not tnterfere during disassembly
- Be ease the ower rad ator hose
- Dlsconnect pendulum suppon affows-.
f EnTqol
_ 10-16 _
< Fenlove I ghl nand nsu at icn arrows-
Loosen the bolts -aTTows- and remove the puley, l - f rom powersreef ing vane pump.
_ 10-17 _
ReLease the power steering pressure pipe - j - f rom the f langes arIOWS-.
Remove the bolts ,arrows and remove the vane pump.
- Secufethevanepumplolhebodyworkinsuch€waythatthehosesare not in tension.
r \ :? . ' Ie -__o ' r al Fo.or3-1.
_ 10_18 .-_
_ 10_19 _
Vehicles with air conditioning
Attention!The ah conditioning cooling circuit must not be opened.
Drsconnect connector f- in the air condit icning compTessor.
Remove the bo ts -arrows-secur ng the air cond t ion ng compressoc
Move the air cond t ioner compressor downwdrus ano secure l rothe ock carrrer sc that the refr gerant hoses/pipes are not underten
- 10_20 _
-ll-_ji t r { i
---/ '-T10012SAT 1O4O TEii-ofi;l
cont inued for al l vehicles
Secure the T 10012 bracket to cy inder block w th Ml0 X 25l8 I nutand bolt
- Li f t the eng ns and gearbox sl ght y w th the SAT 1040 hydrau ic co,
_the en9 ne bracket -arrows--
To remove secuing bolts use a ladder
- Unbolt assembly moLrnt ing support f rom above, gearbox side, f fomIne gearoox aTTows-.
- Careful ly lower the engine and gearbox.
Note:
Engine and gearbox must be guided carefully when lowering ta pre-vent damage to the bodywork.
_ 10-22 _
I
g o
I
@
-m;a
Engine: securing engine to assembty standFor assemb y, the engrne must be secured to the AR2204A assemblystand with the T20082 engine bracket.
Work sequence
- Free the gearbox.
- F t the holdlng tool T20127 to engine and with the aid of the workshop crane VA.G 1202 remove the engine from bracket Tl00l2.
Note:
Check that the hooks are closed with their safety nuts
- Secure the engine with tool T20082 to bracket AR2204A.
- 10-23 _
Installing: notesl^c ia latro- ts _a- ed o t i t - t re er 'e. leceoLrenc6.whe-dongths-otetne ro owtnq
- Check whethef the dowel sleeves for centring engine/gearbox arern the cy nder block, insta I f necessary.
' Fi t intermediate plate onto seaing lange and slde onto dowelsreeves -Efiows-
Check centr ng of clutch drive plate, f necessary.
Check clutch release bear ng for wear, renew i,f necessary.
- Lrght ly grease clutch release bear ng, re ease bear ng guide s eeveand input shaft splLnes wtth G 000 jOO
- When rnsta I ng the engine assembly, ensLlre there s soffrc entciearance wlh relat on to drive shafts
I
- .to-24 _
- Fft the engine brackets
- A ign the engine brackets + page 10-30
Note:
Engine bracket tightening torques+ page 1G2B
- F i t .gea rbox contfo and, i {necessary, adjustgearboxact oningmech-anrsm:
+02M 6.speed ^ran-at gearoo\. 1r4lrr. gearbo\; qepair g.oLp 34;tleaf onve mecnanrsm: adjL'lst nq
- Fit right-hand drive shaft and fit left-hand drive shaft to the gearbox:+ Running gear, axles, steering, front wheeland four wheel d-rive; Re-
pair group 40; Drrve shaft: removing and lnstalling
- Fit f ront exhaust pipe + page 26-11 .
Continue assembly in reverse order of the dismantling procedure
_ 10-25_
Notes:a lf the battery is reconnected check the vehicle equipment lradio /
radio and navigatioh system, clock, power windowsL lolowihg theindicdtions in the Operating lnstructions.
a Other measures after reconnecting the voltage supply + page24-39.
- Carry oui a test drive and interrogate fault memory:+ VAS 5051; Vehicle sell-diagnosis
- 10-26 _
Tightening torques
It
i
III
i
I_ 10-27 _
Ii
!
tI
i
i
-Nost
Engine brackets
Tightening torques
I - Mounting to bodyr) 40 Nm + 90 .(1/a turn) iurther
2- Secur ng bo I to mount ng 25Nm
3 Mounting to eng ne rr 60 Nm + 90 "{ /4 turn)fufther
r) Fep ace bolis
1- Mount ng to body r) 40Nm*90.(r/4 turn) fufther
2 - Mountrng to body 2b Nm
3 - Mounting to gearbox rr 60 Nrn + 90.(r/4 turn)ruftner
1)Fep ace bohs
Elements Tightening
Bo ts, nuts N4 6
M7
MS
lr4 lO
M12
10 Nffl
15 Nm
25Nrn
4AN,TI
60 Nm
Different i tghtening torques
Engine to gearbox M10connecting bo ts
45 Nm
Eng ne to gearbox l\A12connecting bolts
80 Nm
ifl--
I N-dMl
- 10_28 _
/ -3
1 10 gearbcx l
2 to gearbox r
3 to the engine bracketrr
40Nm+90'1r/a tufn) iLrther
40Nm+90'{r /a lurn) fLrr ther
20 Nm + 90'(r /a turn)fuf iher
u-30025E
tw26il
- .10-29-
secure the engine with cross
Engine brackets: Aligning
Special tools, workshop systems, testers, measuring instrumentsand auxiliary items required
a Cross member U-30025E
Note:Beforc loosening engine bracket bolts,member U-30025E.
Engine brackets, gearbox
The edges -a- and b must be paral le with one another
_ 10-30 _
a = 14.0 mm
b = At leasilo.O mm
Eolh bolt h€ads -1- must be in flus* Wid! 6dale c
_ 10-31_
rI
:I
FI
-I
I
!
IIIt-IIIt-III
FIIII
i-II
I
ri_
i
l
G(\u
6-s"Kl\"sf-T-oi ?6 I
Engine: dismantl ing and as-sembl ing
lf when tepatring an engtne, metalshavingsar latge quantties of sma1 metal pafttclescaused, fat e\anple, by patdal seizure afcrankshalt and con rod bea | )ngs - are fau nd i nengtne on, to prevent consequential dam,age, apart f rom tlrcraughly cleanng ailpess-eges, tt ts necessary to renewthe ajlcaoler
I + page 13-2
11 + page l3 6
l l l - page 13 25
V+ page 13,37
Part I
1 - Knock sensors 1 -G61- and 2 -G66-a Checkng
- Page 28-34
2 "20 Nma T ghtening torque Inf uences the
f!nct ion of the knock sensor
3 - Dipsticka The ol l level must not go above the
4 - Coolant pipea Secured to cy nder b ocka Coo a.r ho)e o ,e.r o. o.ag o- >
page 19-12
$Igii1]
\-6
'I
91011
12
14
7f ,e-8
20 19 a17 tEi3-oor5l13-2 _
'6
qiJ)))..
i fIg/r
7l_1, @ 8
121314
16
20 '19
5 -20 Nm
6-15Nm
7 - Oil filter bracketa D smant ing and assemblng
- Page
11 11
8 - 15 Nm + l /a turn (90 ")
9 - Oil coolera Lubrcate contact sudaces wth the
olf i ter bracket beyond the O-r ingwith AMV 188 001 02
a Ensure clearance to adlacent compo,nents
10 '25 Nm
11 - Oil l i l ter,f Loosen w th turn ng loo U40078 or
a un versa ftlter extraciora Tighten by handa Note instructions on f l ter when rn
sra I ng
12 - Gasket
13-10Nm
14 - Engine speed sender -G28-a Checking + page 24-48
15 - Connection sleeve
16-15Nm
13-3 -
rz . t a + 5
l l tF \ \ I\ t \ \ \ , r\ \ | \ \\ t l l A r lP
cJ Y -4"*u1/ ds
7
I
12l ' t
14l5
lo
18 17 t F, ^oq
l
13-4 -
trI/
12i l
dJ- +6
11
12_-13
to
20 19 1A 17 l=-r 3 oorsl
17 - O{inga Flen-.w rf danral ted
18 - Coolant thermostatl | ChecLrng: leat i iE i i r i rn osi ; t
t Open ng comrnences approx 87 'aa Ends approx. 102 'Ct OpenLng i i t min 7 mma D smantl ing and f i t t ng
- page 19 29
19 -45 Nm
20 -Additional sub-frame bracketsa Dismantlng and f i t ng
- page 13 17
21 -45 Nm
22 - Right-hand engine bracket
.$J[t
Ribbed belt
Part ll
1 - Ribbed belta Err rg -he b6\ ro r '6r i . l6r , . - \o.r a.
condit ioning + page 1310t F t t ing the be t 10 veh cLes with a r
conditon ng -
page 13 10a Engines wth an a r condt ioner com
nre<<^r: ,o { lda/ l , ! r l r ! / l^ ha.hFa. l
beti Check for weara Do not kinka Dismant ng and f t tng + page 13-l1
2-23Nm
13-5 -
89
' t7 16 '15TA13-0380-l
13-6 -
89 10
d.
14 fAr-3 o3sdl
8 9 10
16 15 f;i3 b3so ]
3 -Tensioning device for ribbed belt1To reease the lens or ofthe toothed
rel t Lrs.r a f lar spanrer -
page 13 12
4 - Belt pul ley/vibrat ion damperr w th I bbed befta Drsmant ing and fr t t tng > page l3 l5
5 '45 Nm
6-23Nm
7 - Alternatora Removirg and nstal ingl
= Electr ical system; Fepai. group 27;Staft er motol current supply; A ternator:reraovtng and instai ing
a To faci l iate the instalat on of the a -ternator, move the threaded bushestor tne al ternator bolts a t te back_watos.
13-7 _
8 - Air conditioner compressorIAfter rernovng, secure the com-
pressor to the sr l , e.g. wth somew re. Do not let thangfromthecoong agent prpes
a Do not unbovremove the coolngagenr p pes
a Tofac l tate thefr t t ing of the aircond -tron ng compressor, move thethreaded bushes for the compTessorboltsa r t te backwards.
I -Spacer
10 -Additional sub"frame bracketa Disman ng and f i t i lng
- paqe l3-17
11 -45 Nm
12-23Nm
13-8 _
,,to
14 tAi3 o38o-l
'13 - 23 Nm
a For power steer nga Removing an,: ] nsiaLing
+ Funning gear, axles, steering, {rolr t wheeEnd foLrr whee dnve; RePar group 48;Steerlng, Powerass sted steenng Dox:removing and nslal lng
a To faci l tate the f t t ing of the vanePunP, move the ihteaded bLrshestorthe bo ts of the bracket a itt e back'
15 - Belt pul leyi For vane pump
16 -23 Nm
17 - Special boltQ For 8.8 reStstan.. bo t : ono.^ the
ool. . ! g- ior ro l0 N' a_d errohranto 90'
a For 10.9 resistance bots, the bo'should be tghtened to 40 Nm
13_9 -
Ribbed belt routing
Be t rout ing without arr condLt oner compTessol
Belt rout ing wLih arr cond t toner
Note:
Engines wllh an air condn oner fitted with a daubie
- 13-10 -
rwoet
Ribbed belt: removing and installing
Special tools. workshop systems.testers. measuring'instrumentsand auxiliary items required
a Ho ding toolT10060
Notes:
a Before rcmoving the ibbed bel{ matk the drcct@n of rotatian wihchalk or a felt tip marker ../
a 1f the belt has been useiJ and is made to vr'otk n the opposie djrec-tian tt may be destraied
Dismantlirr'g
L}sas<an 0 'g ITp e g -6 cor 'er €.row.
_ 13_11 _
./
. , To re ieve tension on the r ibbed be t , turn the rensionrng dev ce in the,; drrectron oT t fre -arrow,
-' tu,i( |1: eg
_ 13-12_
Lock tension ng e ement !srng too T'10060 arrow
Femove centra insulat ion -4ffows-
,!
reP
'u'-\' t
- Remove rght-hand insuiaton €rrow's.
- Remove r ibbed belt .
Installation
Ensure, befare instalting ribbed belt, that a ancillaries (alternatot, aiconditianer comptessar, PAS vane pump) arc secured tightly.
- Fit the ribbed belt to the crankshait and vane pump pulleys
- Fir the r ibbed belt to the al ternator pul ley last
' Remove toolT10060 irom i ts posi t ion _arlow'and release the ten_slonrng elemenl.
Check correct J tt ng o{ the Rlbbed belt.
Continue assembly in reverse order of the dLsmant ng procedure
Sta.t englne and check how be 1 is runnrng.
- 13-13 --
- 13-14 --.
tI
Belt pulley/vibration damper: removing and in-stalling
Dismantl ing
Ta loosen and ttghten the beit pulley/vibratian dampea immobitise h,holding the central balt whh a ring spanner
- Femove r ibbed bel l -
page 13 TT.
- Remove the bolts and the beit pulley/vrbration damper.
Installation
I lt can only be fitted in one posit on, ihe dfilled hole -arrow' of thevibrat ion dampershould be on the highl lghted part of thetoothedpu ey.
_ 13_15 _
- Tighten the vrbrat on damper/belt pulley bolts as indicated:
a For 8.8 res stance bo ts, renew the bolt , t ghten to l0 Nm and rettghten to 90'
a For 10.9 resistance bolts, the bot should be tightened to 40 Nm
Instal l r lbbed belt + page 13 11.
Contnue assembly tn reverse order of the dismanting procedure
- 13-16 -
r1_.: .-- : -- : :
Additional sub-frame bracket: removing and in-stalling
Removing
t Bet6,s6, ,s n-. qao., t p .o. . r ' ' , "o '5 '1cluded in the radto nanual ':,ust be absetved
a When the bettery is recannected check the 'lelticle equtpmenttadrc, clock, powet wtr)daws), fallawingthe indicatrcns iLl the WorL.o. M I L" lar1o. t . ' ODc a a 11" u\ ia '
Wth igndon swiched off d sconnect battefy eadh srrap
Removing r ibbed belt + Page 13-11
- Loosen the f langes -arrows-, removethe nuts - l -and remove the n-tefcooler connecl ng tube -2
- 13-17 -
Lcosen bolts -arrows- and remove pul ey 1 fromthe powefsteerlng
- Femove the bolts _arrows- and remove the vane pump
' Securethevanepurnptothebodyworkinsuchawnythatthehosesare not n te nsion
- 13-18 -
Femove th€ bo ts -arfows and remove the cover l -
I
ttI
I
tI
ii
I
Remove the connector -arrow of thesender -G235 .
exnaust gas lemperatuae
_ 13_19 _
Felease coolant hose 1 from bracket -4-.
Remove the bo ts -2, and -3- and remove bracket 4-
- 13_20 _
S€p:iaie the conneclor arrow .
Remove r . i -1 ard remove the :1-rndtor eeatr c cair ! 2
Remove bo ts -1- and rernove ihe al ternator.
- 13-21-
Remove bo ts -arrows- and remove the r lbbed belt tensroner.
Attention!The afu conditioning cooling circuit must not be opened.
Vehicles with air conditioning:
- Disconnect conoectof -1- lor the alr cond t lonrng compressor
- Femovethebolts arrows secunngthea rcondrtoningcompressor.
_ 13-22_
- Yo, . e- .or ,d.ro.r 010,6,u oo{. ,y.ro. a.o. ( o. to
, : : : . . . " , - <orha-r - roorroooo-r no.e>,proo a.a or-noel
I
I
Remove bolts fforn the addttional sub{rame bracket n the estab_l ished order -E.. . .A-.
_ 13_23 _
Installation
- Tighlen the bolrs of the addit ona subjrame bracket in the estab_l ished order - ,A . . . . .F- to 45 Nm.
Continue assembly n reverse order of the drslram ng proceoure
Not€s:
a lf the battery is reconnected ctreck the vehrcle equipment lradjo /tadta and nav gahon sistem Toct. pov\e! Andowst. totta^,ng thetndicat@ns in the Operatng lnstuctians.
a Other measures after rcconnecting the voltage supply + page
I
If
t'ii
D
B
-N€et
D E
B
T@;6I
_ 13,24 _
23 22 21 20 19 18 17
Erruqr l
Toothed belt
Part lll
1 '25 Nm
2 -Tensioning device {or ribbed belta To re ease the lension of the toothecl
be t use a f lat spannef + Page 13'12
3 -Toothed belt guard - upper Part
4 - Toothed belt guard - centre section
5 - Toothed belta Mark D.O.R. belore remov nga Check for weara Do not kinka D snrant l ing and f t t ing + page 13 29
- 13-?5 -
6 - ld ler rol ler
7-27Nm
8 -65 NmI Use tool T20018A to loosen and
t ghten
9 - Camshaft sprocketI Note f i t t ng poslt ion:The thin core of
the carnshaft sptocket Ponts oLrtwards and TDC mark of the cylrndelcan be seen. 1
10 - Tensioning rol ler
11 -Tensioning device for toothed belta iest ing the hydraul ic elernent for
12 - O-r ing/
rryt \
23 22 21 20 19 18 17
- 13-26 -
45 6 7 8
10
13
14
23 22 2"1 9 18 17
fEJr oi €l
24
13 Coolant pumpt Lhecl l for elsai of rovenreni and ro
g.p:a T dan ; ! te. l or lsakrng: fenew ccr i
a Drsmanl ing and l in jnq + pale jgt j
14-15Nm
15 - Crankshaft toothed belt sprocketa Thefe musl be no oi l on the contact
sur%ce between the toothed bel l andthe cranksheft
16 - 90 Nm + 1/a turn (90 .)
a use tool T20018A to loosen andtrghten
a Threads and shoLr der m!st befree ofo ano gTease
17-15Nm
18 -20 Nm
19 - Toothed belt guard - lower part
20-10Nm
21 - Pulleya For power ass sled steering pump
22 -25 Nn
23 - Ribbed belta N/ark dlrect on of rolation beiore re-
movinga Dismant ing and lt t jng > page l3 1l
24 -25 Nm
25 - Belt pul ley/vibration dampert Can only be insta ted in one posit on.
Ho es afe of{sett D smant|ng and f i t l nq
- page 1315
_ 13_27 _
TI
4567I 9j
@11
14
21 20 lo 18 17
I c, r -u 4)
_ 13_28 _
6nng!-:-r ,."-
OdB!]:F
*s\.
t L13 0056l
Toothed belt: removing and in-stalling
Special tools, workshop sYstems, testers,measuring instruments and auxiliaryitems required
a Torque spanners SAf 8010
a Holding tooLT20046
a U-30025E bracket
- 13-29 -
Dismantling
Femove r ibbed belt + page 13-11
Remove boLts -arrows- and remove the ribbed beJt tensloner
Englne instal led:
' T\rrn crankshaft to TDC No.1 cylnder
= w7 FN;]
- 13-30 -
Ern rar renr lvgal:
< ' Trr r v ibrat on Canrper ro TDC l . , lo I cyl inder ,arrows
Reiease th€ coolant exfrans on tank ano ay ro s de
- Re eese the vac!L_]f f tube for the charcoalf t l ler system
- Remove pov,,er steer ng tank and ay to side.
Bemove upper paft of toothed belt guard.
- F t the hook of the spindle A- n the r ight hand suspenston eye andpre,tension slght ly.
_ 13_31 _
Femove the bolts -arrows- and remove the engine bracket
Rernove v brat on dampe/belt puley + page 13 j 5
Remove the bolts securing the s upport to the eng ne block €rrows-
Remove toothed be t guard centre and ower pans
Mark D.O.F. oi ioorhed beft.
Ji.i*
_ 13-32 _
' T ghien t . ,ol T2004e to th- ' toolhecl Lr" l l :ns ofrng cev ce
Tighten pressLrre p slon Lrsing iens on ' rg
dev ce orr y r nt l l pressurep sinn cai be sec!fed r ' " l t l_ e ockln! bol - f i io""/
Fenrove toothed beh
lnstal lat ion
a When camshaft is tutred, ensure c?nkshaft ts nat al fDC Dangerof valve/piston crawn damage.
a Marl< D.O.R. af toothed belt, danger af breakage
Algn mark on camshait sprocket with the mark on cyl inder head
- 13"33 -
Engrne removed:
- Turn vibrat ion damper to TDC No. 1cyInder_arfows
f=@51
Erg n. r-s-a ed
- Turn crankshafl to TDC No.1 cyLinder 'alrow_.
- o,aae rootheo o6h on .rarrs^ol pu 6\ oose..e ot 'e.r io o ' 'o la-t on)
- Place toothed be I on coo ant pump, tens oning rol er and camshl
/f"(tt ltlz^... € l-'.Lfl16x-''
\ \\J,/ I /-r,,----.,\-,2 { E
N'\
- 13-34 -
rlItIII
II
Unscrewthelensroning bol loi too T20046and removethe rmmob
a Jhe pressure p slon relufns to i ts work ng pos t ion
Turn the crankshaft two tufns and check i l camshafl and cfankshaftmarks algn with refetence marks.
' Fit toothed beh guard centre and ower pafts.
Note:
Befate fitting the engine bracket attach its balts.
- Fttheengine bracketon thecyl tnderb ock and t ighten the bo ts -ar,rows- to 45 Nm.
- Fi t the vibrai on darnper/be t pul ley + page 13 15.
Frt the eng ne brackel and remove the engrne support tool
- A ign the engrne brackets + page 10-30
Note:Engine bracket tightening torques
- page 1G28
Continue assembly in reverse order of the disfftantling procedure
_ 13-35 _
l
t!
i
- 13_36 _
7
Seal ing f langes and enginef lywheel: removing and in-stalling
Part lV
For repairc to the clutch:+02M 6speed manual gearbox, 4x4lm.
gearbox; Repa r group 30; ClLrtch: repair-ng
1 - 90 Nm + l/a turn 190') further
a l lse tooi T20018A to oosen andtighten
a Threads and shoLrlder mustbe f ree ofor d 'd g ed!.
2 - Crankshaft toothed belt sprocketa There must be no o on the contact
grfa -e belween the roorhed be I d.dthe crankshaft
- 13-37 -
3 - ' t5 Nm
4 - Oil sealI Fenew
- page 13-41
a Do nol oi l
5 - Sealing f langea D smantl ing and ftt lng + page 13'4,
6 - cyl inder blockI Cfankshaft: removing and nstalrnc
+ page T3-51a P ston and conrod: d smantlng anu
assembllng + page 13-58
7 -60 Nm + r/atum (90') further
t Use tool T20075A to loosen andt ghten
123
l l lIL
t t t,Se
10 3 9
- 13-38 -
Fig. 1 Insta ing
- Fi t intermediates eeves arrows-.
intermediate plate
plate onto sealng f lange and slrde onto oowel
8 - F,ywheelI Flemovrng ar id insta ng
p3get 3-49
I - Intermediate platea Do not damage/bend when assem
blrngI Instal lat ion posit ion
- Fig. i
10 -Seal ing f lange with oi l seala On y renew completeaDonotola Make sure the oi seal l ip is not dam-
aged or bent on f i t t tnqa To f t , insert the guide sleeve (suo
pl ied with the seal)on the cranksh;f ta To remove and fit it is necessaryto re,
move l f re sump -
paoe 17_15
_ 13_39 _
10 3 9
=-_ 13.40 _
{01((::-.: . ,,"
fi!1ft:_ ]; -,",,.,
tni0]]+la .,
t Litno54l
nsert exlfactor T20'143 and remove the oil seal 1
Crankshaft oil seal -belt pulleyend: replace
Special tools, workshop systems, testers,measuring instruments and auxiliaryitems required
a Torque spanners SAT 8010
a Ho d ng toolT20018A
a Gulde sleeve T200818
I Extractor T20143
- 1341-
Dismantl ing
Remove toothed belt + page 13-29.
- Remove crankshaft toothed belt sprocket by lockrng wlth counler_hold T20018A.
_ 13-42-
T200818/4
i-I
T20018A
sAT 8010
fmml+ E -__
@Ir:_E
tLi3-oo35 l
Installation
Do not ail the seahng lip cr the e.lge of the ott seat
- Sl de o I seal over g! de steeve T200g1B/4
- P ace set onto crankshaft stub
U'e g- de < ee.. T-005 8 t " o p e"s o. le q.66ve-o l seot d. cFa.
l l lvd,1. , a r . , \ t l oou-- lhe5eol t - l lu.h. lodoths,u.e. .6otdsecuring bolt for v ibrat ion damper
. Femove gurd6 s eeve T20081B/4
' Ft crankshaft toothed bet spfocket and immobilse wth counterhold T20018A.
- Tighten the new centra bolt to: 90 Nm + 1/4 turn {90 ').
Note:Thread and shoulder must be free of ail and grease.
Fittlng the toorhed belt + page j3,29.
_ 13_€ _
Front sealing flange: removingand installing
SpeciaI tools. worftshop systems, testers.measuring instruments and auxiliaryitems required
a Torque spanners SAT 8010
a Ho ding tool T20018A
a Gu de sleeve T200818
a D116404 A2 Silcone sealanr
a Hand drl l with p astic brush insen
i) Flat scraper
- 13_44 _
Dismantl ing
Femove tooihed be t 3 page l3 29.
Femove crankshal l toothed be 1 sprocket by ocking wth counterho d T20018A
Remove slmp -
page 1715.
- Fernove bo ts 1.. .6 securrng the front sealLng f lange
-Removeseaingf lange. l f necessary, releasebygeni lytappngwtha rubber malet.
Femove sea ant residue on cy inder block w th a i lat scraper.
- Remove sealant remains on seal ing fLange with a rotat ing past icbruslr (wear protective goggles).
- leo_ sea rg s ida . . - ' r -st be r ee o- or a-d g ea.6
lnstallation
a Note the use by date of the sealant_a The sealing flange must be installed within 5 minutes of applying
the silicone sealant.
Cut off tube no2zle at lorward marking (nozz e d ameter: appfox. :
App y si cone sea ing compound, as shown, to c ean sump seal n!
o Th ckness of seaLant bead -arrows-: 2 .. 3 mm
- 13-45
- 13-46 -
Ii
tI
I
I
Ti
I
I
tI
t
III
I
The,sealing compound beed r,ust not be thicker, otl)erwise e\cesstvesealtng compaund wjll enter the surnp and may block the oit suctjon
- Appiy-si l icone seaIng coJnpound, as shown, to clean sump seal ing
Fit seahng f lange irnmediate y and l ight ly t ighten al l bol ts.
Use.guide sleeve T20OB1B/4 to fit sealing ftange whh the oil seal already installed.
- Tighlen the bolts securing the sea rng f lange in d agonal seqLrenceto 15 Nm
' Instal lsump + page 17J5.
qtler FsGth,ng sumphe sealahl must DF a|otuedb d,V foroppr|\.30mtFLt es. Anet rfts ttme has passad, tha sumD ma, be litled.
_ 1347 --
- F t^crankshaft toothed be t sprocket by ocking with counter ho dT20018A
- Tighten the new central bo t to 90 Nni + 1/4 turn. {90 .) .
Note:
Thread and shoutder must be frce of oil ano grease.
- Fi t t ing the toothed bett -
page j3 29.
_ 13_48 _
1200754
sAT 8010
fi0m]l*:ln
ll]]mt]H=tri.,.".
mCIl':
t!!@;E
Flywheel: removing and installing
Special tools. workshop systems.testers. measuring instrumentsand auxiliary items required
a Holdrng toolT20075A
t Torqle spanners SAT 8010
Dismantl ing
- N/ larklnstalat on pos t ion oi f ywheelto crankshaftwith a permanent
' Se.u.ecoLnre-hold_200754_ocy ' loe heaohoea-o m-loolsethe f lWvheel.
- Loosen fywhee secur ng bo ts and remove the f lywhee.
lnstal lat ion
' Pace fywheelon crankshaft in the previously marked posit ion. -
T ghlen the new fl\..wheel secur ng bo ts to 60Nm + r/a lurn (90")
- 1349 _
_ 13_50 _
A\r.\hw
Crankshaft: removing andinstal l ing
a The cylinder block will be assgned withthe carrect thick ness bearing shells at thefactory. The thickness ts tdentified by ce
I Far assembly, the engtne must besecuredto the AB2204A assembly stand wnh the720A82 engine bracket.
1 - Bearing shel lI For cyl inder b ock wth oi tgroovea Do not mix !p used bearng shel ls
(mark them)I New bearng shel ls ofthe correct co-
our should be used -
Flq 2. oaoeI3-56
_ 13_51 _
2 - Chain sprocketa For oi pLrmp drve
3 - Bearing shel la For bearng cap wthout oi tgrooverl Do not m x up used bear ng she ls
(mark rhem)o Lower crankshaft bearing she ls are
always supp ied as a spare part wththe colour marking "yel low"
4 -Thrust washersa For cyl inder b ock, bearng 3a Note f ix ing affangemenl
aa'a;,fAl3 otgl
_ 13,52 _
tAi3 oo?r l
fFtm?r-l
5 -6s Nm + 90" (r /a turn)
I Tghten to 65 l . . l rn ^ 'hen
nr.asor ngradrelc leaiance
6 - Bearing caps1 Bear ng cap 1:Puley endI Bear ng cap 3 w th rec€sses for lhrLrst
I Shel l bear ng reta nrng luqs (cyirderblock/beafng cap) must be on the
7 - 10 Nm + g0' (1/a turn)
l} Wheneverthe bo ts are oosened, thesender wheelshould be replaced
-Fq. l , paqe 13-55
8 ' Sender wheela F^. a^d na <naor l co.dar -Ctc-q Can only beft ted n one posrt on ( the
holes afe ofisetla Wheneverthe bolts are loosened, the
<an.]ar M,h6a <h^ d l !a r6^l ! .on
o Dlsmant lng andf ln ng-f ig 1,page13-55
S - Crankshafta Axralclearance, new: 0 07 .0.23 rnm.
Wear l im t: 0.30 mma Check radial cearance with Plasti-
gage. New: 0.02 .0.04 mm. Wearirnl t : 015 mm
a Do not rotate the crankshall whenchecklng the radial clearance
a Crankshafl d mensions-page13 57
_ 13_53 _
_ 13_54 _
3
tM;$ I
Fig. 1 Removing and instal l ing sender wheel
Whenever bolts 1 are oosened, the sender wheel sho! d be replaced -2-
a After a secand assenbly, the countersutlk balts holes arc sa detarmed thatthe heads af the balts make cantactwtth the cankshaft-3- and the sender wheel rcmains loase
a The sendet wheel can only be fifted in ane pasitian;the hales are
I
I
F;A;l
_ 13_55 _
Fig. 2 Assigning the crankshaft shell bearings tor the cylinderblock
n the factory the correct thickness she I beaf ngs are selected. Theth ckness is ident fred by co oured spots.
Note:
The arrow indicates directian of mavement.
The p ace to f t the shel l bearings is indicated by let ters on the lowersealng sudace of the cyl inder block.
Letters on thecylind€r b!ock
Colour of shell bearing
S black
R
G
Note:Replacement cran kshaft bearing shells are always suppliedasa spareparl wtth the colour marking "ye aw".
- 13_56 _
Honingdimensions
Main jou.nal I Conrod journala
Basrc4,411
54,00{,037
-0,42247,44
,a,o42
Phase-0,017
53,75,0,037
4.A2241,55
-0,442
Phase I{ ,017 o,022
47,344,442
Phase l l l-a,017
53,25{,037
4,A2241,45
-a,442
Crankshaft dimensions(Drnrens ons r rnm)
Piston and conrod: dis-mantl ing and assembling
1 - Piston ringsa Offset gaps by 120 'o Femove and nsta I with piston ring
plersI "TOP" faces towafds ptston crowna Checking rng gap + f ig. t , page
13 63t Checking nng 10 groove clearance =
trg. 2, page 13€41) 2 or 3 piece oi scraper r ing, can b-
_ 13-57
11 - \, ) -
-bM,' ! - -F
E
tv lJ - ior t l_ 13_58 _
* -2
11
10c\
-3
R-- 1
7 ---.
6 .----
w13 - 1o1il
2 - Pistona Checking
- Fig. 3, page 13S5
a Mark nstal l : t ion posit on and prsion/cyl tnoer cof iesponoence
a Arrow on plston crov/n ponts tocrankshaft pu ey end
a Insla I Lrsing p ston r ng s eevea Pston and cylnder dimensions +
page 13S7
3 - Conroda Only renew as a seta Mark cyl inder number -B-a Marking A faces towards pul ley endt With a dr led hole for lubf icat ing the
prston prn
4 - Conrod bearing capsa Mark cylnder number It Marking -A-faces towards pulleyend
5-30Nm+ 1/4turn (90')O Renew the conrod bolt ' i tem 8-a Oilthreads and contact surfacea To measure radial clearance t ghten
to 30 Nm
6 - Pressure relief valvea27Nma Opening pressure: 2.5 .. . 3.2 bar
7 - Oil iniectora For piston cooling
_ 13-59 _
12
11
10
8
9
I
6 _- \..?5 ---
l,/-r 3 - lorrl- 13-60 -
.11. .3
o.;2_.\,, ___?10 'H
9
8
7
6
tvL - 101;l
8 - Bearing shella Upperbeanng shel l wrth a dr i :d holr
for ubrcatng ihe plsion p rI Note the {r t t ing posrt ion.a Do not nterchanqe used lreafing
sne tsa Observe I ght posi t oning onto ai laal
ment f angesa Axal c learance. New: 010..0.35
mm. Wear i r . ] i t : 0.40 mmI Check radial c learance with Past
gage. New: 0 01.. .0.05 mm. \ l /earl im i : 0.12 mm
a Do not rotate the crankshaft wherchecklng the rad al c learance
f961 -
9 - Cylinder blocko Checking cyinder bores + Fg. 4,
page 13'66a Piston and cy inder d mens ons =
page 13€7
10 - Conrod boltI Benew
11 - Safety washera Renew
12 - Piston pina lf dif f icult lo move, heat piston to 60
'ca Remove and lnsta I with too T2001
11 ..
-o10
/,'p(Tvt>-;
-i;/:;t'/-
)12 .'-
7
I v-r3 - 1or al- 13-62 -
Fig. 1 Piston r ing gapsr check gap
Special tools, workshop systems, testers, measu.ing instrumentsand auxiliary items required
a Feeler gauge
Checking procedure
l1)e r r1e r-g om.he-oot op-c. -g.ora.6y'- .oraoo\eoo\to aooro, . tb m-r I .o . lhe edoe of Inc - / t -oe.
Piston ring GapNew lweartmt
Compression f ings mm 0 20.. .0,40Oi scraper r ing mm 0,25...0,50 1,00
_ 13,63 _
Fig. 2 Checking ring to groove clearance
Special tools, workshop equipment, testers. measuring instru_ments and auxiliary items required
a Feeler gauge
Checking procedure
Clean groove before checking.
Piston ring Clearance
New lWeartmt1s1 compression mmring
0,06...0,09 0,24
2nd compress on mmring
0,05...0,08 a,24
Orlscraper nng mm 0,03..0,06
_ .13-64 _
It1:4il
Fig. 3 Checking pistons
Special tools, workshop systems, testers, m easu ring instru m entland auxi l iary i tems required
a N/l icrometer 75.. .100 rr ]rn
Checking procedure
Measure to approx. I0 mm from lower edge, at r ig ht ang es to pistor
MaximLrm deviat ion from nominal dimens on 0.04 mm
_ 13_65
Special tools, workshop systems, testers. measurin g instrumentsand auxiliary items requi@d
I Interna d a gauge 50 ..100 mm
Checking procedure
1\e.neasu e.ne1rcal3poslo-st . oot tareral-A-a olo ' rgt ,dnda-B-
Maximum deviat on Jrom nom nal dimension O.O8 mm.
Measuring the cylinder bores must not be done when the cylinde,_block is maunted on a tepairstand with adapter btacket AR 2204A, astncarrect measurements wauld then be posstble
_ .13-66 _
Piston and cylinder dimensions
Itoningdimooglons
Piston O Cylindelboro g
Basicdm€rcion
80.950 81,01
lst ovetsize mm 81,4501r 81,511)Dimensions withoot graphite mating (thj;knoss: O.02 mm)
Nota:The grapute caating wea9 away.
_ 13_67 _
1
11
10
Cyl inder head: removing and instal l ing
a Feptace cylitder head balt!; as a rule
a On assembhng, repiace seri /otlirrg ,'luij, bo/ij s-ir/ecl l' gtllr'neL
ic ttqhtening, as we// as o 'ngs
.?nd gasket's
a The hose sleeves and hases far the supercharyirg sYstem should
be ftee ftom ail and grcase before asse/'b//tg
a When installtng an exchange cylnde( head wih camshaft fitted' ail
the contact surfaces between the ptungers and the cams must be
oled befare installtng the cylndet head covel
a The ptastic packing pieces for protecting apen valves mus.t nat be
r-.mave(l untl imt;ediately bet'ore filling the cylinder head
I After the cyltnder head ot cytifier head gasket ts replacecl' allthe
caolant must also De reneweo
, Cvlinder heads whictt have cncks between lhe valve seats or De'
tieei uatve seat inserts and the spark plug thread can be used
fufthet without reducing service life pravidedthe ctacks do nat ex'' ie)ia naxinum ot o.i-m in wtdth, ar when na mare than the fist
four spark plug threads arc cracked
t5-1 ---
1-capa Fe . . q: .eL: 'dd-ndgod o- reo r-o
2-10Nma, l 'gI . ' (h _ e ^u1>I Tlqhten the outer nuls n dlagona se-
3 - Cyl inder head covera Removlno and nstal lng + Page
4 - Cylinder head cover gasketsa Fenew i f damaqed or leaKngt Apply D 454 300 A2 to doLrblebearing
.dp Lan<r1or cea - IO '
1Apply D 454 300 A2 on the adJusterfor lhe var iab e dlst t ibutLon/charn ten'' 'o e ' Io y| de' lead L an Lo2qns5
- Fig. 4 Page 15€
1
10-_
6
l- N r 5- 01 ?6-l
5 ' Oil deflectort Nolef l t t ng pos 1on on in etcainsl af . t
6 -Cyl inder heada D ef i rant ing aid f ] t1rng
- pag: i5:2
a fhecl fo drstort on = F q I o:oe
t Rewofk the seal ng surface -
F g 2,page 15'5
I l l rep aced, renew al the coolant
7 - Intake manifold gasket
eTo replace, retnove and {t ntakeman io d
- page 15 7
a Note the fitting pos tion.
15"3 -
8 - Cylinder head gasket
a To rernove rernove and frt cylnderhead + page 15,22
a l i rep aced, renew al the coo anta Note f i t t ng postion: Pa.t number
must be visible frorn the ntake srde
I -25 Nma For tens oning rol ler
10 - Exhaust manitold gasket
i To feplace, remove and ftt exhaLtstmanifold
- page 26-10
a Note the f t t nq posit on.
11 - Cylinder head bolt
o 40Nni + 90'+ 90"a Sequence for oosening and t ighten
ing + page 15-30
II
2
4'11
'10
fNi5 oi?61
154 _
Fig. 1 Checking cyl inder head for distort ion
Che.k cyl rder head ior c i s lort of wi l l , stra ghi€dgd ard e feel .gaLrqe.
1 Max. lo efaled d stoft on: 0.1 mm
Fig. 2 Reworking the cyl inder head
The cylnder head can ony be rewo*edmum dLmenston a-.
I Minimum d mens on: a = 139.20 mm
(fat grnd ng)to the min.
15-5 _
Fig. 3 Seal transition areas between double bearing cap anrcyl inder head
- Applyal t t ie gasketsealanton jontngareas errows-of thecyind€heao
'ealng c rr
" -es.a Si lcone sealant D 454 300 42
Fig. 4 Sealthe ioint ing areas between the hydraul ic chain ten-sioner and the cylinder head and between the camshaftadiuster and the cylinder head.
- Aoo,a i -pgosl 'e-reaa-ro-.onL'ga.ee(.d o. j .o-r 'o. ! tehead se: ing sLtr faces.
I Si lcone s€a ant D 454 300 A2
15-6 _
Intake manifold: removing and installing
Removal
, All cable ties v/hich are apened ot cut apen when remavng engine,must be teplaced tn the same positton when re nstelling.
I ln vehicles v\1th coded radp/ coded radta and navigation systemlRl\S), take note af the cade, if necessary, find tt.
W th gnilion swriched olf dLSconnect battery ea|th strap.
D sassembl ng the engine coveT aTTows-
Remove the aLr ccnduit +rrows-
Rernove the Hal sender connector -G40 ,arrow,.
15-7 _
iF-..."i-lI , "
15,8 -
Io mo.e o ' r e. to ' 'or 'L-Le 6
'securing the f t el drsi f bl t on pipe _2
el1d remove lhe bol ts
the fle return tube -2-. Tc do
Attention!
The fuet system is under pressurc' Befote opening tlrc systemolace a ctoth aroundthe connection, Then rclease prcssure lJycarelully loosening the connection
Remove the luel suPPlY tube 1- andso, pfess tfre Lrnlocklng keYS.
15_9 -
Remove the vacuum hose arrow from the rntake mani iold I
Remove connectors 3 for in lake air temperaiure -G42- and -4- ior
the throt ie valve control uni t J338'
Remove air hose -2- from the thrott e valve control un t
Femove the vacuum pipe 1 to the aci ivaled charcoal f i l ter ot thethrott e valve control un t.
- 15-10 -
a o^/<- and remo"/e th. ro\ e: - l -
Remove the connector €rrow of thesender G235-.
exhaust gas lemperature
_ 15,11_
Re ease coo ant hose -1, f rom bracket -4 .
Remove the bo ts -2 and ,3- and remove biackel 4-.
Remove bolts -arrows-ofthe inlet man fold - l -exnausl gas rempera-rufe sen0eI -( l2J5-
- 15-12 _
Remove bolt af f .vr ' f ronr the n et nranifold Lirecket L
Release rhe \ , - .cu !m hoses f rom ihe lower part of the r let man fo d
manifo d.
- 15-13 -
ruotes.a Sealthe cylinder head inlet ducts with clean cloths.
a Replace the gaskets.
a The hose sleeves and hoses fot the supercharying system shoulobe free from ailand grease before assembling.
Installation
- Ft the nletmanfold wtha new gasketandt ightenthe bol tsto 10
( o,rt -e asse^roly _ re/ese o oe' o t e dr:-ani ng procedL e
a lf the battery E reconnected check the vehicie equipment tadjorradio and navigation sistem, clock, powet windaws), folowing theindications in the Operating lnsttucttons.
a Other measures after reconnecting the voltage supply + pag;24-39.
- 15-14 -
Cylinder head cover: removing and installing
I At eL.e. . t . t t aaDa Faol . taoe^' .han,ana\ to\ .g - .. )ustDa-aDd FcJ 1 ' \ a.na aa- a. A\-n.e. . . . ta. ,nq.
a ]n vehicles vith caded radto/ caded radia and nevigatian system/FA/S/, lake note of the code, if necessarv fin(l it
With igni t on sw iched off disconnect battery eafth strap.
Drsassemb rng the eng ne cover affows .
_ 15_.15 _
Remove the a r aondu t €rrows-
Remove uppef pafi of toothed be t guard.
Remove the turbocompressor a I rec rculat ion valve -N24g- -4- andthe vacLJum TeseTVe tank,2- in the cy nder head covea
_ 15_16 _
l i racket -1-
Releasethef ange 2, removetheaclvatedcharcoaicondui 1 anclmove to one stde
head.
- 15-17 _
Remove the bolts arrows-from the aiacondutr Drac(erano rernoL.the bracket.
- 15_18 _
< - Fienlovg i rd trc ts arr lws i rurn i i e vacuLrm la rk braclet
Remove the earth cable -2,, connectors - l ,ano re ease tne caO es
Femove igni t ion cor ls 3 .
_ 15_19 _
SeqUence, and endtng w th the nner.
- Remove the nuts -arrows and remove ihe cylrnder head cover
Installation
a Beplace the cylnder head gasket if tt is damaged.t Beplace the ignition coil seals, f damaged
Apply a t t le gaskel sealant on Joint n9 areas -arrows_ of the uppersea ing sudaces of the cy rnder head
-l -4ll
.- 15_20 _
Apply a l tLe ga5'! i sealsr l cnseal lng sur ls.es oi the c! inder
iornl ng areas atro! /s of th9 Ltpper
- First t ighteir the lnner nuts and then the ol ter nuts of the cyl inde-head cover, n diagonal sequence to 10 Nm.
Conr,r . 6.s.rno , ,n o.erse o de of i le dsma.t ng p,oceoure
a lf the baftery is reconnected check the vehicle equipment (radia /radio and navigation sstem, clock, power windows), fallawing thetndicatians n the Aperating lnstructions.
a Other measures after reconnecting the voltage supply + page24iS.
- 15-21-
Cylinder head: removing andinstalling
Special tools. workshop systems.testersmeasuring instruments and auxiliartitems requi.ed
a Torque spanners SAT 8010
a SAT 8050 socket spanner
a T20029 pl iers
a Holding too T20046
a T20079 Wrench
a VA.G 1306 Dnp tray
|nlnrl::.5_*,"
nm4o:= E b d6
|Ill']Ir:r
saT 8oso
T20029 T20046
T200?9
- 15-22 _
Hemoval
a All cable ties which are opened or cut open wt)en rcmoving engine,must De replaced ln the sarrte pasttbn when re installing
I All ihermal p@tectiorl sleeves renoved rnust be re1tted in thesane place on reassembly.
With ign t on swtched c)1{ d sconnect battery earth strap
Drain cooant -
page l9-15.
- Remove intake mani iold + page 15 7
- Feeaseclamp 4, remove nlethose-5-andconnector- j - f romthe
- Remove boits 2 and 3- and remove the air f i l ter casing.
_ 15-23 _
Disconnect pressure regulator va ve -1 of the engine breather. fromthe air rn et hose -6-
Femove the air recircu a|on valve -2- from the air nlet hose 4-.
Remove connector ,3- of the supercharg ng pressure so enoidevalve -N75-.
Bemove hoses -4- and 5, f rom the supercharging pressure solenoide valve -N75'.
Releasethetube€rrow-and remove the air in el hose € releasinglhe ' ld ge1'ar<a(Le, l -o ihaey aLs'gas .J oocorp essor.
j!stment system N205-.
)
_ 15-24 _
sLde o{ ihe cylnder head. and p ace Li or one srde
Ferrove cyl inder hesd cr]v 'cr -
page 15-15
- Remove the turbocompressor out let alr conduit tube.
Release the thermal insulat ion and remove.
- Removethebots arrows-securing the turbocompressorto the ex-haust man fold wLth socket spanner SAT 8050.
- ,15-25 -
Eng ne Lnstal led:
' Turn cronkshaft to TDCNo.1 cy inder.
Enqine removed:
' Turn vibrai on damper to TDC No. 1 cy inder -arrows
- 15-26 -
l;'furl
Tlghten tensiofrng dev c-. T200.16 unt i the tcolhed belt c! I be removed lrolTi t ie camshafl sprocket
Loosen tens on ng dev ce T20046 ancJ remove
Loosen the cyl inder head boltsthem lrom the cyrnder head.
n the gtven order and then remove
_ 15_27 _
Installation
a Beplace the cyinder head balts.a OF dssemDltng Gpla( e sctLla., t!.g httts. Dat$ subiec. ro gon,anct-
r.c ltgalcltng as ^ell
as o-.ing. ano gast e$a Secure lhe p 1rs De'weenhajes O\ usfig thc sama ctam1s as ong
a lf repaired, carefully remave gasket rernains from cylinder btack andcyhnder head. Avoid making scntches or gooves.
a Carefully remove all traces ol abrasive paftrcles.a Only remove the new cylinder head gasketfram its packing immedi
ately before instalhng.a Handle the new gasketwith extreme carc. tfthe tayer of silicone and
the gtooved arca are damaged there is a possibiity af leakage.a The,e muSI oe 10 or ot caoDnr t . tne C\t tndet haaa bo| por] ,era tn
tne crltndet tatocK
-- 15_28 _
I The hase sleer'es and hoses far the sLtpercharglng systefi shoufuhe free fron oiland grease befa.e assenbltng.
a Bcto F - a t - .1t 6-11- '36 o.d ' l tar l ' \ . d fDa \ t : 'd" l
- Tlrn cranksheft to TDC No.1 cy inde.
T! rn crankshe' i t back slght ly.
Loosen bo t -arrow- on theturns, to avo d tension when
turbocompressor f'racket, approx.f i t t ing the cyl inder head.
9rscn
- 15-29 -
Fit cylrnder head gasket.
Note nstal lal on pos t ion of cy inder head gasket: (The part number
-Lsr be r ' 's ,be rro- L\p ' ra l . s,de.
Note the centr ng pins n cy|nder b ock -arrows-.
lnstal lcyLinder head.
Fi l r ' e cy| | oernoaobo-_a-d d 'drgrter.
- Tighten the cyl inder head in the sequence ind cated below:
First tghten to 40 Nm.
Then re t ighten ol bo ts 1/.1 turn 190 ' l
- Fina ly re t ghten al l bol tsr /4turn (90')
There is na requtrement ta retghten the cylinder head balts altet rc-
I(a9z-1159
r(J;e(>vJ u
- 15-30 -
Trghten the bo ts affows, securirg the tufoocompressor io the er-nausl man 10 d to 30 Nm
a The bolts securing the tubocampressor to fie exhaust manifald
a Apply locking fluid to thread anctcantact surface of cytindet head.
_ 15_31_
Contine assembly in reverse order of the dismantling procedu.e
a lf the baftery is recannected check the vehicte equipment (radia /rad@ and naveation sistem, clock, power windaws), foltowng theindications in the Operating lnstructions.
a Other measures after reconnecting the voltage supply + page24-39.
_ 15_32 _
r20024
-.ra.::t;')(f '
SAT sOI O
rl'irro:-*- -E ",.".
@+..- ,"
mm:
va.G 1763
tr5-ooo6-.l
Compression ratio: check
Specialtools, workshop systems, testers,measuring iestruments and auxi l iaryitems required
I T20028 spafk p !g spanner
I Torque spanners SAT 8010
a VA.G 1763 Compression teslef
' / / t d.T,--€f , t ;:aTi idr f ,
_ 15-33 -
Femove fuse 32
Bemoving fuse Na 32 nterrupts the valtage supply ta the tnle.tars
Test conditions
. Engine o I tempercture, mln. 30'C
. Mn battery volage 12.7 V
- Remove the engrne coveT aTfo\{s-.
- Wth gniton switched oi f , felease the connectors l rom gnrl lorcoi s
- Femove the rgn t on co ls.
- Remove soark plugs wi ih spark p ug spanner T20C28
_ 15-34 -
- Open tfe throti te valve comp etety.
+ Equ pment Instruci on manual.
- Check compression pressure with compression testerVA.G 1763.
- Operate starter unti l tester shows no further pressure increase.
Compression values
New: 10...13 bar pressure
Wear lmit: 75 bar pressure
Permissible d fference between all cylinders: 3 bar max
- Tigthen spark plugs with toolT20028 to 30 Nm.
Contine assembly n reverse order of the disn|amlng proceoure
interrogate fault memory + page 24-28_
I
_ 15-35 _
Valve gear: repairingNotes:a Cyhnder heads which have cracks between the valve seats or be-
tween valve seat nserts and the spark plug thread can be usedfurtherwithout reducing service life, provided the cracks do not ex-ceeda maximum of0,3 fim in width, orwhen no marethanthefistfour spark plug thrcads are cracked.
a Aftet f,lng the camshans da not stad up the engne fot appro\ . 30mtn t he htotaulc cor,pensaton pans ha\e ta seftte lothetwse fievalves would hh the pistons).
a After working on the valve gear, turn the engine carefully at leasttwo turns to ensute that no valve will be stuck when the engine is
a Always renew seals and gaskets.
_ 15_36 _
12 =L-\\> \-tX11'. -- Lr'
- ?,
6-_,-''-,-.'7 -' ,,-"'
4
1
de)TE:=:ni.trd Yss gz et
I -65 Nma Use t iol T20013A 1o oosen and
r !hien
2 ' Canrshaft sprocket. l Fof exhausl carnshefta Note i t t ing pos t on: the thin coie oi
the camshait sproc!. .et ponts oLrt\" , ,ards and TDC mark of the cylndelcnn oe seen 1
3 ' Exhaust camshaft oi l sealI Do nol oi sealng p ol o sealt Renew + page 15118
4 - Cyl inder headt Dismant ing and f t t ing + page 15 22a Rework valve seats
- Page 15€B
t Check valve guides + page 15,72a Sealthe t fans t ion afeas + Fig. 3 and
4, page 15 6a The bearing cap dowel pegs shou d
be f i t ted to the cy rnder head
5 -Valve guidel Check nq + page 15-72
6 - Valve stem sealI Renew
- page 15,73
7 - Valve springI Removrng and Insta ing: Cy nder
head removed wth too T20034/1,cyhnder head i t ted
- page 15 73
I - Valve spring plate
I - Valve cofters
16tc
14't3
12'1110
I7
2I
TE:=:N:E]
\.!-ar-
.NN-'1
N-*
!1
_ 15_38 _
-17 10 - Hydraul ic cam fol lowert Do not r f terchangeI With hydra! ia va ve c earsfce conl
t ClLecking =. page 15 54a Pace wth contact surface down_
t Oi s ding slr face
1'l - Inlet camshaftI Checking axa clearance
- Ftg. 1,
page 15 45t Dismdnt rng and f t l ing
- paqe tE 57
a Checl rad a c e. ance \rr th ptastr-gage, wear I mit : 0.1 mm (c6m fo -rowers Temovedl
a Eccentr c i ty: max C.035 mm
12 - ln let camshaft bearing capa Note the J t t ing posit on.I Fi t t ng pos t on + page 15-66a Must be properly ocated on the
dowelpegs
_ 15-39 _
1413
12'11'1098
1
b---26 fEl s:dr 3, I
13 - Double bearing capI Coat the contact surface wth a i t te
"D 454 300 42" sealant before{tr inqo Sea the trans t icn areas + Fio. 3and
4, page 1 5-6I Must be ocatedonlhedowelsleeves
'14 - Exhaust camshafta Checking ax al c learance : F g. 1,
page 1545I D smant lng and fr t tng + page l5 57a Check radial c learance with plast i
gage, wear lm t : 0.1 mrn (cam fol-owefs Temovedl
a Eccentr chy: max. O 035 mm
l5 - Exhaust camshaft bearing capa Note the f i t t ng post iona F t t ng pos tron + page 15 66a Must be properlv ocated on the
dowe pegs
20
16---€
14 -\5S13
1211'10
I7
4
1
b--26
_ 15-40 _
16j15-. :1413
12111098
oJ
?
fE15:aLtl
! r t lr :^
<:- . \ -zZ
i\\r'-'\\>. 23
-j',.- ' ' ' . '4--,'-)
16-10Nm
17-10Nm
18 ' Drag chaint Mark D O.R. beiore remov ng
- page
t5$lI Check for weara To remove and ir t , t isnecessaryto
remove t fe camshal ls -
page lS 57
19-10Nm
20 - O-r ing
21 "Camshaft adjustment system sole-noid valve -N205-a Checking + page 15 78
22-3Nm
23 - Camshaft adiustera Before remova secure with too
T20044 + paqe 15 61a Wth solenod valve for camshaft re-
gu at ion -N205a To remove and f i t , r t s necessary to
remove the camshafts- page l5-57a Check ng camshaft regu atton
-page 15 76I Coat the contact surtace with a ttie
"D 454300 42' sea ant before I t t ng
24 - Metal"rubber gasket
I Apply sea er + page t5 63
25 - Gasket
_ 15-41 _
14
121110oI7b
21
I Err-u Jz I
'. \\-a5 -"r
_ 15-42 _
16 -€'15
14'13
121110
q
a-
65
'1
b I trE-iii -tl
26 - Exhaust valvea Scdr lm fr led,f Pay afteni ion to d sposal standards
fcr sodiun J led vslves + page t5-,16a ,c not rewofk, only grtnd ng s pef
rnrttedi Va ve dimensions
- Frg
t5 46I Check va ve guides + pagea Rework vaive seals + Page
27 - Inlet valvea Do not fework, only gr nd ng s per-
m tteda valve drmensrons
- Frg 2, page
1546a Check valve gurdes + page 15-72a Fework va ve seats
- Page 15 68
15-1215 68
28 - lnlet camshaft oil sealI Do not oi l seal ng ip of o 1 seaa Fenew
- page l5-51
29 - Frame for Hall senderI For l-ia sendert Make sure i t is f t ted to the camshaft
when assemb ing
30 - Washero cone shapet Note the Jl t l ing post ion.
31 -25 Nm
32-Hal lsender -G40-t To remove, i twi l be necessaryto re-
move tfre upper toothed be t cover.
33-10Nm
_ 15_43 _
16 --eE
la -..\Bt5
121110
876
4
1
fE1s-o-n- 15-44 _
r20020
rwsel
Fig. 1 Camshaftr checking axial c learance
Special tools, workshop systems.testers, measuring instrumentsand auxiliary items required
a T20020 bracker
a D algauge
Test conditions
. Drag cha n rernoved
. Hydraulic cam folLoweTs Temoved
Checking process
Measure with the bearrng caps on the2 litled
Wear im t : max. 0.2 mm
The checking pracess is the
charns de 1'and the doub e cap
same for both camshafts.
- 15_45 _
Fig. 2 Valve dimensions
Valves must nat be rcwarked. anly lappingiin is permitted.
Dim. In let valve Exhaust valve
Aa mm 26 80 2700 29,80...30,00gb mm
104,84 105 34 103,64 104,14
Note:
Sadiun ftlled exhaust valves must not be discarded es atdinary scrapwithout being properly prepared. The stem rnust be cut with a metalsaw at the centre. Avatd contect whh water. The valves will then beplaced ina bucket ofwater lten at e time). Move awayfrornthe bucketas there wll be a chemical reactrcn that burns the sodium After thisthey may be dispased af as normal scrap
- 1546 _
df in+:! . . . , .
i1il101l+-A -,*
6t0t:+,
fi;;;;;;r
rCamshaft oil seals: replace
Special tools, workshop systems,testers,measuring- instruments and auxi l iary
t Torque spanners SAT 8010
t Ho d ng tool T20018A
a Ho ding toolT20046
a GLride sleeve T200818
t Extractor T20143
_ 15-47 _
Exhaust camshaft oil seal: replace
Dismantl ing
- D cacse .b I g -np a q'ae ( 0/6- .a ro^c .
- Remove the c ips from the upper palt of toothed be I guard and remove lne covet.
- 15-48 _
Y d. - .in z:-qll
fArJ--@t
YII
shait I Th€ caffrshaf l sprockel nrarf sholrd co ncrde,"^. , i th the markon the cy nde.head cover
T! rn cranl ishaf l back slght ly.
irom tire camshaft sprocket.
- Bemove camshaft sprocket To loosen the bo t secLtre the sprocketwith ocking tool T2001gA
_ 15_49 _
Instal lat ion
' Do not oi l sealng ip of ort seat.
Frt lheseal jnto gu de sleeveT200Bi B/3 and f t ihe unrt on the cam_shaft.
U'eou ge 700818/ ano o-ess r-e 9- 09 sreer 'e s6a . . tU.LlLneo 9ea cr- o.ce. U,e-h^."-n.ha' tso.o-.91 .o i r r i .gDol Looorns
Femove gulde sleeve T2OOBi B/3.
Conirnue assemb y n reverse order of the d smanl ing procedure
F,
ff i '6i:,ry.i T200818/1tr:.y
*t\t ' r9 ' ,
- 15-50 _
lnlet camshaft oil seal: replace
Dismantl ing
- Drsassemb Ing the e|g ne coveT arrows,
_ 15-51_
Remove the connector of the Hal s,^nder,alow-.
Remove the clps from the upper parl of toothed be t gLtard and re-
Bernove Hal lsender hous ng.
Remove the washer and the f f rotcr r ng ol the Hal sender.
- 15,52 _
ffi,
lnstallation
- Do nct o seal ng |p o{ o I seal.
' Place the o I sea on the guide sleeve T200818/3.
l - . r ' ^ . ' _ .no,P/1 . . r_de sleeveseai uni tunr i lthe oi l seal is in place. To do so use a M 8x45 bolt w th a washet
Remove guide sleeve T200B1B/3.
PIace the Hal l sender rotor r ing with the groove on the lnlet cam-
lnstal l the washer (withthe cone fac ng outward) and t ghten the se-curing bolt to 25 Nm.
Continue assernbly in reverse order of the dlsmantl ing procedufe
Hydraulic cam followers: checking
special tools. workshop systems, testers. measuring instrumentsand auxiliary items required
t Fee er gauge
a Wooden or plastlc wedge
Notes;a The hydraulic cam followers should always be replaced n thei en-
tiety (they cannot be adjusted ar repaired individualy).a Unusual noises frcm the valves during starting are normal.
Checking process
' Slart up the motor and run unti the radiator fan has switched on
- Increase speed to approx. 2,500 rpm for 2 mlnutes.
_ 15-53 -
_ 15-54 -
I I t1e d usLot I et \ e o.sl , a s.Dpaat Dr r d. e - t . I raa-o or - . o- t . t t <_ne oJr,Fl- . r ,o. rdr.c ^, l l \ . ,e
I b- .ne\ed. t , f t .ne.a. e.ao o beott retentton valve: oil filtet bracket + nem 6, pege 17-1i
l f the hydraul c cam iol lowers cont inue to make a noise check to seewh ch one/s is/are faLr ty as folLows:
- Remove cy nder head cover + page lS 15.
- TLrrn the crankshaft c lockwrse unt l l the cams of the fo lowers to bechecked are facing upwards.
- Check the clearance between cams and folowers.
- l f i t is greater than 0.2 mm, replace the fol lowe. l { i t s lessthanO.lmm or f there s no clearance , proceed as fo lows wth the check:
_ 15-55 _
' Press the cam follower slightly downwards w th a wooden or plast cwedge. f it is poss ble to inseft a 0.2 rnm thickfee er gauge betweenthe camshaft and the follower, the atter should btrep]aced.
Note:At'terfitting new cam followers do not start the engne for approx. 30m tn utes. Th e hyd ra u I i c cam p e n s ati on pa rts m ust s att t e (oth e r wi se thevalves would hit the pistans).
- 15_56 _
dowj: Ir" . . ,"
mrlllF::E ---
cEti.+ 5
t Ll5 oom-l
Camshafts: removing and in-stalling
Special tools. workshop systems, testers; i ;; i l ; l ."t*;.nis' and auxiriaryitems required
a TorqLre spannefs SAT 8010
a Holding too T20018A
a Ho d ng toolT20044
a Holdlng too T20046
a Sealant D 454 300 42
- 15-57 -
Dismantl ing
. Cy inder head f i t led
. D sd,.e_rb| |_g 1'e ' ' rq ne r ove -alrow5
- 15-58 -
Fenove the conreclof oi r r H., ,1 senaler i1!ow
Fernove ihe ci ps Jrorn ihe !pper part of toolhed bett guard and re
Remove Hal sender l . rous nl t
Femove the washer and the r fDtor r ng of the Ha sender
SetcamshaftsprockettoTDCcylnder markingbyturn ngthecrank_shaft. 1. The camshaft sprocket mark shou d coincide wiih the markon the cyl inder head cover.
Turn crankshaft back slghtly.
_ 15_59 _
trom the caanshaft sprocket.
Remove camshaft sprocket To loosen the boh secure the sprocketw rh locking toolT20018A
necl0r -aTTow-
- Remove cyl inder head cover page 1S j5
/ , -d.- .^ 'n7ffi '
t ;s@l
- 15_60 _
|;""6.]
- Clean the cha n a rd t l le can LShai l sp ockets 3t the po nis localgo op_pos 1e the two af iows on the beaf ng caps and mark nsta lat onposi-t ior by nreans . ,1 a co o!r maft lng
j Do nat merk chatn with a centre punch ar aDy similar rneans
a The distarrce beiween the two araws ar colau narks is 16 rallersan the dtag chain.
Frrst remove in et and exhaust camshatt bearing caps 3 and 5.
Remove the doube beaf ing cap.
Removebothdoublebeaf ingcapsonthe netandexhaustcamshaft
UnboLt the chain tensioner securlng bo ts.
Loosen in etand exhausl camshaft bearing caps 2 and 4alternat ivelyin diagonalseqLrence and remove thern
Remove in et and exhaust camshafts, cha n tens oner and retalnlngtoolT20044
- 15-62 -
Inslallation
a When tnstalling the camstafts, the cams of cytinder 1 should bepotnttng upwards.
a When installing the bearing caps check that the mark on the caveris legible fron the cylinder head inlet side.
a lf reusing the old drive chain, place the clrive chain according to thecolour Klentificatian on bath camshafts.
- Replace the chain tensioner rubber-metal gasket and thin y coatsealng surJaces ind cated wrth hatched ines with "AMV . lBB 00142" .
_ 15_63 _
Fit the charn onto the camshaft sprockets as Jol lows:
a l f usinga newchain, lhe distance between grooves-A-and B-onthe camshafts shoLl d be 16 rolers on the cha n The Jig. showswhere the 1st and 16th rol lers should be placed on the sprockets.
a G roove -A- hBs a slight dev ation inwards wrth regard to the roller
n9e ( rhe _-a - .e s one- oet(e6n the .hdtn.
Oll slid ng surfaces of both camshafts.
PLacethe carnshaftswiththe chain andthechaintenstonerinthe cyl-
Tighlen the chain tensioner to lO Nm. (note the dowej pegs).
- 15-64 _
Tighlen nlet and exhaust.a nshaf i beari fg caps 2 3n. j 4 al tetnal velyn d agonal sequence to 10 Nm lnole the do\^re pegs)
sprockets. Check that the camshafts are properly f ined and t ghtenthe bearing caps to 10 Nm. (note the dowe pegs).
- Remove retaining toolT20044.
r*dt
_ 15-65 -
Coat the surface wrth hatched l ines on the double bearing cap witha thin ayer of " D 454 300 A2 , f i tandt lghtento10Nm.(becafelulwith the dowel Pegs).
Fi t the remainLng bearing caps and t ighten to 10 Nm. (note the dowelpegs).
- 15-66 -
. :
GEe,t
' Insta I the can-ish3ft spiockr i
pornts outwards -affows and TDC rnark of cyj tnder I can be seenrrom tne tTont.
Contnue asseraby in reverse order oi the o srnanr !ng proceclure
4f1 l 'a,ng ,he (at .shdtts do t oL sta r ua L\e eng;ne'a, app,o\ . JAmtn tne n\d 'd- t t ' rompancaton pct l - 111 t>t sFt110 tothar\ i re thevalves would hh the pistans).
_ .15-67 _
Valve seats: reworking
Special tools, workshop systems. testers, measuring instrumentsand auxiliary items requited
a Depth gauge
a Valve seat refac ng tool
,Votes.I When repatring engineswhh leakingvalves, ttis notsufficient torc,
place ar renewvalve seats and valves. tt is panicularly impotlantonhigh mileage engines ta check the valve guides for wear
i ) rhc '64 e sedt, sro, td ar t I oe .ewo,. eo,L sr enaLgn rc prcour c dpe,fect .eal,ag DaFa,n The rr,a\,r'urt Dcrmissbte rcwo4thg drnenston rnust be catculared belore tewott..g LotFehces t1eteworktng dtmension is exceeded, the functjon af the hydraulictappets can na longer be guaranteed and the cylindet head shauld
_ 15_68 _
IIICalculate the max permissible reworking dimension
'a4va.-onopr- _ ' ln, doai l 1 ea
lfthe valve is tabe renewed as part al a repa[ use a Dew valve fotthe
lVeasure distance tretween end ofvelve stem and upper edge ot cyl
- Calculate max permiss ble reworklng dmension from measLlred
d stance and minrmum dlmensron
Minimum dimensions
ln et vavecentral
Exhaust valves
31.0 mm 322mm 31.9 mm
- 15-69 --
Dlstance measured minus minlmum dimenslon = maxrmum accepr-
able fework ng diTnenslon
Example fo. inlet valve outside:
Measured drstance
- Minimum dimension
31.4 mm
31.0 mm
= max. perm. rework dimenslon
')Themax. permiss b e reworking dimenslon isshown on l lustrat lons
as drmension "b".
Notei
t f . | ,ema\ |ewatt t q dtncnsion b 0 mr o' ! 'ss Ihan A nn raDeaIr 'e
i" i t " i " .""L ^,r , ; 'e vaae /r lne "s.r / I af tho medsu'enent\^t th
a iii vilve is sttlt a mm ar less than o mm, the cylindet head shautd
- 15-70 -
lnlet valve seat: reworking
= A 26.2 nn= lv-a
_p_ermrssrb e re,/ o I nl t d mans onl
= Cyl inder head ower edge= 45 q va ve seat ang e= 30 ' upper coffect on angle= 60 ' lower correct ion angle
Exhaust valve seat: reworking
= O 29.0 mm= Max. perm ssible reworktng dimens on*= approx. ' l I mm= Cylinder head lower edge= 45 " Va ve seat ang e= 30' Upper correction angle= 60 ' Lower correctton angle
a
z
It
tr@2-@t
ab
z
FY-rCalcLrlat ing max. permissible rework ng dimension
- page l5€9
_ 15_71 _
Valve guides: checking
Special tools, workshop systems, testers. measuring instrumentsand auxiliary items required
a T20020 bracket
t Dial gauge
Checking process
- F t a new valve in the guide. The end of the valve stem shou d bef lush with the guide. Due to the sl ight di f ference in stem dimen,srons, ensure that oniy an inLet valve s used in the nlet guide andan exhaust valve n the exhaust gLt de.
Determ ne rock, wear l im t : 0.9 mm- )WJ=^,-
-- a',2
za,)
- 15-72 _
r20024
mirt--5"-" .
GI]BE:+-."
|]ern+E
:H.%ktt. qlu:-
IlI
Dismantl ing
. Cylinder head fLtled
- Remove carnshafts Page + 15_57
Remove the cam {ol lowers and p ace them on the contact surfaceface down, mak ng sule you do not lntercnange lnem
- Remove the spark plugs wth spannerT20028
- Set p ston of appropriate cy indef to "bonom dead centre
- Screw hose T20033 into the spark plug thread.
- Fit compresslon toolT20034B lo the cyl lnder head
Connect pressure hose to a compressed air system oi at least 6 barof compressed alr and remove valve spnngs
Remove vaLve slem seals with exrectorT20058
Valve stem seal: replace
Special tools. workshop systems. testers.measuring instruments and auxiliatyitems required
a TorqLre spanners SAT 8010
a T20028 spark Plug sPanner
a T20033 tLrbe
a Cornpressron tool T200348
a Plunger T20039
a Extfactor T20058
- 15-73 -
- 15-74 -
vA.G 1551--.ffiffi
t*G*A
lnstal lat ion
To avotd dameging vatve se;/:-, p/3.e thepiastc s leeve overvet,.te stem(thts sleeve is inctuded wtth the spatel
- Oi l valve ste.. seal seal ing lp ancl pjess careful ly onto the valvegurde.
- Remove the plast c blsh
, F t the cam fol owers as removed
Cont nue assembly n reverse order of the dismantlng procedure
Ahcr I'Rng ,hp cdmshdhs da nat sblt up th- engn- tot dppta, 30nln. tne nydtaot. canDensatton p. l ts must set lc pthctAtse thevalves would hit the pistons).
_ 15-75 _
Variable valve timing: checking
a The camshaft adjustment is dependant upon toad and speed. Bymeans of the electric valve for the camshaft adjustment system(mechanical device ) whjch rcgulates the camshaft.
a The camshaft adjustment system will not start to operate until 2Eseconds alter the engine is started.
Special tools, workshop systems, testers. measuring instrumentsand auxiliary items required
a Fau t reader VA G 1551 or vehicle syslem tester VA G 1bS2 wlthcable VA.G l55T/38
Checking conditions
. VA.G 155T (VA.G 1552) connected. Selectenginecontrol unitwiththe Address code 01.
- 15-76 _
Sys:e- ,. bas c set ig 09,1-
!*:/min c1r An on Tesl OFF
Checking Process
Press keys O and 4 forthe funct on " Begin baslc sett ing" a| ld conl f t r l
entry wrth the o key
' Presskeys0, gand4for "DispaygroLrpnurnber094 andconlane rvy vvith O key
nd cated on d splaYi
- Take eng ne speed to above 1800 rpm
- Al low the eng ne to run at high speed unt i the message In displayf ield 3 changes from "TEST OFF to "TEST ON'
- The fol lowng message should lhen be drsplaYedl "Sys OK'
- l f "Syst No Ok' is displayed, Intelrogate tne Tal l l l memory
- 15-77 -
Solenoid valve of the camshaftadiustment system: checking
Special tools, workshop systems,testers,measuring instruments and auxiliaryitems required
a Manua mutimeter VA.G 15264
a Diode test lamp VA.G 15278
a A- r 'o y n'eo,, ng reL \ a C 15944 o'VA.G T 594C
a Test box VA.G 1598/31
."2/q\,' ,t/
- 15"78 -
Check solenoid valve
- Drsconnect t fe canrshaft acl lusi ' Ients!stenr so enord vd /e ion
fMml
- Measure the resistance of the solenoid vave with manual nrul t i_meter VA.G 1526 A and adapter cabtes from VA.G 15944 or VA G1594C, speci l icat ions: 10.. . tg O.
lf the specifrcation is not obta ned:
- Renew soleno d valve.
1f the specif icat ion rs oblEined:
Check voltage supp y + page 15,80
-- 15_75 _
Voltage supply of the camshaft adjustment system solenoidvalve: checking
Checking conditions
. Winng ofthe solenoid valve of the camshaftadjustment system OK
. Fue pump re ay must be OK.
Note:
The valtage supply of the solenoid valve af the camshait adjustmentsystem ts carned aut through the rclay of the fuel pump.
- Disconnecl the camsha{t adiustmenl system sc enotd va ve con-
Connect diode test lamp VA.G 1527 to contact I of the connectord sconnected and to earth !s ing adapter cab es from VA.G 1594 C.
The LED must ight up
_ 15"80 _
Tfre LED does not light up:
- Check the continuittlof the electrical installation:
Connoctor, contact Measurg no1 Fuel pumP n lay .2 Engine ground
- Additionally check wires fbr short to one anoiher.
l l no lault can be lound in the wiring:+ Curent flow diagrams, Electricalfault finding and Fitting locations
LED l ights up:+ VAS 5051;Vehicle selfdiagnosrs
- 15€t -
Lubrication system components: removingand installinglvotesia If when repairing an engine, metal shavings or large quantities of
small metal pafticles - caused, for example, by paftial seizure ofcrankshaft and conrod bearings- are found in engine oil, to preventconsequential damage, apaft from thotoughty cleaning oil pass-ages, ft ts necessary to renew the oil cooler.
a The oil level must not be above the max. ma* - danger of damagingcatalr,ttc convefter! Oil level: checking + page 17-9.
Oil in jector jet and pressure relief valve + F g_ 1, page 17€.
Pressure and oil pressure switch: checking + page t7-22
17_1_
Oil capacity
wirh oi l f l trer 4.5 L.
Engine oil specifications
Use engine oilto\ y'y' standard 500 00, 501 01 or 502 OO. Onty in excep-t ionalcasest mult i€rade oi ls corresponding toAplSF or SG specif ica-
17-2 -
?
25-
2122
1620181917
14
?\ -.- -\!_!Fr1 L
/^1 L1o1112q
i ;l f ,
Part I
1-15Nm
2 - Seal ing f langeI D snra t | lng and f i l l ing
- page 13-44
t Assemhle \" , , l th si cone sealantD 176 4A4 A2
- page 1344
I Renew crankshaft ol lsea - pLr l ley end+ page l3-44
3 - Chain tensioner with tensioningplatea 15 Nnla Do not dlsmantle, replace cornpLetea Note the f tt ng posltionaOn a5.- '_rbl g. peenron th-
spr ing and hook t
4 - Dipsticka Tne ot l^ . - - r . ( - -ot go cbo.e lh6
max. maTKla Checking level- page 17-9
5 - Dipstick tubea Remove to extract o lby abrasron
6 - Guide tube
7-Oil iniector iet and pressure rel ief
a For piston cooling + Frg 1, page114
8 - Pressure relief valve427Nma Opening pressure: 2,5 ..3.2 bat +
Flg 1, page 17 8
9-15Nm
10 - Suction pipeI C ean f l tef l f soi led
11 - O-ring
12 - Baffle plate
13-10Nm
17-3 -
25
2122231620181917t5
14
101112
felz-oortl17-4-
ii+ll',.-+a\i.]i'fl
1 4 -f),i
14 ' Oi l level/ temperature senCert Only veh c es wth o' tg te servrce
15 - O-r ing
16 - Sumpa Dsmant ng and i t t ng > page j7 t5a F t with si icone sealanlD 176 4A4 A2
17 - Oi l drain screwa30Nma Wrlh attached seal
l8 - Gasket
-.-L \
242122
23
2018la
171514
Bo
t -;;;tr
19 - Oil return pipeil Fforn turbocompressof
20-10Nm
21 -Oi lpumpa Whh 12 bar re ief valvea D smant ng and f t t ing + page 17 21a Before assemb!y, check that the two
centr ng bushes of o I pump/cylndefblock - tem 25- are fitted
a Fep ace i iscorng sfoLrndonthesid-ng sudaces and gears
a Pump cover to casrng lghlenngtorqLre: 10 Nm
17_5 _
\LI$ r: \
w Llo
li/
'.-7
riI I
101112q
e_o
aEl nin
17-6 -
22 - Oil pump sprocketa t can on y be Insefted nto one pos -
t ion on the oi pump shaft
23-25Nm
24-chain for oi l pumpa V. ' t D.O R befo'" e ' o/nga Check for wear
25 - Centring bushes
19.f1-',-2
IAfo.7|
1 O I injector iet (for piston coolng)2 - Bolt with pressure rel iei valve 27 Nm
a Opening pressurei 2,5. . .3.2 bar
'E242'l222316201819'171514
,) r
c..1j-" cJ7).7 L10
1112q
Oil level: check
Checking conditions
. The oi l level should onlybe checked onahotengrne (oi l temperatureabove 60 'C )
o The vehrcle should be on level ground. Once engine is swttched off,wart a lew mrnutes so that the oil can return to the sump
Checking process
- Remove the oil dipstick, clean with a clean rag and replace fully.
- Then remove the drpstick and check the oil level.
17-9 -
Markings on the dipsrickI -Max. mark2 -Min. marka -Area above halched field up to max. mark: do not add oilb -Oil level wthin hatched fieldi can be topped up with engine oilc -Area from min. mark up to hatched tield: fill with max. 0.5 ltr of
engine oi l
The oil level must not go above the max. mark
- 17_10 _
' l l
- - l0
12 Part ll
1 'Plug4 40 l lm
2 - O" ringa I i the sea nq lng rs leek ng, -r1p op€r
afd rep ace lhe o r lng
3 -SpringI Fof relef va ve approx 4 lar
4 - Pistona For rel ief valv€ approx 4 bar
5 - Gasket
6 -Anti-return valveagNmI Integrated n the o I f l ter bracket
L)- ' -18
fAr;0018 I
l<
16
- ---'----.s
fl*2
2123
6-
@
/ - u-nng
a F t as far as the shou der ol the 1!5epos I
I Cyl inder block breather
I - Securing cliP
10 - Pluga15Nm
11 - O- r inga l l sea lng r ing s leak ng n P open ano
replace seal.
12 -23 Nm
13 - Oi l suPP|Y PiPea To turbocomPressor
14 - Hol low boltt30Nm
- 1l11-
n'-ur17
3
2
4/7;;^--ts- ---------s-6d-
22 21- 17-12 -
78 9 10 11 12
@
-19
22[;i? ool8l
, , - -16
^6,''
15 - O- r ing
16 - Oi l pressure switch -Fl , , 1.4 bar| 25 l ln la Black nsulat ont Checking + page j7,22
17 -O- r inga I sealng r ng is eak ng nip open and
replace.
18 - 15 Nm + 90 . {1/a turn)
19 - O-r ing
a Hold wi lh tabs provded on the oi l
20 - Oil filtera Loosen wtth turning tool U 4OO7B or
a universa f i l ter extractort Tighten by handI Note instrucl ons on f l ter when In_
sral [ng
-25 Nm
- Oi l coolera See note + page 17-1a Ensure c eafance to adlacent compo-
a Lubricate contact surfaces of the o-f lng wth the o I f i l ier bracket wthAMV 188 00] 02
I Cooiant hose connect ion djagrara +page 19,12
23 - Oil filter bracketa Wth re lef valve approx.4 ber
_ 17_13 _
10 11 12
@
21I
22i
n/-uuol
/,/-0^\
2 X$rl:tu\r' -'a dr
-17-14_
sAT 8010
r*M6"1
Sump: removing and installing
Special tools, workshop systems testers' measuring instruments
and auxi l iary i tems requlreo
a Torque spanners SAT 8010
I
u-400s1A
r!@;;1
a Tool U40051A
a Hand drl l with plastic brush insert
a Protective goggles
t D176 404 A2 Sil lcone sealant
- 17-15 -
Removal
Remove centra insulation -arrows
- Drain engine oi l .
- l lnbolt and rernove the oi l feturn tube from the sump -2-' Lt necess_
u'ivl runllu" ir,u rt"t"t securrng the tube to the cvlLnder b ock'
i l r l r ,L,r .__] \ ' -
- 17-16 -
20 19 18 17 16 15
Fiemove iie bolts l.rir ,!J su|iplgearbox -arrows .
- Looser t_ebol ts- l 20 diagonal ly.
tt necessaiy, r-Ernave the bolis from the sunlp wiih taal u 1j00S1A.
a^'- l^ : -
o -d.
06 n6\a dr o etad.- .1, . p o. r :Dp . !gntry w i f a rLrbber herd hainm-"r
Femove sea ant fesrdue on cyl inder b ock w th a f lat scraper.
hand drr l wth a p ast ic brush.
_ 17-17 _
Instal lat ion
a Nate the use by date ol lhe seajanta Replace the gaskets.
a The sump must be fifted wtthin 5 minutes of applying the silicaneseahng campaund.
- Cut off tr.rbe nozzle at fofward mark ng (nozzle diarneter approx. 3
- ^opi , ' i l o eSeal g.o '1 oo,nd a,q-o/ ,7. loc.a-.u^o - .d l .qsu.a.e. \6o. g o po. doeao .-<-o. .
a233mmthck
I RLrn the bead on the inside of bol t ho es -arrows_
The sealing compaund bead must nai be rnorc thart3 nm thick, athetwse.excess seafing compound could enterthe sump and blockthe oilsucuan ptpe stralner.
I
C ean seal ing surface, must be free of oi l arru grease.
_ 17_18 _
Apo' . , - o g o-r lo. " J.Lr laas shown in the L l lst iat on.
ln the area af tta rear sealng flange, take spectal carc applying tLlebead of sealer -aftows-
Fitthesump immediateJy and t ighten al lsumpbots in the indicated
BoLts 1... 20-: f irst ly t ighten in d agonal sequence io 5 Nm
T ghten sump/gearbox bolts arrows- to 45 Nm
Tighten bolts J .. . 20' n diagona sequence to 15 Nm.
'1420 19 18 17 16 1s f{-;; l
- 17-19 -
a On fitting the sump on a dismantled engine see that it is flush withthe cylinder block at the flYwheel end
a Sealant must be left to dry for approx. 3A minutes after fitting thesump. Only then can the engine be ftlled vtith oil.
a Whenengineailis dftinedand is natextracted withthe usedoilvacuurn device, the gasket ring of the oil drain plug has to be replaced
a Observe disposal regulations!
after f i l l ing the engine with oi l , the fol lowing has to be taken Into account when f i rst staTl ing the engrne:
a While the oil pressure vlarning lamp on dash display remains lit theenqine must anly idle. Do nat press accelerator! lf not the turb>co-mpressot could sufler damage at brcak down completely
a Only when the warnng lamp goes aut, has the max- oil pressure
been reached and yau can accelerate
Contine assembly n reverse order of the d smant ing procedure
- 17-20 -
-.,'?
11 .rERS
#\l ) /yrt ii i
' : :.) ' ,4: ' t f.' l"',
l :i ' lL- ' - r
fwl?-ooo1l
Oil pump removing and installing
Removal
Remove sump + page 1715.
- Remove bo t 2 onpurrpshaft
- Femove gear from the oi pLrf frp shaft .
- Unscrew bolts -1, and 3 and remove o I pump with baff le p ate.
Installation
- Fi t the centrng bushes i tem 25, + page j7-7, to the Lrpper part ofthe o I purnp
a Assemblypos tronof theorlpumpshaft /sprocket: tcanon ybef t ted
Contine assenrbly in reverse order of the disrnant l ing procedure
_ 17-21_
Pressure and oil pressureswitch: check
Special tools, workshop systems. testers,measuring instnrments and auxil iaryitems required
a VA.G 1342 Otl pressure tester
a D ode test amp VA.G 15278
a Auxrlary measufing set VA.G 15944 orvA.G 1594C
_ 17-22 _
Buzzer function warning low oil pressure
TheolpressLrreswitch scpenwhenlhereisnopress! lTeand tc loses
on reaching ihe switch ng pressLl le
Low oi lpressurewarnrng comes into act lon in approx' 10 seconds atef
switching on the ignl tron
Low oi l pressure warnlng comes nto act ion with a delay of approx 3
Warning ends with a delay of approx 5 seconds
Note:
Functianat check and setvtcing the optical and acausttc otl pressule
-?ui ""n' 'o" d aq ams. F'- . r 'ca' au, l I nd ng dno lr f l ing local or s
Check the warning lamP
Afier >wrlchr_gon.^ ' lgn: l ro, land ,v l ntheenglreo{ l ' eol o 'essu e
wa-^rng shorla l ghL up fo ' app or ' J seco ds a'd Lhe" go out ! h 'rr -
ing is interrupted i f the engrne ls on
- 17-23 -
Warnings
Act ivat ion of the opt lcal oi l pressure warnrng lamp (warning lamp in
t ,ashtaqmode)dnorn.oewar. t^gbuzles\^ locc- rr 1nelolow, 'qc r_
. " lgnl t ion on", englne off , oi l pressure swi lch closed
. Engine revolutions greater than 1500 R PM ' oi l pressure swltcn
Notes:a Enqine revolutions greatet than 5,000 R PM , watntng |afip stays'
on\rin wnen oit prZssure switch is ctased At less than 5'000 tpnwarntng lamp goes aut agatn
a lf the oit pressure switch is apen at only 0 3 3 0 seconds at an en'
.,;;;;;;;;';;;',;;. i.5i1s 'p1 1t''s s65" 62ne! pracesso' wi"
;;;r;;" 'i n ths happens In-ee t 'les \ \)e enEle ts tr oael
at t o n.- tni oii p r e s s u r e rn r n i ng wil I be i m me d i ate ly a cti va te d a n d wi 1l
not tun off even at less than 1 5AA rpm
- 17-24-
0 F;@5l
a Eliminalion af the ail pressure waffing wll happen when the oilpressure sr1r1'ch has been closed for nlore therj 5 secands ebave1,544 rpm. ar tgnittan is n!rned aff.
Checking condit ions
. O I evel: check ng + page 17 9
. The o i pressure warning amp K3, must ght up Jor approx 3 sec_onds wrth gn t ion on
. Engne ot l ternpereture at least g0.C kadatof fan mLrst have tun
Checking process
D ,o)se- iol g l - . er g '6 .a. .ng -arrov\S-
_ 17-25 _
Remove the securing bolts arrows- and remove the cover -] -
Remove the oI pressure swtch,F]-+ page 1713, tem. j6 andtnread ( onto the tester.
Screw tesler \1A.G 1342 into the o f iher bracket, in place of the or lpressure swrtch.
Connect brown wire of tester to earlh ( )
_ 17-26j _
va.G 1342
0 fN].M I
- Connectdrodetesl anlp \ r .A.G 1527 Br is i rgaux. cablesfrornVA.G15914o. lA6 594r. 'be-o. po( i r '6 r l rndt .o loes,_,e
LED must not lght up.
l f t . i rDl ,ohr up E e!^o'oes,-rer,^,rLch-T - 'pdge / .13
tenl. 16.
l f the LED does not l ight up:
Start engine and run at id l ng speed, at 1.2- 1.6 bar the LED shou dlght up, i f not renew oi lpressure switch -F1-+ page 1713, i iem. 16.
Note:
Observer the tester and the LED durlng the stafting cycle, becausethe response paint af the oil pressure switch can now be surpassedon statting.
Check oi l pressure at di{ferent speedsi
I dLing: mrnimum 2.0 bar
o 2000 RPM.: 3.0 4.5 bar
a above 2,000 RPM: maximum 70 bar
lf the specif ications are not attained:
- Rectify mechan ca damage, e.g. damage in the oi l p pes, oi l f i ter,etc.
- O I fi ter bracket w th relief valve or o I pump faulty: Replace the ollf i l ter bracket + page 17-l4, i tem. 23, or replace the oi pump + page11-21 .
At higher engine speeds, the oi l pressure mLrst not exceed 70 ba.
l f rh. <nc. i f i . , r ^n '<
D,.aa,{a. l
- Check oi l pipes.
- PressLrre rel ief valve or oi l pump faulty, replace oiL pump + page11-21.
- 17-27 -
- 17-28 -
Cooling system components: removing andinstalling
I When the engine is hot the cooling system is under pressure. lfnecessary release pressurc before commencing repair work,
a Hose connections arc secured with spring-type clips. ln cases of rc_parr onty use spnngitwe clips.I To fh spring type ctips use ptiers T20O2g.a Coolant hoses should be stress,free when installing, so that they do
nol come into contact wth ohet components bbserve markingson coolant connection and hosd.
Perform cooling system leakage test with cooling system tester SATT 274 and adaptors VA.G 127418 and V.A.G 12j4lg.
Cooling systern components. body side + page l9-3
19-1 -
Coolrng system components, engine side + page 19€
Coolant hose connection dragram + page l9-12
Coolant: draining and f i l l ing + page tgt5
Notes on coolant mixture ratios + page t9-17
19-2 -
Jif lJ
13
9
12
'I1 8 10
Cooling system comPonents,body side
1 ' RadiatorI Dlsmant lng end f t t lng+paqe19-2)a After replacrng, renew a lcoolaft
2 - O-ring
3 - Upper coolant hosa Securedto rad alorwt l r reta nlngclpa Check for secure sea' l nga oo'o I o,e o ' . lond"gd' l >
page 19-12
4- 10 Nm
5 -Air duct
6 - Cont inued coolant circulat ion pump
-v51-a Checklng
- Page 19 36
7 - Additional fan -V35-a Checking + Page 19-40
8 - securing cl iPa Check lor secure seat lng
9 - Connector
10 - Fadiator fan -V7-a Check ng + Page 19-40
11 - Bracketa For the connectors of the tan tec
12 - Lower coolant hosea Secured to radrator with retaining cl ipa Check tor secure seal ng1 Coolant hose connect on d agram
-page 1912
19_3 -
/,,
1j8 11 8 10 f-r-oo6tl
19-4 -
14
13q
' t2
4
t Err-006-l
'13 - Termoswitch -F18- and -F54-. 35 l..Irra For rhe rrdiator f : rI Swriching iemperaru es:
'| st gear
Connected 92.. .97'C
Disconnecte 84.. .9, ] .C
2nd gear
Connected 99.. .105.C
Dtsconnecte 9i . 9g .Cd
14 - Bracket
t Note the f i t ng positon
15-15Nm
Cooling system components,engine side
1'15Nm
2 -To expansion tanka Coo ant hose connecton diagram +
page l9 l2
3 - Toothed belta Mark D-O.F. betore removinga Check for weara Do not kinka Femoving, inslal ing and tensoning
+ page 13-29
4 - Coolaflt pumpa Check for ease of movementa l f damaged or eaktng: renew com-
p etea Drsmant rng and f nrng + page 19-27
19,5 -
1 2 3 4 s 6 5 7 I 9 5 10 11 . t2
17
18
19
14
20
19-6 _
rir'-:-r,=
456 9 5 10 11 12 l?
5 -O'r ing
6 - Coolant thermostatt Checking: heat the i fernroslal L-
waterl | Open ng coffrrnences approx ET 'Ca Ends approx. 102 "Ct ooeninq l i f t min. 7 mmi Dismanl rnq ancl f t t ng + page 19-29
7 - Coolant connect ing papei Coolant hose connect on dlagram +
page 1912
I - Connection sleeve
I - To heat exchangera Coolant hose connecl on dlagram +
page 19 12
19-7 -
10 - Connector
11 - Coolant temperature sender _G62-
t W th coolant temperature gaugesender _G2-
a For eng ne controL unfa l f necessarV release pressure In cooF
ing system belofe removingI Check ng:
-VAS 5051;Vehlc e sel f diagnosLs
12 - Securing cl ipa Check tor secure seal lng
'a:=1-234 5 6 5 7I9 5 10 11
I
nre. qw_11i '16 5 15 \ . .
fEfg 006? I1g-8 -
I 65 78 9)
17
18
19
tEir-o06?l
&,-' , - A- '
14 ' - )
19
20
13 - To top of radiatora aoolant hose connecl orr c l taqran _
paee 19 12a 5ecL, edroradrr to !1r th ietd,r n(L. l r ,. a l ,e. f ror se!u/e edr|r l r
14-15Nm
l5 - From bottom of radiatorrt Coo ant hose connect ion draqrara _
paoe 1912a Secured to radiatorvr ' th reta nina c io, t Check for secure seat ing
a D srnant lng and f t t ing + paqe 1714,'te.l.l 2?
17 - From heating system heatexchanoera Coolant hose connect ion diagram--
paoe 1912
18 - Central coolant pipea becured to cy inder btoctI Cooant hose connect ion clraqram +
page 1912
19 -Capa Check with cool ng system tesler
VA G 1274 and adapter V.A, c 127419+ page i9 33
t Test presslre I 4 1.6 bar
_ 19-10 _
1 2 3 4 5 6 5 7 I 9 5 10 11 12
17
18
4/
19
20
20 - Expansion tank.) Car:y ol l eak tesr o;.oo ng sysienr
, / , , i th coolng syslcn t :sIer VAG127.1 and adapt-.r ' iAG 12l4l1
-p;ge l9 33
21 'From coolant connect ing pipe,f Coolant hose connecl ion d agram +
pege 19'12
22 -Cont inued coolant circulat ion pump-v51-l Checking
- page 19'36
23 -To turbocompressorI Coo ant hose connect on dragrara +
page 19 12
Coolant hose connection dia-gram
1 - Expansion tankI Caf iy ou1 leak test of coo ng system
with cooing systern tester VA.G1274 and adapter V.A.G 1274/8 +page 19 33
2 -CapaCheck wth cooing system iester
VA.G 1274 and adapter \'l.A.G 121419+ page 19-33
a Test pressure 1.4 - 1 6 bar
3 - lntake manifold
4 - Cyl inder head/cyl inder blocka After rep aclnE, renew al coolant
- 19-11 -
- 19-12-
5 - Heat ing system heat exchangera After replacing, rene!( al cooant
6 -Oi lcoolerI D sn'ani ng ar cj f i t t ng =- pag; t7 '14,
tem 22
7 - Upper radiator hose
I - Radiatora D smani lrng and f in ng + page 19 22I After replacing, rene\ / al coolant
I - Lower radiator hose
10 - Cont inued coolant circulat ion pump-v51-a Checking + page 19 36
11 - Coolant pump/coolant thermostata Coolantpump: d smant ing andfrtt ing
+ page lgt lI Thermostat: drsmanting and frtt ing
+ page I9-29I Checking heat the ihermostat n
water
12 - Exhaust gas turbocompnessora Exhaust gas turbocompressor: dis-
mant lng and f t t ing -
page 2115
- 19_13 _
_ 19_14 _
T10007
@-
120029
v.a.G 1306 saT 8010
dtrU11HA .--
dtd]]]-E
flir-ooorl
Coolant: draining and fil l ing
Special tools, workshop systems, tesiers,measuring instruments and auxrl laryitems required
I Torq!e spannefs SAT 8010
a T10007 Tester
a T20029 Plers
i VA.G 1306 DriP tfay
. - 19-15 -
Empty
Open caP on coolant expans on tanK.
Remove centraL insulat on _arrows-
Place the VA.G 1306 tray under re engrne
To draLn coo anl remove drain p ug _arrow lror i rad ator ' connectan
auxirary hose to the dralnlng s eeve l i necessaly
- 19-16 _-
'-i-'f--- )li-coo er connectron ,arrow_ al owing the coo ant to drain.
Observe disposal reg ulatrcns !
Fi l l ing
a Only use antifreeze additive G 12 according to specification TL lW771 E ldentificatian: purple colaur.
a The purple G 12 ln accordance with standard TL lW 771 F) mav bemixed with the previaus used rcd G 12 antifreeze addiive.
a On no account must G 12 be mixed with other anti-freeze additives.a ll the fluid in expansion tank is brown, G 12 has been mixed with
othet anti-freeze additives. ln this case the caolant must be
.- 19-17 _
G 12 and anti-freeze additives marked ',ln accordance with TL lW772 D" prc,lery hast and conoton ddnao. scahng and atsa,a.seboittng Da;h' OI caalah L fa. fD.S,easo, lt' s] Sler mu sI De tt tled at tyear round with antt-freeze and corrosion protectian addjtives.Because af ns high bailing point, the coalant improves engine relia-bility under heavy wotk laads, pafticula y in cauntries wiih tropical
The a.t, lrceze prc-'clton shaJe oc guaBnteed to apgo\. 25. C tncounrrtcs A 4f aft ltc Aeathet up Ia appto, -35.C)Coolant cancentration must nat be reduced by adding watet, eventn warmerseasans ortnwarmer countries, The antt_freeze additive/coolant ratio must be at least 40 %.
_.19-18_
_f re;E I
a lf far cli|Jatrc ressans a greater frcst pratectton ts requtred, heamounl of G 12 carlbe tncteased, bJt anb, up to60 % (ftost ptotectian to abaut 4A"C) With a greater cancentreton engtne coorngand anti-freeze prcpe)1ies are dinlinished.
a tf radiator, heet exchangea cyitnder head or cYlindet head gasl.etfra3been replaced, do not reuse ald coalant.
Rgcommended mlxture ratros:
Anti-freezeprotectionuntil
Anti-freezeproportion
G 121) WaterlI
-25'C 40 va50%
2.O ltl2.5 t l
3.0 l tr.2.5l t r .
r)AmoLrnt of coolant: 5.0 l i t res; t may vary according to the vehicleequ pment.
- 19-19 -
Screw bleeding screw -arrow into the radiator.
Fl tcoolanthoseontoolcoolerconnect lonandsecurewtnasprngiype clamp using p lers VA.G 1306.
- 19-20 -
7
Close expanstof lank cap.
Start eng ne and r!n engrne ar appror 2,000 rpnr ior airoLr i : l r i r .
Fun engrne unt i radiator fan cuts n.
Check coolant leveland top up i f necessary. When the engine s atnormatoperattngtemperatLrre, thecoolant eve m!stbeonthe max.mark, and when the eng ne is co d, between the m n. and max.marKs.
_ t9_21_
Radiator: removing and installing
S pecial tools, works hop syste ms, testers, mea su ring instru m entsand auxiliary items required
a Torque spanners SAT 8010
T20029
| @-;a
5[).at
sAT 80'10
mTn1n]:-=
[]in]H-E ..".
t!!{t2a
. T20029 plrers
- 19-22 -
Removal
Alwavs rcplace A rings.
n vehrcles with coded radio, take noie ofthe code, f necessary, f indit.
' W th gnitron swrtched off d sconnect battery earth strap.
- Drain coolant + page 19-15.
- Remove upper coo ant hose from rad ator+ page 19-3, itern 3, andthe ower coolant hose + page 194, i tem 12, with pl iers T20029.
Remove the continued coolant c rculation pump -V51-and the hoses+ page T9 13, i tern 10.
- Separate the thermoswitch connector -Fl8- + page 19-5, i tem 13. _- Pull connectors off radiator fan and additiona fan + page 19-4, ilem
10, i tem 7.
- Remove the continued coolant circulation pump -V5T -+ page l9-4, -r lem 6.
Femove fro.t b,nper fn,n9:+ General Body Repairs-instal lat ion work, exterior; Repair group 63;
Front bumper l lning for Le6n Cupra R;front bumper l in ng: removingand instal l ino
drng 'oc. carf ler 'nto se'vrce pos tron:+ Genera Body Repairs-instal lat ion work, exter or; Repair group 50;
Generalbody repairs, front; Lock carrier Le6n Cupra F: servlce posi-t ion
- Lights: removal+ E ectrica system; Repair group 94; L ghts, bulbs, switches - exter-
nal; Headlights: removing and instalhng
- 19-23 -
- 19-24 -
- \
- Remove th_e ; i aandLrit secured lo the racl6ior by ,l bolts + page
- Remove the screws thai secure the rcdiator to the ock carr er a| lc lfenrove the raaj ator carefu iy.
Veh cles with ai f condit ioning:
- Secure the condensor convenient ly to the lock carr ier panel.
- Unscrew the 5 boits -arfows which secure the condenser to the'ad atot a d . . - ' to! . he ,ad aro- .d,eru t l '
Attention!The ah conditioning cooling circuit must not be opened.
Note:To prevent damage to candensersure that the pipes and hoses are
and refigeration pipes/hases, errnot stretched, kinked or bent.
_ 19_25 _
Inslallation
Note:
Always replace O+ings.
- f t t -9 eoac..r . .o1_e.aoiaro roagat9-5,r ien 11.nonngtheTrnrng posrt on
- With help of a second mechanic, f r t al l the oo|rs.
Cont ine assembly n reverse order of the d smantl ing procedure
,Vofes.
a lf the battery is reconnected check the vehicle equipment tadia /tadia and na\.garon sistem - laat poAA! AindaLs,. fa av\t .q
- nstructron Manual
a ather measures aftet rcconnecting the valtage supply + page2439
_ 19-26 _
sAT 8010
[][CGi.:-E,_"-
i ullP;l
trlrE&+,h
{]0filj:;r;
Coolant pump: removing and installing
Special tools,workshop systems, testers. measuring instrumentsand auxi l iary i tems required
I Torque spanners SA.T 8010
Removal
Always replace O ings.
- In vehicles w th coded radro, take note ofthe code, i f necessafy, f indtL
Wrth gnit on switched off disconnect battery earth strap
Drain coolant + page 1915.
Toothed belt: removing + page 13-29.
Unbolt coolant pLranp -1- and remove coo ant pump 2 .
_ 19"27 _
lnstallation
- Mo sten new O-r ing wlth coolant
lnsert coolant pump -2'onto cyl inder block and t ighten securing _bol ts l - to 15 Nm.
Contine assembly n reverse order of the dismantl tng procedure
irotes.a lf the baftety is reconnected check the vehicle equipment (radio /
radia and navigation ststem, clock, powet wndaws), following:+ nstruction Manuala Other measures after reconnectng the voltage supply + page
24-39.
- 19-28 -
sAT 8010
0$ar[+_-,;-h"_
trcorn+*r ." '""'-
f @zml
Coolant thermostat: removing and installing
Special tools, workshop systems, testers, measuring jnstrumentsand auxtt lary i tems required
a Torque spanners SAT g0lO
T20029
fw2sI
a T20029 pliers
Remove the connector,arrow- of thesender -c235-.
_ 19"29 _
Removal
Always replace Orings.
- In veh cles withcoded rad o, take note ofthe code, i f necessary, f nd] l .
With ignition switched off d sconnect battery earth strap.
Drain cooant + page T9 t5
Remove the bo ts -arrows- and remove lne coveT t , .
exnausl gas temperature
_ 19_30 _
- Ljnboh securing bolts 4 of connectrng f lange 3- and remove connect ing s eeve 3_ with gasket -2- and the lhermostat -1 -
Pul coolanl hose ' l - oi i the brac[et 4
Femove brackel '4 {rom the in el nranifo o _2 3_ and releas'o 1redlpst ic l guide tube -4-
- 19-31-
lnstallation
The bftce an the thermostat must be almost verttcal
' Molsten the new O r ng -2- wfth coolant
Fh the thermostai 1_ to the connect ion sleeve -3- and turn r /4 turn(90 ") lo the flght.
Fit the connection sleeve -3_ wlth the thefmostat .1 onto cyllndelblock and t ighlen bolts -4- to 15 Nm
Contine assembly n reverse ordef of the dLsmanl lng procedure
,Votesi
a ]f the baftery is rccannected check the vehtcle equipment (radio /radia and navigatian sistem, clack, power windows) following:
- lnslruct ion Manual
a Ather measures after reconnecting the voltage supplY + page
24 39.
- 19-32-
frt r-oor+l
Cooling system water tight-ness: checking
Special tools, workshop systems, testers,measuring instruments and auxiliarvitems required
I Tester SAT 1274
a VA.G 127418 Adapter
a VA.G 127419 Adapter
_ 19_33 _-
Aftention!
Steam can be released when rcmoving the cap from the expan-sron tan(, I he cap shoulcl be covercd with a cloth and openedcarefullv
Checking conditions
. Eng ne ai service temperature.
Checking process
- Open cap on coo ant expansion tank.
Fit tester SAT 1274 with adapror VA_G 1274lg n expansron tank .
Wrth the tester hand pump a pressure of I baf should be created.
f the pressure fal ls:
- Look for the leak n the f i t t ng and el minate the fauh.
- 19_34 _
V.A.G 1527 B
@ryrM4nl
Checking the pressure relief valve in the lockrng cap
F t tester SAT 1274 with adaptor VA G 121419 tn lacl' ng cap
- Operate hand pump The pressure reief vaLve shouLd open at'14. . .1.6 bar
-- 19-35 -
Continued coolant circulation pump -V51-: check-ing
SDecialtools,workshopsystems'testers, measuring instrumentsa;d auxiliary items required
a VA.G 1527 B Diode test lamp
Note:The cantinued coalant citcutation pump-V51- is secuted ta the nght'
beside the addiional radiator fan in the ai duct
- 19-36 -
2 f[,+61
11 112:13j
-Ei 'i-r !-r
T"rol
Checking condit ions
. Fuse for the cont nued coo anl c lrau at ion puntp Ol i+ Cuf ient f iow diagrams. E ecl f ca fau t f rnd ng anct Ftt t ing iocatrons
Checking process
- Sw tch on ignt ion
O Continued coolant circLr lat on pump V5i-sho!tdwork(shoLrldbevisib y and audibty worklng)
f the pump does notwofk:
Swtch off igni t ion.
Disconnect the cont inued coolant c rculat on pump connector.
2.
_ 19_37 _
- Sw tch on rgntron.
a LED rnust ight up.
LED ights up:
RepLace continued coolant clrculation pump -VSl,.
l f the LED does not hght upi
- Carry out the following checks related to a pointl
Vehicles w;thout air conditioning:
trnued coo anl circulat on pump -V5l - to the relay
- Current f low d agrams, Electr ical fault f ind ng and Fitt ing ocatlons
. Check vo tage supp y to the re ay+ Current f low d agrams, Electr ical faLrlt f indrng and Fitt ng ocatrons
- 19_38 _
Vehicles with air conditioning:
. Check the w r ing of contacl 2 of the coolant fan control un t con-nector -J293 (n the engine bay, i ront le i t hand)
' '6nlrrotur 'oJrornc r l6 iur .o la. ' r r r . l - . q o .o
. Check the vol tage supply to the rad ator fan cont lol un t -J293'.+ Current f ow diagfams, E ectr cal faul i f nd ng and Frt l ing locat ions
Continuation lor both versions
. Check for open circu( from contact 1 of the connector to earth
- Cufrent f ow d agrams, E ectr cal faul t f lnd ng and Ff i ing loc€t ions
f no faul t is found:
- RepLacethe relay for lhecooLantfan orthe controlun t forthe cool-ant fan -J293 .
I
VA.G 1
f"!!@rl
- 19-39 -
Radiator fans -V7- and -V35-: checking
Specialtools,workshopsystems.testers, measuring instrumentsand auxiliary items required
i Auxiiary meas!ring set VA.G 1594A or VA.G 1594C
a Current f low diagram
Checking conditions
. Bas c t!ses should present no problems
. Radiator fan thermoswitch -F]8 and -F54-, OK.
Checking process
F54-.
- 19-40 -
-. Switch on ignition
- Brdge contacts -1,and -2 ot the connector termtna,ustno auxr, iarvcabtes from VA.c 15944 or VA.G r sgaC. naoiatoi tini lvil'rn"i,.vJc- s,)ouK begrn to run at speed L
- Bfldge contacts -2- and 3- of the connector telmtnat usrnq auxrliarvcabtes +rom VA.c tb94A or VA.c rSg+C. naOiatoi faii lri-_ an-i'_\BFshould begin to run at speed 2.
lf fansdo not run at 1st or 2nd speeds:
- Find and elimrnate wtring open ctrcuit accordrnq to:+ uurrent flow diagrams, Electricaltauk frnding a;d Fitting tocatons
lf no wiring fault is detected:
- Replace radiator fans -W- or -V3S-.
_ 1941 _
Fuel supply system components: removingand installing
Arofasia Hose connections are secured with either sprtngitype or clamFr
rype ctlps.a Alw?ys replace clamptype clips with spring-type clips.
a Fuel hoses in engine compaftment must only be secured withsping-type clips. The use of clamp or screw-type clips is not permissibte.
a To {it spting-type.hps use phers T20029.
Observe sdfety precautrons + page 20-12
Observe rules Jor cleanliness + page 20-13
Bemoving and fitting fuel tank with accessofy parts andfuel filter -page 203
Crash fuel shut off iunctron + page 20-29
Electronic power control (EPC): checking -
page 204
Bepairing components of the activated charcoalfilter system + page _2055
2O-1-
2O-2-
1
22
21' ,-Ao l20-)---.;::)
18
16 IE 14 13 t ezo-oo+s I
3 465 6 1*i'l.
?. -tffiFuel tank with accessory partsand fuel fi lter: removing and in-stalling
1 ' O-r ing
2 - cravity/overload valvei) To remove valve unc ip upwards out
I Check vatve ior thfough f low. Perpendicu ar va ve: open. va ve t i ted 45 . i c oseda The grav ty loverloadvalvecan onlybe
Iep aceo tooether w th the breath-^rtube l tem 3
20_3 _
3 - Breather pipea Clpped onlo top oJ fueltanka To the actrvated charcoat .f lter in the
engrne bayI Check for secure seating
4 "Cap
5 -GasketI Replace f damaged
6-1.5Nm
7 - Tank f lap unitt With dust cover
8 - greather valvea To remove valve unc lp sideways out
ol suppofta Before nstal ng, unscrew cap,tem
a Check ng + page 20 9 F g. 2
1 8 9 t0
til)23
21-'1 ,"S :20=+
19
18
15IO
2O4 _
14 13 t E2oroo4s-l
3 - Earth connectionI Cf eck ior secure seal ngI F r t i rg pos t or =oage20-10 Fg :
10-10Nm
11 - Breather pipefWhtea Clpped onio s de of fue tanka Check for secure seat nga Secure with spr ng type cl ips
12 - Fuel tankt D snrant l ng and f i f t ng + page 20 23
13 - Spring washera Check for secufe seatrng
14 - Heat shielda For fuel tank
l5-25Nm
16 - Securing strapi Note dffer ng lengthst Assemb y poslt ion: the arfow (open-
rng) po nts n the d rect on of trave
17 - Supply pipe/hosea B acka To the fuel rai in the engine baya Check for secure seating
18 - Fuelf i l tera Fene\r ' + page 20'28t Assemby posit ion: arrow indicates
the f low drrection
20-5 -
6 7 1 8 9 10
tl)
19
18
1a 13 tEro-oo-as-20-6 -
I?3t"..gr',
23
22
21
20
to
18
1a 13 t Ero-noa5-l
19 - Cl ipt To iLr-r { herI F i l na posit on + p.ge 20 l l , tern 4
20 - O-r ingt Fep ace i f dar.agedI Coat with fue when instalrng
21 -Fuel del ivery unit with fuel qauoesendera D smantl nq .nd i l t rng .- page 20 Ia Hemovrnq and f t j inq ihe iue leve
sendef + page 20 22r Checklng f le pump
- page 20 30
I Note f t t inq post ion on fue tank +pege 20 I , F g. 1
a Ciean strainer i i so ted
2O-7 -
22 ' Union bolta80Nma Remove and /nsta I with tool
u40055A
23 - Supply pipe/hosea BlackI Between the fuel delrvery unit and
the fue f i teri Check for secufe seat ng
24 - Return pipea B ue or wth blue mark ngsa Between the fuel rai and the fuel de,
tvery un tO Clrpped onto s de of fuel tanka Secure with spring,type c ipsa Check for secure seating
\( i ki-" j"-€!,,\.F8'
18
l-,23
21
20
14 .13 ezo-ooli l20-8 _
tt:ou;l
Fig. 1 Fitting position o{ Iuel delivery unit flange
Marl inar or] sender nrLrst a ign \^r t _ the marking on iue tank
Biue or bLue niarked return p pe - l -1o cofnecl on wrth cier ' t i i cal uiL- i - .
B ack supp y p pe -2 to connectron wi lh dent f icai on -V-
Note:
Aftet installing fuel delivery unti flange, check that the sLtpply, retumand breather pip-as arc still clipped onta the fueltank.
Fig. 2 Checking breather valve
Lever rn rest positLon: closed
Lever pushed in direct on of arrow: open
Before installing vent valve remave fueltank cap.
'I
20-9 -
Fig. 3 Fitting position of earth connection
F 1 earth connect ion as shown n the i l lustfat ion.
- First , hook the contact tab -4 for the eafth connecl lon n the fueltank securing hole 4;then, press f t the spacer 5.
Hook the earth connect ion to the secur ng c ip -3- of the fue tankf l ler.
- lVake sure connector-2-ofthe eafth connect ion f i ts coffectytothefuel tank f i ler rneta r ng '1 ' .
- After assernbl lng, checkthe electr c connect ions between the metaLring in rhe f le l tank f l ler and a non painted part of the bodywork,using m!himeter VA.G 1526A or VA.G 1715.
Specif cation: approx. 0 Q
- 20-10 .---
Fig. 4 Fitting position of fuel {ilter screw-type clip
F t the screw-type c ip as shown in the r t ustrat ion
- Fnsure that rhere is suf{ c ient space between screw f iange and iueltank.
Note:
The figurc shows the fuelfiltet ftum the f@nt.
- 20-lt _
Safety precautions when working on the fuelsupply system
a For safety Teasons, Temove fuse No.28 from fuse holder beforeooe- ng tqe r-el svs Fm ds -ha t-al ou-p .an be.c-, /ated o) L.ednver s door contact sw tch
Attention !Fuel supply pipes are under pressute Belore removidg fuelhose connectionswrap a cloth arcund the connection, Then re-lease pressure by carefully pu ing fuel hose frcm connection.
Whenremovingand nsta l ingthefuelgaugesenderorfuelpumplfuelde ivery !nit) from a {ul l or parl ly ful . fuel tank the fo lowing must be
_ 20_12 _
1 Beiorecomnrenclr igvvorL swltchonerhauslexiract i ' l r tystem and
ptu"" an ""tr"" t lon
l ' ,oa" close to the sender opening in the fuel tank
to extract escaplng iuel l !mes
I l { no e.h:Lls1F'I Ia rron 9ys1e-n s dva' l .DlF d "drai ' " a ' olrq " '
motor ' , nol n d. ' r o / ' v\ lLn a o,rpla -e_16n. gradler lhaa l ! rr ' /n can
a Avoid skin contactwith fuel ' wear tuel-reslstant glovesl
Rules for cleanliness
When working on the fuel supply/injection system, pay caretul atten
tron to the fol lowlng "5 rules :
a Thoroughly clean al l un ons and the adjacent areas before discon
nect ing.
a Place parts that have been removed on a clean sLrface and cover
them. Use l int f ree clothsl
- 20-13 -
a l t reoatrs can,lol oe -orpreteo in one sess'or' a' loals a'd comoo'-
""ni . ,hJu," e i l opF'sho-d o ' (ov ' 'ed or ' toreo
wrl_ rhe
greatest of cate.
t o-ly,nstal l cLeaa cornoole^1s
Only unpack replacement parts immediately priof to installatron
Do not use parts that have been stored loose {e g in toolboxes etc')
a When the system is open:
Do not work with compressed air if this can be avoided
Do not move vehicle !nless absolutely necessary
- 20-14-
fAro-537dl
General assembly diagram ofthe fuel delivery unit and fuelgauge sender
1 - Fuel delivery unit with sealing t lange. Lr smanl ng and ttt t nq
- paqe 20 1A
a Fuel pump and fue system: checking
- page 20-30
1 Check ng holdrng pressufe + page24 65
2 - O-ringa Fepace i i damageda Coat with fue when insta l ing
3 - Return pipea Blue or with b ue markingsa From fuel raia Goes to the connection marked "F
In the sea ing f angea To femove from the sea ing ftange,
press the ock ng button
4 -Supply pipe/hosea Blacka To the fue filtera Goes to the connect on marked 'V"
in the sealing f angea To remove from the sea ng flange,
press the ock ng button
_ 20_15 _
_ 20_16 _
5 -4-pin connectort For fue gauge sender and fueL puir-rp
6 - Union bolt| 80 Nrna Remove and Instal l wl th t ! rning lool
u 40055A
7 - Fuel gauge sendera Dismantl ing and l l t t ing+ page2At2
II
I
1I
u-40055A
saT 8010
flTlnt]]j::E,""."-
nmntl]:}-=€ . **
I !!tnP-l
Fuel delivery unit removing and installing
Special tools, workshop systems, testers, measuring instrumentsand auxiliary items required
o Turn ng tool U{0055A
a Torque spanners SAT 8010
---- 20_18 +
Removing
Frrst check whett er a co.ted adro is f i r led. f thsisrhecasecons! l tthe ant i theft codrng.
Note safety precautrons befofe staning work + page 20,12
- Wth the gniton swtched oJf dsconnect bateryearth strap
- Move reaf seat forward.
- Bemove cover frorn fuel del tvery un t unuer fear seat.
Place turn ng tool U-40055 A on union nut and unscrew I f rom thel lange.
Pul l fuel del ivery unit and seal out of the open ng n fuel tank.
lf the dehvery unit ista be rcnewed then dain ald delivery unitbefare
Attention!Fuel supply pipes arc under pressure Beforeremovingfuel hoseconnections wrap a cloth around the connection, Tien rcteasepressurc by carcfully pulling fuel hose from connection.
_ 20,19 _
ply pipes (black) -3-, press ocking buttons to do th s.
u-40055 A
- 2O-2O _
Fitting
- Instal lng the fue de vgry untt s canled oLrt rn ihe reverse ord- ' t
a An fifting the fLtel delivery unit, check that ihe fuel gaLtge sender ls
a Coat flange O+ing with luel when fitting.
a Ensure fuel hoses ate seated securely.
a Note installatbn position of fuel deliver| unit fla nge. The markingonflange must align with marking on fuel tank arows.
a Aftet installing fuel delivery unit, check that the supplY, return andbreather pipes are still clipped anta fueltank.
- Perform the work seqlence ProcedLrre ai ter vol tage suppy opencircui t"
- page 24-39.
Fuel level sender: removing and installing
Removing
- Remove fue de ivery unit + page 2012
- Release and remove the connector terminals ' for wires -3- and -4-
Li f t retaining tabs -1- and '2- with a screwdrlver and p! l l fuel levelsender out downwards -arrows-.
Fitting
lnsta I in reverse order but noie iol lowlng:
- Insert fuel level sender in the guides on the fuel del ivery Lrni t andpush Lrp unt | | t engages.
- Make sure that the tabs of the sender cab es are securely f l t ted
' Fi t fuel del ivery un t + page 20-18.
- 20-21-
- 20-22-
SAT 1O4O
t;Ar-l
Fuel tank: removing and installing
Speciallools, wo rk shop syste m s, testers, measuring instrumenlsano auxttrary r tems required
a Hydraul ic coiumn jack SAT j040
i Torque spanners SAT 8Ol0
_ 20-23 _
Removing
- Note ssfety precaut ons before stan n9 work + page 20 12.
- F rstcheckwhethera coded rad o isf t ted. l i th s sthe caseconsultthe anti-theft coding.
With the lgnit on switched of{ disconnect battery earth strap.
Remove fuel f i ler cap.
- Drain fue tank. c lean fue f j ler and surroLJnding area.
- Unbolt and remove tank f lap un t .
- Move rear seat forward.
- Femove cover from iuel de ivery unit under rear sea1.
- Femove connector from flange -arrow-.
saT 8010
f wc,@t
_ 20-24 _
- Fenrovrr . r lhe raar r l . lh i raf lc l srale r .rheeL hous ng mor 3 rg:
- Genera 6ody Flepa Gjnstsl let lon v, /ork exler or l Repa r group 66;Exter iorequ pnrent;Wheelhous ngrno ldngs;Re: 'whee housrngmou dings: removing and nstalrng
Bemove the {ue tark fLl ler bol ts arrows
- Remove rear axle:
\"eh cles with fronl wheeldrve:
'q--naqqed.a ' Fe ng.Jro t /v16ol 'ndro - t e^dt i teP'p" q 'o-pa:. "eo " lo. reoo no . 'e i '_
^r" on1 '1 lhee'd ' / '1
Remov ng and f t t ing the central and rear exh6ust system sLlencers;
5 FepaLr group26; Exhaustsystem; Exhaustsystem components: removing and instal l lng
- 20-25 -
Remove the suppiy tribe 1 (black), the ret!rn tLlbe -2 lblue) and thebrealher pLpe'3- {white), by pressrng the lockrng buttons
Aftention!Fuel suDplv pipes arc under pressure Before rcmoving fuelhose conn6,aions wrap a cloth arcundthe connection. Then re-Iease pressurc by carefutly Pu ing fuel hose from connection'
- Bemove the ower protect on from the fuel tank
- Remove the luel tank suppoft slraps When dolng this support fueltank with hydrau lc column jack SAT 1040
- Remove fuel ta nk.
- 20.26, -
Fitting
nsta I in reverse order bir t note folow ng:
t Breather and f le hoses are io be instaled l tnk i rea
a Secure hoses with spr ng-iype ciarnps.
a Do not confuse the fue ptpes wth those oi the return pipe or the
a Check f i t t ing posrt ton of earth connect ion + page 20.10, Frg. 3
t Tighten the bolts arrows-.
Tightening torque: lO Nm
a Fit t ing rear ax e:
Vehicles with front wheel drive:+ Runninggeal, axles, steering, f ront wheel and fou r whee dr ive;Fe_
pair group 42; Rear axle: repa ring (vehicles with iront whee d;ive)
_ 20-27 _
Note:
Alter installing fuel tank, check that the suppl' retuh and breatherptpes arc sttllclpped onto the fueltank.
- Perform the work sequence "Procedure after voltage supply opencrrcui t" + page 24-39.
Fuel filter: replace
Removing
- Separate pipes -l-, by pressing the lockrng ourons.
- Loosen the fue i i l tef secur ng clamp 2,.
- Separate the fuelf i l ter.
Fitting
- nstal in reverse order.
_ 20-24 _
Crash fuel shut off
Function
Vehicles vv th airbags are f i t ted wlth a cfash iuel shLrt ofJ system Thisreducesthedangerof af re nacrashasthefue pumpisswltchedoffva the luelpump relay J17-.
S m-haneo-sly th. ) ' l .n p o/ ida< " r p 'or 'ed er o,1' cIa t .
When the door is opened the f !el pump s actvated for 2 seconds tobu ld up the pressure in the fuel system
When opening the lue system:
observe safety precaut ons + page 20-12
- Checking fuel pump relay -J17 :+ VAS 5051; Vehicle se f-diagnosls
Fuel pump and fuel system:checking
Special tools, workshop systems. testers,measuring instruments and auxiliaryitems required
a Adaptor cable SAT 1348/33
o Turn ng too U-40055A
a VA.G 1318 Pressure gauge
a VA.G 1318/l Adapter
a VA.G 1318/11 Adapter
a VA.G 1318/17 Adapter
- 20-29 -
,1
:
*t
sAT 1348,€-3
9ttE-:t
€fi-i'=r=-=-:fi'E +
re.==q, ap
- 20"30 -
{.,!at-=-:=E!:
tL2o-omrl
a VA.c I31823 Adapter
t Fenrole controlVA.c I348l3A
I Auxi lery measLr|ng set VA.G tE94A orr594C
a VA.G 1715 M! t imeter
Checking conditions
. B€ttery vo tage at east 12.7 V
. Allelectr ic consumers, e.9.r ights and reafwindscreen heatermustbe switched off
. lJ the vehicle is equipped with an ar condtt ioner, ths must beswrtched ofl
-- 20-31_
Observe descnptian of crash fuel shut-off+ page 2G29.
Check function and voltage supply
To carry out this wark the battery earth strap must be disconnected.The vehicle shauld be checked for a fitted radio. lf necessary abtaintadia anti theft code firc|
_ 20-32 _
va.G 1348/34 =
iJa,r : rea s:al f . iward
Remov-o cover f fcm luel delvefy !nrt ufder rear seat
- S! ! tc l ionignt lcn.Thefuelpunrpshouldbeh€ardtcsta '11i f th: test' "s lo b. repe".ed. , \ 'o I fo ot reo 6 qo o d. l
l i the iuel pump does not run:
- Switch off gn tion
- Femove cover i rom fuse holder
F..no/e f i -e no 28'o rhe - ' , 'o ldel
Connect Temote control VA.G 1348/34 wth adapter cabe SAT1348/3-3 to contact 28a to fLlel pump and batiery posrtlve termrna(+).
- Operate remote control .
Fuelpump runs:
+VAS 5051 ; Veh c e sef i ragnosis
Fuel plmp does not run:
- PJI 4-o n con eclor t-on 'u. l at . ' la-g€.
- Connect mr] l t imeter VA.G 1715 us ng auxi iary cables from VA.G1594A orVA.G 1594 C to the outer contacts of the connector.
- Operate remote contro.
Speci'f cat on: Approx. battery voltage
_ 20-33 _
- 20-34 -
u-40055 A
l f the specif icat on s r , . r t obta neC:
Locate and elrminate the short c ircurt fol to," !rng the c!rrert i iow d a-grams.
f the spec { cat of ts obta ned (vo tage supply OK ):
Place too U-40055 A on Lrnion nut and unscrew i t f rom the f lange.
- Check ihat the e ectr cal wtres between f ange and fue pump are
t no open circui t can be found:
Feplace fue de very un t + page 2O-18.
- 20_35 _
Checking delivery rate
Checking condit ions
. Fuel pump vohage supply O.K.
. Remote contfol VA.G 1348/34 connec.ted
o Fuel systern pressure and hold ng pressure O.K. + page 24€s
Checking process
- Separate fue supply pipe '1- by presslng the locklng buttons.
Aftention!Fuel supply pipes are under prcssure Before removing tuelhoseconnections wrap a cloth aroundthe connection. Then rc-lease pressure by carefully pu ing fuel hose from connection.
_ 20_36 _
vA.G 1318'1318/11
1318123
vA.G'1318/17f @@t
VA.G 1318/23 to the fuelsupp y p pe
- Push the hose VA G 1318/1 onto the adapter VA G 1318/11 on rhept6 . . -oduo6JndhodloqFt d-n6ac. g.o ro e,
Open shlt-of f tap on pressure gauge. The lever \ / r l rndtcate f towdirection -A'.
- Operate remote controlVA G 1348/3,4 and siowly close cLrt-off tap,Lrnt I pressure gauge shows a read ng of 3 bar.
- From th s point on do not move pos tton of cut off tap
- Empty the measuring container.
- The quantty o' f fueldel ivered by the iuel pump is dependent uponbattery vol tage. Therefore connect the rnuttmetef with adaptercables from VA.G 1594 to the veh ce batterv.
- Operate remote contro VA.G 1348/€4 for 30 seconds and measurebattery vo tage.
- Compare the quant ty of fuel del ivered w ih spec f icat on
*) Vlinimum delvery cm3/30 s
"*) Voltage Ln fuel pump with engine offand the pump working (approx. 2 voltsless than batlery voltage)
Example:
During the test, a vo tage of 12.5 volts is measufed at the battery. Asthevoltage atthe pump is approx. 2 volts lessthan the battefyvohage,th s w l l equate to a m nimum delivery of 200 c.c./30 s
' Ihe rrr ' . 'n- oe r .e 'y ta le s-otdnoreo
- Checkthefue prpeslothef i ter forpossibeconstr ict ionslk lnks)orD OCKageS.
l f the fuel p pes are O.K.:
- Check the fue de rvery before the f ier.
- 20-37 _
TMjml
- 20-38 -
v.A.G 1318
vA.G 1318/17
vA.G 131a/l1
VA,G 131P!l lof f supply prpe/ lrose l- of fhose cor_rp ings ic do thjs
nlel to TLrel f t f ter, press buions cn
Attention!Fuel supply pipes arc under pressurc Befote rcmoving fuethose connections wrap a cloth arcund theconnection. Then re-tease prcssurc by carefully puling fuel hose from connection.
Connect pressLrre gauge VA.c t31B wth adapter 13tg/17 to fuelsupply prpe.
Couple adaptor VA.gauge ano p ace tne
- Open shut-off tap on
G 1318/11 and VA.c 1318/t ro the pressureend oT the pressure regulator In a measuring
pfessure gauge. The ever po nts n d rectton
_ 20_39 _
- Operate remote control VA.G 1348,€4 and s owly close cut€ff tap,unt I pressure gauge shows a read ng o{ approx. 3 bar.
From thts point on do not anove pos tron of cut-off tap.
- Empty the measuring conta ner
- The quant ty of fuel delvered by the f le l l rurnp rs oepenoent uponbattery vol tage. There{ore connect the mu t imeter wth adaptercables i rom VA.G 1594 to the vehicle battery.
- Operate remote controlVA.G T348/34for 30 seconds and measLtreoattery voltage
Repeat de ivery rate check.
I t the minimurn de ivery Tate ts now atta neo:
- Fep ace the fuel f i l ter
f the m nimum del ivery rate rs again not at(a ned:
- Remove the luel del ivery un t and check the f l l ter for di f t .
_ 2O-4t0 _
m:vA.G 1715
Only when up to now nc iaLrk has bee I de1e.1ed:
Feplace fue delvery unf i -
page 20 18.
f the delvery rate has been atalned but nevertheless yoh suspscl afue del ivery system fau t le.g. Intermit tent fai ure of fuel de ivery sys-tem):
Check the clrrrent draw of the fuel pump as fol lows:
- Reconnect al l d lsconnected fuel pipes.
Bv means of the cLrrrent c lamp, connect mult lmeter VA G 1715 too;e of the fLrel pump supp y cables (external contacts of the f langeconnector).
' Start the engine and run at id l ing speed.
- 20-41-
- Measure the current draw oi the fuel pump
Specif icatlon: max. 8 amps.
Note:lf the fuet system malfunction is intermittent, you can perform thecheck during a test drive whh the help of a 2nd person
lf the current draw is exceeded:
- RepLace fuel del ivery unit + page 2018
- 2042-
i :tt.,l o-ooi5l
Electronic power control(Epc)
1 - Bracketi RearcvLfg and instal ing
s Brake system; Repa r group 46; Brakes,rnechanrcs; Brake pads: genera assembly d agfam
2 -Connectora Black, 6 prn
3-10Nm
4 - Accelerator pedal position senders -G79- and -G185-t To remove, t is necessary to f rst re
rnove the footwel covera Checking + page 2047
5 - Bracketa n footwel l cover1 Clpped onto acceleratof peda pos -
ton sender
_ 20-43 _
Function of EPC system
Wth the EPC system the throt i le valve s not operated by a cabeThere is no mechan ca connect ion between accelerator and throl t evalve
The positron of theacce erator is t ransmtl ted to theengine contro unitby two acce erator posi t ion senders lvar iable res stofs together in ahousing) which are connected to the accelerator peda
The posit ion ofthe accelerator (dr ivers requLrerneni) s the main inputvalue ior the englne contro un t
The thrott le vave s operated over the complete revolut ion and oadrange by an e ectr c motor l thrott e valve posit oner) nthethrott eva ve
The throtlle va ve s operated by the throttle valve pos lloner which iscontro led by the 9ng ne contro unit
- 20-44 _
When the enl l ine rs nol runnlng and lhe lgni tron s swtcheo on l leen_oine contro unit moves the thrott le valve exact y as pfescnbed by the;ccelerator pedal posrt ion sender This means ' that when the accelerator is depressed halfway the thrott le vaive posrt ioner opens thethrott le valve by the same amount, the throt i e s then approximale y
nar open
When the engine is r !nninq (under load)the engine control uni t canopen or close the thrott le valve Independent ly oi the accelerator pedal
This meansthatthethrott levalvecanalreadybecompletelyopeneventhough the accelerator pedal rs only depressed half way This avoids
' \o.rng lo."es'al lsed bv tc6 tF onle /a vF
After evaluating the torque requirements of various components (e g
air condit ion ng, automatic Aearbox, ABS/ESP and so on), the englnecontrol uni t calculates the opt ima thrott le valve opening angle {or therespectrve snuatron.
- 20-45 -
ThisaLsogivesvastlylmproved consumptlon and exhaust em ss on levels at ceftain load condntons
l! is incorrecl to believe that the EPC" is comprised of one or twocornponents only. The EPC is a system, which ls comprised of al lcom-oonents which have an lnf luence, controlor mon tor the poslt ion ofthethrottle valve, e.g. the accelerator pedal position sender' the throttlevalve control unit, the EPC warninq lamp, the engrne contro LlnI
II
I
I
I
I
I
- 20-46 -
v.a.c 155i vA_G 1598/31
ffivA.G 1526A
fl2-4-oo1o I
Bapid dat€ t ransler HELP
Accelerator pedal positionsenders: checking
Special tools, workshop systems, testers,measuring instruments and auxiliarVitems required
a Hand mult imetef VA G 15264 or mu tff ieter vA.G l7l5
I Fault feader VA.G 1551 or vehtc e systemtester VA.G 1552 with cabte VAG1551/3 B
aAuxlary measur ing sel VA.c 15944 orvA.G 1594C
a Test box VA.c 1598/31
a Current i ow d agrams
- 20,47 _
Functioning
Both acce le rator peda posit on send€rs -G79 and-G18b,ontheacce,erator pedal pass the drver 's requ rements on to the engtne conlrounrt rndependent ly of one another, Both senders are instal led togetherIn a srngle hoLrsing
Checking conditions
. Bat lery voLtage at east 12.7 V
Checking process
- Connect faul t feaderVA G 155j (VA.G jS52) Star l engine and select Address code" 01 to se ect eng ne contro !ni t .
- Press keys 0and Sforthefuncton'Read measured vaue bock, 'and conf rm entry with O key.
_ 20_48 _
Read measured !al,re blockEiler number group values XY'X
Bead m€asured va !e block 62 -
1234
Inolcated on disp ay:
- Pfess keys 0, 6 and 2entry with O key.
indrcated on d splay: (1. .
Check specification of3:
Specifrcation: 3...100 7o
for "Display group number 62" and conf irn
4=dsplayf ie lds)
sende- I -Gl9 ar id ing sioo In d sptay zo.r
Check spec f ication of sender 2 -G1Bb-at idl inq stop in displayzone4:
Specri icatron: 3 . . l0O qo
No'€;
The engine control unit calculates the voltage vatues of the angle-sender n percent relative to 5 Voltand displaysthese as a percentagefigure (5 Volt supply voltage equates to tOO yo).
- 2049
- Operate the accelerator pedal slowly until fully depressed and ob.serve the percentage figures n disp ay zones 3 and 4:
Specif ication: 3...100 %
Note:The percentfigures in display zone 3and 4 mustrise evenly. Thetolerance ranqe ts not covered completely.
- Press - key.
- Press keys 0 and 6 ior the "End output" function and confjrm inp{rjwih rhe O /ey.
- Switch ofi ignition.
' t tse spec'f icatron ts not obtatneo
- Check accelerator pedal position sender voltage suppiy and wirineconnections + page 20-51.
- 20-50 -
l-'*al
tr.ft I
Check accelerator pedal posi t ion sender vol tage suppty and wir_
Renrove ihe shef or dlvei s s de.
- Ger eralbody fepa rs-tnstalat on \ , !oi i , inrenor, Repa r groi ip 68; Iler or equrpment; she f , covers 3nd i f ms; Lower penels bestde thesreer ng cot!mn: removal
Disconnect 6 pin connector lof acce eralor peda pos t on senderslrorn the accelerator pedal
Switch on gnit ion
Connect mLr t meter to measufe vol tag_a at the fo low ng contacts of
6-pin connector,contact
Measure to
Earth
2 Ea(h
2 Contact 3
Spec f cai on: at Least 4.5 V
_ 20_51 _
- Switch off gnLtron.
l l the specrf lcat ions are not attarned:
- Connecttest boxVA.G 1598/31 tocontro untwnngharness wth-out connect ing the eng ne contro lnt t + page 24 36
current iowdagram.
6-pin connector,conlact
Test box VA.c1598/31, test box
socket1 722 /33 36
35
5 336
_ 20-52 _
Wire resislance: 1,5 O Max.
- Additionally check the wifing for short to battery positive or eafth.
- Addilionally check wires for short to one another.
lf no wiring fa!lt is detected:
- Benow accelerator pedal positlon sender + page 2043, item 4.
Activated charcoal filter systemirotesa Hose connections are secuted with either spritqtype ot clafip
type clgs.a Always replace clametype clips with spting.typ€ clips.a To fft spring-type clips use ptie6 T2Un9.
Observe safety precautions + pag€ 2G12
Observe rules for cleanliness + pags 20-13
- 2063 --
- 20-54 -
8
-@l t lt lCD
Yr-
f Aro O3r?l
Servicing parts of the activatedcharcoal fi lter system: rgt.lrirt
1 - Rubber bush
2 -Activated charcoal filter systemt t . i .o o ofo. ,anL.6.--Fr, _
rnenl, nghtI Secured to bodya To ro-no.e u boLrrh6Oo16 .For i l
.V 6n a.o /o orn ebod)ror,aW.r . re.ol- od." . - I \80. o
the activated charcoal f ilter systenra When the engine swarmthevave
rVr bea . , " r .d 'on . 'eeig ,e, ortro unit (pLr lsed)
3 -Bush
4 - Washer
5-10Nm
_ 20_55 _
6 - Connectora Black,2-plna Wilh the so eno d valve 1 forthe act i
vated charcoalf i l ler system -N80-
7 - greather connectiona Check fof secure seatrnga From the gfevi tyvalve on t i re luel tank
+ page 20 3, i tem 2
I - Non-return valvea Observe f i t t rng positon ( lghvdark
pa.t) : as shown in the l l lustrat on, thearrow indicaies the f low dlrect ion.
I -To the turbocompressor inlet pipe
8
- ."'1odttu-r ""\
/z- +t*t Ii l l l'4U
@
I '
r -€T;t;;w r
_=.- 20"56 ----
.-) t r.|ftPt -\/ /+ 'Y/ t l,U
@IIe
11
12
1€
h2o,m-97l
10-From the gravi ty valve on the fueltank
11 - Non-return valvea Obsefve i i i i fg posi t ion ( ight/da I
part) : as shown in the i lustrairon, thearrow ndrcates the f low direct ion
12 - To throttle valve control part
saT 1368/1
i4! l I l l
f mtt
items required
a SAT 1368/1 Adapter
a SAT 1390 Manua pLrmp
t VA.G 1368 VacLrlm tester
Fuel tank breather: checking
Special tools, workshop systems, testers,measuring instruments and auxil iary
- 20-57 -
I
- 20-58 --
va.G. 1 368
sAT r 368/1
Checkir:g process
- Felease the breather tube for the act ivaled charcoal f l ter systern
- Connect hand vacuum pump SAT 1390 to act ivaled charcoalf i l iersystem -1 wrlh an auxi lary tube 2,
- Uncouple breather pipe -3- which eads lrom fue lank to act ivaledcharcoai f i l ter and connect t t to vacuum tester VA.G i36g -connec-tion A-. To do this, use SAT 1368/t adapter.
Connect the VA.G 1368 vacuLrm meter {onnect on B- to breatherptp€-4 leadingto the act ivatedcharcoa f i tersystem. Todothis, useSAT 1368/1 adapter.
- Put vacuum tester in pos t ion B.
ni t ate thef ina controld agnosis and acttvatethe act ivalecl cha rcoaf i l ter soleno d valve 1 N80-:
+ VAS 5051; Vehicle se f-diagnosLs
- 20_s9 _
vA.G. 1 368
sAT 1368/1
sAT 1390
TE,i-;l
Operate hand vacuum pun-rp SAT 1390 severa t mes. Vacuum must
f vacuum bu lds up:
- Check breathlng connect on at the bottom of the activated charcoalf i ter system l- and clean if necessary.
f vacuum does not bu ld up:
Unscrew fLre fLler cap.
- Connect hand vacuum pump SAT 1390 to vacuum tester VA.G 1368connect on B .
- Set vacuum tester to -A/B- posit on.
- Operate hand vacuum pump SAT 1390 severalt imes. Vacuum mustnot bLr ld up.
_ 20-60 _
l f vacuum builds up:
- Check breather valve + page 20-9, Fig. 2.
- Check pipe/hose -3-irom fueltank for blookage.
lf vacuum does not build up:
- Unscrew fuelf i l ler cap.
- Operate hand vacuum pump $Tl3g0 severs'times. Vacuum mustnot build up.
Not€':lf the fuel level in the tank is low the SATrnust be operated apprcx. 20...30 times.
lf \racuum builds up:
-,Eeplace the fuel i i l ler cap.
1390 hand vacuum pump '
20161 -
tI
14
13
16 ----o,
^"+"rp )17
-18
10
9-
5
32 31 30 292a
tAri oo%l
24
l iuSrerchalging systcn-i r,rith e;:haust gars iur-il6cor.r'ipressol
Rules for cleanlinessFor .o, . ,oo . : :nq ! lu i6s oi ean e5
a Tlrorough y a eaf a Lt | ( ] | : : a . l thE ai l l3.a. i : ar?s l reTor: i : . . ! r i ,necr ng
a P ace parts ihni I ave be,^n errov--d o., a cleal s|rrJace an. l aolert fenr Use nt f ree clothsl
1 i repairs c!nnoi be aompleied r io e seasiDn, a 1 parts anclco- i i ro-nents that are lef t open shol ld be covered or stored vvtth thegreatest ol care.
I Only instal l c lean components Only unpack rep acement parts im-mediately pr ior to rnstal laton. Do not lse pa(s that have beenstored oose (e.9. in tool boxes etc.) .
a l f the sysiem s open, do not use compressed air and do not move
21-1 -
Turbocompressor: removingand installing
1- 10 Nm
2 - Oil return pipeI Towards sur.lp
3-10NmI On f i fr ing apply locl<ing agent
4 -Gasket
5 -10 Nm
6-10Nma Do not adjust sett ing,l Loosen ng is not permitted
g ' ' '
18
.19
22
- \,-23
' i t : : : : , . , i , : r ' i t .i F:r i . . . t : r t . . :Lr i . . - l r lLoi !
. : 1:! i i : : . : ; : - : : l
. i r : , . t : r i , . r
e - fxhaust Eas lufboconlPressor. f l r .ni r ! : r . i i i ] | r l t : p ige r - l
9-25ttm
'i0 - Gasket
+ f lote the f1t rg posl l ! . i r
11 -10Nm
l2 - Hollow bolt130 Nm
32 31 30 29
24
25
'\ 26'-27
28
tArt.0016l21-3 -
13 - Oi l supply pipet From the ol f i ter brackel : page
17-12, r tem.13
14 - Ribe head bolta30Nm
a Remove and InstaL wth socketspanner SAT 8050
t App y locl i ing { uid ior hot workingbolts to threads and contact sur laceof cylnder head
a Lock ng f lu ld fof hot work ng bo ts G5lsee spares caralogLJel
15 - Exhaust mani{oldI Dismairt l ng and l i t t ng + page 26-10
'16 - 23 Nm
17 - Hollow boltr 30 Nrn
18 - Gasket
a Note the fLt ng pcst cn
ZU
.,:d,
l i - -=lo- \ ;
"-)-" litr,(g 5? ..r-:
9 ' -
16---.,.- f..,_ -.::=\\rtt9 l17
25
18
10
32 31 30 29fAtl oor6l
22
21-4 -
,i ' ir-'I
6
' '? $: f l . , r . . l , . l1e : i . l . l
iL. a. ,olar, t reiuf t I ' ipe
21 -20 Nm
22 - Hol low trol ta :[) l] _n
23-10Nm
24 - Coolant supply pipe
25'Hol low bolta35Nm
26 - Lambda probea55Nmi) Before catalytic convertera The thread shou d onty be lubr icared
wth the lockrng f tuid for hot workingbolts. The f l l r id must not get into thesiots on the probe body
t Locking f lu id for hot wofking bolts Gs(see spares cata ogue)
21-5 _
22
24
25
7
4
rl3'+
21
27 -40 Nm
28 - Fronl exhaust pipea With releasrng elemento Do not bend the releas ng elernent
more than '10'(otherw se it cou d beoamageo)
a Dismantl ing and frt nq -
page 26 1l
29 -30 Nma Use origrnal bolts ony
30 -20 Nm
31 - Bracketa For turboccmpressor
32 ' Gasket
' i -,/:' _
14le
12
2
1
17
1q
4\
26
27
2A32 31 30 29
,+-i-oo16l
22
21-6 -
t;"*;.l
Speeia! io 'r i3 w\ ' r l ,shopsf. ' i : r iLs, ieei :rs. i . . : - ; . : i : i i r :Jr ! :s i : 1).r . :x i : !zind ar!xiliary items reg ;re.l
a 5. l i l t lS[r : . . . l ' .1-! ] , i r r , ,Fr
I Tle tLtrboconpLas.ar t:. ten r \.ed ,-lau'nward.
t All lherrnel ttDi--.Ik]l sleeves rerrb.,lti u.t Le rc itn--.] in hes:tre !l3ac arlt r;;;:€;i1t1),:
r h vehicles n tll ,:oded ra'-lt.)/ coded raLlia;rii nevigatiat) svsterrt(Rl'lS), taLe nat. af d1e.irr.le. if /r.'r.ess6/)l
'rd ri
- With gn t on swtched off d sconf ect Lrattery earih strap.
Di d. : . - rb i .g rha 6 g n-. o.o. d orr .
Remove the right'hand drlve shaft:
- FLrnnlnggear,axles,steer i fg, i ronlwhee andfourwheeldrve; Repair gfolrp 40; Drive shaft : remov rg and instal ing
- Remove {foni exhausr pipe -
page 26 '11.
It is not necessaty to remave the suLrfrarne, lust push the front exheust ppe ta an,o side sa i does nat tnteiere during dtsassembly.
- Drcin coo ant -
page 19 15.
- Unscreu,the coolant supply plpe 4 from the cy inder block; at ten-t ion: on doing this a large amount oi coo ant wi l pour out.
- Unbo t the exhaust gas tLrrbocompressor ol l reiurn pipe -1-.
- I xol . b " . I e. - ) - o ' .ne p:pro r ' . ) :nd. 'bo.
Loosen bo t -2- of the lurbocompfessor bracketabouttwo turns ldonot remove conrpletely).
oe o.at e .oe-o o^-or h. , . oo.or pe..o e L".5rgJ'o.- le. o o a --2,r-
- ' ]i IEF-:F- \'
,o3rr i l [ - - [
21-a -
Rernove the bo ts a rows f tontreairconclurtb.acl .etandremovethe bracket.
21-9 -
- Femove the s!pport bar for the thermal prorecI on steeve _arrows .
- Remove the turbocompressor ol t let arr conou i t !oe
- Re ease the therma insulat on and remove.
air mass me1eT.
- Femove boits -2 and 3- and remove the air f l ter casing.
- 21-10 _
i , i : , , , re! i l ' r : r :1 Lf . : , i i . , , v : , i ; : . i , 1Eai : : i L i ,L: : l r r r t l ;i . - : , ! t . r l ,6t . r r i . i i
Fe.rove the , I r . . , . . i i : r . , valve - : - i f i ,n i fe : i i r et l ) ie '6 .
Ferrovg connecic) - : . a l i fa s i r l : ra icharging pressurE solena, idev:lve +.175-.
Benove fos€s -4- a ai -5- i rom t re sLrperchafg ng pressure soler or.le valve l'.175
I _l_".e . ut " , ^ . , r ,J rr 0\6 l - L nl- i l ro.6 . 6 laa. g
the l lanqe thal secures i t to rhe exhaLrst gas tu-bocompressor
- 21-11-
Unboit thecoolantreturnpipe 1 andtheolsupplypipe-2- i romtheturbocornpressor with an 8 mm Alen key.
haust manifold.
'a , j
- 21-12-
L:r.5ar, L.r i l r . . l
- FtE ,-r"a i . i , i , : ,
Installation
i Sear/erhe,o. . . . t - , taer t . , .e. br " . r , , . / , .o. , . r ta np.. : rot .q,
a Th--haa- <t-e.o,d, .o- ,s o, , t , - - tpo, ndtr t r . ) . .* f , . .1 a.cJt e lteF ttan on and g+.se Fefo c d.rp nbt;ng.
I The supercheryiDg systen ntust be frce of leaksI Always replace gaskets, O,rjngs and self-tocking nuts.a Fill the exhaust gas tut boconprcssor with engine ailthtoLtgh the oil
suppty ptpe connectrcn.
- 21-13 _
Before f t t ing the turbocompressor, bol t on the coo ant sLrpply tubeand t fre tubocompressor secur ng f ange
- Fit the turbocompressor from below in the same pos t on as t wasassembled and move i t on the bracket; hand t ighten boh,arrow'.
Contine assembly in reverse order of the dismantlng procedure
Notes:
a lf the battery B reconnected check the vehicle equipment lradio /radta and navlgation sistem, clock, power windows), fo owhg:
+ Instruct ion Manual,t Other measures after reconnecting the wtage supply + page
2439.
_ 21_14 _
1Z I
[!it.erccoiei sYstenl pans: te-rnovir.!€, and installing
Gen-.ral as.e$rl ' l ) ' d iagisnl
Part I
1 ' Pressure hose
2'To intercooler
3-20Nff
4 - Lower bracket for prcssure pipe
5 - Pressure pipe
6 - Upper bracket for pnessune pipe
7 -20 Nm
a'.) 14
t5
1617
' t8
21 20fArl-oos-sl
8 -20 Nm
I - Upper bracket lor pressure pipe
10 - Pressure hose
11 - Exhaust gas turbocompressor
12 -To the sump breathet
13 - Pressure regulator valve{or cylinderblock breather
14-Pressure box for regulating super-charging pressure
- 21-15 -
( r / ' -- -.!.rl
10 11 12
16
18
27/
-4c\
21 20@r- oor8 l
- 21-16 -
1110 '12 1l L i . . i , . .3+
':a . Ta ti.e ai. filisr
17 - To the turbocon]pressor air re.!i.,-''?tion valve -N249-
1a - Mechanical air recircutat ion valve
19 - Connect ing element
20 -Air recirculat ion valve for turbocom-pressor -N249-
21 - Lower bracket for pressure pipe
2021fAzLorB-l
Part ll
1 - Pressure hose
2 - Right-hand intercooler air duct
3 - Righi-hand intercoolera Dismantlng and f i t t ng
- page 21-24
4 - Rubbel no2zlea With bush
5 -10 Nm
6 -To turbocompressor
7-10Nm
I - Right-hand intercooler bracket
I -To intake manifold
10 - Rubber nozzlea Wth bush
- 21-17 _
J.-r.,
78
) )
tu$EU
0 14113
t5
to
181q
202122
25 24 23
TFrl nn"n l
_ 21-14 _
lo
/ - l I
_ 18. , r - 19
1-l - 10 $J!:r
'if greclrett !e i l i . i . i i : , , : . r , : . . i Lr-
13 ' Bnsh
14 - Ruhber no?zle
i5 - Pressltre hose
16-x0Nm
'17 - 10 Nm
1a - Supercharging presslrre sender
I Fep ace the O rrng I d.l-rraged
19 - Pressure pipe
20 - Prcssure hose
- , . - -1o:,, 't1
14t312
-202-l22
2A29 25 24 23
tEr'r oo3o I_ 21-19 _
21 -10Nm
22 - Rubber nozzle
23 - Left-hand intercoolera Dlsmantl ing and i t t inq
- page 21 21
24- 10 Nm
25 -Rubber nozzle
26 - lntercooler bracket
27 - Left-hand intercooler air duct
28 - Flange
29 - Connect ion pipe
30 - Silentbloc
897
t5
18192021
f t r :mul
1413
I
2A2929
_ 21-20 _
.=G r
Disr. ,enr l i r tg
a , . .J . ,
a Eefarc rcpairnli oi |esi/r!, .11:,1, 6// ppes ar.j tta.:es foi i:Dl ect asselj1lJl\/ end tear':;.
I The sleeves and hase s f.)t t]1e s upercha t gtrlg system shau ld l,e freetron ojl and dtea!;e befcre E-.se/1lb/i/rcr.
| lt rehicles witlt .oded raLlia/.oded radta and navigattotl systenllql'ls). take nate of tlle cade, tf nec_ossary, fnd tt.
Left-hand intercooler:
- With igni t on switched off , disconnect bat lery eafth strap and thenthe posft ive terminal.
Fernove secur ng bolts arrows and remove cover I -
_ 21-21_
Unclp the fuseholder support f rame -arrows-
Open and remove the protect ve battery cover -'l-.
Remove bolt'2-, support plate -3- ancl remove the battery.
Remove the bettery holdef -aTTows-
_ 2.t-22 _
: r . ' r . . ' : L. r r : r l i I L ; i . r ) i " :
I r ; :
i l . r r - . / ra l t . i i ! | r l ' . r ' : l :: ;4 , ; ; l i , ' i l i l ; i : , : . i r , i ' : '
F r i i l i l rn ' l ,er i r i ! l ic ! .or i '_ l r :
a. n.rve lef l ' l rand hearl lg l t
t . . . r1. l i :F- t , . . , . ,1 r i lJ .
Fl ; tL i , i i i ,Ei iL, ! r t - ' io/r !
Remove bolts '2 a 1d loosen f lang- ' 1 - of the L pper pipe of ihe nter
Drsconnect the alr conduit f rom the intercooler
Loosen flange 1 of the lower a I hose rernove the lo\'ter secunng
bolt -2 and remove the ntercooler '
Right-hand intercooler:
Remove r ighl_hand headlrght
Renlovebolts 2-and oosenf lange-1 of theuppef plpeof thelnter
- 21-24 -
' DisconneLt the 6 r .onitt i fro 1r e intefcoo el
LOOS6i l lange l,() i t t ,atowe !r f ,rs,r, rer|rrve the l.vver se,L 1.r!rbo t -2- and tefirove the Intercooler.
Installation
Instal in reverce order of the dismaitling proceoure
Notes:I lf the baftery is reconnected clrcck the vehicle equipment lra,jio /
radio and navigation sistem, clock, power windows), following theindications in the Opercting lnstructions.
a Other measures after rccannecting the vottage supply + page2439.
- 21-25 _
Safety precautions
Obselve the fol low -g t f rest and reasur,ng Inst.unen!s are requiredOunng a teslonve:
I Test and measuring instruments must be secured to rear seat andoperated by a 2nd person from rhrs tocatton.
a ' f lesl and .reasuring Insttuments are operateo f-om rronl passen-ger 's seat and the vehicle is invo ved i . an acctoenl, there t> a posst-bi l i ly rhat the person srt t ing i . r rhrs seat rray recerre ser,oLs , i jur iesif the ai|bag is triggered
- 21-26 _
-t ,la
/ r - . .
i . i )
Cannecti{rn diaErarn for' tl-'efleEulation of the super-eharging pressu re and v&c-urrm control
21
lq
1 'Fronl the fuel tank
2 ' Aetivated charcoalfilter canistert With : io le roid va ve f of acl vaie. l chaf
cc,a f ltef 1!!0
3 - Non-return valveI Betvveen t l re act ivated charcoal l i ief
:r i r . r r1-. r , l - - l pf ie rr i fort of the - . ." :haLrsi gas tufbocompressol
a Assembly poslt ior (Llgh1/dark side) las shown in the i l ustrat ion, i l re afrowind cates the l low dlrectron.
fA24 oassl
4 - Exhaust gas turbocompressora Checiing the sLrpercharging pressure
- page 2l '36
5 - Pressure capsule for regulatingsupercharging pressurer Checking + page 21 50
6 - Mechanical air recirculal ion valvea Checking
- page 21-41
7 - Brake servo
I - Non-return valvet Bet\ /een br3ke servo and intake
manifold:I Assenrb y posit lon 1l ght/dark srde).
as shown n the l lstrat on, the arrowrnd cates the f low direct ion
I - Solenoid valve to l imit supercharg-ing pressure -N75-a Checking + page 21-47
- 21-27 -
I10
11
12
14
tc
16
17
- 21-28 -
1 d2
rJ
141 . : i r f t :ss f iL-3ier -Glar
l1 - ' . i : f i l ter
1? Fressure regulator valve fc i cyt i iderblock breather
13 - Vacuum reserve tanka goted' ,r ihe cyl r . tef lead cove
14 - Left-hand intercooler
15 - Fuel pressure regutator
16 -Thrott le valve controt uni t ,J33e-
17 - Intake manifold
_ 21_29 _
) l 910
12
'I
16
17
fA2-4 o45il
18 - Cyl inder block breather
19 - Non-return valveI Assemb y posit ion ( rqhvdark s de):
as shown rn the I lustral on, the arrowrnd cates the f ow d rect on.
20'Air recirculat ion solenoid valve forturbocompressor -N249-a Fr l t ng locat on
- Fig 1,page21-3,]
t Check ng 5 page 21 4r1
21 - Non'return valvei) Between sct ivated charcoalf j l ter sys-
tera and rntake manifo dt Assenrbly post lon ( givdark side):
as shown rn the t l ustrat ion, the arrowndrcates the f low dlrect ion.
22 - Right-hand intercooler
9'10
11
12
'14
t5
16
17
20 19 lAr4-oait_ 21-30 _
Fig. r Fiiring lr,caii.,n oi tlie air rcdrcuictior, s.d6noid valve forthe turbocompressor'I{249-
. | Fi t i rno oaat iol r t fLe cvhnaler hea. l cciver'i To the Lrn of or in ei franrfol.l
2 -Vacuum res-orve tank
3 To the mechanrca arr rec rcular ion va ve
4 -Air recirclrlation soleno d valve {or tufb.rcompressor +.,1249
- 21-31 -
Testing conditions for exhaust gas superchargingsystem. Coo ant temperature, min. 80" C.
a lntefrogate engine control un t fault memory.
. There must be no leaks on the inlet and exhaust s des. Effects ofpossible leaks + page 21-33
. The controlpipe to the supercharging pressure regulation valve must-either be brocLed nor be loose or leal ing
. The engineand injection system should be in pedectstate, i .e.thereshould be no faults e.g. in the compfessron pressure.
_ 21-32 -
Effects of possible leaks in the supercharging sys-tem
A - Leaks after the air mass metet
Possible fault causes:
. Junction hosebetweentheal mass metersandtheexhaustgastur-bocompressot
. Junction hose to the cfankshaft casing breather.
. Junction hose to the activated charcoal lilter system
Repereussions:
Beduction in power
- 21_33 _
B - Leaks after the exhaust gas turbocompresso. (inlet side)
Possible fauh causes:
. Junction hoses between the intercoolers and the exhaust gasturbo-comptessor.
o Junction hose between intercoolef and lntake manifold.
. Supercharging pressure sender gasket -G31- (in the pressure pipe)
. Gasket between throttle valve control unit and lnlet manifold
. Gasket between intake manifold and cylinder head
. Junction hose from the mechanical exhaust gas recirculation valve
. Junction hose tothe solenoid valve to limit supercharging pressufe-N75,.
Repercu3sionr
Supercharging pressure too low
_ 21-34 _
' Leaks aiter the exliausi
Fossihle fault causesi
TLrrL ocorlrpresso/9)ll_ a.rit
Er l ,sust r iani lold, / . y ' i r . ler
Repercussion:
gas iit rrLr,c.r ! r',1!t'Erts'rr' ii, il ,. . t.* :'?,jE)
rM 06l
Supefcharging pess fetooJow n c:er_ta n cases exhaL St lFssnreL'
ikces of soot lrr the el lllne l];llr
- 21-35 -
Supercharging pressure control: checking
Specialtools,workshopsVstems,testers, measuringinstrumentsand auxiliary items required
I Turbocompressor test unit VA G 1397 A
Checking conditions
a Correct sealing and placement af all the hoses and wiing checked'
a There must be na leaks an the inlet and exhaust s/des
a Minimum coolant temperature, 80"C
Checking process
- 21-36 -
vA.G 1397/4
I vn-M I
Dr.a: i ! , r r 1 l ! t i i .
iJ',f;"#H:ii lF,ly:?HillJ::'- *""r vA G 13e7 A hose
:;Jli,'ff Tiff if ,T."'.:'":ffi Aft i:li:fi :t:.""?:[i'"iJ*,
_ 21-37 _
- Actrvale the turbocompressortester and select measufement rangepos t ton l - {absolute pressure).
- Fi t measurement hose to connect ion sleeve l_.
a The hoses must b- t,nFcl absatrLet\ tpdt tree. OtnerA;se themeasurements wtI not be e^act
,, Make sure the measurement hose 6 notcrushed by the bannet or
a press memolr '.\ M on tke tdrbocamprcssot resLet to rnemohseft16 Dsr fieasuted value u.Il M I E,essed again ot tae testet s
a The memo sed vatue is displayect with a flashing decimal paint inthe display feld.
_- 21_38 _--
rm@@
v.A.G 1397/A
F,@N
a ii lh. l.na t, \.ali3!a ,'f tt. rtnlf i:.1mri.essot iesiet ilr)?s belo\ t a
,:pexifie.l l.)ve., en.tffr.\\'wii lt li.)pla't"'l i') LIE tti'l:'i lei' lt'N'L
\:;. Et rl iic .tsf-lav.
a Eefor-. testinq, [t]e vehi.le sh.Llld be dtiven n)oderae a' )tl 'nnittttit
rsti
far at leasi r 11 le g. \uttttL'Lh .ralJpttp at iiaiiii ljJlL:s)
a Due ta the Deeil of obs./ utg the r?/de-s drsplayed vrhile dnvilg an
assislsrt tt /, lre ,eear'-;r
- I ' leasure superchargin!1 pressLrLe at ful l thrott le
- AcceleraLe f o| l r 2,000 pi l l to fuL throl l le ln 3rd geer '
- At 3,000 rpri press nrerory key M on the tlrbocompfessc'r
I Specf lcat ion on VA.G 1397 Al
1,700.. . 2,000 bar Pressure
I f superchargrng pressLlre ls exceeoeo:
Remove connector _2- from the supercharging pressure solenoldevalve -N75 -1-.
- Check the junction hose (between the turbocompressor an0 Inrer-cooler) of the valve to the pressure capsule
- Check the secure sealing of the pressure capsule (for the supercharging pressure regulation valve) in the turbocompressor'
- Check the smooth action of the shaft houslng of the superchargingpressureregulationvalve intheturbocompressor' l{ i t is st i f f replaceturllocomPressor.
l f there is no fa!l t or the supercharging pressure is not reached:
- Check solenoid valve to l imit supercharging pressLrre -N75- + page
2147 .
- 21-39 -
- 21'40 -
sAT 1390
| ",'P;to e,r l [ { 0
Meciranical air recireuiation vaive: clteckiriE
+ I / - re f ia:r_l iar) / t ; ! . i r - . i r : lJ . : r - ; r : : . i r . r / ; i ra, , !3h,Er ' : I I i : r ta: : : _:1a
; . t g. l . t b. , . . . .< ^, d.r ,J - . , , j i .
r . . taal pdu\, . 1, , t . .1 at t .gtr . . , . - ,F t . ot . a, -1. . . , . ) . .evat.ve. lhus the tLtri)oarJntprcssar ts lepi ar a ligher nunibet of rcvc,l-
) Th-^ mechanicai athaLEt ga€ reciculetian valve is c()ntrclect hy tteexhaust gas tLtrbacanl)ressot air recirculatian valve 1,1219 .
a lf the engine does not suppfy' enough po\aet or there are sudden eveLsals in load, it will be necessary ta check the ai reciculatpn valve
Specialtools,workshopsystems,teste.s, measuring instrumentsand auxiliary items required
a SAT 1390 Hand vacuum pump
- 2141 _
Checking process
Drsassemb ing the engrne cover arrows
F'-he S^- 3o0," .Lru^i p.-rp ro t \e o r .c rc. tat :o- Jo ,e
_ 21-42 _
- Worl i l , . , ,a.LLri i p.r , t
Tire : , r-r i : l a l ion ! , . i , . le s : i r , l : , i ' i : r arr
Aite 3! :ecord:, aci vate I re I le ir i r4l vn re.] l i r 'e r la iudi , /a! ! Ll , ' rpL nrp.
Tlre a i feci cu etLcr, va, lve s rcLid c cs-. arTa\ , .
{ lhealr feclrcr latron valve cloes iotopen olclose accord ngtospeclf iaar ions of f th,a r . /a!ve cl isc does rrot sea co ecly i i ts holsing wththe air recirculet io va ve closed:
R,ap ace the a r rec rculat on valve and secL fe the hose corrnect ionsw tr l c ps.
VA.G 1526 A
awo.H;l
tr@4a
- 21-43 -
Air recirculation solenoid valve for turbocompres-sor -N249-: checking
Special tools, workshop sVstems, testers, measuring instrumentsand auxiliary items required
a VA G 1526 Hand mult imeter
I Aux l iary measurlng set VA.G 1594 C
- 21-44 -
Tesi conditions
. F l r : c. , f i roidia! - . : - . . : r - :d. t 1+ VAS 5051; Veh.Je 5. i . t i . . r .s -
Checking process
- Sv,/ltch off rgnit on.
. Femove the engine ccveT EfTc!." ,s
Disconnect connector -2-valve N249,1-.
ol the turbocompressor a r rec rculatton
_ 21-45 _
- Meas!re resistance between the solenoid coniacts N249_, spec f !caIor'_ 21 . . .24 I
l f the specif icat on rs not obtained:
Renew the turbocompressor air recirculat on valve -N24g_
- Interrogate faul t memory:+ VAS 5051; Veh c e setf i agnosis
l f the specif icat ion is obta ned:
- Check_the spec f cal ons jn the measured value b ocks forthe regula_tron of sLtpercharg ng pressurel
+ VAS 5051; Veh cle setf i iagnosis
-Ja-_GJ4
]Eo
_ 21-46 _
VA.G i526 A
vA.G 1594
f$ma
Solenoid valve is tinrit supsrc.lrarglng ptessure -['tr75-: chec!(ing
Specia I tools, workshop syste ms, testers' nreasu ring insttu nretlts
and auxi l iary i tenls requi led
r M3nLraL rru i r . r ' . re Vl i . ; i5201
a Auxil iary meas!rlng seiVA.G 1594C
- 21-47 -
Test conditions
. Final control dlagnosis carr ied out+ VAS 5051; Vehlcle sel f diagnosrs
Checking process
- Switch off ignitron.
- Remove the etlglne coveT -arfows
Remove connector -2 trom thevalve N75-, 1
supercharging pressure soleno d
{" \ \ I4-@-\\((3)r \l \__.:=-rj
- 21-48 -
' f lr 'EarsL] |e fas s l r ] 1_; l ] , i r r i \ r ! - ! r t t
- r : r r lF inor i l . . : : r . i : l i l : , . re l l.at ion: 25 35 ! l
l l t re specif catron rs n.t ohla |ed
- Fep ace the soler i . , rc l va ve lo l i r I i sLrt . ch:rging pressure - f . ,175-
- Interrogate faLr t meiory+ VAS 5051; Veh cle sel f : l agrosis
f the specif icat on is obta ned:
Checf i the specif ical ons in the measLrred va i re blocks forthe regula-tron ol sLrpercharging pressure:
+ VAS 5051; Vehic e sel f-diagnosis
_ 21_49 _
Pressure capsule for regulating superchargingpressure: checking
Test conditions
. Engine oi temperature must be at least 60 .C.
Checking process
- Femove connector -2 from the supercharging pressure soenoidva ve N75. 1-.
Staft eng ne and qu cklymum. The supercharging
increase engrne revolutions 10 the max-pressure regLr at on valve control rod -2-
- 2.1_50 _
' : : .
l i i l , - . .J i , , . d, , ' r . . , .
smooth action. lf it is jammed, .oplace turbocompressor
rf the control rod does nor Inove even ihough ihe lever works snooth-ly:
- Replacoturbocomprcssor
- lnterogating and efasing fault memory:+ VAS 5051; Vehicle selfdiagnosis
- 2t_51 _
l
:
29 28 27 26 25 24 23 22 21 20
Ini*r:tIcrrr system: repa iring
Fitting loeatio|is overvie!,v
'I r-arn['da probe aft€r .atalyti. cor-verter -G130" with heaterlor Lambdaprobe 1 after cata lytic c onuetter -Z2g-1 F t i l . t ocal i . jn + Fi ! 3I Ch. jc l Lambd: probe a 1d Lambda re
! luhi ion : f ter cald yt c converter l,= \Ai 505]; Ve l . lE sc- i l ! a l ln.rs s
I Ctreck rhe Lanbda lrrobe heainganer catalvt tc convertef:
== VAS 5051 ; Vehic e se i -ct iaSnosisI Fe nove anci nstal with spa) rer
u40080a Grease thfead only \ , ! th "G5" 'cS"
must not get nto the sots on the
24"1 _
2 - 4-pin connectora Lambda probe al ter catalylrc con
vef ier c l30- and heater for Lambdapfobe I altercata yt c convertef-229
a F t t ing ocaton-Fg.3
3 - Lambda probe -G39- with heater torLambda probe -219-a n the front exhaust pipe1 Check Lambda probe and Lambda re
gu atron before catalytic converter+ VAS 5051 ; Vehicle self-cl agnos s
I Check age ng of Lambda probe be-rore cata yt c converter
+ VAS 5051 ; Vehicle se f d agnosisa Checkthe Lambda probe heatng be-
lore cala )l c convefter:+ VAS 5051; Vehic e se f i ragnosis
I i011 12
19fAr4:G54 I
I 9 1011
t tJi I ,,.,
iir l.-J-r i.l.r
i r l l29 28 27 26 25 24 23 22 21 20 t9
t5
14
to
17l6
24-2 -
1.D i1. 12s + F.: r . r : d , l r , : , i i i ' ! : r : , , ! , i
| ) : t :i 1r a-nsE i lL r : r . l orr lv rr ' l t l
r r : . t , i : , t : i i , : , i
4 - 6-pirr connectorl' For Larnbda lnobe -G'19 an.l he.itef
ior LanrbCa frobe Zl9
5 - Control unit for Motroric _J220-t Checl i ,an9 re control Lrnt vol tage
sr PP Y -: Fage 24 4'Ja Proceclure after in lerrLpt lon In voi t-
age supp y -
pag-6 24 :r9
-VAS 5051;Vehicle sef diagnos s
6 - lgni t ion coi l -N-, -N128-, -N158- and
-N163-I Check ng + paqe 28-25
24-3 -
7 -Air c irculat ion valve for turbocom-pressor -N249-a Fi t l ng locat on
- Fig. 1
t Checklng + Page 21 44
8 - Accelerator pedal position sencler 'G79- and accelerator pedal positionsender 2 -G185-a Fi t l lng locaton- Fig. 2a Checklng:
= VAS 5051; Veh cLe self i l agnos s
I - Brake lightswitch -F-and brake pedalswitch -F47-a Fi t l ing ocat lon
- F g. 6
10 - Clutch pedal switch -F36-a Fi t t ing locat ion + Fig 7
't4
lo'17
18
26 25 24 23 22 21 20 19I Ar-4:a45tl
8 9 1011
t l l lI i.ll
il, .l-r ll,
26 25 24 23 22 21 20
24-4 -
89
l,l ,'l'
19 r i rz
26 25 24 23 22 2"t 20
' i i i : r ! F3nel insel l. i ' f t , ! ! . r r , ! r : , , t : t t i i , : ! i l
- r a i r : : : : : : : i
I ; . i i . . ,J , t n- : i
rr i : , - l .a, i
'12 - Motronic current supply relay ,J271_o l-,rt ig tocat on : Frq 4+ Ch-..kifg
-. page 28 9
13 -A,r mass meter -c70-+ Che.king:
+ VAS 5051; Vehic e setf d al tnos s
14 - Solenoid valve to l imit supercharo-ing pressure -N75-a Checking + page 2t .17
24-s _
ia
1415to
1718
i'--:.'-l/ ':i
. ' ' ,
II29 t9
tnz4 o?6nl
15 - Coolant temperature sender -G62-a Checl ing:
- VAS 5051 ; Veh c e sel f . l agnos s
a I necessary release pressuTe in coollg syslem beTore fernovtng
16 - Valve 1 lor variable distribution-N205-I Check ng + pege 15 78
17 - Fuel pressure regulatorI Checking
- page 24 65
18 - Knock sensor 2 -G66,t Check ng + page 2e-34
19 ' Sr.rpercharging pressure sender
a Bolted to the pressure p pe + page21-19, i rem l9
24-6 _
2A 26 25 24 23 22 21 20
: i r !n3i . ,1. ! i r+. i s. i , ; ' - t ' i i i - :+ l j i - I . . - i . ! i : r r ' l : :
2 i " Thrcir l€ v: t i re corr t ro l $r ' i l ' .1:1i ,r \ r \ | t i l i i i , r . , / : ! , : , . , l - l . - :
: ! i : i : ! ,1.1! : , r lLI l lL. , t le ' . /5 l tE. . ' : t l
: a l l iT_ ni i . arq. : ,ende 2 '
r iL na: / : ! ' : . l r rr_l l . u ' r i ' i ]88tC e. l !
. : \ / r . . Ftq I \ / . l . j i . l . : .FLir l ragfcss( l r a.a:- a, i lef , l . laalrrar i .arry.rut t rL. .
ad;! taI o i i l: VAS 5051r ' .G1cl, . se l { laq rosis
22 - lntake air temperatLtte sender -G42-a Checi 19:
+VAS 5051;VehLcle sel f_d aq rosis
24-7 -
23 -3-pin connectorlGeya For englne speed sender G28
24 - Exhaust gas temperature sender 1,G235"a - 6 le-np6 aLura.eno6'L onI e ul-
bocomplessoT
25 - Iniectors -N3O-, 'N3'l-. "N32- and
-N33-a CheckLng
- Page 24-52a D'r . - r ' rnq a l 0 ng ' oaqe , l - l
26 - Knock sensor 1 _G61-a Checking
- Pege 28 34
27 - Prcssure switch / power assistedsteering -Fg8-I Frt l ng locelon + F g 5
f .i:,
i. i
29
.,:: I.,.1 r
=i 16
19
f t24--a45lal
7 I 9 1011
l l iI ' : '
,1, r.Jr ii.
13
l4
:= 16
18
19
-eiinr:rl
29 28 27 26 25 24 23 22 21 20
24-a -
i i r t1:i - i-i.:il !:er,.le! -G.!ar
+ , l : , : r i ! r - i j i : i r :
: ! -So{en. i i . l ra lve 1 { . r aci : i r : . , r . i . i , rF.oel f i l ter -N81.? i . l . ' r l . r !
. r ' i ! , 5U5- ; V, . r i ( E : ret j i ln.r r1]sLs
Fig. 1 Fi t t inglocat ionoftheairrecirculat ionvatvefortheturbo-compressor -N249-
F t t ing locrt on: I the cy nder h€ad cover1 To the unicn on rnlet manifotd2 -Vacuum reservoir
3 To the mechanical exhaust gas recircutar on va ve4 Air f - .c ircu at ion valve for turbocompressof -N249
24-9 _
Fig. 2 Fifting location of accelerator pedal posifion sender-G79- and accelerator pedal position sender 2 -G185-
The illustration represents distributrcn in left hand-driv-6 vehicles
:= 16=17
29 28 27 26 25 24 23 22 21 20 19
_ 24-.tO _
Fig. 3 i:iiiiri! l.,ratirn ij.i Lna L:rrrltde i,r.l.ir. 3lier catai!.ii. ri-"i-verter -G130- Enld (:6r'!tiector prri€ctive cover
r-La i t i r , i : r ! r , r . l i l ic . . : r i : , l , r . r , a! . 'a, i : , :_: j , ' r i : r ' i l " l l
2 [ o 1rre. i i . , I pf t r rccive cai ,
To accegs the Lerrbd: prar,e f . raaalrT:nal fa: ier , r rbol l the pr ' ( r lec-rvecoverorthev.hic leunderb. , . ly , i l l L Inr , l s ldc i r r fows
-J271-
Fit t ing locaton: n the dashboard, on the ei1
Note:
To rcmove the protective cover in vehicles with cross member be-tweenthe s uspensian tuffets, release the relay holcler from thedashboardand move downwards Also discon nect the airmass meter catlnector (if fitted)
- 24-11-
Fig. 5 Fitting location of pressure switch / power assistedsteering -F88-
Fig,6 Fitting location oI brake light switchswitch -F47-
-F- and brake pedal
- 24-12 -
/ r' : : I
'1t l
i i
F'9. ? Fidir'g f:ca1idf. .i i i!'rri, fredai :\.,.ii.ir -F36-
_ 24_13 _
Air filter: dismantling and as-sembling
1 - O-ringa Fenew f darnaged
2 -Air mass meter -G70-a Sensor and connectoT contacts ar€
gold p ated
3- l0Nm
4 -Air duct
5 -5-pin connectora Senso' :1d .onnec o contdcts atc
gold plated
6-6Nm
7 -Air f i l ter upper pa.t
I - Filter cartridge
4
2
1
f Fr;:.r,rc]
- 24-14 _
5
e-t i
fi ii.. r.,.:','.
.,.-);rt..
-8
S - ' rC l . l : i i
'iO - Air intai.e .!r',rt
11 . Air filte. t^',,,'{'rt t.'t
12-1CNm
l--;-rorl
Fuel rail with iniectors: dis-mantling and assembling
1 - Intermediate piece for iniectorr3NmI On fitting, apply lock ng f Lrid D 000
600 A2
2 - O-ring
. B. o i . r .>.of . ,g n ,LA ^
. l r .nengrne or l
3 - Iniectors -N30-. -N31-, -N32- and-N33-o Check njectlon rate + irage 24_59
4 - Supply hose
5 - Relurn hose
- 24-15 -
t ,,1 /
-,_8/Yf.\9
-9.-.,'.'.V
12
14
t4[ , r
-_-.
€)8
- 24-16 -
21 20 19 1 I IME_a%lieenl
6 a- ' i r i r ,*c i . r i . r i r jeci . i .
? - 10 I{ iil
A Fuel pressure regulatorI a i,!-.rl.ir!t -. trirqe 24,65
9 - O'r ing
t Belore i r i l i i _at r . s leirenqi re oi
10 - O-r ing
t Betore tstal ng rno stenerlg ne o l
11 - Retain;ng cl ipI E|rsure t ight f i t
12 - Fuel rail
13 - O-r ing
t Before nstal ng mosten wi lh ceaneng ne o
14 - Retaining cl ipI Ensure seated correct ly at nJector
and lue ra l
15-15Nm
16 -Throttle valve control unit -J338-a Wilh thrott le valve controlun t G186 ,
ang esender 1- lor throi t e va ve conlfc Lrnl t G187- and angl-o sender 2lor thrott e va ve control uni i -G188
r Checklng:
- VAS 5051' Veh cle sel f i agnosis
I n case of rep acement, carry cut theaoaptatton
- VAS 5051; Vehrc e se i dr:gnos s
_ 24-'17 _
-a
11
'12
A-16
"-r
1
14
r15.J*
1617
!i24-or-6-il_ 24-18 _
5----- .
A)8
7'
9
' r ; - . c; :skei
're - i0 nlm
19 - lntake ai| temperature sender -G42-r L_neal i rnq:
= VAn 5t5l : Veh c e ier l - . rragnosis
20 -O-r ing
21 - lntake manifoldI Femove + page 15 7
'I
1921 20 t A24-ot6I- 24-19 - _
General notes on iniection
a Fuel hoses in engine campaftment must only be secured withspting type chps. The use of clamp or screw type clips is nat per-
a For trauble free operatton af the electncal components a voltage a)dt least 12 / V is neces-a! \
. Do not use sealants containng slicone. Particles of slicone clrawninto the engtne, will not be bunt in the engine and damage the
a \ehi.t6s A nh ar d rbag are ffied A fih a (,asnfrel shuioft. Tn6 sr s-tem reduces the tisk of a vehicle buntng in the event af a crash irtthat the fuei pump is switched aff by the fuel pump relay. At thesame time this improves the vehicle starting. When the door ie-opened the fuelpump is acttvat-'d for 2 secands ta build up pressuretn the tuel system.
_ 24-20 -
: : i i r i r ' i , r : . : ,u i r , : , : - t , ! . i r . : l
R . : 1. , f . e: l , ; : . : - i r : i : : . : r j : : l
T;c rr a?i :lati = p:,,:j- :i :!
Safety precautions
Waming!
Thefuel system is undet pressure. Beforc opening the systemplace a cloth around the connection. fhen releasi ptessurc bvcarcfully loosening the connection-
To prevent intur es to persons afd/or damage to the injection end igninon system, the folow ng must be observedl
a Forsafetyreasons remove fuse no.28from fuse ho der before open-Ing thefuel system as thefuel pump can be activated bythe dnvelsdoor contact swttch,
_ 24-21_
a Dur ng some checks i t is possible that the control uni t wi l recognise and store a fau t . For th is reason, faul t memory raust benterroga-edandera.edaf.r f t s t .q" l tesrst .d epa s.Ahert"e ta. t me"o.v e ds.d,
^ l l b. ne.e,5a,vro ge.erate Ihe
- VAS 5051; Vehic e selJd agnos s
a Do not touch or disconnect igni t on wrr ing when tre engine is run,ning or being turned ai starter speed.
a The igni t ion must be switched off be{ore connect ng or d sconnectlng lnlect ion or ign t on system w r ing or tester cabLes.
a On y wash the engine with the ignrt ion off .
a Disconnectand connectthe bat leryonywththe rgnitron of i , otheGwrse t fre engrne contro Lln( cou d be damaged.
Obre \ethefo owlgt ' (ac-andr easuf l 9, I lu1- la t ra e eo-r .edouf lno a test of lve:
_ 24-22 _
+t:L: i l , - . : , : , ' r . , . r . r . l - .opeistei l j ' , . , . l fd L, ! s.r i : ' i r . _ j : Lrrair . I
l lestandrrreasL|. l ins ' r fLrr i i : r i :_; , teolreaiedirof , r f ror ' r ipas:Et,o: t 5a,.atelcl thevel.rc lei5 nvol, . , :ar naf ac. i r l€ 11, i re [ ie sot] s t n! t r l ,sseat l r-Lay receve !e iors i r lur ie-.r i thealr : , :g s1-rggered
1 lf the -6l|9 rie s io ire rullt-:d ar siafier slJee.l, w thout stari ig:
Femove the 4.pir conneclrrr ! 'J f rom ai l the :1ni t of .o ls -2-
- Bemove fuse 32.
Note:Remaving fuse No. 32 intenLtpts thevoltage supply to the injectars.
- 24-23 - _
Rules for cleanliness
When working on the fue supp y/inject on system, pay carefu atten-t ion to the folow ng "6 rules":
a Thoroughly clean al l unlons and the adjacent areas before discon- -nec!ng,
I Place parts that have been rernoved on a c ean sudace and cover_them. Use lnt- free cloths I
o l f repairs cannot be compJeted n one session, al lparts and compo-nents that are eft open should be covered or stcred wth the,greatest of care.
a OnLv insta' lL leon corrpon. t_
Only unpack repiacemenl parts immedlaie y pr ior to instal al on
Do.or .se oans tqal have oeon c o eo oo)e e g. t - Ioo bo,a. a1( |
- 24-24 _
I WlrerLt |e sy. i ier I i - i r , l : re, l
trc nct worl !v tl-r ca,rirpresaed a ii this a;i !e avlrqai.,i
Do rrot nt,Jve vehicie urrles; diisvlurely rEccssary
a Separate elecincal connectors.
Protect them from d ft and water
Only connect if dry
Technical data
r) Non-adjustable?)Lalest pan number for enq.ne cont,ol unit
- Parts Catalogue
_ 24-25 _
Eqghe cod. AMKldling dleck
ldl ing speedrl 700..820Engine control unit 2)
System
Pun Ig 2)
Gove|ned engine speed 1/min
Motronic ME75
rML 906 032
from approx. 6800
- 2+26 _
vas s05li
vas 50sl
r,@;al
Checking comPo!.!eftts
Cornponents and f uncti<.'t.rs: adapting
Specialtools, worl'shc.p sysleii;,i;tt;i-r, Inca-iuliii! i::'<:riir'.nrtaand auxiliarv itenrs required
i VAS 5051 Velrcle D agn'rs s, l -estrrr ! : , r i i l r ionnat on Syst;Lr l
a Dagnosis cable \AS 5051/1 . , r VAS 5051/3
On the VAS 5051 iesle seLe.t 'G,-r ided lalr l t f nd rr !1"
Chce a I the control u r i rs have been Ll te roqated:
Press the go to ' bul ton.
qee-L . 616 t , 9 u :on / .orpo ar ls
- Select "Engine"
- SelecI inq ne cooe
Select " Selfdiagnosis sysiems 01 ".
- 24-27 -
- Select "Eng ne management .
Select "Functrons .
- Select the lunction of component to adapt and follow the instru(t ions of the VAS 5051 testing, rneasuring and d agnosis equ pmen*
Engine control unit fault memory: consulting an(clearing
Fault memory: consulting
Specialtools,workshopsystems,testers, measuringinstrumentsand auxiliary items required
r VAS 5051 Veh cle Diagnos s, Testing and niormatlon System
t Diagnosis cable VAS 5051/1 or VAS 5051/3
- Connect the VAS 5051 Veh cle Dlagnos s, Test ng and lnlormatr._System as follows:
- 24-24 -
1-i , . :n i_e ! i , , ' . . r - : q L] l : ! iL. - : ! , r ar. ,
. - i i . , i n; . i . ; i : i , i in l i , , r ; : l l - , r ! . . : , r r :1, : r , r : : . : . : - , .1
- Start en!Jr ' re a r . i run ai i ; in l ts.re--C
lf the engine daes not staft, tun ihe engine wnh the starier raotatfaiat least 5 secand;. Da roi swnch off ih€ iatniii.h ur)Jei an\ citcLl.|
S-.lect operaling mode:
Press button on the VAS 5051 display for "Ve r ic e se i -diagnos s"
Seleci vehicle system:
Brief iy press select on 01 - Engine electronic system ' on screen- t -
The contro unit dent f icat ion and coding are ndicated on the display
24-29 -
! lE:l I lr-" lL-
r;i;ral
Press key > to continue.
Select d agnostrc function:
Indicated on VAS 5051
' Brief ly press o. screen -1'the d agnosis fLrnction "02 - lnterrogate
nd cated on vAS 50571 'Contents oi iau t memofy
a 0 faults recognised
o X Fai-llt(s) recognised
'l1
rat-* l
- 24-30 -
2 Fa )l l
a Fa!lt iocation
a Type of fault
i IdJl.b eere re.og'.rcFLl.
Print the conients of the screen or the selfilagnosis protocol.
End function "02 - " Inteaogaiing fault roemory" by briefly pressinq
- Rectify al l faults
- Bfletly press aga.r or the dragnosis lunction 02 - nre.rogate faultmemory' and erase the fault memory + page 2433.
- Brief ly press on the diagnosis function "06 - End output' .
_ 2441_
- lf the fault memory is erased, it will be necessary to generate th€reaorness cooe:
+ VAS 5051;Vehicle self i iagnosis
lf no faults were recognised:
- End tunctron 02 - " Inrerrogat'ng fauh mernorv" by briefly pressinf
- Briefly press on the dlagnosis function "06 - End output".
,Vofgsia ll no faults are recorded, do not clear fault memory as readinest.._
code wojld be set to zero.a lf the fault memory is emsed, it will be necessary to generate thl
rcadiness code again:+ VAS 5051; Vehicle self i iagnosrs
- 24-32-
Fauli niemory: ei.:ia
Specialtools.workshopsystenrs,testers. iriea!t,rir,g insirLirir?na:and auxi l iary i tems required
a VAS 5051 Veh c e [,La!] os s, i.r:rt q ar ct nf.rflral.n :ivs1-.i
t Diagfosis cable VAS 5|5 / t or V/. ,S 5!at/ , :
Prcrequisitesi
. Fau i rnerirofy has freer-r consL ted = )irqe 24,:8
. Al faLrlts have been repa red
Aler rav ng r ter 'ogdt.o t l re duh - ien ot , , .
Indicated on V,AS 5051
Brief ly pfess on screen 1 the dragnosis funct ion ,05 - Erase faul t
rAji@ 1
fM;:@ I
_ 24-33 _
lndicated on VAS 5051'l -
a No indlcation (before erasing)
a Fault memory erased
Note:lf display field -1- displays the message " Fault memory was not inter-rogated" , this means that thewark sequence was incorrect.ltis anlypossible ta erase the fault memary if it has fist been interrogated.
2 - Nole:
Do you wish to start the functon?
Warningl the data wil be erased
Brefly press the "OK" key in ndication,2-.
- End fLrnct on "05 " Eras ng ' fault memory ' by br efly pressing
- 24-34 _
1-rr . t i t : : i i f : : , -
. . . . r : r i , . . . i . - i i , : : . : - , . t : : i , . : ' l ?; '
I ln thts \^,a\, \/ar carj craEe faLllt tl',i !.rete rni:t11otii:eil ilLtxiti! rtiefault ehnil?ii'jr latoc"ss, e.g \ 11?it t"t navn)o .,c'r rlecrat s.
a lf th e l a u lt m e m.r l i s e/?-sed, ri LL,/ l-,e rttes s a t Y 10 g €. e t Et e t h -areadiness coale agaih:
+ VAS 5051 ; V€h c e self d agn,.j". e
v.A.G 1 598/31
r'VMan
- 24-35 -
Checking cables and components with test boxv.A.G 1598/31
Special tools, workshop systems. tesiers, measuring instrumentsand auxiliary items rcquired
a Test box VA.G 159881
NotP.s:a Test box VA.G 1598/31 is despned sa that it can connect strnulta-
neously to the wiing harness to the engine canttol unit ancl to the
a This has the advantage that ihe engine conttol unit continues tofunction fully with the test box connected (e.9. measurtng stgnalswhile the engine is running).
a The need ta additianally cannect the engine contral unittothe testbox is indicated n the cotrespandtng tesl ptocesses.
- 24-36 -
vA,G 1598/31
l \Aays usd ih.at t ' i l i . . t ) ,n1.- . : ( rnrg:rei U. l , - r ta. rL ir corl )e;l
' / Ji,.:. !r iit! etLrpttei)t te li arr.r.. r. ,,r , .:
i.ieriual nrltif)etei YA t) 1526.:t ,. i: )
Tt te cort tect t r t : ; r ' taci tn i i r ter . - r . , . / i . i r j , r ! , . r , , :
Switch off gni t ion.
Renrove w per arr'rs a-d io!.rl par e .
- Elecrr ical sysi , . rn; Fepa group 92; WirrclscreenWindscreen w per: remov ng and nstal l ing
- Loosen the connectors and separate thern f fom the contfo unit .
The test box earth clp should be confected to the battery negat ive.
- Carry outthe test as descr bed in the corresponding test processes,
_ 24-37 _
Atention!
To avoid destroying the electronic componenE, betorc con-necting the measufing cable. the coftesponding measurtngnnge must be chosen and the testing conditions adhered to.
i : , a
Impoftant noE:
After recannecting the engine control unit, the fallowing operatiansmust be carried out:a Adapting the throttle valve control unit -J339:+ VAS 5051; Vehicle sel fdlagnos sa lnterrcgate fault memory and erase if necessary + page 24-28.a ]f the fault memory is ercsed, it will be necessary to generate the
readiness cade:
- VAS 5051;Vehic e sef i ragnosis
- 24-38 _
Procedure after interruptioll i lr i 'ottaEe supF iv
. . re l ' , , , . . ' 1, 1. . , . .1, d
depenclng o-r i \ rel , ic le nl i leag., v. i .e i l lv r ' - rperf ' rnrr : in 'enrai / l - reseverely afiected
Aiier rcconnecling th-'Iiower sttpply, the follorvi)ll aperettons must
a Adapting the thtoftle vaive cor'tral unn J333 :+VAS 5051; Vehicle sel f 'd lagnosis
a lnterrogate fault memoty and ercse ii Deces$ry + page 2+28
a lf the fault memary is eased, i will be necessary to generate the
rcadiness cade:+ VAS 5051 ; Veh cle sel idLagnosLs
- 24-39 -
Control unit voltage suPPlY:checking
SDecial tools, workshop systems. testers,measuring instruments and auxiliaryitems required
t h"nd r-rr ' r r . re VA.C 1526a or m-l l -meter VA.G 1715
a A,J,r lar) neasur, .g 'e l VA G 15914 o1594C
a Test box VA.G 1598/31
I Current f low dtagrams
- 2440 -
vA.G 1598/31
Checlt ing coir l i t ions
* Tl ,€ fu:-es ln : t L . , :
I Bai le, j " . l i r ! , rLr ! , i r . ; .1! . , ! . t , ; . l
. Al e lectr c carf sL mers, e ! . : I ghig ai ja j reat \4/ t )L lSarT,ren re:rer I nustbe swrtched ofi
. Vehicles Ji t ted wir f ai cofdi |c,r ng InLrst I i rve I orscofnecre. l
. Altern;tor C) f.
Checking process
Connect test box VA G 1598/3' l to control unrt wir ng harness, without connectng ihe eng ne contro uni i + page 24,36
_ 24"41_
Notes:a Positive voltage is supplietJ ta the engine control unit thraugh the
two contacts 3 and 121 (termina! 15) aTl contact 62 (terminal 30.a Negative ualtage is supplied to the errgine control unit thraugh the
contacts 1 and 2.
Measure the voltage with the mLrhimeter and the aux l iary cab es ofVA.G 1594 A or VA.G 1594 C as fo tows:
Test box VA.G1598/31, test box
socket
Measure to
1 Battery posrtrve
2 Battery pos trveEng ne groLJ nd
Specf catron: approx. batteryvoltage
- Switch on ignit on
_ 24-42 _
vAs 5051
rwnml
-rest box VA.G'i598/31, test box
121 ) ErEl l le groLrrd
r)After dscon,e.rr ,g t l ,e rg r i l ic ,n, the cLr nr, t :Lrpply reay for \4c 'lc ,n ic-J271'v.r lst i l l suppjy current to iefrn ns 121 of theengi fe
. , | . . , ,
Speci{rcalion: ap!ro). ba11e y v.'Ia!]e
Switch oi i lgnl i or.
l f the speci l icat ions are not attained:
- Check wring connect ions to relay plate according to current l lowdragram:
- Cuirent flow d agrams. ELectfical fault finding and fitt ng locations
Check the IVotronic J271 - c!rrent supply relay + page 28-9-
- 2443 -
Check intake air system for leaks (unmetered air)
Test with engine leak detector spray G 001 800 A1
Special tools, workshop systems, testers, measurin g instrumentsand auxiliary items required
a VAS 5051 Vehicle Diagnosls, Testing and Informatlon System
a Diagnosis cable VAS 5051/1 or VAS 5051/3
A,otes:a The vacuum in the intake system will ca use the leak detectot spray
to be dnwn in with the unmetercd air. The leak detector spray reduces the llammability of the mixture. This leads ta a drap tn engtnespeed and ta a change oI Lambda prabe readtng
a The safety precautions listed on the container must be adhered to.
- 2444-
: /
theeking pfouess
i ,o.neci t ieVAs.| . r i1 ' . l ]L] l - : i | . l j ' , ] : i : ' l l : : i : : iSystetr as f,:, lrrr^",s:
- Open the ao' , ,et ol t 'e dragia,sis c{, rneqlar
nect lon.
Start engine and 1n at d ng speect.
Select operat ng nrode:
- P ess bLrt ton on t l e VAS 5051 display for "Veh c e se f-c l iagnosrs, ' .
Select veh cle system:
- Bref ly press seect ion 01 , Engine electronrc system, on the
The control un t ident i f icat on and coding are nd cated on the d splay
Brief y press the key >
- 2445 _
I _ _J-,1 _-> _,,:- I \-t . - I I tT- l
l1 l i r l lFr l
l- ': --:- l l t_!. _: : : l l I
i--q il/e l i l i
T iRA
Select d agnost ic funct ion
lnd cated on VAS 5051
- Brief ly press on the screen '1- the d agnosis ' funct on "08 - Readmeasured value block".
ftu tl
Indicated on VAS 50511 - Enter value group nLrmber
Maximum value = 255
- Enter on keyboard -2- "001 fortheconfirm by pressing br ef y key O.
"va ue group number 001 and
J-54ffi-
<|. ] ]**
TAj i@ I
_ 24-46 _
f l i' ' ' 'La-- i t ! l
ti!ff I
fei@l
l-wro-om3l
crfaied !.n \'1.:, : r,:
i1. .m!r : . . i . . . - : , : : i . , . :ed ai :r [ . i . /E4 . T: i i ]
:y: ienrat i r :aly: ip ay r ; f is.1i . i ' - .a la sj 'ster ' | ' . rxt en:!r fa eal i . la-
f the eng |le spee.l deLr-Ea!ie::
- C €jal . sp ayeal3 e!: : c i l r tal :e syslein la ia: f ! rna recT f , / f necess
- Erdfurct ion "0S Reed measured va Lre blD. l i i : r ressing br ief lythe
lndlcated on VAS 5051
- Br ief ypressonselect ion- l - thediagnossfunct ion "06 End oLr{-puI
- Swltch off ignlt on.
Engine speed sender -G28-:checking
Note:The engine speed sender -G2e. is a speedand reference mark sendet. ]f there is no sig-nal f rom -G28-, the engine will nat staft . lf thespeed signal fails when the engine is run-ning, the engine stalls.
Fitting location -
page 247, iren 20
Special tools. workshop systems, testers,measuring instruments and auxillaryitems required
a Hand mult imeter VA.G 1526A or mut-rneter VA G 1715
a Auxll iary measuring sei VA.G 15944 0r1594C
a Test box VA.G 1598/31
a Current f low dragrams
- 24-47 -
- 24-44 -
Cirecliing process
Seicr. d e. f l r . . . : l - , , i r .e ' , . . ,
Dgconnectt f . .gre, , : [ , :a, i ] . : , l t r i . . : . , , ; i r . : in i i . , ! : r ! l r -esl ,eaajs i r r : i€ l
- Measure the resistance between conlacis 2+3 of cornector to
Specif cat on: 730 . . . 1000 g)
The resistance value of the engine speed sender refers to a tempera-tute af 20 "C. The resistance ises when the temperature increases.
- 24-45 _
l f the specif ica|on is not obtainedl
- Replace eng ne speed sender,G2S-.
l f the specrf icat ion is obta ned:
- Adjust the mult meter to measure resistance and connect betweencontacts 2 and 1 (screening), as wel as between contacts 3 and 1lscreen ng).
Specif icat ion: 6 Q (no cont lnui ty l
l f the specif cat ion s not obta ned:
- Rep ace engine speed sender -G28 .
f the specif icat ion is obtained:
- ConnecttestboxVAGlS9S/31 tocontrolunitwirngharness,with-out connectrng t i re engrne control un t + page 24,36.
1
-,*t
_ 24_50 _
i a.- r , i , r ! l ! ! r : ! l ( : i L,o : '
i t . , . :e. i . i r i i ! : : . i ' ' j r l r : i l :
3-pin connector'contact
Test box !:AG1598/31, test box
I (screenrng) 103
2 (eari i , ) 90
3 (srqn3l) a2
Wire -eslstancer r la) i 1 5l)
- Addlt ional ly clreck wires for short to one anolre '
l f no wrnng tault ls detected:
Fenew engine control unl t :+ VAS 5051; Vehlcle sel f i ragnosrs
- 24-5'l -
lniectors: checking
Soecial tools, workshop sYstems, tes_ters'measuring instruments and auxll larvitems requirecl
a Hand mult imeter VA.G 15264 or mult i_meter VA.G 1715
I Diode test lamp VA G 15278
a aL ia , r reag- ng 5 ' - VA o 'b944 o
1594C
a Test box VA G 1598/31
a Current f low dlagrams
f cr4-@l24-52
Vlamang!
The tuel sysiefit is rrnder prcss.tle Eef&re .I'.iriig1 il.r sfrieritlace a cloth around the cantiection. Then releese pre:,st,t: byca rcfully Iooseu;hg tlie confl ecl;o n.
Checking resistance of iniectors
Remove the c.rnnectc,r florn iiie njeatof to be lested.
r- . .1 rF< a = _l ,1tr . - . L. . .
<.6. i f . r r^. r t l t a, 1:r , r ,^ .n lon nar l r_ - ' r l_ej
Resistance value is valid for 20"C apptox. ln the case of htgher tem-peratures the resistance value increases
lf the specifrcation is not obtained:
Renew defect ve injector
'I
:
i '
]TI
l
l
I
- 2+53 -
l+ rha .na. ' f i . , r ^ .
< ^hlr
non
- check vo tage supply.
Checking voltage supply
Check conditions:
. Fuse 32 for injectors OK
. Fuel pump relay'J17- OK
Bemove connectors irom a I Injectors.
Connect diode test lampVA.G 1527 B to the i i jector connecto'asfol lows:
Connector, contact Measure to
Engine ground
' Opefate the starter and check the vol tage supply for the lnlector
The LFD mlst lght-up
_ 24-54 -
V.A.G 1527 B
l i i l , ; - !Et , d ie: nor ! r , L l
S! \ , ic l : . , f : rg i l t l .
' r ' " .1 '
I ' t r - : " _
-
-
'
Io ) ; '
Vvire fesistance: n]a, 1,5 ! ,
LED l i ,u r ts uP:
- Checl:act ivaton oi in lectc 'rs
Checking activation
Check conditions:
. ln jector resistance OK
Checking Process
- Pullthe rubber sleeves back' separating them f rom the injectol con'
nectors, but leaving the connectors on
- 24-55 -
T527 B to contacts of the nlectorConnect diode test lamp VA.Gconnector being checked
Note;
Llse test PrabesUA G 1591AorUA G
- Briefly operate the starter motor ionand check activatron ol Inleclor'
The LED must flicker
Note:
:i;,;i:',":: :::,:;', # :2,i,:n:';' :,:; ::;i: :';';,i: :::, ",;:;i',:,::'si'n,ng weol tv. ii(tearng rtei' 'nte"s't\
&hFn acttvaled
15g4 C if the vehicle has sealed
dorng so the engine may start)
- 24-56 -
: L;Lr al , ra,a, . i : .
: i iL r . i i i : . i : , . , . l l - : t ! ! | j , :.r!ri a:on )ecilra_r rli-: a
-at r_r .o :rr:,r . ,
- ,..1a.'::) ::,::
C\e-( ihe w r i_9 oeiwe^r te) l bo, and 2-o,n conneLtor.tors, usrng current f ow diaqram
- 24-57 _
ol njec-
Wire resistancer max 1,5 Q
Addit iona ly check wifes for shoft to one another
l f there is no faul l in the w lng and the reststance measuremenl valuesare oK.:
- Renew engine control Lrntt :
- VAS 5051; Vehic e sel f diagnosis
cvl. IniectoJ connector,contad
Test box VA.c1598/31, test box
socket2 96
2 2 89
3 2 974 88
- 24_54 _
-- ___ _- -- ] -l:riectors: cil e(:k-;nE tlie ir'-lectors for leaks ar*damcrunt iniected
Special tools, worl(shop systems' testers,nTeasurinq instrr .rnrents and auxi l ia i 'yitems require.l
t Fiernote cor lr i VA G 13'13/3A
. VA G l ;4i i l :2 AJal, ie cahle
aL. ' r , -6 i , . r ' : A ' C9l^ r '
1591i C
I Test box VA.G 1598/31
a.AClo0. e.e L.F,ng nra. . io-f lowthrough.
- 24-59 -
Checking conditions:
. The fuel pressure must be in order, check ng + page 24€5
Checking process
Rernovethefuelrai lcomp etewith the lnjeclors from the nlet mani
fold. The {uel hoses stay connected
- Connect test box VA G 1598,€1 to controlunitwir ing harness wrtn
oLrt connect ng the englne controL !ni i + page 24_36
Checking for leaks
- Bridge the contacts 1 + 65 of the test box wth the a d of the VA G
15944 or 1594C cab es.
- Remove connectors i rom al l Inlectofs.
- Sw tch on rgnLton.
- 24-60 -
va.G.t348/3A r4r-@l
) , f !e, ! ! \1.r !atrnal ? l l i i r - . i , , i , r i r , ; . i t ra l r : : : : \ t l i i . . r , iL, / r r r . . , - r .. . ! . / . . . . - .
. , lvclrcge ra'rn that j]na.iii,Lt bL-'.. The rFllaiiv" conies frctnt the cel:,tebidge n)ade in the Esi bo.
Check ngtfe rqectorslor eaks lv isLral iv) V\ i i t r f !e olrnrF{unct or -ing, only 1 or 2 drops lper nJector) shol l d c. ,r .n" o, , i i , l Jnu;; i ;
l f ihe iue ioss s l t feaier:
- S," /_ o".gn'onr orang^ t .16 e.1 .o. , ,1. . .
Always renew A-nngs as a rule.
- 24-61_
Check iniection rate
P ace the injectorto be checked in a measuring containerfrom VA.G1602.
Connec a conlaci fror t\e in,ecrql pslnt a.a", ed -o eno ne earLnsi- lg a . \ . .ao.c -ro-1VA G l59ror v. lC r !S; i
"" "
- connect.the second contact o{ rniector to batefv oosttive usino anaux.-cable to remote controlVA.G 1348/34 wnn'il" .Oipt* liOf"vA.G 1348/3-2.
- Bridge the contacts 1 + 65 oi the test box wth the ard ot the VA.c1594 A or 1594 C cables.
- Swilch on ignit ion.
Afiel sA;rching on the igntr.iah. the t,ret ou-nD wt. aa Aott no ao.lfiuous\ despt,le lhe englne taetrq stattona-r tot he,aIav,,ig reason.4l?: s:\!;ia.tng
?n lne pn'tton he [,ei p!-tD , eta|e( et@; pos,tive
\a. Iaoe t-om r le 11r(uan aa.. I ,e ^-ga-. \ . an.s f 'om tne cdatebridge made n the test bax.
- ,4-62 _
. a)pEraiE . , ote. , t i l t roL v!a i : r_ i l / i ! . i r r : r r ' i i : l i l -
n; i r ia l i . - : i vv l t I t l eol ierrr j : . i io: . r '€rr : \ \ ' ln! . : I i , j r ' , r . r r - : i r
- Ai ter having st i rnu ated al l t l re inlect.r ls, FLace t l re fv? nreasuf l igconta rrers aTr a f la i su$aia a) i . t lza i f : : r ' roLrr ts of {L le l i r_
lected.
Spe(i f icat lof , per i r j ; . io l : 179 j . 1. l l 11!.
] f the value of any of lhe inleclors is oL. l ts ide i l re speclf icat ions, stop thefuel pump (switch off igni t ion) and renew t l re faul ty i rr jector
l f the measured values of al l the lnjectors do not correspond with thespecification, check the pressure of the fuel system + page 24-65
On checking the fuel iniected, it is also necessary to check the spraypattern. The jet should be the same for all the iniectars
- 24-63 -
Fit the injectors and the fue fa I, taking inlo accounl the fol lowing:
I Beplace the O-rings ot any jolnt opened {to replace the front O-ringdo notremovethe plastic cap on the Injectorhead underany clrcum-stance, place the O-ring over the cap)
a The O-rings should be l ightly coaled with clean engrne oi l .
a Replace O-rings.
a Insert injectors vertically and in the correct position into the fuel railand immobilse wlth the cl lps.
a Fit fuel rai l with secured injectors onto intake manfold evenly
- 24-64 -
t* - -
l l e
. vA G 1318/9
a Bemote contro VA.G t34B/3A
i:it=
.l-rta.'l
i@))i
Check t [ re pres:u.€ iL, iLre iL l* tsupply system ancl the ['.,!.l ingpressur e
Special tools, \,vorkshoF systems, testers.measuring instruments and auxil iarvitems required
a Adaptof ca:Jle SAT 1348i.j 3
t VA.G 1313 Pressure aaUge
I VA.G 1318/l Adapre
a VA G 1318/l l Adapter
t VA.G 1318/17 Adaprer
a VA G 1318/23 Adapter
_ 24_65 _
i le i t - rc
vA.G 1318/9
t'*a
{}{l:ro ep
va.G 1313/23
fq-*;l
- 24-66 _
I 'L i - . ] , . r 'a i i . [ i ] .s :o. TlL ' r r ! ; : : r r : i f i i r i : :L j : '
l
r : i i r i : ! r i i : . lL: i l | . : r i - i . ,
CliecLirrg cai'.1;iiilt:
. Fu-. i plrnp relay ' l l7 [ . r l
. Fuel PUnrP Ol l
. f uel f i ier a l .
. Min. battery voiage I2 7 V
- 24-67 -
Checking Process
- Open the fuel tank cap br ief ly to feduce the pressure'
' Femove fuel supply pipe I - , press buttons on f !el hose coupl ings
to do this
- Connect pressure gauge VA G I3l I with adapter T318/9 and VA G
1318/17 to the fuel suPP]Y P Pe
- Open shut-off tap on pressure gauge The hand e points in drrect lon
ol flow
' Slart the engine and run at idhng speed
- 24-68 -
. r i_.r i i ._r i _ . i : t ' l : ,
FLl l t l eva.u! .n i rar !e i - ._, t i i rF rr€a5Lrr ! r ! . t l : i , I J [ . i t ] : r r i :s ! re sfr .Lr t ( :1 t r cra, i : !
Speci f cat to l :ptr . . . 3 L: t f
Sh| | t of f engi fe
l i i re spea i iGt or : I 01 c l j t i l ed:
- Switch oft rgn tion
- Check quantity supptied by fue pump: page 20 36.
i the specif icat ons are obtained:
Swrtch olf gnrt on
Observe pressur-o drop on gauge After 10 minutes the pressLrremust not drop below 2 bar.
l f the pressufe drops below 2 bar:
_ 24_69 _
{ - 5r ; r l rho. .o .and.u.a1 rdt , .gcpeedun, apressu-aot dppto, .J Oa- ra oee.t ar. ,o. oo 6nono a.d.ose off ]1e cJ__o- laol tever at r ght angle to direct ion of f ow arrow ).
- Observe pfesslr-o drop on gauge. After lO minutes the pressuremust not drop below 2 bar.
l f the pressure does not drop:
- Check fuel pump non-return valve -
page 24 7.1.
f the pressure drops aga n:
- Open pressure gauge VA.G t31g shur-off tap (handie in cl irect on ofr owl.
- Start the engine and run at dlng speed.
- Swtch gnrt ion off after the pressure has buij t up. A1 the same t mecramp ofi trre return hose (with blue mark ng).
v.A.G 1318
vA.G 1318/9
ii"t -:A.G 1318/17
' -7',-t-\ i I ur6e3
_ 24-70 _
. . .
: : =. ] . : : ' : . r . : . ] ] . l : ]
' . , , ". . - , - . . . ' . , , .1 :
al,e. l : plpe L. rre. iL.) s, , , , rL !r : . rr f i re d st Lr i i , r . ' r ! l , j . i . , r ! i . i l
Cfecl t l re piess, e 96Lrge VA.G 1' j l8 ar,d acj . i j to s are I efneir . t ly
Eefote rem..ving the pressLu e gaLtg-a, Ieduat..'tte pressLt!e b\/ apentngthe cutafi tap Ot i dotDg 5a, plsce a cantaiilel whetc the pipes v','tll he
Checking fuel pump non-return valve
Remove cover l rom fLrse ho der.
Remove fuse no 28 from the Juse ho der
vA.G 13181318n 11314t23
vA.G 1318n7
Connect remole control VA.G 1348/3A with adapter SAT 1348/3-3to contact 28a to fuel pump and battery posi l ive terminal (+)
Attention!Fuel supply pipes are under Pressure Beforc removing fuelhose connectionswtap a cloth arcundtheconnection. Then re-Iease pressure by carefully pu ing fuel hose from connection,
_ 24-71-
connect pressure gauge vA.G 1318 with adapter v.A.G 1318/17 lo -f{rel s upp y prpe.
sAT 1348/ts-3
- 24-72 -
131e/11131a123
A,GA.G Frlaclart , r \ '1! , . | l i : , a, / : t . r r l \ ,11,a : r . ] r / : l i , i Et , j . : : : , r - ! : . r :
d,r t ra- , i t - . .
Close pr essLrfe crat gE a | l r { , i i ia[r l lever at ra] ! , i : r ' ,c te ia : l t ; I r , r , . ,1flow -B-).
Operate re i l tea,: ,ni l . , l : t s r , , r1i I iervalsfnl 3 a, ? : s L I 9 . i : l tF i h : sDLl l l Up.
Attention!Danger of spray when opening the shut-off tap. hold containerovet the prcssure gauge free connection
li pressure bLr ds up too h gh, lower excess pressure by carefullyopening the shut off tap.
- Observe pressure drop on gauge. After 10 minutes the pressuremust not drop below 2.5 bar.
- 24-73 _
vA.G I3t8/t7vA.G 131e/1
f M,orct
lf the pressure drops further:
- Check p pe connections for leaks.
i no leaks are found:
- Replace fue delivery unit + page 20-18.
[ .
_ 24_74 _
Exhaust svst€t]1 c(!n I po! lei!t::: |+i '11ir'r i l ' t !; srlLi
iftstat!inE
a X/wrr)s ,a/r i i .e q:r : r ' . is n,r ! : 'err /ur ' r r r : r " '_
a , lncr\ .J _ . ' " t ' )r , de,5r ' .; " . . r - . r , . . ao ! ' t ( atct ' tc . ' .
t J
o.h1 ,<t t !e at ; j t d la l reot\1 '
!4/art 6rd the -slrppori:r Et-' evenlj' l'l3tled
I l\lote ltte assenlbl'y' posillirns an1 d,rren-sioDs of th_a exhaLrst s]'5'
t The anicLlete.l se ctk,n it t the t'ran1 e'.hau 3i pipe should not f)e bent
nore than 1(F or it caLld be danleged
I lf, after assemblingthe exhaustsystem, harsh noises can beheard'
adjust the engine btackets
26-r -
1-25Nm
2 ' Front exhaust PiPea Wrth articulated sectiona Do not bend the artlculated sectlon
more than 1O', otherwise i t could Idamaged
a Protect aqainst lmPact or knocKsr Disrnant lrng andf i t t ing + page 26 "
a Fi t and adjust the exhaust syste Iwlthout subieclng d 10 sttess =page 26-26
3 -40 Nm
4 - Lambda probe before catalytic c( _
verter -G39-
a Checking:
- VAS 5051 | Vehlc e sel f 'd iagnosrs
I Grease thread only wlth "G5" "G'"
must noi get ln lo the slots on tne
Probe bodyI Remove and instal lwith U'40080-1 Lf the sealng r ing s leakrng, nLpopen
and replace' the o r ing
. tE
11
12
14
-zg \zz 20
26-2 -
9 10.4
t - - 'vrt1tll-! v'
5
"12
13
14
20
tEr6 oonl
to-_ lE
5 - Gasket
6 - Brackett Secured to the subJrar iE cio. l
men'rber -
Frg. 2
7 '25 Nm
I -Suspension elementa Renew i f damaged
I - Gasket
10-10Nm
11 -Heatshield
l2-Lambda probe after catalytic corverter -G130-a 50 Nrna Check ng:
- VAS 5051 ; Vehic e se f-diagnosis
a Grease thread only w th "G5". "G5.r .st 01 ger i_ro - i . sorc o- Ic;probe body
a Remove and insta lwtth U40080a l f the sed ng r . q rs l^a. r - g 4pope
ano feprace rne o-r ng
13 - Double catalytic convertero Belor. ' r r 'q. Insral upper reo
26-3 -
11
12
'13
14
20
26-4 -
Id
1
10
{N
7AI
/"-11
't3
14
20
IF,A n
'16,-15r
14.Bol t
15-25Nm
16-40Nm
17 - Suspension elementt Note f i tng post ion + i g. 5i Ft and adlust fear si lencer withoLrr
sublect ing i t to stress : Fig 3
18 - Front silenceri As standard, the front and rear s
encers are a stngie component.When repair ng, the front and rear sr-encers are supp ed indiv dual lywtha doube clamp for connect lng together Cut the exhaust pipe perpen-diculafy at the nd cated pornt wthtoo U'40075 + Fig. 4
26,5 _
19 - Suspension elementa Renew f damaged
20 - Rear si lencera As standard, the iront and rear si
lenceTs aTe a single component.When repair ng, the front and rear si-lencers are supp ed indivldually wrtha doube clamp for connecting to-gether Cut the exhaust p pe perpen-d cu ary at the indrcaled po nt wthtoo U-40075
- F g. 4
21 - Suspension elementa Renew if damaged
22-25 Nm
23-25Nm
24 - Tunnel bridge
11
13
141
[1e1t -
&W.U, tLr.
11,-9-,,9 -10
20
t F,a-anti-l
26-6 -
Fig. 1 Fitting position of doubte ctamp
a The bolted jornl faces forward
Fig. 2 Front exhaust pipe bracket1 - Suspension element2 25 Nm3 -25 Nm4 - Bracket5 - Front exhaust pipe
26-7 -
Fig. 3 Install and adiust rear silencer without subiecting tost.ess
_ The.nounl lg p1<.o. avaust p,oe ̂r .s l r ,n pa-ate, wrrr Lun-elO
'Oge {O m61s on X-thosarreon e{Ta-o.ghi . .
Fig. 4 Cutting point on exhaust pipe
Cr e",ausr oioe at 9. t d-gles al reoarar no po nt d> trdtcdted o/rne €rrow 2 use ptters 4_40075
' O, '1Tr-glr .do. loeclarplo,epa s, t r rLr . tbecolecr,yposi l |o leo{-o6'wee. l te ctde n-ar l ngs .a, ,o,1/. . a. o 3 - ghr.-edlo 40 \_
3--QIJ2A
E
Fig. 5 lnstallation position of suspension element
- Angled side on foot of suspension element irrow- poinls forwards.
Exhaust manifold: removing and installing
Romoval
- Dismantling the turbocompressor + page 21_2.
- Bemove all exhaust manifold nuts -1-.
- R€move the $€shers and the exhau$ manifold.
Ingt6llation
Note:Always replace gaskets and self-loc*ing nuts.
- Tighten the exhaust manifold nuts to 25 Nm
Continue assembly in reverse ord€r of the dismantling procedure
26-9 -
- 26-10 -
@6+:_,"-"..,,*
fiftdl]}:E ..*
ar0i+.ii
t Lr6 oooel
Front exhaust pipe: removingand installing
Specialtools. workshop systems, testers.measunng rnstruments and auxiliarvitems required
I Hydraulc column lack SAT 1040
a TorqLre spanners SAT e01O
a Base T20145
a Holdlng too T20161
_ 26_11 _
Dismantl ing
a All cabie ties .which are apened or cut apen when removing engine,fi)ust be replaced in the same pasitt()n when re_installingl '
a ln vehicles whh coded radia/ caded radia and navigation system(RNS), take note af the code, if necessary, find it.
- With igni t ion sw tched off disconnect batery eann $rap.
Separate 4-pin connector from the Larnbda probe and leave thecable v sible.
Unbolt the front r ight,hand whee
Remove central insulat ion -aTrows-.
_ 26-12 _
2)
rf
Fer ove r ! l [ ]_ar i , _:rrai 'ar _: i r rous
< Remore le1-5" d ' .a o ." on'
F fst unbolt bois -A- and then
Remove pendulum supporl
_ 26-13 -
-3- ol the pendulum support
- Bemove the bolts -2- securlng the PAS box to the unit subJrame
- Release the PAS box lrom the unrl sub frame, lever ng with a screw_driver.
- P ace a hydrau ic co umn lack SAT 1040 with base T20145 and hc dlng tool T20161 under the unit sub-frarne.
- Rernove screws 1 3nd -3- lrorn the Llnl sub-lrame.
N,r\.a-:)
\".
- 26-14 -
., '':-,;!1L1=-- 'i-- i
"1 . , . a.ouo. c. , .rronl e\ r taLrst pipe
Secure the steering bo\ to the vehtc e conver er i y.
Unbo t the proieci ve cover 2_, arrows.
Di. .o-nor I In6 a.rboo o,ooo .o-. error
ilTilr5j;:: " catatytic converrer trom the front exhaust pipe
Unbol ' l_6doLo. (d_at.r . , LonJe. la- ^
le ia l ,o n, 11e I .onr s. len.elr lcageelb 5. oos. l l a d l6 , o,6f- t tv r6no..1,1. do ,b ic, atal \ ,atc
Unbolt the f ronl exhaust pipe from the turbocompressor out let .
--- 26_15 -_
a The upper front e\haust ptpe securno bal
,"; ;i ; ",i ;, ; " ;: :i illl l ij i : ! i ! :, :, : f ! :\ ::i 2: : f , 1, i| 1"2
' '::,3'.i;::;"; zi";::iio,l3,Jl1:;;;*' ,,0" shou'd not be bent
a lf there is not enaugh roam to remove t
- ";" ;;,. ; "; ;;; ;: ; ;;"; ::,;z ;:; ::f" #:,:?x:"il€ i,:"i,"if; {f "-
D rnr- g g.Aa. o,€s. 5r .e. -9, I .onl whee ano to.r . ^neet
dJ,e, De_
fl'n 3;:'-1"'f **-*'
,t,1i,1,';^u '' n '"""' ,"" 'e ass'sieoiiee,. oe-o\eine-o te,-d-st p,pe\ r- .are
: i
I
' l=t
jJ- 2-
lnstal lat ion
Ai,,",'ays replace gasl:ets and se t''l..king n|tr
Before replac ng the subJrame bol ls, place the PAS box on the sub'J o-ne and hon4 tr F o _. 2 e.U, g . 'e FAS bo o 6 ' ' ,b
a Thethreadedbush-1 should be fixed tn the arifice of the suEftame
a The tubber stap an the atherside should be seated in its cavil tn the
a lf it was necessary to remave bolt-1 securing ihe steering calumnto the PAS bax with the univercal jaint sacket to rcmave the frcntexhaust pipe, renevr the boit and ttghten b 3A Nm.
+ Runnjnggear, axles, steering fronl wheel and four whee dr ive;Repairgroup4S; Power ass sted steering: repair ;Powerassisted steeFing box: removing and nsta Ing
F t the subJrame as descr bed be ow:
- 26-17 -
Ft the slbframe to the assemby posit ion and tqhten by hand(using new bo ts).
Tjghten boLts -2- of lhe PAS box to 25 Nm.
Tighten subjrame bo ts -3- 10 100 Nm - rL lLrrn 190'1.
'gnre bo . -o 100 \ ' + z r- ' - 91'
L=
- 26-18 -
- T ghten nevvp€ncl! lurr s!pport bol ts -a.rows 8- to.1O Nm + rL turn(901.
Cont nue
Notes:a lf the battery B reconnected check the vehicle equipment (radrc /
radio and navtgatian system, clock, power winclaws), fallowng:
- lnstructlon lvlanual
a other measures aftet rccannecting the valtage supply + page2439.
asSemDry rn revefse order of the dismantl ing procedure
Exhaust gas temperature sender -G235-: remov-ing and installing
Special tools, workshop systems. testers, measuring instrumentsand auxiliary items required
a TorqLre spanners SAT 8010
Dismantling
a Allcable tleswhich ate opened or cut open when removing engine,must be replaced in the same pasition when re installing.
a ln vehicles with caded rcdto/ coded radio and navigatian system(RNS), take note of the code, if necessary, find it.
a The sender and the turbacomprcssar cannection tube is a single
- Wt' gnrio- srvrlched oH d:sconaoci bater) ea-lF sUap.
_ 26-19 _
sAT 8010
,tmmm:.-E
irTn]]]]]:flE ,,,-",
-w2dt
- 26f20 -
sernove cenlral nsu atcn ar lovts
for the exhaust gas ternpeiai !re sender -G235_
- 26-21--
Remove the boLts arrows- and remove the covel -1
Remove the connectorsender G235 .
-arrow- of the exhaust gas tempetaruf€
- 26-22-
Pulr coolant hose I o11 tie bracli-.r -4
Benrove the bol ls 2-and-3 and remove bralel x
Femove bolts €rrows- of the exhaust gas temperaiufe sender -1-G235- from the inlet manifo d and rem;ve rne senoer.
_ 26-23 _
Installation
nstal rn reverse order of the dismantl ing procedure
Notes:a If the battery is reconnected check the vehrcte equipment (radio /
radio and navtgation system, clock, pawer wjndows), fo owing:+ InstTuctron ManualI Othet measures after reconnecting the voltage supply + page
2439.
- 26,-24 _
r;6@n
Exhaust system: checking for leaks
Sta.t engine and run at rd Ing speecl
- SeaLtheendiubeswhi lecheckingfor leaks(e'g with cloths or caps) '
Check lor leaks by l istening at loints cyl inderhead/exhaustmanifoldgaskeVturbocompressor/catalytic converter/sllencers-
FepaLr anY leaks fo!nd.
- 26-25 -
Exhaust system: lnstall and adiust without sub-
iecting to stress
Vehicles with a double clamp between thefrontand reatsilencers
. Notetheassemblyposil lons and dirnensionsof theexhaustsystem -
. The exhaust system shouid be cold when adlusted
- Release the bolts of thedoubleclamp+page26-1'Fig l
Droo ot ,9 a:5 I I nr .
a Fl t ng posl t ion of double c lamp + page 26-7' Flg l
- Trghten the double clamp bolts unformly to 40 Nm
- 26-26 -
I
:_
:
Cettre the end exhaust pipes
as -a- on the right.
- At the same ttme make sure distance -b- of the bumper cu o tre. enct ptpes ts attained.
a Distance b= 35 mm
- lt may be necessary to loosen the susponsion points oJ the rear si-lencer lo centre the end pipes.
- 26"27 -
lgnition system: repairing
General information: ignition system
i The engine control unit is equipped with self i iagnosis.
a D'sconnecling aro connect.ng rqe batlFry'nJ51 only oe oone wrrhthe ignition swltched off, olherwise the engine controL un it cou ld beoa'nageo
a Fortroublejree operation ofthe electricalcomponents a voltage ofat least 12.7 V is necessary.
a During some checks it is possiblethatthe controlunitwil lrecogn se -and store a fau t. Therefore after completrng all checks and repairsthe fault memory must be interrogated and if necessary erased. lfthe fault memory is erased, it wrll be necessary to generate the _readiness code. lnterrogate fault memory + 24-28.
2A-1-
a l f the engine starts, runs fora shon period andthen stops, afterfaultfinding, repalrs or component tests, then the fault may lie with theimmobiliserwh ch is blockingthe engine control u. it. The fa u lt rnem- -ory must be inteffogated and if necessary the conlrol unit adapted.
Safety precautions + page 28€
Test data, spark plugs + page 28-8
2A-2-
12
11
10
glt
fErs-oors I
lgnition system components:removing and installing
1 - Connectora Black,4 pin
2 -lgnit ion coil with output staoe _N_,-N128-, -N158, and -N163_r Checking + page 2g-2S
3 -Spa* pluga30NmI Rerfove and rnstal l wth soanner
1200?aa Type and e ectrode gap + page 2B_g
4 - Connectora Contacts go d plateda For knock sensor i c6i- and knock
sensor 2 -c66-
28_3 _
5 -20 Nma Tlghtening torque inf luences the
Tunctron of the knock sensor
6 - Knock sensor 1 -G61-a Sensor and connector coftacts are
go d-plateda Checking + page 28-34
7 - Knock sensor 2 -G66-a sensor and connector contacts are
gold-ptateda Checking + page 28-34
8 - Connectora Black, 3,p n
9-10Nm
10 - Hall sender -c40-O Checking + page 28 t8
rs-- €1a-/ , : : j
' t l
10
a
| , -JCar'
F
+* g-,+^
\<=]- 6
IJ
s __,_--{
244 _
615 -'---r!
((.E::::]::4
14----- '/
_-t
T7
w
12
11I
1,-
w
t Er8-oors l
'11 - 25 Nm
12 - Washera cone shape
13 - RotorI For Hal sender -G,10-a When nstal|ng note f x ng arrange-
14 - Earth cable
15-10Nma Tghten or oosen onlywhen the gn-
tion is off
2a-5 -
Safety precautions
ro pre,/e_i r_lL e5 0 pa'sons dnd or oan oge to L'e in.ecfon ano rgn - '
t ion system, the folowing must be observed:
a Do not touch or disconnect ignit ion wiring when the engine rs run- -ning or being turned at starter speed.
a The ignition must be switched ofi beiore connecting or dLsconnect-ing ign t lon system cables, incLLrding hlgh voltage cables or tester -cables.
a l f the engrne is io be turned at startet speed, w thout stal! ng' eg:for compression pressure testing, the ignit lon coiland injector con- -nectors must be removed.
Test data, spark plugs
r)Remove and replace the spark plugs with toolT2OO2B2)Up-toiate figures:
+ Pans Catalog!e
i t Dur ng some checks rt is possiblethatthe controlunltwLlrecogniseand store a fault. Therefofe after completing all checks and repairsthe Jault memory must be intefrogated and if necessary efased. lfthe fault memory is erased, it will be necessary to generate thereadlness code. Interrogate fault memory + page 24-28.
a Only wash the engine wrth the ignition of{.
2A-7 -
Edgine codg AMK
Firing order 't i4-2
SPark Plugsl)2)
Manufacturer's designation
101 000 063 AA
NGK PFR 60
Electrode 9ap ma^.0.8 mm
Tightening torque 30 Nm
2A-A -
"""'ffi'i-q*?e/ rs ; ,//--jr=S/
fw-ri offil
Voltage supply relaY to controlunit -J271-: checking
SDecial lools, workshop systems,tester9,measuring instn ments and auxi l iaryitems required
a -ond
r u rn. .e vA ! lc lo^ or ' \ -meter VA G 1715
a A., ' tor l - ra! .U, o 5o. /A.- qglA o
1594C
a Test box VA.G 1598/31
a Current f low d agrams
fhe.L,terr supP\ .ela\ fo' s\ 'Lem J2 IsuDDh-s ct qenl ro lhe o npuL <tdges o1 l '
'gn, ia! . ats. as v 'a l t dt t t ' c 'otrc car ' ! ' l
unit throuqh contact 121
28-9 -
checking process
- Disassembling the engine cover arrows-
- 2a-10 -
T@l
T€-@l
- Switch on igni t ion.
Specif icat ion: approx. baftery vol tage
lf the specif icaton is not obtained:
- Switch oi f gn t ion.
- Se parate the vol tage supply relay€rrow-underthecover, on the lef tof the dashboard.
Note:
To remove the protective covet in vehicles with ctoss member be-tween the suspension tunets, release the relay holderfram thedash-board and move downwards. Also disconnectthe atr mass meter con-
Check the connection between contacl 2 of the relay hoLder andcontact 1 of the ignit ion coil :
+ Current f low diagrams. Electr ical fault f ind ng and f i t t ing locations
lf the wiring is OK:
- TestvoLtage supplyfor Motronic'J271-currentsupply relay -
page2A-9.
- Testactivat on of Motron c-J27T -current supply relay+ page 28 15.
MeasLrre the vol tage w th lhe nru i i f f ieter and the auri aryc:bles ofVA G 1594 A or VA G 1594 C as folows:
Connector, contact Measue to
I Engine ground
- 2A-11-
- 2&12-
re4 o"* I
Checking vol tage suPPlY
- SwLich of'f gn r.'
- Separatethevo iage sLlppiy relay arrow Lrnderthecovef 'onthe el I
of the dashboard
Ta remave the pratective cover in vehicles wtth crass member be
tween the suspensron turres release the telay holder frcm the dasn
baard and mave downwatds Alsa discannecithe a1r nlass melercon
- Meas!re the vol tage w ththe mult imeter and the aux lLarycables of
VA.G 1594 A or VA.G 1594 C as lolows'
Retay plate under theleft-hand cover of thedashboard, contact
Measure to
Eng ne ground
3 Engine ground
Speclf icat ion: approx batery vol tage
- 2A'13 -
f the spec f ica|on s nol o[ i ta ned:
Car.y ou1the fol lowing checks:
Check fuse 37
s164 s163 5162
s133 s132 S131
- Check f l rse S134 (110Al nthema n battery iLrserrox
C' loct1a-r e^, . g.onre 1o,. , l -o L- 'oo -r le ' "1"-a o "e
odr6 , ._e - : 30 go ng In o-o1{ rse Sl34 and'- 'e J ' ro rne
l i i i "q", ,ppl " ' " . - - : - i , roei -o e! !c dco/6ro r-edacr-
board) s broken:
- Currenit to* Alagrams Electr icaL ' fau t f lnding and I t t ing lccai ions
- 28-14-
tesal
r;;e-l
VA.G 1594 A orVA.G 1594Casfolows:
Relay plate under theleft-ha.d cover of thedashboard, contact
Measure to
5 Battery positive
- 28-15 -
Checking activation
SwLtch ofi rgnit on
Separaie ihe vo tage sLrpply re ay -arro\ / underthe cover, on e 3. i ihand s de oi the dashboard
Note:
Ta renove the pratective cover in vehicles wtth ctass membet be-tween the suspensian turrets, release the relay holderfram the deshbaardand mavedawnwatds. Also dtsconnect the atr mass mercrcon
Sw tch on gnlt ion.
Spec f icatron approx. bai tery vol tage
lf lhe specrf cat ion rs not obtained:
Swnch oft ignit on.
- Connect test box \1A.G 1598/3' l tocontro unitwinngharness,wlth-out connect ng the engine contro Lrn t + page 24-36.
- Check the fo low ng w r ng connect ion for open clrcurt or shof i toearth or short to postve:
Relay plate under theleft-hand cover of thedashboard, contact
Test box VA.G1598/31, test box
socket
5 21
li.I_li-_r 1i
_ 28-16 -
V.AG 1527 B
@ry
l l neces::ry eirnir : r te the l i r rrr ' r ! . ipef . f . - : or shorl . ! rc! 1
f no faLr t is tound:
- Replace the Motron c J271 . !r :ent supp Y re a,\ '
Hall sender -G40-: checking
Lnsla lation position + page 24 9, ile.r, 28
Soecial tools, workshop sYstems, testers,measuring instruments and auxiliaryitems required
I Hand mult imeter VA.G 1526A oI mult -meterVA.G 1715
a Diode test lamp VA.G 15278
a ALr\ ha'\ meos- :no seL VA C '5914 o
I Tesl box VA.G 1598/31
i) Current f low dlagrams
- 2A-17 -
- 2A-14 -
VA.G 1527 B
Tlr€ Hal sender, G40- niof l Is of the gn t ion posinon of cy lnder 1
l i qeira s- ler stoo) ^o.r 'g
i , . lno. . EJUd.on .d, t ,eo,o'ne lg ' n. 'on \ '6 ld ded d I l . . aS t r , no or 96r oorsto e to. o t \ o rr L, eosrgraLro4olL\ . r ders. nFt_ boLo.no.e<soro. . r ( .a ongp e_), ,e
WithouttheHal sendertransm ssion, the engtne w icont nue to workand can be restarted
l i the faLr l t is. ident i f ied, the eng n€ control unrt w l l actrvate an gn t ionspark per cylnder for each turn oi the cranksnan
Checking conditions
. The fuses must be OK.
. Batlery voltage at least 12 7 V
. Hail sender screwed on tight
_ 28-19 _
Checking process
- Pul the rubber sleeves back, separating them fiom the Ha lsenderconnector, but eaving the term nals connected.
sender srgnal) and contact I (posit ive).
No'€:The contacts af the termnalare numbered on the back of the con-
- Operate the stafter for a few seconds.
The LED must f l icker
Note:
The voltage testers with a law cuftent absorption do nat extinguishCompletel, d)ting he aatt,/at'an ol Lne engine co"t,At unn. he; SG\Sntntng wpat tv. tnc eastng then tntensi-\
^he. a(\vdted
_ 28-20 _
, ' \
'--\i\-
l f rhe LED does not fLcler l
Checking voltage suPPlY
- Remove conneclor I- f rom the Hal sender
- Measure the vol lage with the mu t meter and the auxi iary cables of
VA.G 1594.A or VA G 1594 C as tol lows:
connector -1-, contact Measure to
T Engine ground
- Switch on igni t ion.
Speclficatlon: approx. 5 V
Cheek the signal cable
MeasLrre the vol tage with the mult imeter and the auxi l lary cables oi
VA G 1594 A or VA b 1594 L as folows:
Connector -1-. contact Measure to
2 Engine ground
- 2A-21-
- Switch on igni tron.
Specificatlon: approx. battery voltage
Check the earth cable
- Check the fol lowing wir ing connect lon for open or shoft c ircLr i ts:
Connedor -1-, contad Measure to
3 Engine ground
- lf necessary, ellminate the wiring open circuit or short circu t
l f a l the specif ical lons are ai tained and the LED does not f l icker
i-"u*tlng'bet*""n contacts 1 and 2 wLth the startermotoractivatedand the connectors connecteo):
- Replace Hal lsendef -G40-
f the speci{ ical ons are not aftalnedl
- 2A-22 -
Check theconnect ions between the Hal l sender and the enginecontrolunit
Connect tesl box \1A.G 1b98/31 tc,contro un twring harn--ss. wth_out connect ng the engrne convol un t -
page 24 36.
Connector, contact Test box V.A,G1598/31, test box
socket1{posit ive) 9B2 (s gnal) 863 (earth) 108
Wire resistance: max. 1,5 e
_ 2a-23 _
l faf tererasng-he'"- inen ofy.a.auf tsagt,r dsotayed-ed,eoro-.ecarsnan senso' ' ! . sendea even.ho.g. l^ . lo, .ner cheo s werecorrecl that tautt may be ihe {olowrnq
- The Hal l sender rotor is tw sted.
- Loosen the-Hal lsender and check i f the rotor is correct ly f i t ted tothecamshaft (if inco(ectly frtted, the ocking tab is crushed on tlghten_ng the secunng bolt) .
- ll the fotor posltlon s correct, check the co esponoence Deiweencrankshaft / carnshafl.
_ 28-24 _
Checking conditions
. The fuses must be OK
. Battery vol tEge at leasl 12 7 V
. Al electr icconsumers, e g : l ightsand rearwlndscreen heatermLrsl
be swltched ofi.
. Engine speed sender -G28- OK, checkinq + page 24 48
. Ha I sender -G40- OK, checking > page 28 T8
Checking Process
To determlne whrch cyl |ndef s mal iLrnct on ng or laul ty ' do as fol lows
- Check igni l on/comb!st ion faul ts recogn t on:> VAS 5051; VehLcle sel f-diagnosrs
f gn l lon/combust ion faul ts are detected:
- Cont in!e test ng the cylnder where the fa! l t has been detected'
lqnition coils with outputsiages -N-, -Nl28-, -N158- and-N163- checking
lgnition caits and thei respective autputstages ate one untt
Soecial tools, workshopsVstems, testers,measuring instnrments and auxi l iar!items required
a Hano --1 .r , 6-0r v/A ( lE26A or rnurmeter VA.G ' i715
a Drocle test lamp VA.G 15278
a Auxi lLary measuring set VA G 15944 or1594C
I Test box VA.G 1598/31
I Cufrent f low diagrams
- 2A-25 -
- 28-26 -
i t no gnit on/con bLrst;oi 13u ts are cietEciad
- Wrth theeng ne on, rerr tove the r jector cor r ectors one bv ane, ob_servrng the behav our ol the engine
or:
- Comparethe spark pl !gs of at lcyl inders and see t f the electrocles are
j{ the faul ty cyl inder has been dent i f ied:
- Exchangethespark plug ofthe fa! l ty cyl inderforthat ofanother cylnder
l f the fal l t goes with the spark plug:
- Replace the spark plug.
l l the faul t remains in the same cy nder:
- Exchange the coi l of the faul ty cyl inder for that of another cy inder.
l f the faut goes with the coi l :
- Renew the gn t ion coi l .
_ 2A-27 _
Check earth connections
Remove the 4-ptn connector l - f rom the igni t ion coi 2_ tochecked.
Connectot contact Measure to2 Baftery positive
Battery posit ivem
| *;*l
_ 2A-24 _
I\-1
The LED must rght {rP
l i {he LED does not lLgnt !P:
- Check voi tage suppLv + page 28-29
Checking voltage suPP|Y
- Measure the supply vol tage with the mult imetef and the auxLlrary
cables of VA.G 1594 between:
Connector, contact Measure to
1 Fngine grouncl
- Switch on lgnlt on
Specif icat ion: approx battery vol tage
lf lhe specif lcat ion ls obtarneol
Check igni t ion coi ls f inal output stage act ivat ion -
page 28-31
Carry oLrt the fol lowing checks:
- Checkthe connect ion between contact 2 ofthe relay holder and con-
tact 1 of the gn t lon coi l for open crrcuf:
- i r . "" i ;o" oaq an s. Frecrrcar _arJ 'Ltno' .9 a_d t l ing'ocaL'on'
Check the lv lotron c -J27T' current s lpp y relay + page 28-9'
- 2A-29 -
l { the specf lcat lon rs not obtarned:
Separatethevoltage supplyrelay arrow_ trnderthecover ' onthelef l -
hand side of the dashboaro
To remove the protective cover tn vehi,cles with crass member be'
,*-"n j t"
" , rronr ion,uftels rctease oe tetay'aoerf 'am lhedash'
'oi"ra uni
^o, " oo n^
", 6, 4t 5p 6t5l 6npscr tha ai naas fiate' ( on
- 2A-3D -
f tests are Ol: :
- Check rgnit ion cor lsfrna o|r ipui srage act ivat on = Lrage 2g : l
Check final output stage activation
- Pul l of f connectors from aI the inlectors.
On checking da nat inject fLtel so as nat ta damage the catalytic coftve.rter. For this reasan the connectars shoLld be-separated irom ihe
- Remove the 4pn connector l - i rom the rgnt ion coi l -2 to bechecked.
-- 28-31 --
f;dl
- Connect diode test larnpVA.G l b27 B to contacts 2 and 3 of the con_nector.
Brief y operale starter The LED mLrst I icker
The LED does not f[cker:
' Check voltage supply -
page 2g 29
our con, ecr -o t1e eng ne co. r .o unn * paqe 2l_j6
_ 2a-32 _
ts;;l
Connector. contact Test box VA.G1598/31, test box
socket
3 (cyl 1) 102
3 {cyl. 2) e53 (cyl .3) 103
3{cy.4)
W re resistance: max. 1,5 e2
lf necessary, e i rninate the wir ing open clrcui t or short c lrcul t
l f no lau t is found:
- Replace igni t on co I wLth output stage assembly
fw-ro-oo33l
Knock sensors -G61- and -G66-:checking
Fitt ing locatlon:
-66' - page 24 8. {e'r 26
-G66 + page 24€, i tem 18
Special tools, workshop systems, testels,measuring instruments and auxiliarYitems required
a hano nit,nele VA.G -5164 or m"'umeterVA.G 1715
I Auxilary measuring set VA.G 1594,4 or1594C
o Test box VA.G 1598/31
I Current f low diagrams
- 28-33 -
- 28-34.-
a 'sF. - rEr . too-, ta. . .o a.no - /o. . - . . .o oq_ o. . . , \ j
a Anly Eold-plaied cor)tacis may be ,)sed whe, se.r:/rg i/re t nodsensor cannector contacts
t Check lh-6 k ock sensor cannector ta the wiing harness far cor-
Checking condit ions
. oJ I f o ^e
or Doth. .o. . . .o J 16 ogn .60 o\ sa t_oragno. , _
p;oe ZZ la dul ' r en o , ron ul o r-o r eding
Checking process
Pul connector off the knock sensor to be checked.
Swtch mutimeter VA.G i526 A to ressrance measuTement andconnect i t to contacts 1 and 2 0l the knocK sensor.
Spec f icat on: € CJ
_ 28_35 _
orr l connecttng the eng ne control Un t + page 24_36.
Check the fo low ng w r ing connect ions for open or short c ircu ts:
Knock sensof I G61- (cy Inders 1/2):
Conflector. contact Test box VA.G1598/31, test box
soc(et1(signal l 106
2 /earth) 99i i,-r €5-!21 |
- 28-36
Knock sensor 2 466- (cylinders 3/4)l
Connrc{or, cotitlct kboxVA.G1598^ll, t .t bot(
3ockat
1 {signa0 107
2 (earih) 99
- ll ilecessary, eliminats the wiring open circuit or short circult
lf no lallt is tound:
- Renew engine control !nit.
- a-37 -
SseFvrce
Technical Bulletin to Workshop Manual
Toledo 1999 ), Leon
Enter in Repair Group listRepair Group A1l
Engine AMK BAM'
BOOklet 4-cyl. injection engine, (S-valve) Edition 06.02
Bulletin No. 1Affected: All
E) Record the BAM engine denttfication letterc on the title page, the Hepair Group reference.Lhc catd dnd th- tat l .ng srcct tdblp. \ .
E) Record'See Technical Beport Na. 1" on pages A0 2, 00-3 and 24-26.: ..-,.. '
€a Cro:f out pages l3-5, 13 11 to 13-14, 1g 7 and wtite on these pages See Technical RepartNo. 1 '',
SubjectModification process "Ribbed belt: removtng and fitting" far all engines.New engines with BAM engine codes are being intraduced. Regarding manufacture, the BAM engne is similar to the AM K engine, with the exception of the modifications dacumented in the inclu-ded Technical Beport.
Contents
Technica data- Engine data
Engine: assembly and disassembly- Po y -V-beit: d smantling and fltting
Cool ng system components: d smantl ng- Coo ing system cornponents, eng ne side
nject on system: repair ngTechf ca cata
Bullet inpage
Bookletfrom page
00-1oo-2
13-113-5
19-119-7
24-12426
1
T
and f l t t ng
34
BB
1010
D..r^.r- Err+;^^. 1 l r l f
Technical data
Engine data
Engine code BAM
ExhaLrsl emission l imits according to
cm3
Nm/.nin
A mfi.,
min.
D splacement
TorqLre
D ameter
Stroke
Compression ratio
OCT
Inlec!on
gnrtron
Knock control
Var able distribution
Variable intake manifold
EU3 Standard
1741
165/6000
240/2200. . .5500
81,0
86,4
98 unleaded rr
Motronlc ME75
Motronic ME75
yes
, Exceptionally, minimum octane. 95 OCl but with some power loss
Engine code BAM
SelfTAGdiagnos s
Lambda regulation
Catalytic convener
Exhaust gas reclrculation
Supercharging
Secondary air syslem
yes
no
yes
D8124807030001
5--.12
atd
3r. f'.\i!glill
7
8
1011
I2'l 12
1314
16
18 17 I Ein:nn6;l20 19
T20167
f !!@*l
Engine: assembly and disas-sembly
17 - O-r inga FeP ace I oamageal
18 - Coolant thermostatl Veri l car lol : heat tre t !e;morlat n
a Beg rf ln l t ol open ng:a AN4( efglne approx 87'Ca BAM engine approx 80'Ct Ope1 ng l f t mrn. I mnlI Disnrent lng and f 11lng .- pag-a l9 29
19 -45 Nm
20 - Additional subframe bracketsa Disassembing and assembrng
-page 13 T7
2l -45 Nm
22 - Bight hand side engine bracket
Poly -V-belt: removing and fitting
Specialtools, workshop system s, testers, measuring instrumentsand auxiliary items required.
a Reiainlng iool 120167
a Befare remaving the Paly V Belt, mark the DOR ldircctian of raiationi ustatg a permanent marKer ar ctaYan
a lf the belthas been used and is made ta wark tn ihe appasite dtrectian t! may be destroyed
Removing
- D a." . b g:5e.19. o. . . - '
ta 2,raa7030001
To releve lens onontheribbed bet l , turn the tens oningdevce nthed rectron of the -arrow .
DB 2480703000r
' Flerr" : ! i_ i l r : r al t ! ! art an 3 orra
Fie fcre I bhcd beit
lnstal lat ion
E sure, belo/e irsr://r/)g tltbed bel!. that ail anctllanes lal!-otnaia.. arcondilloner cornptes!:.)a PAS van-. punp)ate secued tphtly.
- F t ihe Poly V be t to th-- cfsiksheir and vane pump pu eys.
F r the r bbed be t to the a le. iator p! ey asl
- Removetoo T20l67irom is alch nl i a 'ow andloosenlfetenson-rng 0ev ce.
- EnsLrre thal l re Po y V s correct ly f i l led.
ContrnLre assembly n reverse order of the drsmant rg procedirfe
Staf i engine and check how be t rs runf inel .
Cooling system components:removing and fitting
Cool ing system components. engine side
5 - O-rtnsa Replacemenl
6 - Coolant thermostata Verf icat ion : heat the ihermostal ln
waieTI Beg nn ng of openingI AMK eng net approx 87 "Ct BAM eng ne: approx 80 'ClOpenng i f tmn 7mma Dlsniant ing and f t t ing
- page 19-29
7 - Rigid connect ing hosea Coo ant hose connectron d agrarn :
page 19-12
*7-=---=--==-=fi
12 3 4 5 6 5 7 I I 5 10 11 12
19
14
20
r-;;;-;]D3r2.18117C30001
. " . -T=1 2 3 4 5 6 5 7 I 9 5 10 11
17
18
19
14
13
--1,.-q-:
I - Connecting sleeve
9 -To heat exchanger
' l Coo ant hose connecton d agfam =page I9J2
{
Inlection system: repairing
Technicaldata
, Not adlLrstabie' -o ie oa- . .^ oF. o e. q , 6 co-t to ut . .
- Parts Cala oque
Engine code BAMld lng check
ld ing speed 1) 'I rpm 700.. .820Engine control un t 2)
Syslem
Governed engine speed 'l rpm
Moironic ME75
1ML 906 032 A
irom approx. 6800
DB 24807030001 10
