Servicing 4-Cylinder TDI Engine, Common Rail EA288 EVO

Service
Workshop Manual
Audi A4 2015 ➤
Audi A5 2016 ➤
Audi A6 2019 ➤
Audi A7 Sportback 2018 ➤
Servicing 4-cylinder TDI engine, common rail (EA 288
EVO)
Engine ID
DEZ DEZ DFB DEZF DEZ
E B A D
Edition 11.2018
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Audi A4 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2019 ➤ , Audi A7 Sportback 20 ...
Servicing 4-cylinder TDI engine, common rail (EA 288 EVO) - Edition 11.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 2
2.3 Safety precautions when using testers and measuring instruments during a road test . . . . 3
2.4 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.5 Safety precautions when working on the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.6 Safety precautions when working on the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.7 Safety precautions when working on the subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Foreign particles in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.7 Installing radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.8 Performing adaptions after renewing a component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Removing engine from scissor-type assembly platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Securing engine to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.1 Exploded view - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2 Exploded view - sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.6 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.7 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.8 Removing and installing sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.1 Exploded view - cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3 Removing and installing sealing flange (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.1 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.2 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.1 Exploded view - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.3 Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Contents i
4.4 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.5 Separating parts of new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.6 Checking radial clearance of conrod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

1 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.1 Exploded view - toothed belt cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.2 Exploded view - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.3 Removing and installing toothed belt cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.4 Detaching toothed belt from camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.5 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.1 Exploded view - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.2 Exploded view - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.3 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.4 Removing and installing seals for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.5 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.6 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.7 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.1 Exploded view - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.2 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.3 Removing and installing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.1 Exploded view - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.3 Removing and installing sump (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.4 Removing and installing sump (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.5 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.6 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 109
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3 Oil filter/oil pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.1 Exploded view - oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.2 Exploded view - oil pressure switches/oil pressure control . . . . . . . . . . . . . . . . . . . . . . . . 113
3.3 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.4 Removing and installing oil pressure sender G10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.5 Removing and installing valve for oil pressure control N428 . . . . . . . . . . . . . . . . . . . . . . . . 116
3.6 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.7 Removing and installing piston cooling jet control valve N522 . . . . . . . . . . . . . . . . . . . . . . 118
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.3 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2 Coolant pump/thermostat assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.1 Exploded view - coolant pump/thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.2 Exploded view - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.3 Exploded view - coolant valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
ii Contents
2.4 Exploded view - coolant temperature senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

2.5 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.6 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.7 Removing and installing mixing valve for charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . 126
2.8 Removing and installing coolant valve for cylinder head N489 . . . . . . . . . . . . . . . . . . . . . . 126
2.9 Removing and installing coolant distribution module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.10 Removing and installing temperature sensor G18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.11 Removing and installing engine temperature sender G27 . . . . . . . . . . . . . . . . . . . . . . . . 129
2.12 Removing and installing engine temperature sender 2 G652 . . . . . . . . . . . . . . . . . . . . . . 129
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4 Radiators/radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.1 Exploded view - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
2.1 Exploded view - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
2.2 Exploded view - hose connections for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . 146
2.3 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
2.4 Removing and installing charge air temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . 147
2.5 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.1 Overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.2 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.3 Filling and bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.4 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
3 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
3.1 Exploded view - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
3.2 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
3.3 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
4 Injectors/high-pressure reservoir (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.1 Exploded view - injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.2 Exploded view - high-pressure reservoir (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.3 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.4 Performing adaption of correction values for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.5 Checking for injectors sticking open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4.6 Checking return flow rate of injectors with engine running . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.7 Checking return flow rate of injectors at starter cranking speed . . . . . . . . . . . . . . . . . . . . 172
4.8 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4.9 Removing and installing high-pressure pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
4.10 Removing and installing high-pressure reservoir (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
5 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
5.1 Exploded view - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
5.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
6.1 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
6.2 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
6.3 Removing and installing fuel pressure sender for low pressure G410 . . . . . . . . . . . . . . . . 188
6.4 Removing and installing exhaust gas pressure sensor 1 G450 . . . . . . . . . . . . . . . . . . . . 189
6.5 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Contents iii
6.6 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 192
7 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
7.1 Exploded view - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
7.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
7.3 Removing and installing NOx senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
8 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

1 Exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.1 Exploded view - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.2 Removing and installing front exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.3 Removing and installing silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.4 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.5 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2 Emission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2.1 Exploded view - emission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2.2 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
2.3 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2.4 Removing and installing trap catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
2.5 Removing and installing exhaust flap control unit J883 . . . . . . . . . . . . . . . . . . . . . . . . . . 216
3 SCR (selective catalytic reduction) system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3.1 Exploded view - reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3.2 Exploded view - reducing agent supply line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3.3 Exploded view - delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
3.4 Releasing pressure in SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
3.5 Draining reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
3.6 Removing and installing reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
3.7 Removing and installing injector for reducing agent N474 . . . . . . . . . . . . . . . . . . . . . . . . 220
3.8 Removing and installing control unit for reducing agent metering system J880 . . . . . . . . 222
3.9 Removing and installing pump for reducing agent V437 . . . . . . . . . . . . . . . . . . . . . . . . . . 222
3.10 Removing and installing pressure sender for reducing agent metering system G686 . . . . 222
3.11 Removing and installing connection for SCR supply line . . . . . . . . . . . . . . . . . . . . . . . . . . 222
4 Exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
4.1 Exploded view - exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
4.2 Removing and installing parts of exhaust gas temperature control . . . . . . . . . . . . . . . . . . 224
5 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
5.1 Exploded view - exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
5.2 Removing and installing exhaust gas recirculation valve 1 GX5 . . . . . . . . . . . . . . . . . . . . 230
5.3 Removing and installing exhaust gas recirculation valve 2 GX6 . . . . . . . . . . . . . . . . . . . . 231
5.4 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 232
5.5 Checking exhaust gas recirculation cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
1.1 Exploded view - glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
1.2 Removing and installing glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.3 Removing and installing automatic glow period control unit J179 . . . . . . . . . . . . . . . . . . . . 241
1.4 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
iv Contents
00 – Technical data
1 Identification
(ARL006163; Edition 11.2018)
⇒ “1.1 Engine number/engine data”, page 1
1.1 Engine number/engine data

Engine number
♦ The engine number (“engine code” and “serial number”) is lo‐
cated on the front of the joint between the engine and the
gearbox -arrow-.
♦ Additionally there is a sticker on the toothed belt cover (top)
with engine code and serial number.
♦ Engine codes starting with the letter “C” have four letters (pre‐
viously three letters).
♦ The first 3 characters of the engine code stand for the engine
capacity and the mechanical construction and design. They
are stamped onto the cylinder block together with the serial
number.
♦ The 4th character indicates the power output and torque of the
engine and is determined by the engine control unit.
Engine data
♦ For allocation of engine code, refer to ⇒ Technical data for
engines; Rep. gr. 00 ; Overview of engines .
1. Identification 1
2 Safety precautions
⇒ “2.1 Safety precautions when working on the fuel supply sys‐
tem”, page 2
⇒ “2.2 Safety precautions when working on vehicles with start/
stop system”, page 2
⇒ “2.3 Safety precautions when using testers and measuring in‐
struments during a road test”, page 3
⇒ “2.4 Safety precautions when working on the cooling system”,
page 3
⇒ “2.5 Safety precautions when working on the exhaust system”,
page 3
⇒ “2.6 Safety precautions when working on the SCR system”,
page 4
⇒ “2.7 Safety precautions when working on the subframe”,
page 5
2.1 Safety precautions when working on the fuel supply system

Risk of injury - fuel system operates under high pressure
The fuel system is pressurised. There is a risk of injury as fuel
may spray out.
Before opening the fuel system:
– Put on safety goggles.
– Put on protective gloves.
– Release pressure (wrap a clean cloth around connection and
open connection carefully).
Risk of fire due to escaping fuel

If the battery is connected, the door contact switch activates the
fuel pump when the driver's door is opened. Escaping fuel may
ignite, causing a fire.
– Before opening the fuel system, disconnect power supply to
fuel pump.
2.2 Safety precautions when working on vehicles with start/stop system

Risk of injury - engine may start unexpectedly
The engine can start unexpectedly if the vehicle's start/stop sys‐
tem is activated. A message in the instrument cluster indicates
whether the start/stop system is activated.
– To deactivate the start/stop system, switch off the ignition.
2 Rep. gr.00 - Technical data

2.3 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury if test equipment is not secured
If an accident occurs and the front passenger's airbag is triggered,
test equipment which is not secured adequately may be catapul‐
ted through the vehicle with potentially serious consequences.
– Secure test equipment on the rear seat with a strap.
Or:
– Have a second mechanic operate test equipment on the rear
seat.
2.4 Safety precautions when working on the cooling system

Risk of scalding as hot coolant can escape
The cooling system is under pressure when the engine is hot. Risk
of scalding due to hot steam and hot coolant.
– Cover filler cap on expansion tank with a cloth and open care‐
fully to release pressure.
2.5 Safety precautions when working on the exhaust system

Risk of injury caused by components of the exhaust system
Danger of injury to hands and other parts of the body due to hot
or sharp parts of the exhaust system.
– Allow exhaust system to cool down.
Risk of injury when disconnecting the exhaust system

There is a risk of eye irritation caused by soot particles in the air.
Components of the exhaust system can pose health risk

Risk to health if exhaust gas temperature sender is dismantled.
– Do not dismantle exhaust gas temperature sender.
2. Safety precautions 3
Danger from toxic exhaust gases

Auxiliary/supplementary heater produces toxic exhaust gases.
There is a risk of poisoning and of damage to the respiratory tract.
– In enclosed spaces, only switch on the auxiliary/supplemen‐
tary heater if there is an exhaust extraction system.
– In enclosed spaces without an exhaust extraction system,
switch off the auxiliary/supplementary heater.
Risk of damage to flexible joint

The flexible joint can be damaged or develop leaks if it is handled
incorrectly.
– Do not bend flexible joint more than 10°.
– Install flexible joint so that it is not under tension.
2.6 Safety precautions when working on the SCR system

Risk of injury caused by reducing agent
Reducing agent can cause eye and skin irritation, damage to the
respiratory tract and poisoning.
– Wear protective clothing.
– Ensure that there is sufficient fresh air. In enclosed spaces,
switch on the exhaust extraction system.
Risk of damage caused by reducing agent

Reducing agent which has come into contact with trim or body
components can crystallise after some time and damage the af‐
fected surfaces.
– Ensure that no reducing agent makes contact with parts of trim
or body.
– Clean any surfaces which have come into contact with reduc‐
ing agent immediately with water and a cloth.
When removing and installing components at the SCR system,

note the following:
♦ The reducing agent tank must be empty when you are working
on the SCR system. Refer to the corresponding work descrip‐
tion to find out when the reducing agent must be drained from
the tank. Drain the reducing agent tank if necessary; proce‐
dure ⇒ page 220 .

When removing and installing the reducing agent tank, note the
following:
♦ The reducing agent tank must be empty. Drain the reducing
agent tank if necessary; procedure ⇒ page 220 .
Automatic drawing back of reducing agent
• After the ignition is switched off, the reducing agent is auto‐
matically drawn back into the reducing agent tank from the
metering line leading to the injector for reducing agent - N474- .
• Before performing work in this area, you must therefore wait
until the reducing agent has been drawn back; this can take
up to 10 minutes after the ignition has been switched off.
• It is also important to wait until the reducing agent has been
drawn back (i.e. 10 minutes after the ignition is switched off)
before disconnecting the battery ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery .
2.7 Safety precautions when working on the subframe

Risk of damage to components
Lowering the vehicle onto its wheels can damage components if
the assembly mountings, steering rack or subframe cross brace
are not properly fitted.
– Never lower vehicle onto its wheels with suspension compo‐
nents unfastened or detached.
– Never support weight of vehicle on subframe or subframe
cross brace with suspension components unfastened or de‐
tached.
2. Safety precautions 5
3 Repair instructions
⇒ “3.1 Rules for cleanliness”, page 6
⇒ “3.2 General notes”, page 6
⇒ “3.3 General repair instructions”, page 7
⇒ “3.4 Foreign particles in engine”, page 8
⇒ “3.5 Contact corrosion”, page 8
⇒ “3.6 Routing and attachment of pipes, hoses and wiring”, page
9
⇒ “3.7 Installing radiators and condensers”, page 9
⇒ “3.8 Performing adaptions after renewing a component”,
page 9
3.1 Rules for cleanliness

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

Fuel supply/injection
♦ The engine control unit has a self-diagnosis capability. Before
carrying out repairs and fault finding, the event memory must
be interrogated. The vacuum hoses and connections must al‐
so be checked (unmetered air).
♦ A voltage of at least 11.5 V is required for proper operation of
the electrical components.

♦ Do not use sealants containing silicone. Particles of silicone

drawn into the engine will not be burnt in the engine and will
damage the Lambda probe.
♦ The vehicles are fitted with a crash fuel shut-off system. This
system is designed to reduce the risk of a vehicle fire after a
crash by deactivating the fuel pump.
♦ At the same time, this system also improves the engine's start‐
ing performance. When the driver's door is opened, the fuel
pump is activated for 2 seconds in order to build up pressure
in the fuel system ⇒ page 2 .
Glow plug system
♦ The glow plug system is activated via the automatic glow pe‐
riod control unit - J179- . The control unit is self-diagnosis
compatible.
♦ Fitting location of automatic glow period control unit - J179-
⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
♦ A fault is stored in the engine control unit - J623- if a fault oc‐
curs in the glow plug system.
♦ Checking glow plug system ⇒ Vehicle diagnostic tester
♦ For faster starting, the vehicle is equipped with electronically
controlled glow plugs and a separate glow period control unit.
♦ Each glow plug is activated and diagnosed separately.
♦ Wait for 60 seconds each time after performing final control
diagnosis of the glow period control unit. The ignition must re‐
main switched on.
♦ If you do not wait for 60 seconds (if ignition is switched off and
immediately switched on again), the glow plugs can be dam‐
aged (due to repeated pre-heating).
♦ The activation of the glow plugs is controlled according to
coolant temperature.
3.3 General repair instructions

If components of the fuel system between the fuel tank and the
high-pressure pump are removed or renewed, the fuel system
must be bled
⇒ “1.3 Filling and bleeding fuel system”, page 153 .
Risk of irreparable damage to fuel pump
After working on the fuel system, the fuel pump may be irreparably
damaged if it is allowed to run while empty.
– Never allow fuel pump to run while it is empty.
– Fill/bleed fuel pump.
♦ Clean tools and workbench etc. before working on the injection

system.
♦ Before installing, check the injectors and their surroundings
visually; they must be undamaged and clean. Make sure the
injector bores in the cylinder head are clean. Wipe out if nec‐
essary using a clean cloth, taking care not to cause damage.
Do not use sharp objects of any kind.
3. Repair instructions 7
♦ If the high-pressure fuel lines are to be re-used, you must mark

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

♦ When performing assembly work on the engine, all open pas‐
sages in the intake and exhaust systems must be sealed with
suitable plugs (e.g. from engine bung set - VAS 6122- ) to
prevent foreign particles from entering the engine.
If the turbocharger has suffered mechanical damage (e.g. dam‐
aged compressor wheel), it is not sufficient merely to fit a new
turbocharger. The following work must be performed in order to
avoid further damage:
• Check air cleaner housing, air filter element and air hoses for
dirt and foreign particles.
• Check the entire charge air system (including the charge air
cooler) for foreign matter.
• If foreign matter is found in the charge air system, clean all
relevant ducts and hoses and renew charge air cooler if nec‐
essary.
3.5 Contact corrosion

Contact corrosion can occur if unsuitable fasteners are used (e.g.
bolts, nuts, washers, etc.).
For this reason, only fasteners with a special surface coating are
fitted.
Additionally, all rubber and plastic parts and all adhesives are
made of non-conductive materials.

Always install new parts if you are not sure whether used parts
can be re-fitted ⇒ Electronic parts catalogue .
Please note:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.
♦ We recommend the use of Audi Genuine Parts.
♦ Damage caused by contact corrosion is not covered by war‐
ranty.
3.6 Routing and attachment of pipes, hoses

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

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

component
The learnt values must be adapted if components of the engine
or reducing agent system have been renewed or if a reducing
agent line has been opened.
After renewing engine, pistons, cylinder head or turbocharger,
“run-in function with increased oil pressure” must be activated.
– Connect ⇒ Vehicle diagnostic tester.
– Select Diagnosis mode and then Start diagnosis .
– Choose Select own test tab and select following options
one after the other:
ODIS path for A4/A5:
♦ Drive train
♦ Select engine code and engine
♦ 01 - Self-diagnosis compatible systems
♦ 01 - Engine electronics
♦ 01 - Engine electronics, functions
♦ 01 - Adapt learnt values for tank for reducing
agent
ODIS path for A6/A7:

♦ Systems with diagnostic capability
♦ 00AC - Control unit for reducing agent metering
system -J880
3. Repair instructions 9
♦ 00AC - Control unit for reducing agent metering

system, functions
♦ 00AC - Adapt reduction agent tank learned values

10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 11
⇒ “1.2 Removing engine from scissor-type assembly platform”,
page 11
⇒ “1.3 Securing engine to engine and gearbox support”,
page 13
⇒ “1.4 Installing engine”, page 14
1.1 Removing engine

All procedures are described in ⇒ 4-cylinder TDI engine, 2.0 ltr.
4-valve common rail; Rep. gr. 10 ; Removing and installing en‐
gine; Removing engine .
1.2 Removing engine from scissor-type as‐

sembly platform
Special tools and workshop equipment required
♦ Lifting tackle - 3033-
♦ Workshop hoist - VAS 6100-
1. Removing and installing engine 11

♦ Lift arm extension/workshop hoist - VAS 6101-
Procedure
• Engine/gearbox assembly removed and placed on scissor-
type assembly platform - VAS 6131 B- (with engine detached
from gearbox) ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve com‐
mon rail; Rep. gr. 10 ; Removing and installing engine; Sep‐
arating engine and gearbox
CAUTION
Risk of injury when weight of engine is shifted.
Danger of trapping or crushing parts of the body.
– Transport engine only with gearbox removed and using the
method described.
– Attach lift arm extension - VAS 6101- to workshop hoist -

VAS 6100- .
– Attach lifting tackle - 3033- to engine lifting eyes and workshop
hoist, as shown.
– Take up weight of engine with workshop hoist, but do not lift.
– Detach engine support - T10533/1- from engine.

– Raise engine using workshop hoist.
12 Rep. gr.10 - Removing and installing engine

1.3 Securing engine to engine and gearbox

support
♦ Engine and gearbox support - VW 540-
♦ Engine and gearbox support - VAS 6095A-
Procedure
• Engine removed from scissor-type assembly platform -
VAS 6131 B- ⇒ page 11
– Remove drive plate ⇒ page 27 .
– Disengage intermediate plate from sealing flange -arrow B-
and dowel sleeves -arrows A- and remove.
– Pull dowel sleeves off cylinder block.
1. Removing and installing engine 13

– Secure engine to engine and gearbox support - VW 540- using

engine and gearbox support - VAS 6095A- .
1.4 Installing engine

4-valve common rail; Rep. gr. 10 ; Removing and installing en‐
gine; Installing engine .

2 Assembly mountings
All procedures and components are described in ⇒ 4-cylinder TDI
engine, 2.0 ltr. 4-valve common rail; Rep. gr. 10 ; Assembly
mountings .
2. Assembly mountings 15
3 Engine cover panel

⇒ “3.1 Removing and installing engine cover panel”, page 16
3.1 Removing and installing engine cover

panel
Removing
– Carefully pull engine cover panel off ball studs one after an‐
other -arrows-. Do not jerk engine cover panel away, and do
not try to pull on one side only.
Installing
– To avoid damage, do not strike the engine cover panel with
your fist or with any kind of tool.
– Position engine cover panel, paying attention to oil filler neck
and dipstick.
– Press engine cover panel into ball studs first on left side, then
on right side.

13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Exploded view - cylinder block (pulley end)”, page 17
⇒ “1.2 Exploded view - sealing flange (pulley end)”, page 19
⇒ “1.3 Removing and installing poly V-belt”, page 20
⇒ “1.4 Removing and installing tensioner for poly V-belt”,
page 21
⇒ “1.5 Removing and installing vibration damper”, page 22
⇒ “1.6 Removing and installing bracket for ancillaries”,
page 22
⇒ “1.7 Removing and installing engine support”, page 23
⇒ “1.8 Removing and installing sealing flange (pulley end)”, page
23
1.1 Exploded view - cylinder block (pulley end)
1 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tip pen
❑ Do not kink
❑ Routing of poly V-belt
⇒ page 19
❑ Removing and installing
⇒ page 20
❑ When installing, make
sure it is properly seated
on pulleys.
2 - Bolt
❑ Renew after removing
❑ 20 Nm +180°
3 - Vibration damper
❑ With poly V-belt pulley
❑ Installation position:
hole in vibration damper
must be positioned over
raised section of crank‐
shaft sprocket
⇒ page 22
4 - Tensioner for poly V-belt
⇒ page 21
5 - Bolt
❑ Tightening torque ⇒
Electrical system; Rep.
gr. 27 ; Alternator; Ex‐
ploded view - alternator
Volkswagen Technical Site: http://vwts.ru http://vwts.info
1. Cylinder block (pulley end) 17

6 - Dowel sleeve
❑ Ensure correct seating in bracket for ancillaries
7 - Bracket for ancillaries
❑ Removing and installing ⇒ page 22
8 - Bolt
❑ 8 Nm
9 - Bracket
❑ For electrical connector
10 - Bolt
❑ 8 Nm
11 - Ball stud
❑ For engine cover panel
❑ 8 Nm
12 - Bracket
13 - Bush
❑ ⇒ Fig. ““Bracket for ancillaries - tightening torque and tightening sequence”“ , page 19
14 - Bolt
❑ Different lengths ⇒ page 19
❑ Tightening torque and sequence ⇒ page 19
15 - Starter-alternator - C29-
❑ Exploded view ⇒ Electrical system; Rep. gr. 27 ; Alternator; Exploded view - alternator
16 - Bolt
❑ Different lengths ⇒ page 19
17 - Air conditioner compressor
❑ Exploded view ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Exploded view -
air conditioner compressor drive unit
18 - Bracket
❑ For SCR line
19 - Nut
❑ 8 Nm
20 - Bolt
❑ Tightening torque ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Exploded view
- air conditioner compressor drive unit
21 - Dowel sleeves
❑ Ensure correct seating in air conditioner compressor
22 - Bolt
❑ 8 Nm +90° in diagonal sequence in stages
18 Rep. gr.13 - Crankshaft group

Routing of poly V-belt

1- Vibration damper
2- Idler roller
3- Starter-alternator - C29-
4- Tensioner for poly V-belt
5- Air conditioner compressor
Bracket for ancillaries - tightening torque and tightening sequence

• After removing, renew bolts tightened with specified tightening
angle.
– Fit bolts/bush in the following sequence:
♦ Bolts -1 … 4- M10x35
♦ Bolt -5- M10x175
♦ Bolt -6- M10x115
♦ Bolt -7- M8x60
♦ Bush -8-
– Tighten bolts/bush in stages in the sequence shown:
Stage Bolts/bush Tightening torque/angle specification
1. -1 … 6- Screw in by hand until contact is made
2. -1 … 6- 40 Nm
3. -1 … 4- Turn 45° further
4. -5, 6- Turn 180° further
5. -8- 6 Nm
6. -8- Turn 40° further
7. -7- 23 Nm
1.2 Exploded view - sealing flange (pulley end)

1 - Bolt
❑ Tightening torque
⇒ Item 1 (page 45)
2 - Crankshaft sprocket
❑ Contact surface be‐
tween sprocket and
crankshaft must be free
of oil
❑ Can only be installed in
one position
3 - Sealing flange (pulley end)
❑ With crankshaft oil seal
⇒ page 23
4 - Bolt
❑ Tightening torque and
sequence ⇒ page 20
Sealing flange (pulley end) - tightening torque and sequence

– Tighten bolts -arrows- in stages in the sequence shown:
Stage Tightening torque
1. Screw in by hand until contact is made
2. Tighten in stages and in diagonal sequence; final tor‐
que 13 Nm
1.3 Removing and installing poly V-belt


♦ Locking tool - T40098-
Removing
NOTICE
Risk of irreparable damage due to running a used belt in the
opposite direction when it is refitted.
– Mark running direction before removing.
– Pay attention to running direction when reinstalling.
– To slacken poly V-belt, turn tensioner clockwise -arrow- using

ratchet.
– Lock tensioner with locking tool - T40098- .
– Take off poly V-belt.
Installing
Installation is carried out in reverse order; note the following:
– Fit poly V-belt ⇒ page 19 .
– Hold tensioner with ratchet and remove locking tool - T40098- .
– Release tensioner.
– Check that poly V-belt is properly seated.
– Start engine and check that poly V-belt(s) run properly.
1.4 Removing and installing tensioner for

poly V-belt
Removing
– Remove poly V-belt ⇒ page 20 .
– Remove bolts -arrows- and take off poly V-belt tensioner -1-.
Installing
angle.
– Install poly V-belt ⇒ page 20 .
Tightening torques
♦ ⇒ “1.1 Exploded view - cylinder block (pulley end)”, page 17

1.5 Removing and installing vibration damp‐

er
♦ Key -T40405- (not illustrated)
Removing
Preparatory work may be necessary depending on model ⇒ 4-
cylinder TDI engine, 2.0 ltr. 4-valve common rail; Rep. gr. 13 ;
Cylinder block (pulley end); Removing and installing vibration
damper .
– To slacken bolts for vibration damper, counterhold crankshaft
using key -T40405- .
• Notch -2- aligns with “OT” (TDC) marking -1- on vibration
damper.
– Loosen bolts -arrows- for vibration damper.
– Remove bolts and take off vibration damper.
Installing
angle.
– Move vibration damper into installation position -arrow- (pay

attention to raised section of crankshaft sprocket -2-).
Additional work depending on model ⇒ 4-cylinder TDI engine, 2.0
ltr. 4-valve common rail; Rep. gr. 13 ; Cylinder block (pulley end);
Removing and installing vibration damper
Tightening torques
♦ ⇒ “1.1 Exploded view - cylinder block (pulley end)”, page 17
1.6 Removing and installing bracket for an‐

cillaries
Removing
– Remove starter-alternator - C29- ⇒ Electrical system; Rep.
gr. 27 ; Alternator; Removing and installing alternator .
– Remove high-pressure pump ⇒ page 183 .

– Move electrical wiring clear.

– Unscrew bolt -7- and loosen bush -8- approx. two turns.
– Loosen bolts in the sequence -6 ... 1-.
– Remove bolts and detach bracket for ancillaries.
Installing
angle.
– Check that a dowel sleeve is fitted between bracket for ancil‐
laries and cylinder block.
– Install high-pressure pump ⇒ page 183 .
– Install starter-alternator - C29- ⇒ Electrical system; Rep. gr.
27 ; Alternator; Removing and installing alternator .
Tightening torques
♦ ⇒ Fig. ““Bracket for ancillaries - tightening torque and tighten‐
ing sequence”“ , page 19
♦ ⇒ “1.2 Exploded view - toothed belt”, page 45
1.7 Removing and installing engine support

4-valve common rail; Rep. gr. 13 ; Cylinder block (pulley end);
Removing and installing engine support .
1.8 Removing and installing sealing flange

(pulley end)
♦ Counterhold tool - 3415-

♦ Assembly tool - T10053-
Removing
– Remove toothed belt ⇒ page 53 .
– Remove sump (top section) ⇒ page 106 .
– Loosen bolt -1- for crankshaft sprocket -2- using counterhold
tool - 3415- .
– Remove bolt and detach crankshaft sprocket.
– Remove bolts -arrows-, press out sealing flange -1- and re‐
move flange.
– Remove toothed belt -2- for oil pump.

Installing
– Fit toothed belt -arrow- for oil pump on crankshaft.
– Fit guide sleeve -T10053/1- onto crankshaft journal.
– Slide sealing flange over guide sleeve.
• Dowel pins should then engage in bores on cylinder block.
– Take off guide sleeve.
– Tighten sealing flange bolts ⇒ page 20 .
– Install sump (upper section) ⇒ page 106 .
– Install toothed belt (adjust valve timing) ⇒ page 56 .
Tightening torques
♦ ⇒ Fig. ““Sealing flange (pulley end) - tightening torque and se‐
quence”“ , page 20
♦ Crankshaft sprocket ⇒ Item 1 (page 45)

2 Cylinder block (gearbox end)

⇒ “2.1 Exploded view - cylinder block (gearbox end)”, page 26
⇒ “2.2 Removing and installing drive plate”, page 27
⇒ “2.3 Removing and installing sealing flange (gearbox end)”,
page 28
2.1 Exploded view - cylinder block (gearbox end)
1 - Intermediate plate
❑ Do not damage or bend
when assembling
❑ Installing ⇒ page 26
2 - Dowel sleeve
❑ 2x
3 - Cylinder block
4 - Dowel pin
❑ 2x
5 - Sealing flange (gearbox
end)
❑ With oil seal
❑ Renewing ⇒ page 28
6 - Bolt
7 - Drive plate
❑ Lock with counterhold
tool - 10-201- to slacken
off bolts
⇒ page 27
8 - Bolt
❑ 60 Nm +90°
Installing intermediate plate

– Engage intermediate plate on sealing flange -arrow B- and
push onto dowel sleeves -arrows A-.

Sealing flange (gearbox end) - tightening torque and sequence

– Tighten bolts -arrows- in stages in the sequence shown:
que 13 Nm
2.2 Removing and installing drive plate

♦ Counterhold tool - 10-201-
Removing
• Gearbox removed ⇒ Gearbox; Rep. gr. 34 ; Removing and
installing gearbox; Removing gearbox .
NOTICE
Risk of damage to thread if an impact driver (or similar) is used.
– When screwing in bolts, fit them manually and perform the
first few turns by hand.
– Do not use an impact driver to loosen or tighten bolts.
– Insert counterhold tool - 10-201- in hole on cylinder block,

slacken bolts for drive plate -1-.
– Remove bolts and take off drive plate.
Installing
angle.
– Pay attention to dowel pin when installing drive plate.
– Fit counterhold tool - 10-201- the other way round to tighten
bolts.
Tightening torques
♦ ⇒ “2.1 Exploded view - cylinder block (gearbox end)”,
page 26
2. Cylinder block (gearbox end) 27

2.3 Removing and installing sealing flange

(gearbox end)
♦ Open end spanner insert, AF 24 - V.A.G 1332/11-
♦ Depth gauge - VAS 6082-
♦ Bolt, M6x35 (3x)

♦ Bolt, M7x35 (2x)
Pressing out sealing flange with sender wheel
• Gearbox removed
– Remove drive plate ⇒ page 27 .
– Detach intermediate plate -1- from dowel sleeves -arrows A-.
– Guide intermediate plate upwards; at the same time, pull re‐
taining tab -arrow B- out of opening behind sealing flange
-2-.

– Rotate crankshaft by turning bolt for toothed belt sprocket until

crankshaft is positioned at “TDC”, as shown in illustration.
• The hole -2- in the sender wheel -3- must be aligned with the
punch mark -1- on the sealing flange.
– Remove engine speed sender - G28- ⇒ page 242 .
– Remove bolts -arrows- for sealing flange -1-.
• The sealing flange -1- is pressed off the crankshaft -3- together
with the sender wheel -2-.
– To press off, screw 3 bolts M6x35 -arrows- alternately into
sealing flange not more than 1/2 turn at a time.
– Detach sealing flange together with sender wheel.
Pressing in sealing flange with sender wheel

♦ The sealing flange with PTFE oil seal is fitted with a sealing lip
support ring -2-. This support ring acts as an assembly sleeve
and must not be removed before installation.
♦ Sealing flange and sender wheel -1- must not be separated or
rotated out of position after removal from packaging.
♦ The sender wheel is held in its installation position by a locat‐
ing pin on the assembly tool - T50010- .
♦ The sealing flange and oil seal are one unit and can only be
replaced together with the sender wheel.
♦ The assembly tool - T50010- is held in the correct position rel‐
ative to the crankshaft by a guide pin which is inserted into a
hole in the crankshaft.

Construction of assembly tool - T50010- :

A - Tensioning flats
B - Nut
C - Guide pin
D - Assembly housing
E - Hexagon socket head bolts (2x)
F - Inner section
G - Locating pin
H - Knurled screw (3x)
Fitting sealing flange with sender wheel onto assembly tool -

T50010- :
– Unscrew nut -B- until it is just in front of tightening flats -A- on
threaded spindle.
– Clamp assembly tool - T50010- in a vice -1- on tightening flats

-A- of threaded spindle.
– Press assembly housing -D- downwards -arrow- so that it rests
on nut -B-.
– Place sealing flange (with front side downwards) on a clean

flat surface.
• Do not take the sender wheel out of the sealing flange or rotate
it out of position.
– Press sealing lip support ring -1- downwards in direction of
-arrow- until it touches flat surface.

• Upper edge of sealing lip support ring -1- must be flush

-arrows- with front edge of sealing flange -2-.
– Place front side of sealing flange -2- on assembly tool -

T50010- so that locating pin -G- is seated in hole -1- in sender
wheel -3-.
• Ensure that sealing flange lies flat on assembly tool.
– Screw knurled screws -H- onto sealing flange -1-.

Note:
Only the two knurled screws shown in the illustration can be
screwed on.
– When tightening, press sealing flange and sealing lip support
ring -2- against surface of assembly tool - T50010- .
– This prevents locating pin from sliding out of hole in sender
wheel.
– Ensure that sender wheel remains fixed on assembly tool
when installing sealing flange.
Securing assembly tool - T50010- with sealing flange -1- on

crankshaft flange:
• Crankshaft flange must be free of oil and grease.
• Engine is at “TDC” position.
– Screw nut -B- to end of threaded spindle.
– Press threaded spindle of assembly tool - T50010- in direction
of -arrow- until nut -B- makes contact with assembly housing
-D-.
– Position flat edge of assembly housing towards sealing sur‐
face for sump on cylinder block.

– Secure assembly tool - T50010- with sealing flange -2- to

crankshaft flange -1-.
– To do so, screw hexagon socket head bolts -E- approx. 5 turns
into crankshaft flange with hexagon key -3-.
– Insert guide pin -C- into crankshaft flange.
– Screw bolts M7x35 -item 1- into cylinder block to guide sealing

flange -2-.
Securing assembly tool - T50010- on crankshaft flange:

– Press assembly housing -D- by hand in direction of -arrow-
until sealing lip support ring -2- makes contact with crankshaft
flange -1-.
– Check that guide pin -C- is fitted correctly in hole in crankshaft.
This ensures that sender wheel reaches its final installation
position.
– Use hexagon key -3- to tighten the two hexagon socket head
bolts on assembly tool - T50010- hand-tight.
– Screw nut -B- onto threaded spindle by hand until it touches
assembly housing -D-.
Pressing sender wheel onto crankshaft flange with assembly tool

- T50010- :
– Tighten nut -B- on assembly tool - T50010- to 35 Nm.
• There must be a small gap between cylinder block -2- and
sealing flange -1- after nut has been tightened to 35 Nm.

Checking installation position of sender wheel on crankshaft:

– Screw nut -B- to end of threaded spindle.
– Remove both bolts -2- from cylinder block.
– Unscrew knurled screws -H- from sealing flange -1-.
– Unbolt assembly tool - T50010- from crankshaft flange (re‐
move hexagon socket head bolts -E- from crankshaft flange).
– Detach sealing lip support ring.
– Apply depth gauge - VAS 6082- to crankshaft flange -1-.
– Measure distance -a- between crankshaft flange -2- and send‐

er wheel -1-.
• Specification: Distance -a- = 0.5 mm.
– Press sender wheel in further if measurement is too small
⇒ page 33 .
– If reading matches specification, continue with assembly
⇒ page 34 .
Pressing sender wheel in further:

– Secure assembly tool - T50010- to crankshaft flange.
– Ensure that locating pin of assembly tool - T50010- is fitted in
hole in sender wheel.
– Use hexagon key -3- to tighten the two hexagon socket head
bolts -E- hand-tight.

– Slide assembly tool - T50010- onto sealing flange -1- by hand.

– Screw nut -B- onto threaded spindle by hand until it touches
assembly tool - T50010- .
– Insert guide pin -C- into crankshaft flange.
– Screw 2 bolts M6x35 -item 2- into cylinder block to guide seal‐
ing flange -1-.
– Tighten nut -B- on assembly tool - T50010- to 40 Nm.

– Check installation position of sender wheel on crankshaft
again ⇒ page 33 .
– Tighten nut on assembly tool - T50010- to 45 Nm if measure‐
ment is too small.
– Check installation position of sender wheel on crankshaft
again ⇒ page 33 .
Assembling:
Assembly is performed in reverse sequence; note the following:
– Install intermediate plate ⇒ page 26 .
– Install drive plate ⇒ page 27 .
Tightening torques
♦ ⇒ Fig. ““Sealing flange (gearbox end) - tightening torque and
sequence”“ , page 27
♦ ⇒ “1.1 Exploded view - glow plug system”, page 238

3 Crankshaft
There is currently no provision for removing and installing the
crankshaft.
⇒ “3.1 Crankshaft dimensions”, page 35
⇒ “3.2 Measuring axial clearance of crankshaft”, page 35
3.1 Crankshaft dimensions

Main bearing journal Conrod journal ∅
∅ mm
mm
Basic dimension 48.000 -0.022 47.800 -0.022
-0.042 -0.042
3.2 Measuring axial clearance of crankshaft

♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge - VAS 6079-
Procedure
– Bolt dial gauge - VAS 6079- with universal dial gauge bracket
- VW 387- onto cylinder block (as shown in illustration) and set
it against crankshaft.
– Press crankshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Push crankshaft away from dial gauge and read off value.
Axial clearance:
• New: 0.07 ... 0.17 mm
• Wear limit: 0.37 mm
3. Crankshaft 35
4 Pistons and conrods

⇒ “4.1 Exploded view - pistons and conrods”, page 36
⇒ “4.2 Removing and installing pistons”, page 38
⇒ “4.3 Measuring piston projection at TDC”, page 40
⇒ “4.4 Checking pistons and cylinder bores”, page 41
⇒ “4.5 Separating parts of new conrod”, page 42
⇒ “4.6 Checking radial clearance of conrod bearings”,
page 43
4.1 Exploded view - pistons and conrods
1 - Bolts
❑ Lubricate threads and
contact surface
❑ When measuring radial
clearance, tighten used
bolts to 30 Nm and turn
90° further
❑ 30 Nm +90°
2 - Conrod bearing cap
❑ Note installation posi‐
tion
❑ Due to the cracking
method used to sepa‐
rate the bearing cap
from the conrod in man‐
ufacture, the caps only
fit in one position and
only on the appropriate
conrod
❑ Mark conrod and cylin‐
der allocation with paint
-B-
❑ Installation position:
Projections -A- face to‐
wards pulley end
3 - Bearing shells
❑ Installation position
⇒ page 38
❑ Renew used bearing
shells
❑ Note version: Upper
bearing shell (closest to
piston) is constructed
from a more wear-re‐
sistant material ⇒ Electronic parts catalogue
❑ Check that it is securely seated
4 - Conrod
❑ With industrially cracked conrod bearing cap
❑ Only renew as a complete set
❑ Mark conrod bearing cap and cylinder allocation with paint -B-
❑ Axial clearance: wear limit: 0.37 mm
❑ Measuring radial clearance ⇒ page 43

❑ Separating parts of new conrod ⇒ page 42

❑ Installation position: Markings -A- face towards pulley end
5 - Circlip
❑ 2x
6 - Piston pin
7 - Piston
❑ With combustion chamber
❑ Renew piston if cracking is visible on piston crown or piston skirt
❑ Mark installation position and cylinder number
❑ Checking pistons and cylinder bores ⇒ page 41
❑ Measuring piston projection at “TDC” ⇒ page 40
8 - Compression rings
❑ Measuring ring gap ⇒ page 42
❑ Measuring ring-to-groove clearance ⇒ page 42
❑ Install using piston ring pliers - VAS 211 003- ⇒ page 38
❑ Allocation and installation position ⇒ page 37
❑ Offset gaps by 120°
9 - Oil scraper ring
❑ Measuring ring gap ⇒ page 42
❑ Measuring ring-to-groove clearance ⇒ page 42
❑ Install using piston ring pliers - VAS 211 003- ⇒ page 38
❑ Allocation and installation position ⇒ page 37
❑ Offset gap by 120° to bottom compression ring
Allocation of piston rings

1- Compression ring with marking “TOP” on top
2- Compression ring with marking “TOP” on top and chamfer
-arrow- on inner side (bottom)
3- Two-part oil scraper ring with marking “TOP” on top
4. Pistons and conrods 37

Installing piston rings

• Open up piston ring -2- using piston ring pliers - VAS 211 003-
just far enough to be able to slide it over piston -1-.
Installation position of bearing shells in conrods

– Insert bearing shells centrally in conrod and conrod bearing
cap.
• Dimension -a- = dimension -a-
Oil spray jet and pressure relief valve

1- Bolt with pressure relief valve, 24 Nm
2- Oil spray jet (for cooling of pistons)
• Installation position: align locating edge of oil spray jet with
machined surface of cylinder block.
NOTICE
Risk of damage to oil spray jets due to deformation.
– Never bend oil spray jets.
4.2 Removing and installing pistons


♦ Pin - VW 222A-
♦ Piston ring pliers - VAS 211 003-

Removing
• Engine secured to engine and gearbox support ⇒ page 13
– Remove cylinder head ⇒ page 67 .
– Mark installation position and matching of conrod bearing caps
to cylinder and to conrods for re-installation
⇒ Item 2 (page 36) .
– Unbolt conrod bearing caps.
– Pull out pistons upwards with conrods.
– Take circlip -2- out of piston pin boss.
– Use drift - VW 222A- to drive out piston pin -3-.
Note:
If piston pin is difficult to remove, heat piston to approx. 60 °C.
– Detach piston -1- from conrod -4-.
Installing
angle.
– Oil running surfaces of bearing shells.
– Install piston rings ⇒ page 38 .
– Install pistons using piston ring clamp.
Installation position:
• Bearing shells in conrods ⇒ page 38
– Install conrod bearing caps according to markings.
– Install cylinder head ⇒ page 67 .
– Perform adaptions required after renewing piston using ⇒ Ve‐
hicle diagnostic tester
page 9 .
Tightening torques
♦ ⇒ “4.1 Exploded view - pistons and conrods”, page 36

4.3 Measuring piston projection at TDC

Measure piston projection at “TDC” when installing new pistons
or a short engine.
♦ Measuring bridge -VW 382/7- from measuring tool - VW 382-
♦ Measuring plate -VW 385/17- from universal measuring tool -

VW 385-

Procedure
– Secure dial gauge - VAS 6079- with measuring bridge -
VW 382/7- and measuring plate -VW 385/17- to cylinder block
as shown in illustration.
– Measure projection at each piston at both locations marked
with -arrows- (seen in longitudinal direction of engine: at front
and rear of piston).
– Depending on piston projection, install corresponding cylinder
head gasket according to following table:
Piston projection above top sur‐ Identification
face of cylinder block (no. of holes)
mm
0.91 … 1.00 1
1.01 … 1.10 2
4.4 Checking pistons and cylinder bores

Checking piston
– Using a micrometer (75 ... 100 mm), measure approx. 15 mm
from the lower edge, perpendicular to the piston pin axis.
• Maximum deviation from nominal dimension: 0.04 mm.
• Check for wear on piston skirt coating and for any carbon de‐
posits.
• Renew piston if cracking is visible on piston skirt.
Piston ∅ mm
Nominal dimension 80.92 1)
• 1)Dimensions including coating (thickness 0.02 mm). The
coating will wear down in service.
Measuring cylinder bore

– Use a cylinder gauge - VAS 6078- to take measurements at 3
points in transverse direction -A- and in longitudinal direction
-B-.
• Maximum deviation from nominal dimension: 0.10 mm.
Checking cylinder bore
– Check cylinder bore for wear, scoring and other abnormalities.
Cylinder bore ∅ mm
Nominal dimension 81.0
• Do not measure the cylinder bore when the cylinder block is
mounted to the engine and gearbox support , as this may result
in incorrect measurements.

Measuring piston ring gap

– Insert ring at right angle to cylinder wall from above and push
down into lower cylinder opening approx. 15 mm from bottom
of cylinder.
– To do so, use a piston without rings.
Piston ring new Wear limit
mm mm
1. Compression ring 0.30 … 0.40 0.55
2. Compression ring 0.20 … 0.45 0.95
Oil scraper ring 0.25 … 0.50 0.75
Measuring ring-to-groove clearance

– Clean groove in piston before checking clearance.
Piston ring Wear limit
mm
1. Compression ring 0.08
2. Compression ring 0.08
Oil scraper ring 0.08
4.5 Separating parts of new conrod

It is possible that the two parts of a new conrod are not completely
separated as intended. If it is not possible to take off the conrod
bearing cap by hand, proceed as follows:
– Mark cylinder number of conrod ⇒ Item 4 (page 36) .
– Clamp conrod -1- lightly in a vice using aluminium jaw covers
as shown in illustration.
• To avoid any risk of damage, the conrod should only be clam‐
ped lightly.
• The conrod is clamped in a position below the dotted line.
– Loosen the two bolts -2- approx. 5 turns.
– Using a plastic hammer, carefully knock conrod bearing cap

-1- loose in direction of -arrow-.

4.6 Checking radial clearance of conrod

bearings
♦ Plastigauge
Procedure
– Remove conrod bearing cap. Clean bearing cap and bearing
journal.
– Place a length of Plastigauge corresponding to the width of the
bearing on the bearing journal or in the bearing shell.
– Fit conrod bearing cap and secure with old bolts
⇒ Item 1 (page 36) without rotating crankshaft.
– Remove conrod bearing cap again.
– Compare width of Plastigauge with measurement scale.
Radial clearance:
• Wear limit: 0.08 mm.
– Renew conrod bolts.

15 – Cylinder head, valve gear

1 Toothed belt drive
⇒ “1.1 Exploded view - toothed belt cover”, page 44
⇒ “1.2 Exploded view - toothed belt”, page 45
⇒ “1.3 Removing and installing toothed belt cover”, page 46
⇒ “1.4 Detaching toothed belt from camshaft”, page 48
⇒ “1.5 Removing and installing toothed belt”, page 53
1.1 Exploded view - toothed belt cover
1 - Toothed belt cover (bottom)

⇒ page 47
2 - Bolt
❑ With collar
❑ Captive in toothed belt
cover
❑ 12 Nm
3 - Bolt
❑ With collar
cover
❑ 12 Nm
4 - Bolt
❑ 2.5 Nm
5 - Coolant lines
6 - Bolt
❑ With collar
cover
❑ 12 Nm
7 - Toothed belt cover (side)
8 - Bolt
❑ 2.5 Nm
9 - Bracket
❑ For SCR supply line
10 - Bracket
❑ For electrical wiring
11 - Bracket
12 - Toothed belt cover (rear)
❑ To remove, take out coolant pump ⇒ page 126
13 - Bolt
❑ With collar
❑ Captive in toothed belt cover
44 Rep. gr.15 - Cylinder head, valve gear

❑ 12 Nm
14 - Toothed belt cover (top)
1.2 Exploded view - toothed belt
1 - Bolt
❑ Slacken and tighten with
counterhold tool - 3415-
❑ Do not additionally oil
threads and shoulder
❑ 180 Nm +135°
2 - Crankshaft sprocket
❑ Contact surface be‐
tween sprocket and
crankshaft must be free
of oil
❑ Can only be installed in
one position
3 - Bolt
❑ 20 Nm +90°
4 - Damper wheel
5 - Nut
❑ Make sure that stud
⇒ Item 7 (page 45) is
fitted securely
❑ 20 Nm +45°
6 - Tensioning roller
7 - Stud
❑ 15 … 18 Nm
8 - Toothed belt
❑ Before removing, mark
direction of rotation with
chalk or felt-tip pen
❑ Check for wear Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ Removing ⇒ page 53
❑ Installing (adjusting valve timing) ⇒ page 56
9 - Bolt
❑ Use counterhold tool - T10051A- when loosening and tightening
❑ Do not additionally oil threads and shoulder
❑ 100 Nm
10 - Locking bolt
❑ Self-locking
❑ 9 Nm
1. Toothed belt drive 45

11 - Camshaft sprocket
❑ Contact surface between sprocket, camshaft and locating arm for camshaft must be free of oil
12 - Locating arm for camshaft
13 - Idler roller
14 - Nut
❑ Tightening torque ⇒ Item 3 (page 182)
15 - High-pressure pump hub
❑ Exploded view ⇒ page 182
❑ Contact surface between high-pressure pump, high-pressure pump hub and high-pressure pump sprock‐
et must be free of oil
16 - High-pressure pump sprocket
❑ Contact surface between high-pressure pump, high-pressure pump hub and high-pressure pump sprock‐
et must be free of oil
17 - Bolt
❑ 20 Nm +90°
18 - Coolant pump
1.3 Removing and installing toothed belt

cover
⇒ “1.3.1 Removing and installing toothed belt cover (top)”,
page 46
⇒ “1.3.2 Removing and installing toothed belt cover (bottom)”,
page 47
1.3.1 Removing and installing toothed belt

cover (top)
♦ Hose clamps, up to 25 mm - 3094-

♦ Hose clip pliers - VAS 6362-
Removing
– Remove engine cover panel ⇒ page 16 .
– Move electrical wiring and SCR supply line -1- clear.
– Clamp off coolant hoses -4- with hose clamps, up to 25 mm -
3094- and move coolant lines clear.
– Place a cloth underneath to catch escaping coolant.
– Release hose clips -3- and disconnect coolant hoses.
– Remove bolt -2-, move coolant lines clear and push lines to‐
wards front.
– Remove bolt -2-.

– Release catches -arrows-, disengage toothed belt cover (top)
-1- and detach.
Installing
• Secure all hose connections with correct type of hose clips (as
original equipment) ⇒ Electronic parts catalogue .
– Install engine cover panel ⇒ page 16 .
Tightening torques
♦ ⇒ “1.1 Exploded view - toothed belt cover”, page 44
1.3.2 Removing and installing toothed belt

cover (bottom)
Removing
– Remove toothed belt cover (top) ⇒ page 46 .
– Remove vibration damper ⇒ page 22 .
– Remove bolt -arrow- and detach toothed belt cover (side)
-1-.

– Remove bolts -arrows-.

– Remove toothed belt cover (bottom) -1-.
Installing
– Fit toothed belt cover -arrow- (note position of dowel pin).
– Install vibration damper ⇒ page 22 .
– Install toothed belt cover (top) ⇒ page 46 .
Tightening torques
1.4 Detaching toothed belt from camshaft

♦ Counterhold tool - T10051A-
♦ Offset screwdriver - T10264-

♦ Crankshaft stop - T10490-
♦ Locking pin - T10492-
Removing
– Remove vibration damper ⇒ page 22 .
• Only turn crankshaft in direction of engine rotation.
– Rotate crankshaft by turning bolt on crankshaft sprocket until
camshaft sprocket is positioned at “TDC”.
• Locating arm -2- for camshaft must align with hole -1- behind
it in camshaft housing.

– Lock crankshaft sprocket in position with crankshaft stop -

T10490- .
• Pins of crankshaft stop - T10490- must engage in threaded
holes of crankshaft sprocket.
• Locking pin of crankshaft stop - T10490- must engage in hole
-arrow- on sealing flange.
– Slacken nut -1- for tensioning roller.

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

juster of tensioning roller clockwise -arrow- as far as stop and
tighten nut -1- by hand.
– Slacken bolt -arrow- by 90°; counterhold camshaft sprocket

-1- with counterhold tool - T10051A- when doing so.
– Take toothed belt -2- off camshaft sprocket. If necessary, push
toothed belt cover (right-side) slightly to right side.

NOTICE
Risk of damage to camshaft if handled incorrectly
– Never use camshaft clamp as a counterhold tool.
– Insert locking pin - T10492- through locating arm -2- for cam‐
shaft and into hole behind it in camshaft housing.
– If necessary, align camshaft sprocket using counterhold tool -
T10051A- .
– Remove locking bolt -1- and screw in new locking bolt loosely.
– Slacken nut -arrow- for toothed belt sprocket of high-pressure

pump approx. 90° using counterhold tool - T10051A- .
– Insert locking pin - T10492- into hub -2- and into hole -1- be‐
hind it in bracket for ancillaries.
– To do so, adjust toothed belt sprocket for high-pressure pump
using counterhold tool - T10051A- .
Installing (adjusting valve timing)
• Perform adjustments on toothed belt only when engine is cold.
• Renew nut for tensioning roller.
Requirements:
• Base plate -1- for tensioning roller must be engaged in cast
recess -arrow- on cylinder head, as shown.
• Tensioning roller is locked with locking tool - T10265- and se‐
cured at right stop with nut -2-.
• Crankshaft is locked in position with crankshaft stop - T10490-

-arrow-.

• Contact surface between high-pressure pump, high-pressure

pump hub and high-pressure pump sprocket must be free of
oil.
• Hub -1- of high-pressure pump locked in place with locking pin
- T10492- .
• Nut -arrow- for toothed belt sprocket for high-pressure pump
-2- screwed on loosely. It should just be possible to easily turn
the high-pressure pump sprocket, but there must be no axial
movement.
• Contact surface between camshaft, camshaft sprocket and

locating arm for camshaft must be free of oil.
• Locating arm for camshaft -1- is locked with locking pin -
T10492- .
• Bolt -arrow- for camshaft sprocket -2- screwed on loosely. It
should just be possible to turn the sprocket on the camshaft
easily without axial movement.
– Turn the camshaft sprocket and high-pressure pump sprocket

in their adjustment area clockwise as far as the stop.
– Install toothed belt in the specified sequence:
4 - High-pressure pump sprocket
3 - Idler roller
1 - Tensioning roller
2 - Camshaft sprocket
– Check positions of camshaft sprockets. To do so, turn cam‐

shaft sprocket -3- by hand as far as stop in direction of
-arrow- and hold it in place.
• Locking bolt -1- should now be positioned in approx. the bot‐
tom half of elongated hole -2-, as shown in illustration.
• At approx. centre of area of rotation -α-, toothed belt sprocket
for high-pressure pump -4- should now be aligned with locking
pin - T10492- , as shown in illustration.
• If the installation position of the toothed belt sprockets is not
correct, adjust position of toothed belt on sprocket in question.

• Base plate for tensioning roller must remain engaged in cast

recess on cylinder head.
– Loosen nut -1- for tensioning roller and detach locking tool -
T10265- .
– Carefully turn eccentric adjuster of tensioning roller clockwise

-arrow- using offset screwdriver - T10264- until pointer -2-
aligns with centre of slot on base plate.
• Nut -1- must not turn.
– Hold tensioning roller in this position and tighten nut.
– Using counterhold tool - T10051A- , apply tension to camshaft

sprocket in anti-clockwise direction -arrow-.
– Tighten bolt -1- for camshaft sprocket and nut -2- for high-
pressure pump sprocket to 20 Nm.
– Remove locking pins -T10492- and crankshaft stop - T10490-
and check valve timing ⇒ page 59 .
Checking valve timing ⇒ page 59
1.5 Removing and installing toothed belt


♦ Offset screwdriver - T10264-
♦ Locking pin - T10492-
♦ Crankshaft stop - T10490-
Removing
– Remove toothed belt cover (bottom) ⇒ page 47 .

NOTICE
Risk of damage to camshaft if handled incorrectly
– Never use camshaft clamp as a counterhold tool.
– Rotate crankshaft by turning bolt on crankshaft sprocket until

camshaft sprocket is positioned at “TDC”.
• Locating arm -2- for camshaft must align with hole -1- behind
it in camshaft housing.
– Lock crankshaft sprocket in position with crankshaft stop -

T10490- .
• Pins of crankshaft stop - T10490- must engage in threaded
holes of crankshaft sprocket.
• Locking pin of crankshaft stop - T10490- must engage in hole
-arrow- on sealing flange.
– Slacken nut -1- for tensioning roller.

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

juster of tensioning roller clockwise -arrow- as far as stop and
tighten nut -1- by hand.

– Slacken bolt -arrow- by 90°; counterhold camshaft sprocket

-1- with counterhold tool - T10051A- when doing so.
– Remove toothed belt -2-.
– Insert locking pin - T10492- through locating arm -2- for cam‐
shaft and into hole -arrow- behind it in camshaft housing.
– If necessary, align camshaft sprocket using counterhold tool -
T10051A- .
– Remove locking bolt -1- and screw in new locking bolt loosely.
– Slacken nut -arrow- for toothed belt sprocket of high-pressure

pump approx. 90° using counterhold tool - T10051A- .
– Insert locking pin - T10492- into hub -2- and into hole -1- be‐
hind it in bracket for ancillaries.
– To do so, adjust toothed belt sprocket for high-pressure pump
using counterhold tool - T10051A- .
Installing (adjusting valve timing)
• Perform adjustments on toothed belt only when engine is cold.
• Renew nut for tensioning roller.
Requirements:
• Base plate -1- for tensioning roller must be engaged in cast
recess -arrow- on cylinder head, as shown.
• Tensioning roller is locked with locking tool - T10265- and se‐
cured at right stop with nut -2-.

• Crankshaft is locked in position with crankshaft stop - T10490-

-arrow-.
• Contact surface between high-pressure pump, high-pressure

pump hub and high-pressure pump sprocket must be free of
oil.
• Hub -1- of high-pressure pump locked in place with locking pin
- T10492- .
• Nut -arrow- for toothed belt sprocket for high-pressure pump
-2- screwed on loosely. It should just be possible to easily turn
the high-pressure pump sprocket, but there must be no axial
movement.
• Contact surface between camshaft, camshaft sprocket and

locating arm for camshaft must be free of oil.
• Locating arm for camshaft -1- is locked with locking pin -
T10492- .
• Bolt -arrow- for camshaft sprocket -2- screwed on loosely. It
should just be possible to turn the sprocket on the camshaft
easily without axial movement.
– Turn the camshaft sprocket and high-pressure pump sprocket

in their adjustment area clockwise as far as the stop.
– Install toothed belt in the specified sequence:
1- Crankshaft sprocket
2- Tensioning roller
3- Camshaft sprocket
4- Damper wheel
5- High-pressure pump sprocket
6- Coolant pump sprocket

– Check positions of camshaft sprockets. To do so, turn cam‐

shaft sprocket -3- by hand as far as stop in direction of
-arrow- and hold it in place.
• Locking bolt -1- should now be positioned in approx. bottom
half of elongated hole -2-.
Note:
Locking bolt must not come into contact with top or bottom end of
elongated hole after toothed belt has been tensioned.
– Check that locking bolt -1- is located between centre and lower
end -2- of elongated hole. If necessary, adjust position of cam‐
shaft sprocket by moving it one tooth clockwise then fit toothed
belt again.
• At approx. centre of area of rotation -α-, toothed belt sprocket
for high-pressure pump -4- should now be aligned with locking
pin - T10492- .
Note:
Toothed belt sprocket for high-pressure pump must not reach up‐
per or lower end of area of rotation -α- after toothed belt has been
tensioned.
• If the installation position of the toothed belt sprockets is not
correct, adjust position of toothed belt on sprocket in question.
• Base plate for tensioning roller must remain engaged in cast

recess on cylinder head.
– Loosen nut -1- for tensioning roller and detach locking tool -
T10265- .
– Carefully turn eccentric adjuster of tensioning roller clockwise

-arrow- using offset screwdriver - T10264- until pointer -2-
aligns with centre of slot on base plate.
• Nut -1- must not turn.
– Hold tensioning roller in this position and tighten nut.

– Using counterhold tool - T10051A- , apply tension to camshaft

sprocket in anti-clockwise direction -arrow-.
– Tighten bolt -1- for camshaft sprocket and nut -2- for high-
pressure pump sprocket to 20 Nm.
– Remove locking pins -T10492- and crankshaft stop - T10490-
and check valve timing ⇒ page 59 .
Checking valve timing:
• Only turn crankshaft in direction of engine rotation.
– Turn crankshaft two rotations in direction of engine rotation by
turning bolt for crankshaft sprocket until crankshaft is just be‐
fore “TDC”.
– Fit crankshaft stop - T10490- to crankshaft sprocket again.

– Then turn crankshaft in direction of engine rotation until pin on
crankshaft stop - T10490- engages in hole -arrow- in sealing
flange as crankshaft rotates.
• If crankshaft has been turned past “TDC” position, turn crank‐
shaft two further rotations until it is again positioned just before
“TDC”. Then turn further in the same direction and lock crank‐
shaft with crankshaft stop - T10490- .
• It must be possible to lock locating arm -2- for camshaft using

locking pin - T10492- .
• It is very difficult to reproduce the locking position of the high-

pressure pump hub. However, a slight deviation -arrow- does
not influence engine operation.

• Pointer -1- on tensioning roller must be centred between tabs

on base plate -2-.
Note:
The maximum permissible sideways deviation from the specified
position is 5 mm.
If requirements are met, continue with procedure after adjusting
valve timing correctly as described below ⇒ page 61 .
Re-adjust valve timing if requirements are not met ⇒ page 60 .
Re-adjusting valve timing:

– If camshaft hub cannot be locked, withdraw crankshaft stop -
T10490- until pin is clear of bore -arrow-.
– Turn crankshaft in opposite direction of engine rotation slightly
past “TDC”.
– Now turn crankshaft slowly in direction of engine rotation until
it is possible to lock camshaft hub with locking pin - T10492- .
– After locking camshaft in place, loosen bolt for camshaft
sprocket; counterhold with counterhold tool - T10051A- to do
so.
If pin of crankshaft stop - T10490- is on left side of hole:

– Then turn crankshaft in direction of engine rotation until pin on
crankshaft stop - T10490- engages in hole -arrow- in sealing
flange as crankshaft rotates.
– Tighten bolt -arrow- for camshaft sprocket -1- to 20 Nm; to do

so, remove locking pin - T10492- and counterhold camshaft
sprocket using counterhold tool - T10051A- .

If pin of crankshaft stop - T10490- is on right side of hole:

– Turn crankshaft slightly in opposite direction to engine rota‐
tion.
– Turn crankshaft in direction of engine rotation again until pin
of crankshaft stop - T10490- engages in sealing flange as
crankshaft rotates.
– Tighten bolt -arrow- for camshaft sprocket -1- to 20 Nm; to do

so, remove locking pin - T10492- and counterhold camshaft
sprocket using counterhold tool - T10051A- .
Procedure after adjusting valve timing correctly:
– Remove locking pin - T10492- and crankshaft stop - T10490- .
– Turn crankshaft two rotations in direction of engine rotation by
turning bolt for crankshaft sprocket until crankshaft is just be‐
fore “TDC”.
– Check valve timing once again ⇒ page 59 .
– If locating arm for camshaft can now be locked, tighten bolt

-1- for camshaft sprocket to final torque ⇒ Item 9 (page 45) ;
to do so, remove locking pin - T10492- and counterhold cam‐
shaft sprocket using counterhold tool - T10051A- .
– Tighten nut -2- for high-pressure pump sprocket to final torque
⇒ Item 3 (page 182) ; to do so, use counterhold tool -
T10051A- .
– Check valve timing once again ⇒ page 59 .
Assembling
Further installation is carried out in the reverse order; note the
following:
• Renew seals after removing.
– Tighten locking bolt -arrow-.

– Install toothed belt cover ⇒ page 47 .
Tightening torques

2 Cylinder head
⇒ “2.1 Exploded view - cylinder head cover”, page 62
⇒ “2.2 Exploded view - cylinder head”, page 64
⇒ “2.3 Removing and installing cylinder head cover”, page 65
⇒ “2.4 Removing and installing seals for injectors”, page 66
⇒ “2.5 Removing and installing cylinder head”, page 67
⇒ “2.6 Removing and installing camshaft housing”, page 83
⇒ “2.7 Checking compression”, page 87
2.1 Exploded view - cylinder head cover
1 - Gasket
❑ Renew if damaged or
leaking
2 - Cylinder head cover
⇒ page 65
3 - Bolt
❑ Renew if gasket is dam‐
aged
4 - Heat shield
5 - Bolt
❑ 8 Nm
6 - Grommet
❑ In cylinder head cover
7 - Seal
❑ For injector
8 - O-ring
❑ Not supplied separately
❑ Renew hose
⇒ Item 9 (page 62) if
damaged or leaking
9 - Hose
❑ For crankcase breather
❑ Press release tabs on
both sides to detach
10 - O-ring
❑ Renew hose ⇒ Item 9 (page 62) if damaged or leaking
11 - Sealing cap
12 - Seal
❑ For sealing cap

13 - Grommet
14 - Noise insulation
Cylinder head cover - tightening torque and sequence

– Tighten bolts for cylinder head cover in the sequence -1 ... 8-
to 9 Nm.
2. Cylinder head 63
2.2 Exploded view - cylinder head
1 - Cylinder block
2 - Cylinder head gasket
❑ Identification of cylinder
head gasket
⇒ page 65
❑ If renewed, change
coolant and engine oil
3 - Cylinder head
⇒ page 67
❑ To prevent damage to
glow plugs, always
place cylinder head on a
soft foam surface after
removal.
❑ Checking for distortion
⇒ page 65
❑ Must not be machined
❑ Before installing, check
that the two dowel
sleeves for centring cyl‐
inder head are fitted on
cylinder block
❑ If renewed, change
coolant and engine oil
4 - Washer
5 - Bolt
❑ Correct sequence when
slackening ⇒ page 82
6 - Bolt
❑ 20 Nm +45°
7 - Engine lifting eye
8 - Seal
9 - Plug
❑ 14 Nm
10 - Dowel pin
❑ For camshaft housing
11 - Dowel pin
❑ For intake manifold with charge air cooler
12 - Dowel pin
❑ For cylinder head

Checking cylinder head for distortion

– Use straight edge 500 mm - VAS 6075- and feeler gauge to
measure cylinder head for distortion at several points.
• Max. permissible distortion: 0.1 mm.
• Cylinder heads must not be reworked on TDI engines.
Identification of cylinder head gasket

1- Holes
2- Part number
♦ Select new cylinder head gasket on basis of number of holes
in old cylinder head gasket.
♦ If parts of the crankshaft drive have been renewed, select the
new cylinder head gasket by measuring the piston projection
at “TDC” ⇒ page 40 .
Cylinder head - tightening torque and sequence

angle.
– Tighten bolts -1 ... 10- in stages in the sequence shown:
Stage Tightening torque/angle specification
1. 30 Nm
2. 70 Nm
3. Turn 90° further
2.3 Removing and installing cylinder head

cover
Removing
– Remove high-pressure reservoir (rail) ⇒ page 179 .
2. Cylinder head 65
– Remove injectors ⇒ page 173 .

– Press release tabs on both sides and disconnect crankcase
breather hose from cylinder head cover -arrow-.
– Slacken cylinder head cover bolts in the sequence -8 ... 1- and
remove.
– Detach cylinder head cover.
Installing
• Renew gasket and bolts for cylinder head cover if damaged or
leaking.
– Install injectors ⇒ page 173 .
– Install high-pressure reservoir (rail) ⇒ page 179 .
– Install toothed belt cover (top) ⇒ page 46 .
Tightening torques
♦ ⇒ Fig. ““Cylinder head cover - tightening torque and se‐
2.4 Removing and installing seals for injec‐

tors
♦ Carrier - 3390-
♦ Pliers -VAS 211 007- (not illustrated)

Procedure
• Injector removed ⇒ page 173 .
– Pull off seal -1- using pliers -VAS 211 007- -arrow-.

– Use suitable thrust piece (e.g. carrier - 3390- ) and short ex‐
tension -1- to press new injector seal in from above -arrow- as
far as stop.
2.5 Removing and installing cylinder head

⇒ “2.5.1 Removing and installing cylinder head - version without
water-cooled turbocharger”, page 67
⇒ “2.5.2 Removing and installing cylinder head - version with wa‐
ter-cooled turbocharger”, page 76
2.5.1 Removing and installing cylinder head -

version without water-cooled turbo‐
charger
♦ Lifting tackle - 2024A-
2. Cylinder head 67
♦ Tensioning strap - T10038-
♦ Bracket - T10059-
♦ Bit XZN 10 - T10501-
♦ Bolt, M8x20 (2x)

Removing
Cylinder head; Removing and installing cylinder head .

– Remove heat shield for drive shaft (right-side) ⇒ Running

gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
installing heat shield for drive shaft .
– Unplug electrical connector -arrow- and move electrical wire
clear.
– Open clip -1- and move electrical wiring clear.

– Release screw-type clip -3- and detach air pipe.
– Lift retaining clip -2-, release hose clip -1- and disconnect
coolant hoses.
– Release screw-type clips -arrows- and detach exhaust gas

recirculation pipe -1-.
2. Cylinder head 69
– Unplug electrical connectors and move electrical wiring clear:

1- For turbocharger 1 control unit - J724- (fitting location varies)
2- For heater element for crankcase breather - N79-
3- For exhaust gas pressure sensor 1 - G450-
4- For exhaust gas recirculation valve 2 - GX6-
6- For fuel pressure regulating valve - N276-
7- For fuel pressure sender - G247-
Pfeile - For injectors

1- For injector for reducing agent - N474-
2- For coolant valve for cylinder head - N489-
3- For exhaust gas temperature sender 1 - G235-
4- For Hall sender - G40-
5- For fuel pressure sender for low pressure - G410-
6- For charge air temperature sender after charge air cooler -
G811-
9- For throttle valve module - GX3-
10 - For charge pressure sender - G31-
11 - For charge air temperature sender before charge air cooler
- G810-
Pfeile - For glow plugs
– Pull wiring duct off fuel rail and move electrical wiring harness
to side.
– Remove nuts -3- and detach bracket -2-.

– Remove catalytic converter ⇒ page 205 .
– Unscrew bolts -5- and move particulate filter to right side.
– Bring engine support and engine mounting into installation po‐
sition and hand-tighten bolts.
– Lower engine onto engine mounting and detach support
bracket - 10-222A- ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve
common rail; Rep. gr. 10 ; Engine mountings; Supporting en‐
gine in installation position .

– Unscrew bolts -arrows- and detach oil return line -3-.

– Remove bolt -1- and union nut -4- and detach oil supply line
-2-.
– Unscrew bolts -1, 3- and detach bracket -2- for turbocharger.
– Remove bolts -2- and press bracket -1- with auxiliary pump for
heating - V488- downwards slightly (different versions).
– Loosen bolt -4- and remove bolt -3- for bracket.
– Release hose clips -2, 3- and disconnect coolant hoses.

– Lift retaining clips -4- and detach coolant connection.
2. Cylinder head 71
– Unplug electrical connector -arrow- for engine temperature

sender - G27- .
– Remove camshaft housing ⇒ page 83 .
– Remove bolt -3- for dipstick guide tube.

– Unscrew bolt -arrow- and remove idler roller.

– Unplug electrical connector -1- and move clear.

– Remove bolt -1- for bracket for ancillaries.

– Unscrew bush -2- a few turns.

VAS 6100- .
– Attach lifting tackle - 2024A- to cylinder head and workshop
hoist, as shown.
CAUTION
Risk of injury if cylinder head drops when it is lifted
– The support hooks and retaining pins on the lifting tackle
must be secured with locking pins.
2. Cylinder head 73
– Slacken cylinder head bolts in the sequence -1 ... 10-.
NOTICE
Risk of damage to lines and hoses when lifting out cylinder head
– Check that all lines and hoses have been disconnected at
cylinder head.
– Lift off cylinder head.

• After removal, the cylinder head must not be put down on the
sealing surface with the glow plugs still installed because the
glow plugs project slightly beyond the sealing surface.
Installing
angle.
• Renew self-locking nuts, seals, gaskets and O-rings.
• Oil contact surfaces between roller rocker fingers and cams.
• After fitting a new cylinder head or cylinder head gasket,
change engine oil and coolant in entire cooling system.
• Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
• Handle the cylinder head gasket very carefully to ensure it is
not damaged.
– Carefully remove sealant residue from cylinder head and cyl‐
inder block.
– Carefully remove any remaining emery and abrasive material.
– Clean blind holes for cylinder head bolts in cylinder block so
that they are free of oil and coolant residue.
– Before fitting cylinder head, remove crankshaft stop - T10490-
and turn crankshaft against normal direction of rotation until
all pistons are positioned approximately equally below “TDC”.
– If not already fitted, install dowel sleeves for centring cylinder
block and cylinder head in cylinder block.
– Note cylinder head gasket identification ⇒ page 65 .

– Fit cylinder head gasket onto dowel pins -arrows- in cylinder

block.
• Installation position of cylinder head gasket: the word
“oben” (top) or the part number should face towards the cyl‐
inder head.
– Fit cylinder head.
– Fit and tighten cylinder head bolts ⇒ page 65 .
Note:
Cylinder head bolts do not have to be torqued down again later
after repair work.
Remaining installation steps are carried out in reverse sequence;
note the following:
– Install camshaft housing ⇒ page 83 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Install catalytic converter ⇒ page 205 .
– Install exhaust gas recirculation cooler ⇒ page 232 .
– Change engine oil ⇒ page 104 .
– Connect coolant hose with plug-in connector ⇒ 4-cylinder TDI
engine, 2.0 ltr. 4-valve common rail; Rep. gr. 19 ; Radiators/
radiator fan; Exploded view - radiators/radiator fan .
– Change coolant; to do so, fill coolant expansion tank and carry
out bleeding routine using ⇒ Vehicle diagnostic tester ⇒ 4-
Cooling system/coolant; Draining and filling cooling system .
ltr. 4-valve common rail; Rep. gr. 15 ; Cylinder head; Removing
and installing cylinder head
– Perform adaptions required after renewing cylinder head using
⇒ Vehicle diagnostic tester
page 9 .
Tightening torques
♦ ⇒ “2.2 Exploded view - cylinder head”, page 64
♦ ⇒ “1.1 Exploded view - sump/oil pump”, page 102
♦ ⇒ 4-cylinder TDI engine (2.0 ltr. 4-valve common rail); Rep.
gr. 19 ; Coolant pump/thermostat assembly; Exploded view -
electric coolant pump
♦ ⇒ “1.1 Exploded view - turbocharger”, page 134
♦ ⇒ Fig. ““Intake manifold with charge air cooler - tightening tor‐
que and sequence”“ , page 157
♦ ⇒ “5.1 Exploded view - exhaust gas recirculation system”,
page 228
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
Removing and installing heat shield for drive shaft
2. Cylinder head 75
2.5.2 Removing and installing cylinder head -

version with water-cooled turbocharger
♦ Lifting tackle - 2024A-
♦ Tensioning strap - T10038-
♦ Bracket - T10059-

♦ Bit XZN 10 - T10501-
♦ Bolt, M8x20 (2x)

Removing
Cylinder head; Removing and installing cylinder head .
– Remove exhaust gas recirculation cooler ⇒ page 232 .
– Unplug electrical connector -arrow- and move electrical wire
clear.
2. Cylinder head 77

1- For turbocharger 1 control unit - J724-
2- For heater element for crankcase breather - N79-
3- For exhaust gas pressure sensor 1 - G450-
6- For fuel pressure regulating valve - N276-
7- For fuel pressure sender - G247-

G811-
- G810-
to side.
– Remove bolt -arrow-.

– Loosen bolt -1- for coolant line.

– Release hose clips -arrows- and disconnect coolant hoses.
– Remove nuts -3- and detach bracket -2-.

– Unscrew bolts -5- and move particulate filter to right side.
– Bring engine support and engine mounting into installation po‐
sition and hand-tighten bolts.
– Lower engine onto engine mounting and detach support
bracket - 10-222A- ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve
common rail; Rep. gr. 10 ; Engine mountings; Supporting en‐
gine in installation position .

-2-.
– Unscrew bolts -1, 3- and detach bracket -2- for turbocharger.
2. Cylinder head 79
heating - V488- downwards slightly.

– Lift retaining clips -4- and detach coolant connection.
– Unplug electrical connector -arrow- for engine temperature

sender - G27- .



– Remove bolt -1- for bracket for ancillaries.

– Unscrew bush -2- a few turns.
2. Cylinder head 81

VAS 6100- .
– Attach lifting tackle - 2024A- to cylinder head and workshop
hoist, as shown.
CAUTION
Risk of injury if cylinder head drops when it is lifted
– The support hooks and retaining pins on the lifting tackle
must be secured with locking pins.
– Slacken cylinder head bolts in the sequence -1 ... 10-.
NOTICE
Risk of damage to lines and hoses when lifting out cylinder head
– Check that all lines and hoses have been disconnected at
cylinder head.
– Lift off cylinder head.

• After removal, the cylinder head must not be put down on the
sealing surface with the glow plugs still installed because the
glow plugs project slightly beyond the sealing surface.
Installing
angle.
• Renew self-locking nuts, seals, gaskets and O-rings.
• Oil contact surfaces between roller rocker fingers and cams.
• After fitting a new cylinder head or cylinder head gasket,
change engine oil and coolant in entire cooling system.
• Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
• Handle the cylinder head gasket very carefully to ensure it is
not damaged.
– Carefully remove sealant residue from cylinder head and cyl‐
inder block.
– Carefully remove any remaining emery and abrasive material.
– Clean blind holes for cylinder head bolts in cylinder block so
that they are free of oil and coolant residue.
– Before fitting cylinder head, remove crankshaft stop - T10490-
and turn crankshaft against normal direction of rotation until
all pistons are positioned approximately equally below “TDC”.
– If not already fitted, install dowel sleeves for centring cylinder
block and cylinder head in cylinder block.
– Note cylinder head gasket identification ⇒ page 65 .

– Fit cylinder head gasket onto dowel pins -arrows- in cylinder

block.
• Installation position of cylinder head gasket: the word
“oben” (top) or the part number should face towards the cyl‐
inder head.
– Fit cylinder head.
– Fit and tighten cylinder head bolts ⇒ page 65 .
Note:
Cylinder head bolts do not have to be torqued down again later
after repair work.
note the following:
– Change engine oil ⇒ page 104 .
– Change coolant; to do so, fill coolant expansion tank and carry
out bleeding routine using ⇒ Vehicle diagnostic tester ⇒ 4-
Cooling system/coolant; Draining and filling cooling system .
ltr. 4-valve common rail; Rep. gr. 15 ; Cylinder head; Removing
and installing cylinder head
– Perform adaptions required after renewing cylinder head using
⇒ Vehicle diagnostic tester
page 9 .
Tightening torques
♦ ⇒ “2.2 Exploded view - cylinder head”, page 64
♦ ⇒ Fig. ““Intake manifold with charge air cooler - tightening tor‐
que and sequence”“ , page 157
2.6 Removing and installing camshaft hous‐

ing
2. Cylinder head 83
♦ Puller - T10055-
♦ Electric drill with plastic brush attachment

♦ Safety goggles
♦ Sealant ⇒ Electronic parts catalogue
Removing
• Cylinder head installed.
– Detach toothed belt from camshaft
⇒ “1.4 Detaching toothed belt from camshaft”, page 48 .
– Remove cylinder head cover
⇒ “2.3 Removing and installing cylinder head cover”,
page 65 .
– Unplug electrical connector -1- for exhaust gas pressure sen‐
sor 1 - G450- .
– Take electrical connector -2- for exhaust gas temperature
sender 4 - G648- out of bracket.
Note:
♦ Make sure that you do not damage vacuum hose.
♦ If damaged, vacuum hose must be renewed.
– Unlock -arrow A- and release -arrow B- fastener, and detach
vacuum hose.
– Remove bolts -3- and press bracket to one side.
– Remove bolt -4- for fuel lines.
– Unplug electrical connector -1- for Hall sender - G40- .

– Remove bolts -arrows- and press fuel lines to side.

– Remove locking pin - T10492- .

– Remove bolt -arrow- and detach camshaft sprocket -2-.
– Remove bolt -arrow- and detach toothed belt cover (side)

-1-.
– Remove bolt -arrow- for toothed belt cover (rear) -1-.
– Loosen and remove bolts for camshaft housing in the se‐

quence -15 ... 1-.
2. Cylinder head 85
– Using puller - T10055- , carefully release camshaft housing

from bonded joint at projections -arrows- and detach it.
• Press toothed belt cover (rear) slightly to front in order to de‐
tach camshaft housing.
Installing
Requirements:
• Crankshaft locked in position with crankshaft stop - T10490- .
– Cover exposed parts of the engine with clean cloths.
CAUTION
Risk of eye injury due to sealant residue.
– Remove remaining sealant from cylinder head and camshaft

housing -1- using rotating plastic brush or similar.
– Clean surfaces; they must be free of oil and grease.
• Note expiry date of sealant.

– Cut off nozzle of tube at front marking (nozzle ∅ approx.
1.5 mm).

– Apply bead of sealant -arrow- onto clean sealing surfaces of

camshaft housing, as shown.
• Width of sealant bead: 2 mm.
• Install the camshaft housing within 5 minutes after applying
the sealant.
• After installing the camshaft housing, wait about 30 minutes
for the sealant to dry.
– Carefully fit camshaft housing on cylinder head, paying atten‐
tion to dowel pins.
– Bring camshaft sprocket -2- into installation position and screw

in bolt -arrow- until it makes contact.
– Lock locating arm for camshaft -1- with locking pin - T10492- .
– Tighten camshaft housing bolts ⇒ page 91 .
note the following:
– Install cylinder head cover ⇒ page 65 .
Tightening torques
♦ ⇒ Fig. ““Camshaft housing - tightening torque and sequence”“ ,
page 91
♦ ⇒ “4.2 Exploded view - high-pressure reservoir (rail)”,
page 165
♦ ⇒ “7.1 Exploded view - Lambda probe”, page 195
2.7 Checking compression

⇒ “2.7.1 Checking using diagnostic tester”, page 87
⇒ “2.7.2 Checking using compression tester”, page 88
2.7.1 Checking using diagnostic tester

Compression pressure can be checked with a vehicle diagnostic
tester or with compression tester - V.A.G 1763- .
♦ Vehicle diagnostic tester
Procedure
– Switch on ignition.
– Select Engine electronics in vehicle self-diagnosis.
2. Cylinder head 87
– Select Subsystems, conditions .

– Select Compression check from list.
• If the result for one of the cylinders is unusual, check the com‐
pression using the compression tester - V.A.G 1763- .
2.7.2 Checking using compression tester

♦ Compression tester - V.A.G 1763- with adapter - V.A.G
1763/8-
Procedure
• Engine oil temperature at least 30 ℃
• Battery voltage at least 12.5 V
– Unplug electrical connector -arrow- at fuel pressure regulating
valve - N276- .
– Remove all glow plugs ⇒ page 239 .

– Screw in adapter - V.A.G 1763/8- in place of corresponding

glow plug and connect compression tester - V.A.G 1763- .
(Using the compression tester ⇒ Operating instructions .)
• A second mechanic is required for the following step.
– Have a second mechanic operate starter until tester shows no
further pressure increase.
– Repeat procedure on each cylinder.
Compression pressure bar
When new 25.0 … 31.0
Wear limit 19.0
Maximum difference between cylinders 5.0
Assembling
– Install glow plugs ⇒ page 239 .
– Erase any entries in event memory resulting from testing ⇒ Ve‐
hicle diagnostic tester.
Tightening torques
2. Cylinder head 89
3 Valve gear
⇒ “3.1 Exploded view - valve gear”, page 90
⇒ “3.2 Removing and installing camshaft oil seal”, page 91
⇒ “3.3 Removing and installing valve stem oil seals”, page 93
3.1 Exploded view - valve gear

Cylinder heads with cracks between the valve seats may be used
without reducing engine life, provided the cracks are small and
not more than 0.5 mm wide.
1 - Valve
❑ Must not be machined;
only grinding-in is per‐
missible
❑ Mark installation posi‐
tion for re-installation
❑ Checking ⇒ page 100
❑ Valve dimensions
⇒ page 101
❑ Checking valve guides
⇒ page 100
2 - Cylinder head
❑ Valve seats may not be
machined due to the
very small tolerances
3 - Valve stem oil seal
4 - Valve spring
5 - Valve spring plate
6 - Valve cotters
7 - Roller rocker finger
⇒ “2.6 Removing and in‐
stalling camshaft hous‐
ing”, page 83
❑ Mark installation posi‐
tion for re-installation
❑ Check roller bearings
for ease of movement
❑ Lubricate contact surfa‐
ces before installing
8 - Sealing cap
❑ Renew if damaged or leaking
❑ Removing: With camshaft housing installed, pierce sealing cap in centre with an awl and pry out
❑ Installing: Drive in without sealant onto stop using suitable thrust piece, e.g. carrier - 3390-
9 - Oil seal
10 - Camshaft housing
❑ With integrated camshafts
❑ Removing and installing ⇒ “2.6 Removing and installing camshaft housing”, page 83

11 - Bolt
❑ Correct sequence when slackening ⇒ page 85
12 - Gasket
13 - Bolt
❑ Tightening torque ⇒ Brake system; Rep. gr. 47 ; Vacuum system; Exploded view - vacuum pump
14 - Vacuum pump
❑ Exploded view ⇒ Brake system; Rep. gr. 47 ; Vacuum system; Exploded view - vacuum pump
15 - Retaining clip
❑ For roller rocker fingers
16 - Hydraulic compensation element
❑ Mark installation position for re-installation
❑ Lubricate contact surfaces before installing
17 - Dowel pin
❑ For camshaft housing
Camshaft housing - tightening torque and sequence

angle.
Stage Procedure/tightening torque
1. Screw in by hand until bolt heads make contact with
retaining frame
2. Continue tightening 1 turn at a time in several stages
until retaining frame makes full contact with cylinder
head and a torque of 8 Nm is reached
3. 8 Nm
3.2 Removing and installing camshaft oil

seal
♦ Assembly tool - T10493- with -T10493/3- , -T10493/4- and -
T10493/5-
3. Valve gear 91
♦ Hook - T40207-
Removing
– Detach toothed belt from camshaft ⇒ page 48 .
– Remove locking pin - T10492- .
– Remove bolt -arrow- and detach camshaft sprocket -2-.
– Engage hook - T40207- at oil seal -1- -arrow- and pull out oil
seal.
– Clean contact surface and sealing surface.
– Fit guide sleeve -T10493/4- onto camshaft.

– The sealing lip of the oil seal must not be additionally oiled or
greased.
– Carefully push oil seal -1- over guide sleeve and onto cam‐
shaft.
• When pressing in oil seal, guide sleeve remains on camshaft.
– Press oil seal in onto stop using press tool -T10493/5- and bolt
-T10493/3- .
3.3 Removing and installing valve stem oil

seals
⇒ “3.3.1 Removing and installing valve stem oil seals (cylinder
head installed)”, page 93
⇒ “3.3.2 Removing and installing valve stem oil seals (cylinder
head removed)”, page 96
3.3.1 Removing and installing valve stem oil

seals (cylinder head installed)
♦ Removal and installation device for valve cotters - VAS 5161
A-
♦ Assembly cartridge, spacer sleeve and fitting tool from guide

plate - VAS 5161A/32- (not illustrated)
♦ Guide plate - VAS 5161A/41- (not illustrated)
♦ Valve stem seal puller -T40426- (not illustrated)
♦ Valve shaft seal fitting tool -T404196- (not illustrated)
♦ Assembly sleeve ⇒ Electronic parts catalogue
Procedure
– Remove all glow plugs ⇒ page 239 .
– Mark original positions of roller rocker fingers and hydraulic
compensation elements for re-installation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and put down on a clean surface.
– Set piston of appropriate cylinder to “bottom dead centre”.
3. Valve gear 93
– Fit guide plate -VAS 5161 A/41- onto cylinder head and align
it with valves.
• The lettering “A” faces towards turbocharger side
• The lettering “E” faces towards intake manifold side
– Secure guide plate with bolts -arrows- by hand.
– Screw sealing pin -VAS 5161/10- into guide plate.

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

VAS 5161/5- into guide plate.
– Insert assembly cartridge -VAS 5161/32-1- (slide on spacer
sleeve -VAS 5161 A/32-2- ) in guide plate.
– Connect adapter to compressed air line using a commercially
available connection piece and apply constant air pressure.
• Minimum pressure: 6 bar
– Attach pressure fork -VAS 5161/2- to snap-in device and push
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth slightly; the valve cotters
are thus forced apart and taken up by the assembly cartridge.
– Release pressure fork.
– Take off assembly cartridge with sleeve.
– Detach valve spring with valve spring plate.

– Pull off valve stem oil seal with valve stem seal puller -
T40426- .
• To avoid damaging the new valve stem oil seal -4- during in‐
stallation, fit the assembly sleeve -3- onto the valve stem -2-.
– Lightly oil sealing lip of valve stem oil seal.
– Insert valve stem oil seal into valve shaft seal fitting tool -
T40419- and use assembly sleeve to carefully press it onto
valve guide -1- as far as stop.
– Remove assembly sleeve .
If valve cotters have been removed from assembly cartridge, they

must first be inserted in fitting tool -VAS 5161 A/32-3- .
• Larger diameter of valve cotters faces upwards.
– Insert valve spring and valve spring plate.
– Press assembly cartridge onto insertion device from above
and take up valve cotters.
3. Valve gear 95
– Insert assembly cartridge in guide plate -VAS 5161 A/41-

again.
– Press down pressure fork and pull knurled screw upwards
while turning screw in both directions - this will insert the valve
cotters.
– Release pressure fork with knurled screw still in pulled posi‐
tion.
– Repeat procedure for each valve.
Assembling
– Ensure that all roller rocker fingers make contact with the ends
of the valve stems correctly and are clipped onto their respec‐
tive hydraulic compensation elements.
– Install glow plugs ⇒ page 238 .
3.3.2 Removing and installing valve stem oil

seals (cylinder head removed)
♦ Removal and installation device for valve cotters - VAS 5161
A-
♦ Assembly cartridge, spacer sleeve and fitting tool from guide

plate - VAS 5161A/32- (not illustrated)
♦ Guide plate - VAS 5161A/41- (not illustrated)
♦ Engine and gearbox support - VAS 6095A-

♦ Cylinder head tensioning device - VAS 6419-
♦ Valve stem seal puller -T40426- (not illustrated)

♦ Valve shaft seal fitting tool -T404196- (not illustrated)
♦ Assembly sleeve ⇒ Electronic parts catalogue
Procedure
– Mark original positions of roller rocker fingers and hydraulic
compensation elements for re-installation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and put down on a clean surface.
– Remove cylinder head ⇒ page 67 .
• Intake manifold with charge air cooler and turbocharger must
be detached from cylinder head after it has been removed.
– Insert cylinder head tensioning device - VAS 6419- into engine
and gearbox support - VAS 6095- .
– Secure cylinder head in cylinder head tensioning device as
shown.
– Connect cylinder head tensioning device to compressed air
supply.
– Using lever -arrow-, slide air pad under combustion chamber
where valve stem oil seal is to be removed.
– Apply just enough compressed air to bring air pad into contact
with valve heads.
– Fit guide plate -VAS 5161 A/41- onto cylinder head and align
it with valves.
• The lettering “A” faces towards turbocharger side
• The lettering “E” faces towards intake manifold side
– Secure guide plate with bolts -arrows- by hand.
3. Valve gear 97
– Insert drift -VAS 5161/3A- into guide plate and use plastic-
headed hammer to release sticking valve cotters.
– Screw snap-in device -VAS 5161/6- with engaging fork -

VAS 5161/5- into guide plate.
– Insert assembly cartridge -VAS 5161/32-1- (slide on spacer
sleeve -VAS 5161 A/32-2- ) in guide plate.
– Attach pressure fork -VAS 5161/2- to snap-in device and push
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth slightly; the valve cotters
are thus forced apart and taken up by the assembly cartridge.
– Release pressure fork.
– Take off assembly cartridge with sleeve.
– Detach valve spring with valve spring plate.
– Pull off valve stem oil seal with valve stem seal puller -
T40426- .

• To avoid damaging the new valve stem oil seal -4- during in‐
stallation, fit the assembly sleeve -3- onto the valve stem -2-.
– Lightly oil sealing lip of valve stem oil seal.
– Insert valve stem oil seal into valve shaft seal fitting tool -
T40419- and use assembly sleeve to carefully press it onto
valve guide -1- as far as stop.
– Remove assembly sleeve .
If valve cotters have been removed from assembly cartridge, they

must first be inserted in fitting tool -VAS 5161A/32-3- .
• Larger diameter of valve cotters faces upwards.
– Insert valve spring and valve spring plate.
– Press assembly cartridge onto insertion device from above
and take up valve cotters.
– Insert assembly cartridge in guide plate -VAS 5161 A/41-

again.
– Press down pressure fork and pull knurled screw upwards
while turning screw in both directions - this will insert the valve
cotters.
– Release pressure fork with knurled screw still in pulled posi‐
tion.
– Repeat procedure for each valve.
Assembling
– Ensure that all roller rocker fingers make contact with the ends
of the valve stems correctly and are clipped onto their respec‐
tive hydraulic compensation elements.
3. Valve gear 99
4 Inlet and exhaust valves

⇒ “4.1 Checking valve guides”, page 100
⇒ “4.2 Checking valves”, page 100
⇒ “4.3 Valve dimensions”, page 101
4.1 Checking valve guides

♦ Universal dial gauge bracket - VW 387-
Procedure
• If the valve has to be renewed as part of a repair, use a new
valve for the measurement.
• Only insert inlet valve into inlet valve guide and exhaust valve
into exhaust valve guide, as the stem diameters are different.
– Attach dial gauge - VAS 6079- with universal dial gauge brack‐
et - VW 387- to cylinder head.
– Insert valve into guide.
• End of valve stem must be flush with guide.
– Measure the amount of sideways play.
• Wear limit: 1.0 mm.
– If the wear limit is exceeded, repeat the measurement with
new valves.
– Renew cylinder head if wear limit is still exceeded. Valve
guides cannot be renewed.
4.2 Checking valves

– Visually inspect for scoring on valve stems and valve seat sur‐
faces.

– Renew valve if scoring is clearly visible.
4.3 Valve dimensions

• Inlet and exhaust valves must not be machined. Only grinding-
in is permitted.
Dimension Inlet valve Exhaust valve
∅a mm 28.1 ± 0.1 25.0 ± 0.1
∅b mm 4.975 ± 0.007 4.965 ± 0.007
c mm 99.3 99.3
α ∠ 45° 10’ ± 10’ 45° 10’ ± 10’
4. Inlet and exhaust valves 101

17 – Lubrication
1 Sump/oil pump
⇒ “1.1 Exploded view - sump/oil pump”, page 102
⇒ “1.2 Engine oil”, page 104
⇒ “1.3 Removing and installing sump (bottom section)”,
page 105
⇒ “1.4 Removing and installing sump (top section)”, page 106
⇒ “1.5 Removing and installing oil pump”, page 109
⇒ “1.6 Removing and installing oil level and oil temperature send‐
er G266 ”, page 109
1.1 Exploded view - sump/oil pump

♦ If large quantities of metal shavings or particles are found in
the engine oil when repairing the engine, the oil passages
must be cleaned carefully in order to prevent further damage
occurring later. In addition, renew oil spray jets, engine oil
cooler and oil filter.
♦ Oil spray jet and pressure relief valve ⇒ page 38
1 - Spreader rivet
2 - Noise insulation
3 - Sealing plug/oil drain plug
❑ Drive in sealing plug as
far as stop
❑ Oil drain plug: 30 Nm
4 - O-ring
5 - Bolt
❑ Self-locking
❑ Clean threaded holes
for bolts using a thread
tap or similar
❑ 8 Nm +90°
6 - Oil intake pipe
7 - O-ring
8 - Bolt
sequence
⇒ Fig. ““Oil pump - tight‐
ening torque and se‐
9 - Oil pump
⇒ page 109
10 - Toothed belt
❑ To remove, remove
sealing flange (pulley
102 Rep. gr.17 - Lubrication

end) ⇒ page 23
11 - Cylinder block
12 - O-ring
❑ Renew if leaking
13 - Plug
❑ For dipstick guide tube
14 - Bolt
❑ 8 Nm
15 - Dipstick guide tube
16 - Bolt
❑ 8 Nm
17 - O-ring
18 - Sump (top section)
❑ Removing and installing ⇒ “1.4 Removing and installing sump (top section)”, page 106
19 - Bolt
❑ Tightening torque and sequence
⇒ Fig. ““Sump (top section) - tightening torque and sequence”“ , page 104
20 - Bolt
⇒ Fig. ““Sump (top section) - tightening torque and sequence”“ , page 104
21 - Gasket
22 - Sump (bottom section)
❑ Removing and installing ⇒ “1.3 Removing and installing sump (bottom section)”, page 105
23 - Bolt
⇒ Fig. ““Sump (bottom section) - tightening torque and sequence”“ , page 104
24 - Seal
25 - Nut
❑ 8 Nm
26 - Oil level and oil temperature sender - G266-
1. Sump/oil pump 103

Sump (bottom section) - tightening torque and sequence

– Tighten bolts -arrows- in stages:
que 8 Nm
Oil pump - tightening torque and sequence

angle.
– Tighten bolts -1, 2, 3- in stages in the sequence shown:
2. 12 Nm
Sump (top section) - tightening torque and sequence

– Tighten bolts in stages in the sequence shown:
Stage Bolts Tightening torque
1. -1 … 27-, 5 Nm
-arrows-
2. -1 … 25- 13 Nm
3. -1 … 25- 13 Nm
• This procedure has been specified
in order to compensate for the set‐
tling of the components.
4. -26, 27- 40 Nm
5. -arrows- ⇒ Gearbox; Rep. gr. 34 ; Removing
and installing gearbox; Tightening tor‐
ques for gearbox
1.2 Engine oil

♦ Draining and filling up engine oil, checking oil level, removing
and installing oil filter element ⇒ 4-cylinder TDI engine (2.0 ltr.
4-valve common rail); Rep. gr. 17 ; Sump/oil pump; Engine oil
♦ Oil capacities, oil specifications and viscosity grades ⇒ Main‐
tenance tables .

1.3 Removing and installing sump (bottom

section)
Removing
• Engine oil drained ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve
common rail; Rep. gr. 17 ; Sump/oil pump; Engine oil
– Lower subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Subframe; Lowering subframe .
– Detach wiring duct -1- with B+ wire from sump and press wiring
duct upwards.
– Unplug electrical connector -1- for oil level and oil temperature
sender - G266- .
– Release spreader rivets -arrows- and detach noise insulation
for sump.

– Loosen bolts -arrows- in diagonal sequence and remove.

– Remove sump.
Installing
• Renew gasket after removing.
– Install subframe ⇒ Running gear, axles, steering; Rep. gr.
– Top up engine oil and check oil level ⇒ page 104 .
Tightening torques
♦ ⇒ Fig. ““Sump (bottom section) - tightening torque and se‐
1.4 Removing and installing sump (top sec‐

tion)
♦ Socket - T10058-
♦ Safety goggles
♦ Electric drill with plastic brush
♦ Sealant ⇒ Electronic parts catalogue
Removing
Sump/oil pump; Removing and installing sump (top section) .

– Unscrew bolt -top arrow-.

– Move electrical wiring clear.
– Remove bolts -top arrows-.

– Remove oil pump ⇒ page 109 .
– Unscrew bolts -bottom arrows- and remove engine support
(left-side).

– Loosen bolts -1 ... 27- and remove.
– Carefully release sump (top section) from bonded joint, pry
sump off dowel sleeves and detach.
Installing
• Renew gaskets, seals and O-rings after removal.

– Place clean cloths over open sections of engine to prevent

lubrication system from being contaminated by sealant resi‐
due.
CAUTION
Risk of eye injury due to sealant residue.
– Remove sealant residue from sump (top section) -1- and cyl‐
inder block using rotating plastic brush or similar.
– Clean surfaces; they must be free of oil and grease.
• Note expiry date of sealant.

– Cut off nozzle of tube at front marking (nozzle ∅ approx. 2.5
mm).
NOTICE
Make sure lubrication system is not clogged by excess sealant.
– The sealant bead must not be thicker than specified.
– Apply bead of sealant -arrow- onto clean sealing surfaces of

sump (top section) as shown.
• The bead of sealant must project 3.5 mm above the sealing
surface.
• Install sump (top section) within 5 minutes of applying sealant.
– Carefully fit sump (top section) onto cylinder block but do not
press sealant bead on yet.
• Sealant must not be allowed to get into threaded holes.
– First, screw all bolts in by hand and then tighten.
note the following:
– Install oil pump ⇒ page 109 .
ltr. 4-valve common rail; Rep. gr. 17 ; Sump/oil pump; Removing
and installing sump (top section)
Tightening torques
♦ ⇒ Fig. ““Sump (top section) - tightening torque and se‐
gr. 10 ; Assembly mountings; Exploded view - assembly
mountings
♦ ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve common rail; Rep. gr.
19 ; Coolant pipes; Exploded view - coolant pipes

1.5 Removing and installing oil pump

Removing
– Remove sump (bottom section) ⇒ page 105 .
– Remove bolts -1, 2, 3-.
– Disengage toothed belt -arrow- and remove oil pump.
• The bolt on the pump impeller must NOT be loosened.
Installing
angle.
– Install sump (bottom section) ⇒ page 105 .
Tightening torques
♦ ⇒ Fig. ““Oil pump - tightening torque and sequence”“ ,
page 104
1.6 Removing and installing oil level and oil

temperature sender - G266-
Removing
• Engine oil drained ⇒ page 104 .
– Lower subframe ⇒ Running gear, axles, steering; Rep. gr.
– Remove bolt -arrow-, move cable duct -1- with B+ wire clear
and push it to one side.

– Unplug electrical connector -1- for oil level and oil temperature
sender - G266- .
– Release spreader rivets -arrows- and detach noise insulation
for sump.
– Remove nuts -1- and detach oil level and oil temperature
sender - G266- -item 3-.
Installing
• Renew seal -4- and self-locking nuts -1- after removal.
– Install subframe ⇒ Running gear, axles, steering; Rep. gr.
– Fill with engine oil and check oil level ⇒ page 104 .
Tightening torques

2 Engine oil cooler

Engine oil cooler must not be separated from oil filter housing. If
defective, engine oil cooler must be renewed together with oil filter
housing ⇒ page 113 .
2. Engine oil cooler 111

3 Oil filter/oil pressure switches

⇒ “3.1 Exploded view - oil filter”, page 112
⇒ “3.2 Exploded view - oil pressure switches/oil pressure control”,
page 113
⇒ “3.3 Removing and installing oil filter housing”, page 113
⇒ “3.4 Removing and installing oil pressure sender G10 ”,
page 115
⇒ “3.5 Removing and installing valve for oil pressure control N428
”, page 116
⇒ “3.6 Checking oil pressure”, page 116
⇒ “3.7 Removing and installing piston cooling jet control valve
N522 ”, page 118
3.1 Exploded view - oil filter
1 - Oil filter housing with engine

oil cooler
❑ Do not separate oil filter
housing and engine oil
cooler
⇒ page 113
2 - Seals
3 - O-ring
4 - Piston cooling jet control
valve - N522-
⇒ page 118
5 - Bolt
❑ 9 Nm
6 - O-ring
7 - Sealing cap
❑ 25 Nm
8 - Oil filter element
❑ See note ⇒ page 102
⇒ page 104
9 - O-ring
10 - Bolt

Oil filter housing/engine oil cooler - tightening torque and se‐

quence
angle.
– Fit bolts at top left and bottom right first.
1. 20 Nm
3.2 Exploded view - oil pressure switches/oil pressure control
1 - Valve for oil pressure con‐

trol - N428-
⇒ page 116
2 - Bolt
❑ 8 Nm
3 - O-ring
4 - Oil pressure sender - G10-
❑ Checking ⇒ Vehicle di‐
agnostic tester
⇒ page 115
❑ 10 Nm + turn +45° fur‐
ther
3.3 Removing and installing oil filter housing

3. Oil filter/oil pressure switches 113

Removing
– Drain coolant ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve common
rail; Rep. gr. 19 ; Cooling system/coolant; Draining and filling
cooling system .
– Remove engine support (left-side) ⇒ 4-cyl. TDI engine, 2.0 ltr.
– Release hose clip -1- and disconnect coolant hose.
– Remove bolt -2- and push coolant pipe to one side.
– Lift retaining clips -1, 2-, disconnect coolant hoses and press
to one side.

– Place a cloth underneath to catch escaping engine oil.

– Release hose clip -1- and disconnect coolant hose.
– Detach electrical wiring from engine speed sender at oil filter
housing.
– Unscrew bolts -arrows- and detach oil filter housing together
with engine oil cooler.
– Unplug electrical connector -2-.
Installing
• Renew seals and O-ring after removal.
• Do not reuse coolant.
– Install engine support (left-side) ⇒ 4-cyl. TDI engine, 2.0 ltr.
– Fill coolant expansion tank and carry out bleeding routine us‐
ing ⇒ Vehicle diagnostic tester ⇒ 4-cylinder TDI engine, 2.0
ltr. 4-valve common rail; Rep. gr. 19 ; Cooling system/coolant;
Draining and filling cooling system .
Tightening torques
♦ ⇒ “3.1 Exploded view - oil filter”, page 112
♦ ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve common rail; Rep. gr.
19 ; Coolant pipes; Exploded view - coolant pipes
♦ ⇒ “3.1 Exploded view - intake manifold”, page 156
3.4 Removing and installing oil pressure

sender - G10-
♦ Socket, AF 24 mm - T40284-
Procedure
cylinder TDI engine, 2.0 ltr. 4-valve common rail; Rep. gr. 17 ; Oil
filter/oil pressure switches ; Removing and installing oil pressure
sender - G10- .

– Lift retaining clips -arrows- and disconnect coolant hoses.

– Unplug electrical connector -arrow-.

– Unscrew oil pressure sender - G10- using socket, 24 mm -
T40284- .
– Fit new oil pressure sender immediately so that as little oil as
possible is lost.
– Check oil level ⇒ page 104 .
ltr. 4-valve common rail; Rep. gr. 17 ; Oil filter/oil pressure
switches ; Removing and installing oil pressure sender - G10-
Tightening torques
♦ ⇒ “3.2 Exploded view - oil pressure switches/oil pressure con‐
trol”, page 113
3.5 Removing and installing valve for oil

pressure control - N428-
Procedure
– Remove toothed belt cover (bottom) ⇒ page 47 .
– Unscrew bolt -1- and remove valve for oil pressure control -
N428- .
• Renew O-ring after removal.
– Fit new valve for oil pressure control immediately so that as
little oil as possible is lost.
– Install toothed belt cover (bottom) ⇒ page 47 .
– Check oil level ⇒ page 104 .
Tightening torques
♦ ⇒ “3.2 Exploded view - oil pressure switches/oil pressure con‐
trol”, page 113
3.6 Checking oil pressure


♦ Oil pressure tester - V.A.G 1342-
Procedure
• Oil level OK
– Remove oil pressure sender - G10- ⇒ page 115 .
– Connect oil pressure tester - V.A.G 1342- to bore for oil pres‐
sure sender.
– Screw a used oil pressure switch into threaded hole on oil
pressure tester - V.A.G 1342- to seal hole.
– Start engine and leave it running only as long as required for
the test.
• Oil pressure when starting and then at idling speed: at least
1.4 bar.
If specification is not obtained, switch off engine immediately and
check oil pump drive; renew oil pump if necessary ⇒ page 109 .
If specification is obtained, higher oil pressure must be checked
using ⇒ Vehicle diagnostic tester.
– Allow engine to warm up.
Note:
It is not possible to test all levels of the oil pressure control system
while the vehicle is stationary. The higher oil pressure must there‐
fore be checked using the ⇒ Vehicle diagnostic tester:
– Switch on ignition.
– Select Engine electronics in vehicle self-diagnosis.
– Then select Basic setting .
– Select Test of pressure level change-over for oil
pump on the Basic setting page and then click on > (not >I).
– No settings are required on the parameter settings page. Now

click on > (not >I).
– Select Operating instructions and Oil pressure ac-
tual value on the measured values page and then click on
> (not >I).
– Start the basic setting routine and follow the operating instruc‐
tions.
– Do not press the pedals until requested; otherwise the routine
will be cancelled for safety reasons.
• Oil pressure must rise to at least 3.5 bar.

Assembling
– Install oil pressure sender - G10- ⇒ page 115 .
3.7 Removing and installing piston cooling

jet control valve - N522-
Removing
– Remove oil filter housing ⇒ page 113 .
– Remove bolt -1- and detach piston cooling jet control valve -
N522- -item 2-.
Installing
– Install oil filter housing ⇒ page 113 .
Tightening torques
♦ ⇒ “3.1 Exploded view - oil filter”, page 112

19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 119
⇒ “1.2 Checking cooling system for leaks”, page 119
⇒ “1.3 Draining and filling cooling system”, page 122
1.1 Connection diagram - coolant hoses

All components are described in ⇒ 4-cylinder TDI engine, 2.0 ltr.
4-valve common rail; Rep. gr. 19 ; Cooling system/coolant; Con‐
nection diagram - coolant hoses .
1.2 Checking cooling system for leaks

♦ Cooling system tester - V.A.G 1274 B-
♦ Adapter for cooling system tester - V.A.G 1274/8-
♦ Cooling system tester adapter - V.A.G 1274/9- for filler cap

(version 2)
1. Cooling system/coolant 119

♦ Cooling system tester adapter - V.A.G 1274B/15- for filler cap

(version 1)
♦ Safety goggles
♦ Protective gloves
Note:
• To ensure that the leak test is carried out correctly, a self-test
must first be performed on the cooling system tester -
V.A.G 1274 B- .
Checking cooling system tester - V.A.G 1274 B- (self-test)
– Operate cooling system tester - V.A.G 1274 B- several times.
– Build up a pressure of 3.0 bar on cooling system tester.
– Monitor pressure on pressure gauge of cooling system tester

- V.A.G 1274 B- for 30 seconds.
If pressure does not build up, or if pressure dissipates again:
• Cooling system tester - V.A.G 1274 B- is leaking and must not
be used.
Checking cooling system for leaks
• Engine must be warm.
• Ignition switched off.
120 Rep. gr.19 - Cooling

CAUTION
The cooling system is under pressure when the engine is hot.
Risk of scalding due to hot steam and hot coolant.
Danger of scalding skin and other parts of the body.
– Cover filler cap on expansion tank with a cloth and open
carefully to release pressure.
– Release fastener -arrow- and open filler cap -1- on coolant

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

V.A.G 1274/8- onto coolant expansion tank.
– Using hand pump on cooling system tester, build up a pres‐
sure of approx. 1.5 bar.
• The pressure should not drop more than 0.2 bar within 10 mi‐
nutes.
Note:
The drop in pressure of 0.2 bar within 10 minutes is caused by
the decrease in coolant temperature. The colder the engine is,
the less the pressure will fall. If necessary, check again when the
engine is cold.
If the pressure drops by more than 0.2 bar:
– Examine engine and radiator to find and eliminate the leak.
Checking pressure relief valve in filler cap, version 1
1. Cooling system/coolant 121


V.A.G 1274 B/15- onto filler cap.
– Using hand pump on cooling system tester, build up a pres‐
sure of approx. 2 bar.
Blue filler cap
• The pressure must be reduced to 1.6 ... 1.4 bar and kept at
this level.
– Renew filler cap if pressure relief valve does not react as de‐
scribed.
Black filler cap
• The pressure must be reduced to 1.8 ... 1.6 bar and kept at
this level.
scribed.
Checking pressure relief valve in filler cap, version 2

V.A.G 1274/9- onto filler cap -1-.
– Build up pressure with hand pump on cooling system tester.
Blue filler cap
♦ The pressure relief valve should open at a pressure of
1.4 ... 1.6 bar.
scribed.
Black filler cap
♦ The pressure relief valve should open at a pressure of
1.6 ... 1.8 bar.
– Renew filler cap if pressure relief valve does not open as de‐
scribed.
1.3 Draining and filling cooling system

4-valve common rail; Rep. gr. 19 ; Cooling system/coolant; Drain‐
ing and filling cooling system .

2 Coolant pump/thermostat assembly

⇒ “2.1 Exploded view - coolant pump/thermostat”, page 123
⇒ “2.2 Exploded view - electric coolant pump”, page 124
⇒ “2.3 Exploded view - coolant valves”, page 125
⇒ “2.4 Exploded view - coolant temperature senders”,
page 125
⇒ “2.5 Removing and installing electric coolant pump”,
page 125
⇒ “2.6 Removing and installing coolant pump”, page 126
⇒ “2.7 Removing and installing mixing valve for charge air cooler”,
page 126
⇒ “2.8 Removing and installing coolant valve for cylinder head
N489 ”, page 126
⇒ “2.9 Removing and installing coolant distribution module”, page
127
⇒ “2.10 Removing and installing temperature sensor G18 ”, page
128
⇒ “2.11 Removing and installing engine temperature sender G27
”, page 129
⇒ “2.12 Removing and installing engine temperature sender 2
G652 ”, page 129
2.1 Exploded view - coolant pump/thermostat
2. Coolant pump/thermostat assembly 123

1 - Bolt
2 - Damper wheel
3 - Coolant pump
⇒ page 126
4 - O-ring
❑ Lubricate with coolant
5 - Coolant valve for cylinder
head - N489-
⇒ page 126
6 - Bolt
❑ 6 Nm
7 - Seals
8 - Coolant distribution module
❑ On engines above
140 KW, the coolant dis‐
tribution module is
called the engine tem‐
perature regulation
module - GX33- and
contains the compo‐
nents actuator for en‐
gine temperature regu‐
lation - N493- and
position sender for en‐
gine temperature regu‐
lation - G1004-
❑
❑ On engines below 140 kW, the coolant distribution module is called the actuator for engine temperature
regulation - N493-
9 - Bolt
❑ Tighten in stages and in diagonal sequence; final torque 20 Nm
10 - Seal
11 - Bolt
❑ 20 Nm +45°
2.2 Exploded view - electric coolant pump

4-valve common rail; Rep. gr. 19 ; Coolant pump/thermostat as‐
sembly; Exploded view - electric coolant pump .

2.3 Exploded view - coolant valves

sembly; Exploded view - coolant valves .
2.4 Exploded view - coolant temperature senders
1 - Spacer ring
❑ Renew if damaged
2 - O-ring
3 - Engine temperature sender
- G27-
⇒ page 129
4 - Bolt
❑ 8 Nm
5 - Engine temperature sender
2 - G652-
⇒ page 129
6 - Bolt
❑ 8 Nm
7 - O-ring
8 - Spacer ring
9 - Bolt
❑ 8 Nm
10 - Temperature sensor -
G18-
⇒ page 128
11 - Spacer ring
12 - O-ring
2.5 Removing and installing electric coolant

pump
sembly; Removing and installing electric coolant pump .

2.6 Removing and installing coolant pump

Removing
cooling system .
– Remove toothed belt ⇒ page 53 .
– Remove bolt -4- and detach coolant valve for cylinder head -
N489- -item 3-.
– If renewing coolant pump, remove bolt -1- and detach damper
wheel -2-.
– Remove bolts -arrows- and detach coolant pump.
Installing
NOTICE
Risk of damage to coolant pump if functional check is performed
manually.
– Never pull the modulating mechanism of the coolant pump
with your hand to check its function.
• Do not hold or carry the coolant pump by the modulating

mechanism.
• Do not operate the modulating mechanism.
• Renew seal and O-ring after removal.
– Clean and smoothen sealing surface for O-ring.
– Lubricate O-ring with coolant.
– Fill and bleed coolant circuit ⇒ 4-cylinder TDI engine, 2.0 ltr.
4-valve common rail; Rep. gr. 19 ; Cooling system/coolant;
Tightening torques
♦ ⇒ “2.1 Exploded view - coolant pump/thermostat”, page 123
2.7 Removing and installing mixing valve for

charge air cooler
On engines above 140 kW, the mixing valve is called the coolant
circuit control unit - GX28- .
On engines below 140 kW, the mixing valve is called the control
unit for charge air cooler bypass - J865- .
sembly; Removing and installing mixing valve for charge air cool‐
er .
2.8 Removing and installing coolant valve

for cylinder head - N489-
Removing
• Engine cold.

– Relieve residual pressure in cooling system by releasing fas‐

tener -arrow- and opening filler cap -1- on coolant expansion
tank.
– Close filler cap again (make sure it engages).
– Detach toothed belt from camshafts ⇒ page 48 .

– Remove bolt -2- and detach coolant valve for cylinder head -
N489- .
Installing
– Bleed high-temperature cooling circuit and low-temperature
cooling circuit ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve com‐
mon rail; Rep. gr. 19 ; Bleeding high-temperature cooling
circuit and low-temperature cooling circuit .
Tightening torques
♦ ⇒ “2.4 Exploded view - coolant temperature senders”,
page 125
2.9 Removing and installing coolant distri‐

bution module
On engines above 140 KW, the coolant distribution module is
called the engine temperature regulation module - GX33- and
contains the components actuator for engine temperature regu‐
lation - N493- and position sender for engine temperature regu‐
lation - G1004- .
On engines below 140 kW, the coolant distribution module is

called the actuator for engine temperature regulation - N493- .
Removing
– Remove oil filter housing ⇒ page 113 .

to one side.

– Lift retaining clips -2- and press coolant lines -3- to side.

– Lift retaining clips -2- and disconnect coolant hoses.
– Unscrew bolts -arrows- and remove coolant distribution mod‐
ule.
Installing
• Renew seals after removing.
– Install oil filter housing ⇒ page 113 .
Tightening torques
♦ ⇒ “2.1 Exploded view - coolant pump/thermostat”, page 123
2.10 Removing and installing temperature

sensor - G18-
Removing
• Engine cold.

– Relieve residual pressure in cooling system by releasing fas‐

tener -arrow- and opening filler cap -1- on coolant expansion
tank.
– Close filler cap again (make sure it engages).

– Unscrew bolt -2- and pull off temperature sensor - G18- .
Note:
If an O-ring or spacer ring remains lodged in coolant line, lift it out
with a piece of wire, taking care not to damage sealing surface.
Installing
• Renew spacer ring if damaged.
– Bleed high-temperature cooling circuit and low-temperature
cooling circuit ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve com‐
mon rail; Rep. gr. 19 ; Bleeding high-temperature cooling
circuit and low-temperature cooling circuit .
Tightening torques
page 125
2.11 Removing and installing engine temper‐

ature sender - G27-
sembly; Removing and installing electric coolant pump .
2.12 Removing and installing engine temper‐

ature sender 2 - G652-
Removing
Coolant pump/thermostat assembly ; Removing and installing
engine temperature sender 2 - G652- .

– Unscrew bolt -1- and press coolant line -3- slightly to one side.
to one side.
– Remove bolts -1, 2- and detach bracket for intake manifold.


– Unscrew bolt -1- and pull off engine temperature sender 2 -
G652- .
Note:
If an O-ring or spacer ring remains lodged in cylinder block, lift it
out with a piece of wire, taking care not to damage sealing sur‐
face.
Installing
• Renew spacer ring if damaged.
– Fill and bleed coolant circuit ⇒ 4-cylinder TDI engine, 2.0 ltr.
4-valve common rail; Rep. gr. 19 ; Cooling system/coolant;
ltr. 4-valve common rail; Rep. gr. 19 ; Coolant pump/thermostat
assembly ; Removing and installing engine temperature sender
2 - G652-
Tightening torques
page 125

3 Coolant pipes
engine, 2.0 ltr. 4-valve common rail; Rep. gr. 19 ; Coolant pipes .

4 Radiators/radiator fans
engine, 2.0 ltr. 4-valve common rail; Rep. gr. 19 ; Radiators/ra‐
diator fans .
4. Radiators/radiator fans 133

21 – Turbocharging/supercharging
1 Turbocharger
⇒ “1.1 Exploded view - turbocharger”, page 134
⇒ “1.2 Removing and installing turbocharger”, page 136
1.1 Exploded view - turbocharger

♦ Exploded view - turbocharger, part I ⇒ page 134
♦ Exploded view - turbocharger, part II ⇒ page 135
Exploded view - turbocharger, part I
1 - Bolt
❑ 8 Nm
2 - Heat shield
3 - O-ring
4 - Bolt
❑ 8 Nm
5 - Pulsation damper
6 - Bolt
❑ Captive
❑ 5.5 Nm
7 - Connecting piece
8 - Intake connecting pipe
❑ With heater element for
crankcase breather -
N79-
9 - Hose
❑ For crankcase breather
❑ Press release tabs on
both sides to detach
10 - O-ring
❑ Renew hose
damaged or leaking
11 - O-ring
12 - Gasket
❑ Renew after removing Volkswagen Technical Site: http://vwts.ru http://vwts.info
13 - Turbocharger
❑ With turbocharger 1 control unit - J724-
❑ Performing adaptions required after renewing a component (using ⇒ Vehicle diagnostic tester)
⇒ page 9
134 Rep. gr.21 - Turbocharging/supercharging

14 - Nut
❑ Allocation, tightening torque and sequence ⇒ page 136
❑ Lubricate exhaust manifold studs with high-temperature paste
❑ If studs are renewed, too, tighten them to 14 Nm
15 - Seal
16 - Bolt
❑ 20 Nm
17 - Bracket
❑ For turbocharger
18 - Bolt
❑ 20 Nm
Exploded view - turbocharger, part II
1 - Oil supply line

❑ Check for obstructions
❑ Before installing turbo‐
charger, fill connection
for oil supply line with
engine oil
❑ Union nuts, 22 Nm
2 - Bolt
❑ 8 Nm
3 - O-ring
4 - Turbocharger
❑ Depending on engine:
water-cooled or not wa‐
ter-cooled
⇒ page 136
❑ Reset learnt values after
renewing turbocharger
⇒ page 9
5 - Gasket
❑ For water-cooled ver‐
sion
6 - Bolt
sion
❑ 14 Nm
7 - Coolant lines
sion
8 - Bolt
❑ For water-cooled version
❑ 20 Nm
1. Turbocharger 135
9 - Bolt
❑ 8 Nm
10 - Bolt
❑ 20 Nm
11 - Bolt
❑ 8 Nm
12 - Retaining clips
13 - Bracket
14 - Heat shield
15 - Gasket
16 - Bolt
❑ 14 Nm
17 - Oil return line
18 - Bolt
❑ 8 Nm
19 - O-ring
Turbocharger - distinguishing feature of nuts, tightening torque

and tightening sequence
Engine power class Nuts Version
1 -1 … 10- -B-
2 -1 … 7-, -B-
-9, 10-
2 -8- -A-
– Tighten new nuts -1 ... 10- in stages in the sequence shown:
1. 11 Nm
2. 22 Nm
3. 22 Nm
• This procedure has been specified in order to com‐
pensate for the settling of the components.
1.2 Removing and installing turbocharger

⇒ “1.2.1 Removing and installing turbocharger (not water-
cooled)”, page 136
⇒ “1.2.2 Removing and installing turbocharger (water-cooled)”,
page 140
1.2.1 Removing and installing turbocharger

(not water-cooled)

♦ Socket - T40055-
Removing
• If the turbocharger has suffered mechanical damage
⇒ page 8
cylinder TDI engine (2.0 ltr. 4-valve common rail); Rep. gr. 21 ;
Turbocharger; Removing and installing turbocharger .
– Remove front exhaust pipe ⇒ 4-cyl. TDI engine (2.0 ltr. 4-valve
common rail); Rep. gr. 26 ; Exhaust pipes/silencers; Remov‐
ing and installing front exhaust pipe .
– Move electrical wiring clear at clip -1-.

1. Turbocharger 137
– Unscrew bolts -arrows- and detach pulsation damper -1-.
– Unplug electrical connectors -4, 5-.

breather hose -2-.
– Unscrew bolt -3-, turn connection -1- slightly in direction of
-arrow- and detach.
– Remove catalytic converter
⇒ “2.2 Removing and installing catalytic converter”,
page 205 .

-2-.
– Unscrew bolts -1, 3- and remove bracket -2-.

– Detach electrical connectors -1, 3- from bracket, unplug them

and move them clear.
– Remove bolts -arrows- and detach heat shield -1-.
1. Turbocharger 139
– Slacken and remove nuts in the sequence: -10 ... 1-.

– Detach turbocharger with exhaust manifold from cylinder
head.
Installing
• Renew gaskets, seals, O-rings and self-locking nuts after re‐
moval.
• Fill turbocharger with engine oil at connection for oil supply
line.
• Hose connections and air pipes/hoses must be free of oil and
grease prior to fitting.
• After installing the turbocharger, allow the engine to idle for
approx. 1 minute without pressing the accelerator to ensure
that the turbocharger is supplied with oil.
– Install front exhaust pipe ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-
valve common rail; Rep. gr. 26 ; Exhaust pipes/silencers;
Removing and installing front exhaust pipe .
– Reset learnt values after renewing turbocharger ⇒ page 9 .
Tightening torques
♦ ⇒ Fig. ““Turbocharger - distinguishing feature of nuts, tighten‐
ing torque and tightening sequence”“ , page 136
page 228
1.2.2 Removing and installing turbocharger

(water-cooled)

♦ Socket - T40055-
Removing
• If the turbocharger has suffered mechanical damage
⇒ page 8
cooling system .
– Remove exhaust gas recirculation cooler
⇒ “5.4 Removing and installing exhaust gas recirculation cool‐
er”, page 232 .
– Unplug electrical connectors -2, 5-.

breather hose -3-.
-arrow- and detach.
– Remove catalytic converter
page 205 .
1. Turbocharger 141

-2-.
– Unscrew bolts -1, 3- and remove bracket -2-.
– Detach electrical connectors -1, 3- from bracket, unplug them

and move them clear.
– Loosen bolt -1- for coolant line.


– Unscrew bolts -1- and remove bracket -2-.

– Unscrew bolts -arrows- and detach coolant lines -3-.
– Remove bolts -arrows- and detach heat shield -1-.
1. Turbocharger 143
– Slacken and remove nuts in the sequence: -10 ... 1-.

– Detach turbocharger with exhaust manifold from cylinder
head.
Installing
• Renew gaskets, seals, O-rings and self-locking nuts after re‐
moval.
• Fill turbocharger with engine oil at connection for oil supply
line.
• After installing the turbocharger, allow the engine to idle for
approx. 1 minute without pressing the accelerator to ensure
that the turbocharger is supplied with oil.
– Reset learnt values after renewing turbocharger ⇒ page 9 .
Tightening torques
♦ ⇒ Fig. ““Turbocharger - distinguishing feature of nuts, tighten‐
ing torque and tightening sequence”“ , page 136
page 228

2 Charge air system

⇒ “2.1 Exploded view - charge air system”, page 145
⇒ “2.2 Exploded view - hose connections for charge air system”,
page 146
⇒ “2.3 Removing and installing charge pressure sender G31 ”,
page 147
⇒ “2.4 Removing and installing charge air temperature sender”,
page 147
⇒ “2.5 Checking charge air system for leaks”, page 148
2.1 Exploded view - charge air system
1 - Intake manifold with charge

air cooler
❑ Intake manifold and
charge air cooler are
combined as one unit
⇒ page 158
2 - Charge air temperature
sender after charge air cooler -
G811-
⇒ page 147
❑ 22 Nm
3 - Air hose
4 - Air pipe
5 - Seal
❑ Check for damage and
renew if necessary
6 - Bolt
7 - Charge air temperature
sender before charge air cool‐
er - G810-
⇒ “2.4 Removing and in‐
stalling charge air tem‐
perature sender”,
page 147
❑ 22 Nm
8 - Bolt
❑ 8.5 Nm
9 - Air hose
10 - Charge pressure sender - G31-
2. Charge air system 145

Air pipe - tightening torque and sequence

– Tighten bolts in the sequence -1, 2, 3- to 8 Nm.
2.2 Exploded view - hose connections for

charge air system
• If using used hose clips to secure the air hoses at their con‐
nections, spray rust remover onto the worm threads before
installing.
Hose clips on pressure side are fitted with retaining hooks
-arrows-.
• To disconnect air hose, hose clip must be loosened far
enough.
• Hose clips which have been loosened can be re-used.
• Hose clip -1- with retaining hooks -arrows- must not be pulled
off air hose.
• If a hose clip with retaining hooks is pulled off air hose, air hose
must be renewed.
• New air hoses are supplied with hose clip fitted.

Air hoses to air pipes/charge air cooler - installation position and

tightening torque
• The markings on the air hose and on the resonator must align
-arrow-.
– Tighten screw-type clip -1- to 5 Nm.
2.3 Removing and installing charge pres‐

sure sender - G31-
Removing
NOTICE
Irreparable damage to charge pressure sender can be caused
if the connection breaks off.
– Carefully disconnect hose from connection, taking care to
keep hose straight.

– Release hose clip -1- and disconnect hose.
– Detach charge pressure sender - G31- .
Installing
Tightening torques
♦ ⇒ “2.1 Exploded view - charge air system”, page 145
2.4 Removing and installing charge air tem‐

perature sender
♦ Crow-foot ring spanner, 16 mm (commercially available)

Removing
Charge air temperature sender before charge air cooler - G810-
– Unplug electrical connector -2- and remove charge air tem‐
perature sender before charge air cooler - G810- .
Charge air temperature sender after charge air cooler - G811-
– Unplug electrical connector -1- and remove charge air tem‐
perature sender after charge air cooler - G811- .
Installing
Tightening torques
2.5 Checking charge air system for leaks

♦ Charge air system tester - V.A.G 1687-
♦ Adapter - V.A.G 1687/11-
♦ Adapter - V.A.G 1687/13-2-

♦ Adapter - V.A.G 1687/14-

♦ Turbocharger tester - V.A.G 1397A-
♦ Engine bung set - VAS 6122-
♦ Y-connector - VAS 691 005/1-
♦ Test instrument adapter - VAS 691 005/5-

Procedure
Charge air system; Checking charge air system for leaks .
expansion tank.

Connecting turbocharger tester - V.A.G 1397A- :

– Fit test adapter - VAS 691 005/5- onto coolant expansion tank.
– Fit Y-connector - VAS 691 005/1- onto test adapter - VAS 691
005/5- .
– Close valve -1- for connection »C« and open valve -2- for con‐
nection »A«.
– Attach hose from connection »A« on Y-connector to connec‐
tion »II« on turbocharger tester - V.A.G 1397A- .
– Set turbocharger tester - V.A.G 1397A- to switch position
»II« (relative pressure measurement) and switch it on. The »II«
must be visible.
– Disconnect crankcase breather pipe -arrow-.

– Seal off connecting piece with a plug -2- from engine bung set
- VAS 6122- .
– Secure plug with a hose clip -1-.
– Connect adapter - V.A.G 1687/6- with adapter - V.A.G

1687/13-2- to turbocharger.
– Connect hose -1- of charge air system tester - V.A.G 1687- to
adapter.

– Loosen clamp on exhaust pipe -arrows- and push towards

rear.
– Seal off front exhaust pipe with adapters -V.A.G 1687/11- and
-V.A.G 1687/14- .
– Seal hole in -V.A.G 1687/11- with plug-in connector -1- (com‐
mercially available).
Prepare charge air system tester - V.A.G 1687- as follows:

– Connect charge air system tester - V.A.G 1687- to adapter.
– Pull pressure control valve -2- upwards, then unscrew com‐
pletely and close valves -3- and -4-.
– Using a commercially available connection piece, connect
charge air system tester - V.A.G 1687- to compressed air -1-.
– If there is water in sight glass -6-, drain it off via drain plug.
– Open valve -3-.
NOTICE
Risk of damage to components if test pressure is set too high
– Never set test pressure higher than specified.
– Adjust pressure to 0.5 bar via pressure control valve -2-.

– Open valve -4- and wait until test system is pressurised. If
necessary, adjust pressure to 0.5 bar again.
• A small amount of air escapes through the valves and enters
the engine and the exhaust gas recirculation cooler. Therefore
it is not possible to perform a pressure retention test.
• For operation of ultrasonic tester -V.A.G 1842- , refer to ⇒
Operating instructions .
– Check entire charge air system for leaks:
♦ By listening
♦ By feeling
♦ Using a commercially available leak detection spray
If no leak is found in the charge air system, check water-cooled
charge air cooler for leaks.

Reading off values from turbocharger tester - V.A.G 1397A- :

– Pressure must remain set to 0.5 bar.
• Observe turbocharger tester for approx. 5 minutes.
• The pressure displayed on the turbocharger tester must not
rise.
– If pressure displayed on turbocharger tester rises, this means
that compressed air is escaping into the cooling system.
– Charge air cooler has a leak, renew intake manifold with
charge air cooler.
• If there are no leaks in the charge air cooler, a vacuum may
form when the coolant cools down. A minus sign on the tur‐
bocharger tester indicates that a vacuum has formed.
Cleaning Y-connector - VAS 691 005/1- :

• After the leak test has been completed, the Y-connector - VAS
691 005/1- must be cleaned to remove any water which may
have entered.
– Insert cleaning nozzle -D- in hose from connection -A- on Y
connector .
– Fit test adapter - VAS 691 005/5- onto hose from connection
-B-.
– Fit compressed air hose on connection -C-.
– Open cut-off valves and blow through hose for approx. 15
seconds.
– Release pressure in test circuit by detaching hose coupling
from adapter before removing adapter.
Assembling
ltr. 4-valve common rail; Rep. gr. 21 ; Charge air system; Check‐
ing charge air system for leaks
Tightening torques
♦ ⇒ “2.2 Exploded view - hose connections for charge air sys‐
tem”, page 146

23 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Overview - fuel system”, page 153
⇒ “1.2 Overview of fitting locations - injection system”,
page 153
⇒ “1.3 Filling and bleeding fuel system”, page 153
⇒ “1.4 Checking fuel system for leaks”, page 154
1.1 Overview - fuel system

4-valve common rail; Rep. gr. 23 ; Injection system; Overview -
fuel system .
1.2 Overview of fitting locations - injection

system
4-valve common rail; Rep. gr. 23 ; Injection system; Overview of
fitting locations - injection system .
1.3 Filling and bleeding fuel system

If components of the fuel system between the fuel tank and the
high-pressure pump are removed or renewed, the fuel system
must be bled.
NOTICE
Running when dry causes irreparable damage to fuel pump.
Proceed as follows to fill high-pressure pump with fuel.

• Check fuel gauge in instrument cluster; fuel gauge needle
must indicate that fuel is above reserve level.
– Select Diagnosis mode and then Start diagnosis .
– Choose Select own test tab and select following options
one after the other:
♦ 01 - Systems with diagnostic capability
♦ 0001 - Engine electronics
♦ 0001 - Engine electronics, functions
♦ 0001 - Activate fuel pump
♦ Press Carry out check
♦ Select 120 seconds.
– The fuel pump must run for 120 seconds to ensure that the
fuel system is filled sufficiently with fuel.
– Start engine after filling fuel system.
1. Injection system 153

– Run engine at moderate speed for several minutes and then

switch off.
– Check fuel system for leaks.
– Erase entry in event memory.
– Road-test vehicle and accelerate with full throttle at least once.
– Then check high-pressure system again for leaks.
1.4 Checking fuel system for leaks

Procedure
– Run engine at idling speed for several minutes (do not press
accelerator) and then switch off. Fuel system will bleed itself
automatically.
– Check complete fuel system for leaks.
– If leaks are found although the connections have been tight‐
ened to the correct torque, the relevant component must be
renewed.
– Road-test vehicle and accelerate with full throttle at least once.
– Then check high-pressure system again for leaks.
154 Rep. gr.23 - Mixture preparation - injection

2 Air cleaner
engine, 2.0 ltr. 4-valve common rail; Rep. gr. 23 ; Air cleaner .
2. Air cleaner 155

3 Intake manifold
⇒ “3.1 Exploded view - intake manifold”, page 156
⇒ “3.2 Removing and installing throttle valve module J338 ”, page
157
⇒ “3.3 Removing and installing intake manifold”, page 158
3.1 Exploded view - intake manifold
1 - Bolt
sequence
⇒ Fig. ““Intake manifold
with charge air cooler -
tightening torque and
sequence”“ , page 157
2 - Intake manifold with charge
air cooler
❑ Intake manifold and
charge air cooler are
combined as one unit
⇒ page 158
3 - Gasket
4 - Bracket
5 - Bolt
❑ 8 Nm
6 - Bracket
❑ For electrical connec‐
tors
7 - Bolt
❑ 8 Nm
8 - Coolant bleeder screw
9 - Bolt
❑ 8 Nm
10 - Bolt
❑ 10 Nm
11 - Throttle valve module - GX3-
12 - Seal
13 - O-rings
14 - Ball stud
❑ For engine cover panel
❑ 8 Nm
15 - Bracket
❑ For intake manifold

16 - Coolant pipe
17 - Bolt
❑ 8 Nm
18 - Bolts
⇒ Fig. ““Intake manifold with charge air cooler - tightening torque and sequence”“ , page 157
19 - Bolt
❑ 8 Nm
20 - Coolant connection
21 - Bolts
⇒ Fig. ““Intake manifold with charge air cooler - tightening torque and sequence”“ , page 157
22 - Bracket
❑ For intake manifold
Intake manifold with charge air cooler - tightening torque and se‐
quence
angle.
– Tighten bolts in stages in the sequence shown:
Stag Bolts Tightening torque/angle specification
e
1. -1 … 10- Screw in by hand until contact is made
2. -1 … 10- 8 Nm
3. -1 … 10- Turn 90° further
4. -11, 12- Screw in by hand until contact is made
5. -11- 20 Nm
6. -12- 20 Nm
3.2 Removing and installing throttle valve

module - J338-
Removing
Intake manifold; Removing and installing throttle valve module -
GX3- .
– Move electrical wiring clear at clip -1-.
3. Intake manifold 157


– Remove bolts -arrows- and detach throttle valve module -
J338- -2-.
Installing
• Renew seals and O-ring after removal.
– When fitting connection with throttle valve module - J338- , pay
attention to dowel pins.
ltr. 4-valve common rail; Rep. gr. 23 ; Intake manifold; Removing
and installing throttle valve module - GX3-
– Perform adaptions required after renewing a component (us‐
ing ⇒ Vehicle diagnostic tester) ⇒ page 9 .
Tightening torques
tem”, page 146
3.3 Removing and installing intake manifold

Intake manifold and charge air cooler are combined as one unit.
♦ Socket Torx T30 - T10405-

Removing
Intake manifold; Removing and installing intake manifold .
– Remove high-pressure pipe
⇒ “4.9.1 Removing high-pressure pipe between high-pressure
reservoir (rail) and high-pressure pump”, page 177 .

1 - For turbocharger 1 control unit - J724- (fitting location varies)
2 - For heater element for crankcase breather - N79-
3 - For exhaust gas pressure sensor 1 - G450-
5 - For exhaust gas recirculation valve 2 - GX6-
6 - For fuel pressure regulating valve - N276-
7 - For fuel pressure sender - G247-


G811-
- G810-
to side.
heating - V488- downwards slightly. (Different versions.)

– Lift retaining clip on coolant connection (top) -4- and detach
coolant connection.


– Take electrical connector -2- for exhaust gas temperature

sender 4 - G648- out of bracket.
– Remove bolts -3- and press bracket to one side.
– Remove bolt -4- for fuel lines.
– Release hose clips -1 and 2- and detach fuel hoses.

– Remove bolts -arrows- and press fuel lines to side.
– Remove exhaust gas recirculation valve 1 - GX5-
⇒ “5.2 Removing and installing exhaust gas recirculation valve
1 GX5 ”, page 230 .

– Remove bolts -arrows- and detach intake manifold with charge

air cooler.
Installing
• Renew gasket and spring-type clips for fuel hoses after re‐
moving.
– Fit new gasket onto dowel pins in cylinder block.
– Fit intake manifold onto dowel pins in cylinder block and tight‐
en bolts.
note the following:
– Install high-pressure pipe
⇒ “4.9 Removing and installing high-pressure pipes”,
page 177 .
– Install exhaust gas recirculation valve 1 - GX5-
1 GX5 ”, page 230 .
– Bleed fuel system
Tightening torques
page 165

4 Injectors/high-pressure reservoir
(rail)
⇒ “4.1 Exploded view - injectors”, page 163
⇒ “4.2 Exploded view - high-pressure reservoir (rail)”, page 165
⇒ “4.3 Checking injectors”, page 167
⇒ “4.4 Performing adaption of correction values for injectors”,
page 167
⇒ “4.5 Checking for injectors sticking open”, page 168
⇒ “4.6 Checking return flow rate of injectors with engine running”,
page 169
⇒ “4.7 Checking return flow rate of injectors at starter cranking
speed”, page 172
⇒ “4.8 Removing and installing injectors”, page 173
⇒ “4.9 Removing and installing high-pressure pipes”, page 177
⇒ “4.10 Removing and installing high-pressure reservoir (rail)”,
page 179
4.1 Exploded view - injectors

When installing a new base engine, you must check whether
there is a sticker on the cylinder head cover.
If a sticker is attached which states Spannpratzen auf vor-
geschriebenes Drehmoment angezogen (clamping pieces tight‐
ened to specified torque), the clamping pieces have already been
tightened to the specified final torque at the factory.
If no sticker is attached, it is essential that the clamping pieces for
the injectors are tightened to the specified torque after installing
the high-pressure pipes. If these instructions are not observed,
the engine could be damaged.
4. Injectors/high-pressure reservoir (rail) 163

1 - Seal
❑ Renew if leaking
⇒ page 66
2 - Copper seal
3 - O-ring
4 - Injector
❑ Use a coloured pen to
mark allocation of injec‐
tors to corresponding
clamping piece and
high-pressure pipe, and
to corresponding cylin‐
der for re-installation;
pay attention to mark‐
ings when installing
❑ Renew copper seal after
removing
❑ To remove carbon de‐
posits from the injector
sealing surface, clean
the injector bore in the
cylinder head with
cleaning kit - VAS 6811-
(it is important to do this
to avoid leaks)
⇒ page 173
5 - O-ring
6 - Fuel return line
❑ To fuel tank
❑ Must not be kinked, damaged or clogged
❑ Do not dismantle
❑ Fill and bleed fuel system after renewing ⇒ page 153
7 - Clamping piece
❑ Use a coloured pen to mark injectors and corresponding clamping piece and cylinder for re-installation;
pay attention to markings when installing
❑ The clamping pieces can be re-used when installing new injectors
❑ Each clamping piece secures two injectors
❑ Installation position: Side with lettering faces upwards
8 - Bolt
❑ Tighten initially to 2 Nm, then screw on union nuts for high-pressure pipes hand-tight and align injectors
❑ 8 Nm + 270° (3x 90° further)
9 - High-pressure pipe
❑ From high-pressure reservoir (rail) to injector
❑ Do not alter shape
❑ Check for damage before re-installing
❑ Lubricate threads of union nuts with clean engine oil
❑ If an injector is renewed, the corresponding high-pressure pipe must also be renewed

❑ Tightening torques:
♦ 28 Nm if re-installing high-pressure pipe
♦ 15 Nm +60° if installing a new high-pressure pipe
10 - Grommet
4.2 Exploded view - high-pressure reservoir (rail)
1 - Fuel hose
2 - Bolt
❑ 8 Nm
3 - Retaining clamp
❑ Between high-pressure
pump and high-pres‐
sure reservoir (rail)
❑ Check for damage be‐
fore re-installing
❑ Lubricate threads of un‐
ion nuts with clean en‐
gine oil
❑ If the high-pressure
pump is renewed, the
corresponding high-
pressure pipe must also
be renewed
♦ 28 Nm if re-installing high-
pressure pipe
♦ 15 Nm +60° if installing a
new high-pressure pipe
5 - Fuel pressure sender -
G247-
⇒ page 186
♦ Pre-tighten to 50 Nm.
♦ Loosen by a maximum of
one turn.
♦ Tighten to 55 Nm +20°.
♦ Tighten to final torque of 130 Nm.
❑ From high-pressure reservoir (rail) to injector
❑ If an injector is renewed, the corresponding high-pressure pipe must also be renewed

7 - Damping element
8 - High-pressure reservoir (rail)
❑ If the high-pressure reservoir is renewed, all corresponding high-pressure pipes must also be renewed
9 - Bolt
❑ 20 Nm
10 - O-ring
11 - Fuel pressure regulating valve - N276-
❑ Checking ⇒ “6.5 Checking fuel pressure regulating valve N276 ”, page 190
⇒ “6.6 Removing and installing fuel pressure regulating valve N276 ”, page 192
⇒ page 9
❑ Tightening torques
♦ Pre-tighten to 60 Nm.
♦ Loosen to 5 Nm.
♦ Tighten to 20 Nm +15°.
♦ Tighten to final torque of 130 Nm.
12 - Spring-type clips
13 - Bolt
❑ 8 Nm
14 - Fuel lines
15 - Fuel return hose
17 - Fuel hose
18 - Bolt
❑ 18 Nm
19 - Fuel pressure sender for low pressure - G410-
20 - Spring-type clip
21 - Clip
22 - Fuel return hose

4.3 Checking injectors

There are four different tests for checking the operation of the
injectors.
♦ ⇒ “4.4 Performing adaption of correction values for injectors”,
page 167
♦ ⇒ “4.5 Checking for injectors sticking open”, page 168
♦ ⇒ “4.6 Checking return flow rate of injectors with engine run‐
ning”, page 169
♦ ⇒ “4.7 Checking return flow rate of injectors at starter cranking
speed”, page 172
Perform the following tests first if the engine does not start at all:
♦ ⇒ “4.5 Checking for injectors sticking open”, page 168
♦ ⇒ “4.7 Checking return flow rate of injectors at starter cranking
speed”, page 172
♦ ⇒ “6.5 Checking fuel pressure regulating valve N276 ”,
page 190 .
4.4 Performing adaption of correction val‐

ues for injectors
♦ The “Injector delivery calibration” and “Injector voltage cali‐
bration” serve to correct the injection rates for each cylinder of
a common rail system individually across the entire operating
range.
♦ The 7-digit adaption values are marked on each injector. The
values may consist of letters and/or numbers.
Injector (view from above)

1- Adaption value (checksum; details in illustration are only an
example)
2- Data matrix code
3- Part number

– Perform adaption ⇒ Vehicle diagnostic tester.

– When a new injector is installed, the adaption value for the new
injector must be stored in the engine control unit.
– Additionally, check that the “Injector delivery calibration val‐
ues” with “Injector voltage calibration values” are correctly
entered for all the other injectors. Do NOT attempt to re-enter
these values if the correct values are already stored in the en‐
gine control unit.
– When the engine control unit is renewed, the appropriate “In‐
jector delivery calibration values” with “Injector voltage cali‐
bration” values must be written into the new engine control
unit.
4.5 Checking for injectors sticking open

If one of the injectors is sticking open, this means that the injector
needle is not closing fully and fuel escapes into the cylinder.
♦ Hand vacuum pump - VAS 6213-
♦ Adapter of return flow meter - VAS 6684-
Procedure
• Observe rules for cleanliness when working on the fuel supply
system ⇒ page 6 .
– Clean all connections (with commercial cleaning solution or
similar) before removing.
– Dry all components after cleaning.
Start with cylinder No. 1.

– Press retaining clip -arrow- and pull return line connection

-1- off injectors.
– Connect adapter -arrow- of return flow meter - VAS 6684- to

return line connection of injector to be tested after adapter has
been cleaned and blown out.
– Generate a vacuum of -500 mbar using the hand vacuum
pump - VAS 6213- .
• If the vacuum reading remains the same for 30 seconds, the
injector is OK.
• If the injector is faulty, the vacuum reading will fall back to 0 bar
within 2 to 3 seconds.
– Repeat test if necessary; note drop in vacuum reading on hand
vacuum pump - VAS 6213- .
– Renew faulty injectors ⇒ page 173 .
Installing fuel return lines
– Check O-ring for fuel return line connection for damage and
deformation.
If O-ring is damaged or deformed, renew O-ring.
• Lubricate all seals with engine oil or assembly oil before in‐
stalling.
– Push return line connections carefully over seals and onto in‐
jectors. The catch should engage audibly. Then press release
pin down carefully.
– Erase entry in event memory using ⇒ Vehicle diagnostic test‐
er.
Checking fuel system for leaks
automatically.
– Check the entire fuel system for leaks.
Renew the affected component if leakage occurs.
– After completing the repair, road-test the vehicle. Accelerate
with full throttle at least once. Then check the high-pressure
section of the fuel system again for leaks.
4.6 Checking return flow rate of injectors

with engine running
Each injector normally has a relatively low fuel return flow rate. If
the return flow rate at one injector is relatively high compared to
the other injectors, that injector is probably defective.

Checking return flow rate of all injectors

♦ Fuel-resistant measuring container

Procedure
system ⇒ page 6 .
– Disconnect hose at non-return valve -1-.
– Seal off open return hose with clean plug -2- from engine bung
set - VAS 6122- .
– Hold end of fuel return hose (lengthen if necessary) in a meas‐
uring container to measure the total return flow rate.
– Start engine and run at idling speed for two minutes.
• Specification for 2 minutes: 0 ml to 50 ml
– If specification is attained, increase engine speed to 2000 ...
2500 rpm for approx. 2 minutes and then check return flow rate
again.
• Specification for 2 minutes: less than 250 ml
Note:
1000 ml = 1 litre
If specification is exceeded, this indicates that one or more injec‐
tors are defective. Check return flow rate of each individual injec‐
tor.
Checking return flow rate of individual injectors


♦ Adapter of return flow meter - VAS 6684-
Procedure
system ⇒ “3.1 Rules for cleanliness”, page 6 .
– Clean all return line connections with engine cleaner or brake
cleaner and dry.
– Clamp off fuel return hose -arrow- using hose clamp up to
25 mm - 3094- .

-1- off injectors.
– Connect adapters of return flow meter - VAS 6684- to return
line connections of all 4 injectors.
NOTICE
Risk of damage to injectors when return lines are disconnected.
– Do NOT press the accelerator during this test; the engine
must only run at idling speed.
– Start engine and run at idling speed for several minutes:

– When the engine is warm and running at idling speed, the re‐
turn flow rates at each of the 4 return lines must not differ by
more than a small amount (example -1-).
– If one injector has a significantly higher return flow rate than
the others (example -2-), it must be renewed ⇒ page 173 .
– When the engine is warm and running at idling speed, the re‐
turn flow rates at each of the 4 return lines must not differ by
more than a small amount.
deformation.
stalling.
– Push return line connections carefully onto injectors. The
catch should engage audibly. Then press release pin down
carefully.
er.
automatically.
4.7 Checking return flow rate of injectors at

starter cranking speed
Only perform this test if the engine does not start at all.
♦ Return flow meter - VAS 6684- and adapter
Procedure
Each injector normally has a relatively low fuel return flow rate. If
the return flow rate at one injector is relatively high compared to
the other injectors, that injector is probably defective.


system ⇒ page 6 .
– Clean all return line connections with engine cleaner or brake
cleaner and dry.
-1- off injectors.
– Connect adapters of return flow meter - VAS 6684- to return
line connections of all 4 injectors.
– Connect hoses of return flow meter - VAS 6684- to adapter.
– Operate starter three times (wait approx. 20 seconds each
time after operating starter to prevent it from overheating).
• Specification of return flow rate: 0 ml
– If fuel comes out of an injector, that injector must be renewed.
deformation.
stalling.
– Push return line connections carefully onto injectors. The
catch should engage audibly. Then press release pin down
carefully.
er.
automatically.
4.8 Removing and installing injectors

♦ Cleaning kit - VAS 6811-

♦ Puller - T10055-
♦ Assembly sleeve - T10377-
♦ Puller - T10415-
♦ Socket - T40055-
Removing
system ⇒ page 6 .


-1- off injectors.
– Unplug electrical connector -1- for fuel pressure regulating

valve - N276- .
– Unplug electrical connectors -arrows- at injectors.
– Mark allocation of high-pressure pipe to cylinder for re-instal‐
lation.
– Unscrew union nut on corresponding high-pressure pipe
(-2 to 5-) and detach corresponding high-pressure pipe.
– Seal off open lines and connections with clean plugs.

– Detach noise insulation.

– Mark allocation of injector to cylinder for re-installation.
Note:
Each clamping piece always secures two injectors and can only
be taken out if both injectors are removed.
• Sequence for removing injectors: First remove injector for cyl‐
inder 2, then for cylinder 1/cylinder 4, and then for cylinder 3.
– Apply puller - T10055- with puller - T10415- as shown in illus‐
tration, and pull out injectors upwards with clamping piece.
Note:
To avoid damaging the sealing lip, rotate the injector while pulling
it out.
– Place removed injectors on a clean cloth.
Installing
NOTICE
Risk of damage to injector sealing surface if it is not cleaned
properly.
– To remove carbon deposits from the injector sealing surface,
clean the injector bore in the cylinder head with cleaning kit
- VAS 6811- .
Installing new injectors

When installing new injectors, the following components must be
renewed:
♦ Bolt for clamping piece
♦ O-ring for injector bore
♦ O-ring for fuel return line connection
♦ Corresponding high-pressure pipes
Installing used injectors
When re-installing used injectors, the following components must
be renewed:
♦ Bolt for clamping piece
♦ Copper seal
♦ O-ring for injector bore
♦ O-ring for fuel return line connection
– Spray tip of injector nozzle with rust-solvent spray. Wait ap‐
prox. 5 minutes and wipe off soot particles and oil with a cloth.
– To remove the old copper seal from the injector, clamp the seal
carefully in a vice so that it is just held between the jaws without
turning. Then carefully pull and twist the injector out of the
copper seal by hand.
– Clean off deposits under the copper seal using a suitable scra‐
per.
Continued (same procedure for used and new injectors):
– Fit new copper seal.

– Lubricate all O-rings with engine oil or assembly oil before in‐
stalling.
– Renew O-ring for injector bore using assembly sleeve -

T10377- .
– Install injectors.
note the following:
– Install high-pressure pipes ⇒ page 177 .
• Lubricate all O-rings with engine oil or assembly oil before in‐
stalling.
– Push the return line connections carefully over the new seals
and onto the injectors.
• The connection must engage audibly.
– Carefully press down release pin.
• After renewing one or more injectors, the “injector delivery cal‐
ibration values” and “injector voltage calibration values” for the
new injectors must be written into the engine control unit using
⇒ Vehicle diagnostic tester ⇒ page 9 .
Tightening torques
♦ ⇒ “4.1 Exploded view - injectors”, page 163
4.9 Removing and installing high-pressure

pipes
⇒ “4.9.1 Removing high-pressure pipe between high-pressure
reservoir (rail) and high-pressure pump”, page 177
⇒ “4.9.2 Installing high-pressure pipe”, page 178
4.9.1 Removing high-pressure pipe between

high-pressure reservoir (rail) and high-
pressure pump

♦ Socket - T40055-
Removing
system ⇒ page 6 .
– Unscrew union nuts -arrows- and detach high-pressure pipe.
4.9.2 Installing high-pressure pipe


♦ Socket - T40055-
Installing
• Note identification marks for cylinder allocation when re-in‐
stalling high-pressure pipes.
• The high-pressure pipes can be re-used after performing the
following checks:
• Check taper seats of high-pressure pipes for deformation and
cracks.
• The bore of the pipe must not be distorted, restricted or oth‐
erwise damaged.
• Corroded pipes must not be used again.
NOTICE
High-pressure pipes must be free of tension when installed.
Risk of damage to high-pressure pipes.
– If necessary, the high-pressure reservoir can be slackened
and moved slightly so that the injector pipes are not installed
under tension.
– Never bend the high-pressure pipes or subject them to ten‐
sion.
– Use vacuum cleaner to remove dirt from taper seat at high-

pressure reservoir.
– Lubricate threads of union nuts with clean engine oil.
– Hand-tighten union nuts on high-pressure pipes (ensure that
pipes are not under tension).
– To tighten unions of high-pressure pipes at high-pressure res‐
ervoir and injectors, use torque wrench - V.A.G 1331- with
open end spanner insert, AF 17 - V.A.G 1331/6- or socket -
T40055- .
– Check fuel system for leaks ⇒ page 154 .
Tightening torques
page 165

reservoir (rail)

♦ Socket - T40055-
Removing
system ⇒ page 6 .
Injectors/high-pressure reservoir (rail); Removing and installing
high-pressure reservoir (rail) .
– Remove high-pressure pipe ⇒ page 177 .
1 - For turbocharger 1 control unit - J724- (fitting location varies)
2 - For heater element for crankcase breather - N79-
3 - For fuel pressure regulating valve - N276-
5 - For fuel pressure sender - G247-
– Detach wiring duct -4- from high-pressure reservoir and move
to side.

– Place a cloth underneath to catch escaping fuel.

– Release hose clip -2- and detach fuel return hose.
– Remove union nuts -1- for high-pressure pipes.
– Remove bolts -arrows- and detach high-pressure reservoir
-3-.
Installing
• Renew spring-type clip for fuel hose after removing.
• If the high-pressure reservoir is renewed, all corresponding
high-pressure pipes must also be renewed.
– Observe all instructions for installing high-pressure pipes
⇒ page 178 .
ltr. 4-valve common rail; Rep. gr. 23 ; Injectors/high-pressure
reservoir (rail); Removing and installing high-pressure reservoir
(rail)
Tightening torques
page 165

5 High-pressure pump
⇒ “5.1 Exploded view - high-pressure pump”, page 182
⇒ “5.2 Removing and installing high-pressure pump”, page 183
5.1 Exploded view - high-pressure pump
1 - Bolt
❑ Tightening torques
♦ M8x30 - 20 Nm +45°
♦ M8x65 - 20 Nm +180°
♦ M8x90 - 20 Nm +180°
2 - High-pressure pump
sprocket
3 - Nut
❑ Do not additionally oil
threads and shoulder
❑ Use counterhold tool -
T10051A- when loosen‐
ing and tightening
❑ 95 Nm
4 - Hub
❑ To remove, use puller -
T10489-
5 - Bracket for ancillaries
❑ Exploded view
⇒ page 17
6 - High-pressure pump
❑ With fuel metering valve
- N290-
❑ Do not dismantle
⇒ page 183
❑ Performing adaptions
required after renewing
a component (using
⇒ Vehicle diagnostic
tester) ⇒ page 9
❑ Between high-pressure reservoir (rail) and high-pressure pump
❑ If the high-pressure pump is renewed, the corresponding high-pressure pipe must also be renewed

8 - Fuel hoses

pump
♦ Puller - T10489-
Removing
system ⇒ page 6 .
– Detach toothed belt from camshaft ⇒ page 48 .
– Remove high-pressure pipe ⇒ page 177 .
5. High-pressure pump 183

– Apply counterhold tool - T10051A- to high-pressure pump

sprocket.
– Detach locking pin - T10492- and slowly turn high-pressure
pump shaft to a position in which it is not under tension.
– Remove nut -arrow- and detach counterhold tool - T10051A- .
– Detach high-pressure pump sprocket.
– Engage puller - T10489- at hub of high-pressure pump by

turning it 60° clockwise -arrow-.
– Detach hub of high-pressure pump.

– Release hose clips -1- and detach fuel hoses.
– Carefully remove high-pressure pump -2-.
Installing
angle.
• Renew spring-type clips after removing.
– Apply hub to high-pressure pump shaft.
• The parallel key -1- on the high-pressure pump shaft must en‐
gage in the groove -2- in the hub.

– Place high-pressure pump sprocket on hub.

• Contact surface between hub and toothed belt sprocket must
be free of oil.
– Screw nut -arrow- onto thread of high-pressure pump shaft.
– Apply counterhold tool - T10051A- to high-pressure pump
sprocket and hand-tighten nut.
– Turn high-pressure pump sprocket with counterhold tool -
T10051A- until it can be locked in position with locking pin -
T10492- .
– To do so, insert locking pin - T10492- into fork -2- on hub and
into hole -1- behind it in bracket for ancillaries.
– Loosen nut again.
• The high-pressure pump sprocket should still just turn, but
there must be no axial movement.
– Observe all instructions for installing high-pressure pipes
⇒ page 178 .
NOTICE
Running when dry causes irreparable damage to fuel pump.
– Bleed fuel system

Tightening torques
♦ ⇒ “5.1 Exploded view - high-pressure pump”, page 182
5. High-pressure pump 185

6 Senders and sensors

⇒ “6.1 Removing and installing air mass meter G70 ”, page 186
⇒ “6.2 Removing and installing fuel pressure sender G247 ”, page
186
⇒ “6.3 Removing and installing fuel pressure sender for low pres‐
sure G410 ”, page 188
⇒ “6.4 Removing and installing exhaust gas pressure sensor 1
G450 ”, page 189
⇒ “6.5 Checking fuel pressure regulating valve N276 ”,
page 190
⇒ “6.6 Removing and installing fuel pressure regulating valve
N276 ”, page 192
6.1 Removing and installing air mass meter

- G70-
4-valve common rail; Rep. gr. 23 ; Senders and sensors; Re‐
moving and installing air mass meter - G70- .
6.2 Removing and installing fuel pressure

sender - G247-
• The fuel pressure sender - G247- continuously measures the
fuel pressure in the high-pressure system. It transmits a cor‐
responding voltage signal to the engine control unit - J623- .
• Should the fuel pressure sender fail, the engine control unit
will control the fuel pressure via a mapped open-loop backup
function. Maximum engine speed in this mode is restricted.
• The fuel pressure sender - G247- has a deformable sealing lip
and no separate seal; it can therefore be used only once.

♦ Socket, 27 mm - T40218-
Removing
– Clean area all around fuel pressure sender - G247- with en‐
gine cleaner or brake cleaner and dry.
• Clean carefully; cleaning solution must not enter the electrical
connector.
• Make sure no dirt gets into opening in high-pressure reservoir
(rail).
6. Senders and sensors 187

– Move electrical wiring and fuel hoses clear, and press them to
one side.
• Do not use an open-end spanner for loosening or tightening.
– Unscrew fuel pressure sender - G247- -item 1- using socket,
27 mm - T40218- .
– Remove dirt from opening in high-pressure reservoir (rail) us‐
ing a vacuum cleaner. Do not use metal tools, etc.
– Seal off hole in high-pressure reservoir (rail) with a plug (thor‐
oughly cleaned) from engine bung set - VAS 6122- .
Installing
• Fuel pressure sender - G247- must always be renewed after
it has been removed.
• Check sealing surface at opening in high-pressure reservoir.
• Check that the deformable sealing lip and the thread on the
new fuel pressure sender are not damaged.
• The beginning of the thread and the deformable sealing lip of
the fuel pressure sender must be coated with diesel fuel.
– Screw in fuel pressure sender - G247- by hand until it makes
contact and then tighten.
After installing fuel pressure sender - G247- , leave engine run‐
ning at moderate speed for a few minutes when bleeding fuel
system and then switch off again.
• The fuel system is “self-bleeding”; do NOT open the high-
pressure connections.
– Switch off ignition.
– Carefully check the entire fuel system for leaks.
Renew affected component if leakage still occurs after tightening
to correct torque.
Note:
If there is any air left in the fuel system, the engine may switch to
the backup mode ('emergency running' mode) during the road
test. Switch off the engine and erase the event memory. Then
continue the road test.
– After road test, interrogate event memory again.
Tightening torques
page 165

sender for low pressure - G410-

Removing
– Release hose clips -arrows- and disconnect fuel return hoses.
Installing
– Check fuel system for leaks ⇒ page 154 .
Tightening torques
page 165
6.4 Removing and installing exhaust gas

pressure sensor 1 - G450-
♦ Silicone-free lubricant spray (commercially available)
Removing


– Press exhaust gas pressure sensor 1 - G450- slightly to side.
– Before disconnecting, spray hoses at pressure sensor with
silicone-free lubricant.
NOTICE
Risk of damage to pressure differential sender if connection
breaks off.
– Carefully disconnect hoses from connections, taking care to
keep hoses straight.
Installing
• Before installing, blow out control pipes from exhaust gas
pressure sensor 1 - G450- to particulate filter towards partic‐
ulate filter with compressed air (pipes can become obstructed
or may ice up due to condensation).
• Make sure that hose is securely fitted and that there are no
leaks.
Tightening torques
6.5 Checking fuel pressure regulating valve

- N276-

♦ Fuel-resistant measuring container

Procedure
system ⇒ page 6 .
– Lift wiring duct slightly and release hose clip -arrow-.
– Disconnect fuel return line from high-pressure reservoir and
seal off immediately with a plug (thoroughly cleaned) from en‐
gine bung set - VAS 6122- .

– Connect test hose -2- to return line connection of high-pres‐

sure reservoir -1- and place end of hose in a measuring
container -3-.
1) Checking while engine is running
– Start the engine and run at idling speed.
• Specification: more than 75 ml in 30 seconds
If specification is not obtained, fuel pressure regulating valve -
N276- is defective.
2) Checking while engine is running
If condition for 1) is met, start engine and increase engine speed
to ≥ 2000 rpm.
• Fuel is still discharged in the first few seconds after the engine
is started
• Specification after a few seconds: return flow rate = 0 ml
• Drip leaks are permissible
If specification is not obtained, fuel pressure regulating valve - N
276- is defective.
3) If engine can no longer be started
Perform test with engine at cranking speed.
• Specification of return flow rate: 0 ml
• Drip leaks are permissible
If specification is not obtained, fuel pressure regulating valve - N
276- is defective.
Assembling
• Renew spring-type clips after removing.

regulating valve - N276-

♦ Open end spanner insert, AF 30 - T10553-
Removing
– Remove high-pressure reservoir (rail)
⇒ “4.10 Removing and installing high-pressure reservoir (rail)”,
page 179 .
– Before removal, clean area around thread for fuel pressure
regulating valve - N276- using e.g. commercial cleaning solu‐
tion.
• Make sure no dirt gets into opening in high-pressure reservoir.
• Clean carefully; cleaning solution must not enter the electrical
connector.
– Dry off fuel pressure regulating valve - N276- .
Note:
The high-pressure reservoir can be clamped in a vice in order to
remove the pressure regulating valve; however, it is essential that
protective jaw covers are used. Do NOT take up the weight of the
high-pressure reservoir by the threaded connections for the high-
pressure pipes or the retaining tabs for the cylinder head.
– Mark installation position of connector of fuel pressure regu‐
lating valve - N276- relative to high-pressure reservoir.
– Unscrew fuel pressure regulating valve - N276- -item 2- from
high-pressure reservoir -1- using insert tool (30 mm) -
T10553- .
– Remove dirt from opening in high-pressure reservoir (rail) us‐
ing a vacuum cleaner. Do not use metal tools, etc.
– Seal off open connection in high-pressure reservoir with a plug
(thoroughly cleaned) from engine bung set - VAS 6122- .
Installing
• Renew fuel pressure regulating valve - N276- after removing.
• Check sealing surface at opening in high-pressure reservoir.
• Check that the deformable sealing lip and the thread on the
new regulating valve are not damaged.
• Coat beginning of thread, deformable sealing lip and O-ring of
regulating valve lightly with diesel fuel.

– Tighten fuel pressure regulating valve - N276- -item 2- using

insert tool (30 mm) - T10553- .
– Turn valve body to align connector of fuel pressure regulating
valve - N276- with high-pressure reservoir according to mark
made previously.
– Install high-pressure reservoir (rail) ⇒ page 179 .
– If necessary, turn valve body to align regulating valve so that
connecting wire is free of tension after connector is attached.
ing ⇒ Vehicle diagnostic tester)
page 9 .
After installing fuel pressure regulating valve - N276- , leave en‐
gine running at moderate speed for a few minutes to bleed fuel
system and then switch off again.
Note
♦ The fuel system is “self-bleeding”; do NOT open the high-
pressure connections.
– Interrogate event memory.
– Carefully check the entire fuel system for leaks.
Renew affected component if leakage still occurs after tightening
to correct torque.
– After road test, interrogate event memory again.
Tightening torques
page 165

7 Lambda probe
⇒ “7.1 Exploded view - Lambda probe”, page 195
⇒ “7.2 Removing and installing Lambda probe”, page 197
⇒ “7.3 Removing and installing NOx senders”, page 198
7.1 Exploded view - Lambda probe
1 - Bracket
❑ For control unit 2 for
NOx sender - GX46-
2 - Bolt
❑ 5 Nm
3 - Control unit 2 for NOx send‐
er - GX46-
❑ with
♦ NOx sender 2 - G687-
♦ Control unit 2 for NOx send‐
er - J881-
⇒ page 198
❑ Tightening torque for
NOx sender 2 - G687- :
52 Nm
4 - Nut
❑ 2.5 Nm
5 - Pressure pipe
❑ For exhaust gas pres‐
sure sensor 1 - G450-
⇒ Fig. ““Pressure pipe -
installation position”“ ,
page 196
❑ Union nut, 45 Nm
6 - Exhaust gas temperature
sender 4 - G648-
7 - Bolt
❑ 8 Nm
8 - Exhaust gas pressure sensor 1 - G450-
9 - Bracket
❑ For exhaust gas pressure sensor 1 - G450-
10 - Bolt
❑ 8 Nm
11 - Control unit for NOx sender - GX30-
❑ with
♦ NOx sender - G295-
♦ Control unit for NOx sender - J583-
7. Lambda probe 195


❑ Tightening torque for NOx sender - G295- : 52 Nm
12 - Exhaust gas temperature sender 3 - G495-
❑ Removing and installing ⇒ Item 12 (page 223)
13 - Lambda probe 1 before catalytic converter - GX10-
❑ with
♦ Lambda probe - G39-
♦ Lambda probe heater - Z19-
❑ Observe fitting instructions ⇒ page 197
⇒ page 9
❑ 52 Nm
16 - Pressure pipe
❑ Installation position ⇒ Fig. ““Pressure pipe - installation position”“ , page 196
❑ Union nut, 45 Nm
Pressure pipe - installation position

• Two lines visible - installed incorrectly
• One line visible - installed correctly

7.2 Removing and installing Lambda probe

Lambda probe open ring spanner set - 3337-
Removing
Lambda probe; Removing and installing Lambda probe .
– Detach electrical connector -2- from bracket, unplug and move

electrical wire clear.
CAUTION
Risk of injury caused by soot particles in the air.
Eyes and skin can suffer irritation or injuries.
– Unscrew Lambda probe 1 before catalytic converter - GX10-

-item 1- using a tool from Lambda probe open ring spanner
set - 3337- .
Installing
• Threads of new Lambda probes are already coated with as‐
sembly paste; the paste must not get into the slots on the probe
body.
• In the case of a used Lambda probe grease only the thread
with high-temperature paste. The paste must not get into the
slots on the Lambda probe body. For high-temperature paste
refer to ⇒ Electronic parts catalogue
• When installing, the Lambda probe wiring must always be re‐
attached at the same locations to prevent it from coming into
contact with the exhaust pipe.
ltr. 4-valve common rail; Rep. gr. 23 ; Lambda probe; Removing
and installing Lambda probe
Tightening torques
7. Lambda probe 197

7.3 Removing and installing NOx senders

⇒ “7.3.1 Removing and installing NOx sender G295 ”,
page 198
⇒ “7.3.2 Removing and installing NOx sender 2 G687 ”,
page 198
7.3.1 Removing and installing NOx sender -

G295-
♦ Lambda probe open ring spanner set - 3337-
Removing
Lambda probe; Removing and installing NOx senders .
CAUTION
– Unscrew NOx sender - G295- -arrow- using a tool from Lamb‐

da probe open ring spanner set - 3337- and move electrical
wiring clear.
Installing
Installation is carried out in reverse sequence.
and installing NOx senders
Tightening torques
7.3.2 Removing and installing NOx sender 2 -

G687-

Removing
• Re-install all cable ties in the same locations when installing.
Lambda probe; Removing and installing NOx senders .
CAUTION
– Unscrew NOx sender 2 - G687- -arrow- using a tool from

Lambda probe open ring spanner set - 3337- .
Installing
Installation is carried out in reverse sequence.
and installing NOx senders
Tightening torques
7. Lambda probe 199

8 Engine control unit

engine, 2.0 ltr. 4-valve common rail; Rep. gr. 23 ; Engine control
unit .

26 – Exhaust system
1 Exhaust pipes/silencers
⇒ “1.1 Exploded view - silencers”, page 201
⇒ “1.2 Removing and installing front exhaust pipe”, page 201
⇒ “1.3 Removing and installing silencers”, page 201
⇒ “1.4 Stress-free alignment of exhaust system”, page 201
⇒ “1.5 Checking exhaust system for leaks”, page 201
1.1 Exploded view - silencers

4-valve common rail; Rep. gr. 26 ; Exhaust pipes/silencers; Ex‐
ploded view - silencers .
1.2 Removing and installing front exhaust

pipe
4-valve common rail; Rep. gr. 26 ; Exhaust pipes/silencers; Re‐
moving and installing front exhaust pipe .
1.3 Removing and installing silencers

4-valve common rail; Rep. gr. 26 ; Exhaust pipes/silencers; Re‐
moving and installing silencers .
1.4 Stress-free alignment of exhaust system

4-valve common rail; Rep. gr. 26 ; Exhaust pipes/silencers;
Stress-free alignment of exhaust system .
1.5 Checking exhaust system for leaks

Procedure
– Start the engine and run at idling speed.
– Plug tailpipes during leak test (e.g. with cloth or plug).
– Listen for noise at the connection points of cylinder head/ex‐
haust manifold, turbocharger/front exhaust pipe etc. to locate
any leaks.
– Rectify any leaks that are found.
1. Exhaust pipes/silencers 201

2 Emission control system

⇒ “2.1 Exploded view - emission control system”, page 202
⇒ “2.2 Removing and installing catalytic converter”, page 205
⇒ “2.3 Removing and installing particulate filter”, page 210
⇒ “2.4 Removing and installing trap catalytic converter”,
page 214
⇒ “2.5 Removing and installing exhaust flap control unit J883 ”,
page 216
2.1 Exploded view - emission control sys‐

tem
♦ Exploded view - emission control system, part I ⇒ page 202
♦ Exploded view - emission control system, part II ⇒ page 204
Exploded view - emission control system, part I
1 - Compensation element
❑ Checking and aligning
⇒ page 210
2 - Bolt
3 - Bolt
4 - Stud
❑
5 - Nut
6 - Bracket
❑ For catalytic converter
7 - Catalytic converter
⇒ page 205
8 - Bolt
9 - Screw-type clip
⇒ Fig. ““Screw-type clip
for particulate filter - in‐
stallation position”“ ,
page 204
10 - Seal
202 Rep. gr.26 - Exhaust system

11 - Turbocharger
12 - Screw-type clip
❑ Installation position ⇒ Fig. ““Screw-type clip for particulate filter - installation position”“ , page 204
13 - Seal
❑ Installation position ⇒ Fig. ““Seal for particulate filter - installation position”“ , page 204
14 - Bolt
❑ 40 Nm
15 - Bracket
❑ For catalytic converter and particulate filter
16 - Particulate filter
17 - Nut
18 - Bracket
❑ For particulate filter
19 - Nut
20 - Bracket
⇒ Fig. ““Screw-type clips for exhaust gas recirculation pipe - installation position”“ , page 230
22 - Seal
❑ Installation position ⇒ Fig. ““Seal for exhaust gas recirculation pipe - installation position”“ , page 230
23 - Pipe
❑ For exhaust gas recirculation
24 - Seal
❑ Installation position ⇒ Fig. ““Seal for exhaust gas recirculation pipe - installation position”“ , page 230
⇒ Fig. ““Screw-type clips for exhaust gas recirculation pipe - installation position”“ , page 230
26 - Bolt
❑ 20 Nm
27 - Bracket
28 - Bolt
2. Emission control system 203

Screw-type clip for particulate filter - installation position

– Screw -arrow- screw-type clip -1- onto catalytic converter -2-
as far as stop.
Seal for particulate filter - installation position

• Protrusion -1- on seal must engage in groove -arrow- on par‐
ticulate filter.
Screw-type clip for particulate filter - installation position

• Angle -α- = 45°
Exploded view - emission control system, part II

1 - Bolt
❑ 20 Nm
2 - Mounting
❑ Red-coloured mounting
must be renewed after it
has been pulled off
3 - Front exhaust pipe
❑ With flexible joint
❑ Do not bend flexible joint
more than 10°
❑ Install flexible joint so
that it is not under ten‐
sion.
❑ Take care not to dam‐
age wire mesh on flexi‐
ble joint
⇒ 4-cylinder TDI en‐
gine, 2.0 ltr. 4-valve
common rail; Rep. gr.
26 ; Exhaust pipes/si‐
lencers; Removing and
installing front exhaust
pipe
4 - Seal
5 - Screw-type clip
❑ 7 Nm
6 - Nut
❑ 9 Nm
7 - Exhaust flap control unit - J883-
8 - Bolt
9 - Clamp
❑ Installation position and tightening torque ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve common rail; Rep. gr.
26 ; Exhaust pipes/silencer; Exploded view - silencers
10 - Trap catalytic converter
❑ Protect against knocks and impact
11 - Gasket
12 - Nut
❑ 25 Nm
2.2 Removing and installing catalytic con‐

verter

Removing
Emission control system; Removing and installing catalytic con‐
verter .
– Remove underbody trim (front) ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Underbody trim; Exploded view - under‐
body trim .
– Remove air cleaner housing ⇒ 4-cylinder TDI engine (2.0 ltr.
4-valve common rail); Rep. gr. 23 ; Air cleaner; Removing and
installing air cleaner housing .
CAUTION



– Unscrew bolts - 5- and nuts -3- and remove bracket -2-.

Note
If particulate filter is to be removed subsequently, remove union
nuts -1 and 4- and move pressure pipes clear.
– Unscrew NOx sender - G295- -arrow- using a tool from Lamb‐

da probe open ring spanner set - 3337- and move electrical
wiring clear.
– Detach electrical connectors from bracket, unplug them and

move them clear:
2- For Lambda probe 1 before catalytic converter - GX10-
– Remove engine support (right-side) ⇒ 4-cyl. TDI engine, 2.0
ltr. 4-valve common rail; Rep. gr. 13 ; Cylinder block (pulley
end); Removing and installing engine support .
– Remove bolt -arrow-, move cable duct -1- with B+ wire clear
and push it to one side.

– Release screw-type clips -arrows- and detach injector for re‐

ducing agent - N474- -item 2-.
– Place particulate filter to right side.
– Remove bolts -1, 3- and nuts -4- and detach bracket -5- and
catalytic converter.
Installing
• Renew seals, gaskets, nuts and screw-type clips after remov‐
al.
– Check and align compensation element ⇒ page 210 .

– Note installation position of screw-type clip ⇒ page 204 .
NOTICE
Catalytic converter must be installed free of tension to avoid risk
of stress fractures and engine damage.
– Adhere to sequence of steps given below.
– Move catalytic converter with screw-type clip into installation

position and loosely screw in bolts -1, 3- and nuts -4-.
• Catalytic converter is now suspended approximately in instal‐
lation position with its weight supported.
Tightening sequence - catalytic converter
Stage Threaded con‐ Step
nections
1. Screw-type Fit over sealing flange, engage screw
clip -2- and tighten to 1 Nm
2. Bolt -1- Tighten to 5 Nm and loosen immedi‐
ately by 90°
3. Nuts -4- Tighten to 5 Nm and loosen immedi‐
ately by 90°
4. Screw-type Tighten to 17 Nm
clip -2-
5. Bolt -1- Tighten to 20 Nm
6. Bolts -3- Tighten to 20 Nm
7. Nuts -4- Tighten to 20 Nm
note the following:
– Install engine support (right-side) ⇒ 4-cyl. TDI engine, 2.0 ltr.
– Install particulate filter ⇒ page 210 .
– Install injector for reducing agent - N474- ⇒ page 220 .
– Install air cleaner housing ⇒ 4-cylinder TDI engine (2.0 ltr. 4-
valve common rail); Rep. gr. 23 ; Air cleaner; Removing and
ltr. 4-valve common rail; Rep. gr. 26 ; Emission control system;
Removing and installing catalytic converter
Tightening torques
gr. 26 ; Exhaust pipes/silencers; Exploded view - silencers
page 228
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation

2.3 Removing and installing particulate filter

♦ The particulate filter is secured to the engine in part by a com‐
pensation element. This compensation element has a left-
hand thread on the outside. When the bolt -1- is screwed in,
the friction against the retaining tabs -3- initially causes the
compensation element -2- to turn as well. Even though the bolt
is turned clockwise, the left-hand thread causes the compen‐
sation element to move towards the bolt head, which com‐
pensates for the play between the components. The compen‐
sation element must rotate freely on the left-hand thread,
otherwise the retaining tabs will not produce enough friction
on the bolt to turn the compensation element. To avoid im‐
pairing the required friction, ensure that the retaining tabs do
not come in contact with any lubricant.

♦ Socket - T40055-
♦ Calibration tool - T10512-
Removing
• Re-fit all cable ties and heat insulation sleeves in the same
locations when installing.


– Take electrical connector -arrow- for exhaust gas temperature

sender 4 - G648- out of bracket, unplug it and move wiring
clear.
– Release screw-type clip -arrow-.

-2-.
– Remove bolts -arrows- and detach bracket -1- for catalytic

converter and particulate filter.

Vehicles with water-cooled turbocharger only:

– Remove exhaust gas recirculation cooler
er”, page 232 .

breather hose -3-.
-arrow- and detach.

– Unscrew bolts -1- and remove bracket -2-.

– Unscrew bolts -arrows- and detach coolant lines -3-.
All vehicles:
– Remove particulate filter towards front.
Installing
angle.
• Renew O-rings, seals, gaskets and screw-type clips for par‐
ticulate filter after removing.
NOTICE
Particulate filter must be installed free of tension to avoid risk of
stress fractures and engine damage.
– Adhere to sequence of steps given below.
♦ Prior to installation, ensure that the compensation element

moves easily and does not stick.
♦ Compensation element must turn easily on its threads.
♦ Lubricant must only be applied to thread; retainer tabs must
remain free of lubricant.
♦ The retainer tabs for the bolt must be bent together so that
when the bolt is screwed in, the compensation element turns
as well.
– Check to ensure freedom of movement of compensation ele‐

ment -arrow-.
– Unscrew compensation element completely in clockwise di‐
rection (left-hand thread).
– Clean thread if it does not turn easily and lubricate lightly with
rust remover if necessary.
• Do not use any kind of lubricant on the retainer tabs of the
compensation element. Reducing the build-up of friction would
compromise the function of the compensation element.
– Adjust retainer tabs to functional dimension using calibration

tool -T10512/1-2- as follows:
– Slide compensation element -1- onto pin -T10512/1- , insert
into centring sleeve -T10512/2- and bend back retainer tabs
by gently striking -arrow- ball head with heel of your hand.

– Tighten compensation element -arrow- to 3 Nm and slacken

again by 90°.
note the following:
– Move particulate filter into installation position.
– Move particulate filter and screw-type clip into installation po‐

sition -3- and loosely screw in bolt -5- and nuts -1, 2-.
• Particulate filter is now suspended approximately in installa‐
tion position with its weight supported.
Stage Threaded con‐ Step
nections
2. Screw-type Move into installation position
clip -3- ⇒ page 204 and tighten to 7 Nm
4. Bolt -4- Screw in and tighten to 20 Nm; when
doing so, check that compensation el‐
ement moves and makes contact with
particulate filter
5. Nut -2- Tighten to 20 Nm
6. Nut -1- Tighten to 20 Nm
note the following:
– Install exhaust gas recirculation cooler
er”, page 232 .
– Install catalytic converter
page 205 .
Perform adaptions required after renewing a component (using
⇒ Vehicle diagnostic tester)
page 9 .
Tightening torques
2.4 Removing and installing trap catalytic

converter

Removing
– Remove noise insulation (front and rear) ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Noise insulation; Exploded view
- noise insulation .
– Unscrew NOx sender 2 - G687- -arrow- using a tool from
Lambda probe open ring spanner set - 3337- .
CAUTION
– Remove nuts -arrows-.
– Unplug electrical connector -1- for exhaust flap control unit -

J883- -item 2-.

– Loosen clamp -arrows- and push towards rear.

– Remove trap catalytic converter.
Installing
• Renew gasket and self-locking nuts after removal.
page 9 .
– Install noise insulation (front and rear) ⇒ General body repairs,
exterior; Rep. gr. 66 ; Noise insulation; Exploded view - noise
insulation .
Tightening torques
♦ ⇒ “2.1 Exploded view - emission control system”, page 202
2.5 Removing and installing exhaust flap

control unit - J883-
Removing
CAUTION
– Unscrew bolts -arrows- and remove exhaust flap control unit -

J883- .
Installing
– Fit exhaust flap control unit.
• Coupling -1- must engage in retainer of exhaust flap -2-.

– Tighten upper bolt first, then tighten lower bolt.

note the following:
ing ⇒ Vehicle diagnostic tester)
page 9 .
Tightening torques
gr. 26 ; Exhaust pipes/silencers; Exploded view - silencers

3 SCR (selective catalytic reduction)

system
⇒ “3.1 Exploded view - reducing agent tank”, page 218
⇒ “3.2 Exploded view - reducing agent supply line”, page 218
⇒ “3.3 Exploded view - delivery unit”, page 219
⇒ “3.4 Releasing pressure in SCR system”, page 219
⇒ “3.5 Draining reducing agent tank”, page 220
⇒ “3.6 Removing and installing reducing agent tank”, page 220
⇒ “3.7 Removing and installing injector for reducing agent N474
”, page 220
⇒ “3.8 Removing and installing control unit for reducing agent
metering system J880 ”, page 222
⇒ “3.9 Removing and installing pump for reducing agent V437 ”,
page 222
⇒ “3.10 Removing and installing pressure sender for reducing
agent metering system G686 ”, page 222
⇒ “3.11 Removing and installing connection for SCR supply line”,
page 222
3.1 Exploded view - reducing agent tank

4-valve common rail; Rep. gr. 26 ; SCR (selective catalytic re‐
duction) system; Exploded view - reducing agent tank .
3.2 Exploded view - reducing agent supply line

1 - Catalytic converter
❑ Exploded view
⇒ page 202
2 - Seal
3 - Screw-type clip
⇒ page 219
❑ 9 Nm
4 - Injector for reducing agent -
N474-
⇒ page 220
❑ Lugs in injector for re‐
ducing agent - N474-
must be inserted in cor‐
responding mountings
5 - Supply line
❑ From reducing agent
pump - V437-
❑ With heater
❑ Clip onto fuel tank
6 - O-ring
❑ Renew supply line
damaged or leaking
7 - Coolant hoses
Screw-type clip for injector for reducing agent - N474- - installation

position
– Align screw-type clip with weld seam -arrow- on catalytic con‐
verter.
3.3 Exploded view - delivery unit

duction) system; Exploded view - delivery unit .
Only fitted on Q5 and A6/A7
3.4 Releasing pressure in SCR system

3. SCR (selective catalytic reduction) system 219

♦ Safety goggles
♦ Protective gloves
Procedure
CAUTION
The SCR system is pressurised.
Risk of injury as fuel may spray out.
– Release pressure (wrap a clean cloth around connection
and open connection carefully).
3.5 Draining reducing agent tank

duction) system; Draining reducing agent tank .
3.6 Removing and installing reducing agent

tank
duction) system; Removing and installing reducing agent tank .
3.7 Removing and installing injector for re‐

ducing agent - N474-

Removing
• Re-install all heat insulation sleeves in the same locations
when installing.
CAUTION
Risk of injury caused by escaping reducing agent
Reducing agent can cause eye and skin irritation, damage to
the respiratory tract and poisoning.
– Wear protective clothing.
– Ensure that there is sufficient fresh air. In enclosed spaces,
switch on the exhaust extraction system.

– Remove air cleaner housing ⇒ 4-cylinder TDI engine (2.0 ltr.
4-valve common rail); Rep. gr. 23 ; Air cleaner; Removing and
– Detach electrical connector -1- from bracket, unplug and move
electrical wire clear.
– Clamp off coolant hoses -2- with hose clamps, up to 25 mm -
3094- .
– Hold a cloth under separating point to catch escaping reducing

agent.
– Release pressure in SCR system ⇒ page 219 .
– Press release tab and disconnect SCR supply line -2- from
injector for reducing agent - N474- .
– Release hose clips -3- and disconnect coolant hoses.
– Release screw-type clip -1- and detach injector for reducing
agent - N474- .
Installing
• Renew seal and screw-type clip after removing.
Installation positions:
3. SCR (selective catalytic reduction) system 221

• Screw-type clip ⇒ page 219

• Lugs in injector for reducing agent - N474- -item 2- must be
inserted -arrows- in corresponding mountings in catalytic con‐
verter -1-.
After renewing component(s) or draining reducing agent (opening
a reducing agent line), perform required adaptions using vehicle
diagnostic tester
page 9 .
Tightening torques
♦ ⇒ “3.2 Exploded view - reducing agent supply line”,
page 218
3.8 Removing and installing control unit for

reducing agent metering system - J880-
All procedures are described in ⇒ 4-cyl. TDI engine, 2.0 ltr. 4-
valve common rail; Rep. gr. 26 ; SCR (selective catalytic reduc‐
tion) system ; Removing and installing control unit for reducing
agent metering system - J880- .
3.9 Removing and installing pump for re‐

ducing agent - V437-
tion) system ; Removing and installing pump for reducing agent -
V437- .
3.10 Removing and installing pressure send‐

er for reducing agent metering system -
G686-
tion) system ; Removing and installing pressure sender for
reducing agent metering system - G686- .
3.11 Removing and installing connection for

SCR supply line
tion) system ; Removing and installing connection for SCR supply
line.

4 Exhaust gas temperature control

⇒ “4.1 Exploded view - exhaust gas temperature control”,
page 223
⇒ “4.2 Removing and installing parts of exhaust gas temperature
control”, page 224
4.1 Exploded view - exhaust gas temperature control
1 - Bracket
❑ For control unit 2 for
NOx sender - GX46-
2 - Bolt
3 - Control unit 2 for NOx send‐
er - GX46-
❑ Removing and instal‐
ling, tightening torque
4 - Nut
5 - Pressure pipe
❑ For exhaust gas pres‐
sure sensor 1 - G450-
❑ Installation position,
tightening torque
6 - Exhaust gas temperature
sender 4 - G648-
⇒ page 224
❑ 45 Nm
7 - Bolt
8 - Exhaust gas pressure sen‐
sor 1 - G450-
❑ ⇒ Item 8 (page 195)
9 - Bracket
10 - Bolt
11 - Control unit for NOx sender - GX30-
❑ Removing and installing, tightening torque ⇒ Item 11 (page 195)
❑ 45 Nm
13 - Lambda probe 1 before catalytic converter - GX10-
❑ Removing and installing, tightening torque ⇒ Item 13 (page 196)
4. Exhaust gas temperature control 223


❑ 45 Nm
❑ 45 Nm
16 - Pressure pipe
4.2 Removing and installing parts of ex‐

haust gas temperature control
⇒ “4.2.1 Removing and installing exhaust gas temperature sender
G235 / G448 / G495 ”, page 224
⇒ “4.2.2 Removing and installing exhaust gas temperature send‐
er 4 G648 ”, page 225
4.2.1 Removing and installing exhaust gas

temperature sender -G235- / -G448- / -
G495-
♦ Flared ring spanner tool insert (17 mm) - V.A.G 1331/10-
Removing
– Exhaust gas temperature sender 3 - G495- : Remove air
cleaner housing ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve com‐
mon rail; Rep. gr. 23 ; Air cleaner; Removing and installing air
cleaner housing .

– Detach electrical connectors from bracket, unplug them and

move them clear:
CAUTION
– Unscrew exhaust gas temperature senders using flared ring

spanner tool insert (17 mm) - V.A.G 1331/10- :
1- Exhaust gas temperature sender 3 - G495-
Installing
• Take care to protect exhaust gas temperature sender from
knocks and impact; if dropped, the exhaust gas temperature
sender can no longer be used.
Installation position of exhaust gas temperature sender 3 -

G495- :
• Angle -α- = max. 15°
Tightening torques
♦ ⇒ “4.1 Exploded view - exhaust gas temperature control”, page
223
4.2.2 Removing and installing exhaust gas

temperature sender 4 - G648-

♦ Tool set - T10395 A- with suitable tool insert
Removing
Exhaust gas temperature control; Removing and installing parts
of exhaust gas temperature control .
– Take electrical connector -arrow- for exhaust gas temperature
sender 4 - G648- out of bracket, unplug it and move wiring
clear.

CAUTION
– Unscrew exhaust gas temperature sender 4 - G648- -arrow-.

Installing
• Take care to protect exhaust gas temperature sender from
knocks and impact; if dropped, the exhaust gas temperature
sender can no longer be used.
ltr. 4-valve common rail; Rep. gr. 26 ; Exhaust gas temperature
control; Removing and installing parts of exhaust gas temperature
control
Tightening torques
♦ ⇒ “4.1 Exploded view - exhaust gas temperature control”, page
223

5 Exhaust gas recirculation

⇒ “5.1 Exploded view - exhaust gas recirculation system”,
page 228
⇒ “5.2 Removing and installing exhaust gas recirculation valve 1
GX5 ”, page 230
⇒ “5.3 Removing and installing exhaust gas recirculation valve 2
GX6 ”, page 231
⇒ “5.4 Removing and installing exhaust gas recirculation cooler”,
page 232
⇒ “5.5 Checking exhaust gas recirculation cooler for leaks”, page
234
5.1 Exploded view - exhaust gas recircula‐

tion system
♦ Exhaust gas recirculation valve 1 - GX5- ⇒ page 228
♦ Exhaust gas recirculation valve 2 - GX6- ⇒ page 229
Exhaust gas recirculation valve 1 - GX5-
1 - Bolt
❑ 9 Nm
2 - Exhaust gas recirculation
valve 1 - GX5-
❑ with
♦ Exhaust gas recirculation
control motor - V338-
♦ Exhaust gas recirculation
potentiometer - G212-
⇒ page 230
❑ Performing adaptions
required after renewing
a component (using
tester) ⇒ page 9
3 - Seal
4 - Gasket
Volkswagen Technical Site: http://vwts.ru http://vwts.info

Exhaust gas recirculation valve 2 - GX6-

pipe
2 - Seal
⇒ page 230
3 - Screw-type clip
⇒ page 230
❑ 6 Nm
cooler
⇒ page 232
5 - Bolt
❑ 20 Nm
6 - Bracket
❑ For exhaust gas recircu‐
lation cooler
7 - Bolt
❑ 20 Nm
8 - Bolt
❑ 9 Nm
9 - Connecting piece
pipe
11 - Bolt
❑ 9 Nm
12 - Gasket
13 - Exhaust gas recirculation valve 2 - GX6-
❑ with
♦ Exhaust gas recirculation control motor 2 - V339-
♦ Exhaust gas recirculation potentiometer 2 - G466-
– Perform adaptions required after renewing a component (using ⇒ Vehicle diagnostic tester) ⇒ page 9 .
14 - Gasket
15 - Bolt
❑ 20 Nm
❑ Installation position ⇒ page 230
❑ 6 Nm
5. Exhaust gas recirculation 229

17 - Seal
❑ Installation position ⇒ page 230
Screw-type clips for exhaust gas recirculation pipe - installation

position
– Screw -arrows- screw-type clip -2- onto particulate filter and
onto exhaust gas recirculation pipe as far as stop -1-.
Seal for exhaust gas recirculation pipe - installation position

• Protrusion -1- on seal must engage in groove -2- on exhaust
gas recirculation pipe.
5.2 Removing and installing exhaust gas re‐

circulation valve 1 - GX5-
Contains exhaust gas recirculation control motor - V338-
Removing

CAUTION
– Remove bolts -arrows- and press fuel lines -1- slightly to side.
– Detach exhaust gas recirculation valve 1 - GX5- -item 3-.
Installing
• Renew connecting piece, seals and gaskets after removal.
page 9 .
Tightening torques
page 228
page 165

circulation valve 2 - GX6-
Contains exhaust gas recirculation control motor 2 - V339-
Removing
Emission control system; Removing and installing exhaust gas
recirculation valve 2 - GX6- .

– Remove bolts -arrows- and detach exhaust gas recirculation

pipe -1-.
CAUTION

valve 2 - GX6- -item 2-.
Installing
• Renew insulation mat for control motor if damaged. Addition‐
ally check control motor for thermal damage and renew if
necessary.
• Renew gasket and O-ring after removal.
ltr. 4-valve common rail; Rep. gr. 26 ; Emission control system;
Removing and installing exhaust gas recirculation valve 2 - GX6-
page 9 .
Tightening torques
page 228
tem”, page 146

circulation cooler

♦ Bit XZN 10 - T10501-
Removing
Exhaust gas recirculation; Removing and installing exhaust gas
recirculation cooler .

pipe -1-.
CAUTION


– Lift retaining clip -2-, release hose clip -1- and disconnect
coolant hoses.
cooler -4-.
– If renewing exhaust gas recirculation cooler, remove exhaust
gas recirculation valve 2 - GX6-
2 GX6 ”, page 231 .
Installing
• Renew connecting piece, seals and gaskets after removal.
ltr. 4-valve common rail; Rep. gr. 26 ; Exhaust gas recirculation;
Removing and installing exhaust gas recirculation cooler
Tightening torques
page 228
tem”, page 146
5.5 Checking exhaust gas recirculation

cooler for leaks
♦ Charge air system tester - V.A.G 1687-

♦ Adapter - V.A.G 1687/11-
♦ Adapter - V.A.G 1687/14-

♦ Y-connector - VAS 691 005/1-
♦ Test instrument adapter - VAS 691 005/5-

♦ Turbocharger tester - V.A.G 1397A-
Test condition:
• Coolant temperature must be at least 40°C.
expansion tank.

Connecting turbocharger tester - V.A.G 1397A- :

– Fit test adapter - VAS 691 005/5- onto coolant expansion tank.
– Fit Y-connector - VAS 691 005/1- onto test adapter - VAS 691
005/5- .
– Close valve -1- for connection »C« and open valve -2- for con‐
nection »A«.
– Attach hose from connection »A« on Y-connector to connec‐
tion »II« on turbocharger tester - V.A.G 1397A- .
– Set turbocharger tester - V.A.G 1397A- to switch position
»II« (relative pressure measurement) and switch it on. The »II«
must be visible.
Connecting tester - V.A.G 1687- :

– Loosen clamp on exhaust pipe -arrows- and push towards
rear.
– Connect adapter - V.A.G 1687/11- with adapter - V.A.G

1687/14- to trap catalytic converter.
– Connect hose of charge air system tester -V.A.G 1687- to
adapter -1-.

Prepare charge air system tester - V.A.G 1687- as follows:

– Pull pressure control valve -2- upwards, then unscrew com‐
pletely and close valves -3- and -4-.
– Using a commercially available connection piece, connect
charge air system tester - V.A.G 1687- to compressed air -1-.
– If there is water in sight glass -6-, drain it off via drain plug.
– Open valve -3-.
– Adjust pressure to 0.5 bar via pressure control valve -2-.
– Open valve -4- and wait until test system is pressurised. If
necessary, adjust pressure to 0.5 bar again.
Reading off values from turbocharger tester - V.A.G 1397A- :

• Observe turbocharger tester for approx. 5 minutes.
• The pressure displayed on the turbocharger tester must not
rise.
– If pressure displayed on turbocharger tester rises, this means
that compressed air is escaping from the exhaust end into the
cooling system. There is a leak in exhaust gas recirculation
cooler; renew exhaust gas recirculation cooler.
• If there are no leaks in the exhaust gas recirculation cooler, a
vacuum may form when the coolant cools down. A minus sign
on the turbocharger tester indicates that a vacuum has
formed.
Cleaning Y-connector - VAS 691 005/1- :

• After the leak test has been completed, the Y-connector - VAS
691 005/1- must be cleaned to remove any water which may
have entered.
– Insert cleaning nozzle -D- in hose from connection -A- on Y
connector .
– Fit test adapter - VAS 691 005/5- onto hose from connection
-B-.
– Fit compressed air hose on connection -C-.
– Open cut-off valves and blow through hose for approx. 15
seconds.

28 – Glow plug system

1 Glow plug system
⇒ “1.1 Exploded view - glow plug system”, page 238
⇒ “1.2 Removing and installing glow plug”, page 239
⇒ “1.3 Removing and installing automatic glow period control unit
J179 ”, page 241
⇒ “1.4 Removing and installing Hall sender G40 ”, page 241
⇒ “1.5 Removing and installing engine speed sender G28 ”, page
242
1.1 Exploded view - glow plug system
1 - Glow plug
♦ Glow plug 1 - Q10-
♦ Glow plug 3 - Q12- with cyl‐
inder 3 combustion cham‐
ber pressure sender -
G679-
❑ Glow plug versions and
tightening torques
⇒ page 239
❑ After renewing glow
plug 3 - Q12- with cylin‐
der 3 combustion cham‐
ber pressure sender -
G679- , perform adap‐
tions required using
tester
⇒ “3.8 Performing adap‐
tions after renewing a
component”, page 9 .
⇒ page 239
2 - Electrical connector
3 - O-ring
❑ Renew Hall sender -
G40- if damaged
4 - Hall sender - G40-
⇒ page 241
5 - Bolt
❑ 9 Nm
6 - Sealing flange (gearbox end)
❑ With sender wheel for engine speed sender - G28-
❑ Cannot be dismantled
238 Rep. gr.28 - Glow plug system

7 - Bolt
❑ 4.5 Nm
8 - Engine speed sender - G28-
Glow plug versions and tightening torques

1 - Glow plug with combustion chamber pressure sender
♦ Only fitted on cylinder 3 on some versions; glow plug 3 - Q12-
with cylinder 3 combustion chamber pressure sender - G679-
♦ 12 Nm
2 - Glow plug without combustion chamber pressure sender
♦ 12 Nm
1.2 Removing and installing glow plug

♦ Articulated wrench, 10 mm - 3220-
♦ Socket insert AF 12 for glow plugs 4-cyl.TDI CR diesel - VAS

6454- for glow plug with combustion chamber pressure sender
1. Glow plug system 239

♦ Pliers - 3314-
Removing
NOTICE
Risk of damage to support sleeves when removing.
– Do not squeeze pliers - 3314- too firmly when removing glow
plug connectors.
– Release retaining clips at wiring harness and detach electrical

connectors from glow plugs as follows.
– Apply groove -arrow A- of pliers - 3314- to collar of support
sleeve -arrow B- as shown in illustration.
– Carefully detach glow plug connectors from glow plugs.
– Clean glow plug opening to make sure no dirt gets into cylin‐
ders; note the following:
CAUTION
♦ Use a vacuum cleaner to remove coarse dirt.

♦ Spray brake cleaner or suitable cleaning agent into glow plug
apertures, let it work in briefly, and blow out with compressed
air.
♦ Clean glow plug opening with an oily cloth.
– Loosen glow plugs using tool and unscrew by hand:

♦ Use U/J extension and socket, 10 mm - 3220- for glow plugs

without combustion chamber pressure sender.
♦ Use socket insert AF 12 for glow plugs 4-cyl.TDI CR diesel -

VAS 6454- for glow plugs with combustion chamber pressure
sender.
Installing
– Fit glow plug connectors -1- back onto glow plugs -arrow-.
• Check that glow plug connectors are securely seated.
After renewing glow plug 3 - Q12- with cylinder 3 combustion
chamber pressure sender - G679- , perform adaptions required
using ⇒ Vehicle diagnostic tester
page 9 .
Tightening torques
♦ ⇒ Fig. ““Glow plug versions and tightening torques”“ ,
page 239
1.3 Removing and installing automatic glow

period control unit - J179-
4-valve common rail; Rep. gr. 28 ; Glow plug system; Removing
and installing automatic glow period control unit - J179- .
1.4 Removing and installing Hall sender -

G40-

♦ Socket Torx T30 - T10405-
Removing
– Release hose clip (left-side) -1- and detach fuel hose (left-
side).

– Unscrew bolt -2- and pull off Hall sender - G40- -item 1-.
Installing
Tightening torques
1.5 Removing and installing engine speed

sender - G28-

♦ Socket (4 mm) - T10370-
Removing
– Remove engine support (left-side) ⇒ 4-cyl. TDI engine, 2.0 ltr.
– Use assembly tool - T10118- to unplug electrical connector
-1-.
– Unscrew bolt -2- and detach engine speed sender - G28- .
Installing
– Install engine support (left-side) ⇒ 4-cyl. TDI engine, 2.0 ltr.
Tightening torques

Servicing 4-Cylinder TDI Engine, Common Rail EA288 EVO

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Service

Service Department. Technical Information

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.4 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2.4 Exploded view - coolant temperature senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

1.1 Engine number/engine data

2.1 Safety precautions when working on the fuel supply system

Risk of fire due to escaping fuel

2.2 Safety precautions when working on vehicles with start/stop system

2 Rep. gr.00 - Technical data

2.4 Safety precautions when working on the cooling system

2.5 Safety precautions when working on the exhaust system

Risk of injury when disconnecting the exhaust system

Components of the exhaust system can pose health risk

Danger from toxic exhaust gases

Risk of damage to flexible joint

2.6 Safety precautions when working on the SCR system

Risk of damage caused by reducing agent

When removing and installing components at the SCR system,

4 Rep. gr.00 - Technical data

2.7 Safety precautions when working on the subframe

3.1 Rules for cleanliness

3.2 General notes

6 Rep. gr.00 - Technical data

♦ Do not use sealants containing silicone. Particles of silicone

3.3 General repair instructions

♦ Clean tools and workbench etc. before working on the injection

♦ If the high-pressure fuel lines are to be re-used, you must mark

3.4 Foreign particles in engine

3.5 Contact corrosion

8 Rep. gr.00 - Technical data

3.6 Routing and attachment of pipes, hoses

3.7 Installing radiators and condensers

3.8 Performing adaptions after renewing a

ODIS path for A6/A7:

♦ 00AC - Control unit for reducing agent metering

♦ 00AC - Adapt reduction agent tank learned values

10 Rep. gr.00 - Technical data

10 – Removing and installing engine

1.1 Removing engine

1.2 Removing engine from scissor-type as‐

♦ Workshop hoist - VAS 6100-

1. Removing and installing engine 11

♦ Lift arm extension/workshop hoist - VAS 6101-

– Attach lift arm extension - VAS 6101- to workshop hoist -

– Detach engine support - T10533/1- from engine.

12 Rep. gr.10 - Removing and installing engine

1.3 Securing engine to engine and gearbox

♦ Engine and gearbox support - VAS 6095A-

1. Removing and installing engine 13

– Secure engine to engine and gearbox support - VW 540- using

1.4 Installing engine

14 Rep. gr.10 - Removing and installing engine

3 Engine cover panel

3.1 Removing and installing engine cover

16 Rep. gr.10 - Removing and installing engine