Volkswagen Touareg 2003->
(7L)
Technical data
Engine identification
Engine data
00-1, Engine identification
00-1, Engine specifications
Engine identification
The engine number ( "engine code" and "serial number" )
is located on cylinder block, below the cylinder head of
cylinder bank 2.
The engine number consists of up to nine characters
(alphanumeric). The first part (maximum 3 letters)
represents the "engine code" , the second (six digit) is the
"serial number" . If more than 999,999 engines with the
same engine code are produced, the first of the six
characters is replaced with a letter.
In addition, a sticker with "engine code" and "serial
number" is affixed to acoustic cover of cylinder head at
cylinder bank 1.
The engine code is also included on the vehicle data plate.
Numbering of cylinders begins on right side - A - as seen
in direction of travel (cylinder bank 1) opposite the power
Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru
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transfer side - C - . Cylinders are counted on each side in
sequence.
Engine specifications
Engine code
BKW
12.03
Production
02.06
Tier 1
Emission values in accordance with
Displacement
10.04
BWF
ltr.
4.9
4.9
Output
kW at 1/rpm
230/3750
230/3750
Torque
Nm at rpm
750/2000
750/2000
Dia. mm
81.0
81.0
mm
95.5
95.5
18.5
18.5
51
51
Bore
Stroke
Compression ratio
CN
Ignition sequence
min.
1-6-5-10-2-7-3-8-4-9 1-6-5-10-2-7-3-8-4-9
Catalytic converter
yes
yes
Particle filter
no
yes
Exhaust gas recirculation
yes
yes
Charging
yes
yes
Charge air cooler
yes
yes
Engine, removing and installing
Page 1 / 21
10 - 1
Engine, removing and installing
Engine, removing
10-1, Engine, removing
Removing engine from Scissor Lift Table VAS 6131
10-1, Removing engine from Scissor Lift Table VAS 6131
Notes on installing
10-1, Notes on installation
Engine, removing
Special tools, testers and auxiliary items
required
„
Scissor lift table VAS 6131
„
Drip tray V.A.G 1306
„
Frame support T10191
Engine, removing and installing
„
Spring-type clip pliers VAS 5024
A
„
Torque wrench (40 to 200 Nm)
V.A.G 1332
„
Tensioner Hooks (2) VW 552
Not illustrated:
„
Standard set for Touareg VAS 6131/6
„
Support F/Vas6131 For V6/V10/V8 VAS6131/8
„
Container for removed components V.A.G 1698
„
Engine bung set VAS 6122
„
Cable tie
The engine with transmission is removed downward.
- Before removing engine, check DTC memories of all
control modules Vehicle Diagnosis, Testing and
Information System VAS 5051 or VAS 5052 "Guided
functions"
Note:
„
To allow free rotation of the driveshaft, move the
selector lever to the "N" position.
„
Leave the key in the ignition lock to prevent the
steering wheel lock from engaging.
„
It is advisable to remove the front wheels before the
disassembly. The vehicle can be lowered on the
hoist until the cover plates of the brake discs are just
above the floor. This ensures the greatest ability to
perform work at body-level regarding accessibility of
components in the engine compartment.
Page 2 / 21
Engine, removing and installing
„
When the engine is installed in the engine
compartment some components cannot be removed
or can only be removed with great difficulty.
Determine which components are faulty before
removing engine.
„
To prevent damage to removed components, use
the container for removed components V.A.G 1698
for storage.
„
All cable ties which are opened or cut open when
removing engine, must be replaced in the same
position when installing engine.
Caution!
Always observe the exact procedure for disconnecting
the battery!
- Switch off ignition and all electrical consumers.
- First, disconnect batter under drivers seat.
- Then disconnect the auxiliary battery, in luggage
compartment in spare wheel well.
Repair Manual, Electrical Equipment, Repair Group 27,
Battery, disconnecting and connecting
- Remove left and right windshield wiper arms
Repair Manual, Electrical Equipment, Repair Group 92,
Windshield wiper system
- Remove engine compartment cover seal off bulkhead.
Page 3 / 21
Engine, removing and installing
- Remove covers - A - , - B - (if equipped) and - C - in
engine compartment and - D - for plenum chamber.
- Disconnect smaller connector - A - from Engine Control
Modules (ECM) and remove Ground (GND) connection arrow - for wiring harness.
- Open fuse box cover on left in plenum chamber and
disconnect connectors - A - , - B - and - C - .
- Remove wiring harness from plenum chamber and place
it on engine.
- Remove intake line on both sides between air filter and
intake manifold.
Note:
„
With connector couplings, follow the installation
instructions closely 21-1, Hose connections with
connector couplings, installing .
Vehicles with engine code BKW
Page 4 / 21
Engine, removing and installing
- Disconnect vacuum lines - arrows - for Exhaust Gas
Recirculation (EGR) valve and brake booster as well as
harness connector - A - for Heated Oxygen Sensor
(HO2S) G39 of cylinder bank 1.
- Disconnect vacuum line - arrow - for Exhaust Gas
Recirculation (EGR) valve as well as harness connector A - for Heated Oxygen Sensor (HO2S) 2 G108 of cylinder
bank 2.
Vehicles with engine code BWF
- Disconnect vacuum lines - 1 - for the bypass flap
vacuum actuators (mark lines before separating) and brake
booster - 2 - .
Page 5 / 21
Engine, removing and installing
- Disconnect the following connections and free up wiring
harness to components:
1 - 6-pin harness connector, black: For Heated Oxygen
Sensor (HO2S) G39
2 - 6-pin harness connector, brown: For Heated Oxygen
Sensor (HO2S) 2 G108
3 - 2-pin harness connector, black: For Turbocharger
intake temperature sensor G507
4 - 2-pin harness connector, brown: For Turbocharger
intake temperature sensor 2 G499
Continuation for all vehicles
- Disconnect harness connectors - arrows - for glow
plugs in cylinder bank 1 and cylinder bank 2.
Page 6 / 21
Engine, removing and installing
- Secure suspension struts using spring compressor VW
552. as shown.
- Remove upper suspension struts
Repair Manual, Suspension, Wheels, Steering, Repair
Group 40, II - Assembly overview: Front suspension
.
- Remove noise insulation
Repair Manual, Body Exterior, Repair Group 50, Noise
insulation
.
- Extract refrigerant from air conditioning system
Repair Manual, Heating Air Conditioning, Repair Group
87,
- Drain coolant
filling .
19-1, Cooling system, draining and
Page 7 / 21
Engine, removing and installing
- Disconnect line - arrow - from transmission oil cooler
below on right. Catch fluid which runs out.
- Disconnect line - A - from servo oil cooler at lower left.
Catch fluid which runs out.
- Remove charge air connecting pipe - B - for cylinder
bank 1 and cylinder bank 2.
- Loosen clamp - arrow - from connecting pipe to air filter
for cylinder bank 1 and cylinder bank 2 and remove it.
Page 8 / 21
Engine, removing and installing
- Disconnect coolant hoses - arrows - and place them so
that they cannot be pinched when removing and installing
engine.
- Disconnect starter wire - A - and generator wire - B and place them on engine.
- Unclip transmission ventilation line - arrows - .
Page 9 / 21
Engine, removing and installing
- Disconnect connector from Intake Air Temperature (IAT)
sensor G42 - A - and from Mass Air Flow (MAF) sensor
G70 - B - for cylinder bank 1.
- Disconnect connector from Mass Air Flow (MAF) sensor
2 G246 - A - and from Intake Air Temperature (IAT)
sensor 2 G299 - B - for cylinder bank 2.
- Remove wire connection - arrow - of air suspension
compressor on air filter housing 23-1, Line connection to
compressor for air suspension
- Remove both top sections of air filter upward.
Page 10 / 21
Engine, removing and installing
- Open clamp and pull off servo-line - A - . Catch fluid
which runs out. Remove A/C lines - B - from A/C
compressor.
Vehicles with engine code BKW
- Disconnect fuel lines - arrows - from fuel filter.
- Separate connection of catalytic converter/center muffler
and remove exhaust system 26-1, Muffler with
mountings (vehicles with engine code BKW), assembly
overview .
Vehicles with engine code BWF
- Disconnect fuel lines - arrows - from fuel filter.
Page 11 / 21
Engine, removing and installing
- Separate connection of particle filter/exhaust pipe and
remove exhaust system 26-1, Muffler with mountings
(vehicles with engine code BWF), assembly overview .
Continuation for all vehicles
- Remove heat shield on steering box and loosen universal
joint
Repair Manual, Suspension, Wheels, Steering, Repair
Group 48, Steering column
.
- Disconnect connectors on transmission as well as
transfer case and loosen selector lever cable
Repair Manual, 6 Spd. Automatic Transmission 09D All
Wheel Drive, Repair Group 37, Shift mechanism, servicing
- Remove rear driveshaft
Repair Manual, Rear Final Drive, Repair Group 39,
Driveshafts, removing and installing
- Remove transmission transverse support - A - .
Page 12 / 21
Engine, removing and installing
- Disconnect brake lines at points indicated - arrow - .
Catch escaping brake fluid.
- Disconnect all harness connectors between chassis and
front axle in wheel housings.
Preparing Scissor lift table VAS 6131 for further
steps:
Note:
„
The basic set for Touareg VAS 6131/6 consists of
supports supports VAS 6131/6-1 to VAS 6131/6-7 .
To describe the following work sequence more
clearly, they are called support 1 (for VAS 6131/6-1)
to support 7 (for VAS 6131/6-7).
- Install support - 1 - on left and support - 2 - on right
(arrows point in direction of travel) on the Scissor lift table
VAS 6131 and secure bolts at the following positions:
„
Left support - 1 - : A5, B4 and B5
Page 13 / 21
Engine, removing and installing
„
Right support - 2 - : G4, H4 and H5
- Tighten support 3 and support 4 on Scissor lift table VAS
6131 in the following positions:
„
Left support - 3 - : A6 and C6
„
Right support - 4 - : F6 and H6
- Screw down turntables of supports - 3 - and - 4 - .
- Place supports - 5 - for subframe and - 6 - for
transmission console in corresponding positions on lift
table.
Engine and transmission are separated after removal:
- Remove insulation mat under lower section of oil pan.
- Loosen clamp for starter cable.
- Loosen and remove transmission bolts - A - .
- Remove six bolts for torque converter through hole in
upper section of oil pan - arrow - . To do so, rotate engine
at vibration damper using Counterhold Tool Touareg V10
T10172 and associated pin T10172/2 .
Page 14 / 21
Engine, removing and installing
- Install support - 7 - for transmission support in
corresponding positions on Scissor lift table VAS 6131 and
tighten down turntables completely.
- Before moving up Scissor lift table VAS 6131 , always
engage Support F/Vas6131 For V6/V10/V8 VAS6131/8 ,
which was completely tightened down earlier, into hole of
transmission flange - arrow - as shown.
Continued:
Page 15 / 21
Engine, removing and installing
- Position horizontally adjusted Scissor lift table VAS
6131 under engine/transmission assembly. The supports 1 - and - 2 - must be guided into corresponding mount arrows - at right and left.
- At the same time, guide support - 6 - for transmission
cross bar into corresponding holes - arrows - at right and
left.
When all four supports are in the appropriate receptacle
holes without pressure:
- If installed, check support height of support for V10, V8
and V6 assembly, Touareg VAS 6131/8 at knurled nut and
secure support in position D7 on Scissor lift table VAS
6131 .
Page 16 / 21
Engine, removing and installing
- Using light pressure beneath control arm, screw both
turning knobs of supports 3 and 4 until securing device can
be removed using Tensioner Hooks (2) VW 552 .
- Guide support - 5 - into corresponding mount in
subframe, if necessary check support height on knurled
nut.
- Locate subframe to body
Repair Manual, Suspension, Wheels, Steering, Repair
Group 40, I - Assembly overview: Subframe, stabilizer bar,
lower control arms
- Loosen subframe bolts - 2 - and - 3 - , as well as
transmission transverse support - 4 - .
If subframe was not located:
- Loosen subframe bolts - 1 - .
Page 17 / 21
Engine, removing and installing
Note:
„
If the subframe was not located, it is necessary to
perform a vehicle alignment
Repair Manual, Suspension, Wheels, Steering, Repair
Group 44, Vehicle alignment
.
- Slowly lower assembly, constantly observing clearances.
Removing engine from Scissor Lift Table VAS 6131
Special tools, testers and auxiliary items required
„
Shop crane VAS 6100
„
Transportation plate T10126
„
Transportation plate T10126/1
„
Frame support T10191
Work procedure
- Disconnect transmission from engine
Repair Manual, 6 Spd. Automatic Transmission 09D All
Wheel Drive, Repair Group 37, Transmission, removing
and installing
- Loosen threaded connection - A - of engine mount on
Page 18 / 21
Engine, removing and installing
both sides of engine.
- Loosen support for V10, V8 and V6 assembly, Touareg
VAS 6131/8 from scissor lift platform and remove it.
- Install transportation plates T10126 and transportation
plates T10126/1 on cylinder heads as shown - arrows - .
- Hook lifting tackle 3033 into workshop crane VAS 6100
and into transportation plate .
- Lift engine from Scissor Lift Table VAS 6131 .
- Set engine in frame support T10191 .
Notes on installation
Caution!
When doing any repair work, especially in the engine
compartment, pay attention to the following due to
clearance issues:
„
Route lines of all types (e.g. for fuel, hydraulic,
additive, coolant and refrigerant, brake fluid,
vacuum) and electrical wiring so that the original
path is followed.
„
To prevent damages to the lines, make sure
there is sufficient clearance to all moving or hot
components.
Installation is performed in reverse order. When doing
this note the following:
Page 19 / 21
Engine, removing and installing
Page 20 / 21
- Make sure centering sleeves for engine to transmission
are installed in cylinder block. Install if necessary.
- Reconnect all lines, hoses and connections that were
disconnected for removal sequence.
- Electrical connections and routing Electrical Wiring
Diagrams, Troubleshooting and Component Locations
binder .
- Connect air conditioning lines
Repair Manual, Heating Air Conditioning, Repair Group
87,
.
- Top off oil level for power steering system
Repair Manual, Maintenance
.
- Fill with coolant
filling .
19-1, Cooling system, draining and
- Check headlight adjustment, correct if necessary
Repair Manual, Maintenance
:
- Perform test drive and check all DTC memories Vehicle
Diagnosis, Testing and Information System VAS 5051 or
VAS 5052 "Guided Fault Finding" .
Torque specifications
Bolted connections
Torque specifications
Engine to transmission
M10
45 Nm
(except starter)
M12
80 Nm
Engine support to cylinder block
50 Nm
Engine support to engine mount
75 Nm
Engine mount to engine carrier
Engine carrier to body
Transmission carrier to body
Subframe to body
60 Nm
100 Nm plus an additional 1 / 2 turn (180
50 Nm plus an additional 1 / 4 turn (90
)
)
Engine, removing and installing
Page 21 / 21
Repair Manual, Suspension, Wheels, Steering, Repair Group 40, I - Assembly overview:
Subframe, stabilizer bar, lower control arms
Engine, disassembling and assembling
Page 1 / 17
13 - 1
Engine, disassembling and assembling
Caution!
„
Upper section of bearing bracket is bolted to the
cylinder with two multi-point socket bolts M8,
which are found in the valley between the
cylinder heads. These bolts must not be
loosened under any circumstances, because it
causes a deformation of the cylinder block which
is no longer reparable.
„
Crankshaft, piston, and connecting rods must
not be replaced! Only removal and installation of
these components is permitted.
Note:
„
If large quantities of metal particles or other deposits
(caused, for example, by partial seizure of the
crankshaft or connecting rod damage) are found in
the engine oil, the oil passages must be cleaned
thoroughly and the oil cooler replaced in order to
prevent further damage from re-occurring.
„
The engine must not be set down on the oil pan
otherwise the liquid gasket between the upper and
lower oil pan will be damaged. To set down the
engine, use frame T10191 .
„
Secure engine using engine and transmission holder
VAS 6095 when working on the engine.
Components in engine valley, assembly overview
13-1, Components in engine valley, assembly overview
Engine timing module, assembly overview
Engine timing module, assembly overview
13-1,
Engine timing module (wheel cassette), removing and
installing 13-1, Engine timing module (wheel cassette),
removing and installing
Engine mounts and engine supports (right and left),
removing and installing 13-1, Engine mounts and
engine supports (right and left), removing and installing
Drive plate, removing and installing
13-1, Drive plate,
Engine, disassembling and assembling
Page 2 / 17
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removing and installing
Components in engine valley, assembly overview
„
Input hub
„
8 Nm
„
Clutch
„
Phased in introduction of a
torsion elastic clutch
Repair Manual, Electrical Equipment,
Repair Group 27, Generator
„
50 Nm plus an additional 1 / 4
turn (90
)
Engine, disassembling and assembling
„
Replace
„
20 Nm
„
Generator
„
Removing and installing
Repair Manual, Electrical Equipment,
Repair Group 27, Generator
„
Oil filter housing, upper section
„
Coolant connection
„
„
With Engine Coolant
Temperature (ECT) Sensor
G62
„
Removing and installing
19-1, Coolant connection,
removing and installing
Gasket
„
„
Seal
„
„
Replace
Replace
20 Nm plus an additional 1 / 4
turn (90
„
„
)
Replace
Oil filter housing, lower section
„
Oil filter housing, assembly
overview 17-3, Oil filter
housing, assembly
overview
„
With coolant thermostat
housing: Assembly overview
19-1, Coolant thermostat
housing, assembly
Page 3 / 17
Engine, disassembling and assembling
overview
„
Cover
„
Noise insulation
„
„
„
„
Installation not necessary
Bypass flap with cooler for
Exhaust Gas Recirculation
(EGR)
„
On vehicles with engine
code BWF
„
Assembly overview 26-2,
Bypass flap with cooler for
Exhaust Gas Recirculation
(EGR) (vehicles with engine
code BWF), assembly
overview
Fuel filter
„
For vehicles with engine
code BKW
„
Assembly overview 20-1,
Fuel filter (vehicles with
engine code BKW),
assembly overview
Alignment bushing
„
Secure with commercially
available grease, if
necessary, before
installation
Engine timing module, assembly overview
Page 4 / 17
Engine, disassembling and assembling
„
Sleeve
„
For linkage mounting
components
„
Replace with compensation
linkage in case of noticeable
formation of deposits
„
Compensation linkage
„
Camshaft gear
„
For cylinder bank 1: with
sensor wheel for camshaft
position
„
Removing and installing
15-1, Camshaft
compensation wheel and
input gear, removing and
installing
Page 5 / 17
Engine, disassembling and assembling
„
Compensation wheel
„
„
Removing and installing
15-1, Camshaft
compensation wheel and
input gear, removing and
installing
150 Nm plus an additional 1 / 4
turn (90
)
„
Full-floating axle
„
Compensating piston
„
„
20 Nm
„
„
„
Observe tightening
sequence 13-5,
Tightening sequence of bolts
for control housing
Seal
„
Do not oil or grease sealing
lip of sealing ring
„
Before installing, remove oil
residue from crankshaft
journal with a clean cloth
„
Replace 13-4, Crankshaft
seal (engine timing side),
replacing
Control housing
„
„
Replace
Assembly overview 13-5,
Control housing, assembly
overview
Cylinder bolt
„
Tighten to 60 Nm, then to
150 Nm plus an additional 1 /
4
turn (90
)
Page 6 / 17
Engine, disassembling and assembling
„
Oil pan, upper section
„
„
Assembly overview 17-2,
Oil pan (upper section),
assembly overview
Hex bolt
„
Tighten to 60 Nm, then to
150 Nm plus an additional 1 /
4
„
turn (90
)
Engine timing module
„
Removing and installing
13-1, Engine timing module
(wheel cassette), removing
and installing
Engine timing module (wheel cassette), removing and
installing
Page 7 / 17
Engine, disassembling and assembling
Special tools, testers and auxiliary items
required
„
Engine and transmission holder
VAS 6095
„
Guide pins T10200
„
Assembly tool T10208/3
Not illustrated:
„
Torque wrench (40 to 200 Nm) V.A.G 1332
Requirements:
„
Engine and transmission removed
Page 8 / 17
Engine, disassembling and assembling
„
Page 9 / 17
Engine secured to engine and transmission holder
VAS 6095
Removing
- Drain engine oil
Repair Manual, Maintenance
.
- Set crankshaft to TDC Cylinder 1
checking , check valve timing.
- Remove cylinder heads
15-1, Valve timing,
15-1, Cylinder head .
- Disconnect transmission from engine
Repair Manual, 6 Spd. Automatic Transmission 09D All
Wheel Drive, Repair Group 37, Transmission, removing
and installing
.
- Remove all required hoses, lines and pipes from the
engine management side.
- Remove lower and upper sections of oil pan
pan, assembly overview .
17-2, Oil
- Loosen bolts for engine timing module.
Caution!
Make sure that the input shafts for oil- and coolant
pumps do not fall off cylinder block.
- Carefully pull engine timing module off inclined splines.
Installing
Engine, disassembling and assembling
- Screw guide pins T10200 into threaded holes of upper
section of bearing bracket as shown.
- Place engine timing module on guide pins.
Note:
„
Observe the following adjustment marks and
requirements and note the inclined splines while
doing so (wheels turn slightly when sliding on the
module):
Page 10 / 17
Engine, disassembling and assembling
- Holes on splines of crankshaft gear and input gear for oil
pump must align as shown.
- Input shaft fits only in one position. Rotate shaft so that
the wide cut-out in the hole aligns to the broad tooth on the
pin.
- The hole on the drive wheel of cylinder bank 1 must align
with cast tab on inside of engine timing module as shown.
- Carefully slide engine timing module on guide pins in its
seat, note the mentioned adjustment markings while doing
so.
Page 11 / 17
Engine, disassembling and assembling
- Center engine timing module by placing pressure piece
of assembly tool T10208/3 on generator shaft end - A - .
Pressure piece must be able to be set into countersink
without force.
- Replace individual guide pins with bolts and tighten bolts
to 60 Nm.
- Tighten bolts to 150 Nm plus an additional 1 / 4 turn. (90
) turn.
Engine mounts and engine supports (right and left),
removing and installing
Special tools, testers and auxiliary items required
„
Torque wrench (40 to 200 Nm) V.A.G 1332
Page 12 / 17
Engine, disassembling and assembling
„
Engine/transmission jack V.A.G 1383 A
„
Assembly support T10296
Removing
- Remove front sound insulation
Repair Manual, Body Exterior, Repair Group 50, Sound
insulation
- Remove front wheelhousing liners
Repair Manual, Body Exterior, Repair Group 66,
Wheelhousing liners
- Remove lower part of air filter for cylinder bank 1 and 2
23-1, Air filter, assembly overview , Air filter - Assembly
overview.
- Remove nut - 2 - on engine mount at left and right
engine supports.
Page 13 / 17
Engine, disassembling and assembling
- Align mounting pins of assembly support T10296
centrally at the mountings of the cylinder block - arrows to assembly support . Tighten mounting pins.
- Insert assembly support T10296 into
engine/transmission jack V.A.G 1383 A and support
assembly (engine and transmission) at mountings of
cylinder block - arrows - with slight pretension.
- Remove right and left bolts - 1 - for engine mount.
- Carefully lift assembly with assembly support T10296
and remove engine mount.
Caution!
Page 14 / 17
Engine, disassembling and assembling
Page 15 / 17
Be aware of the available clearance between the
cylinder heads and the bulkhead.
- If necessary, unfasten engine supports at cylinder block
and remove engine mounts together with engine supports.
Installing
- Make sure the alignment pin of engine mount is correctly
positioned in engine carrier.
- Start all bolts and nuts by hand and then tighten to torque
specification.
Torque specifications
Bolted connections
Torque specifications
Engine support to cylinder block
50 Nm
Engine mount to engine carrier - 1 -
60 Nm
Engine support to engine mount - 2 -
75 Nm
The rest of assembly is basically a reverse of the
disassembling sequence.
Drive plate, removing and installing
Special tools, testers and auxiliary items required
Engine, disassembling and assembling
„
Flywheel lock adapter VW 558
„
Torque wrench (40 to 200 Nm) V.A.G 1332
Not illustrated:
„
Caliper gauge
„
Hex bolt M8×50 and three M12-hex nuts
Drive plate, loosening and tightening
- Secure flywheel lock adapter VW 558 with hex bolt
Page 16 / 17
Engine, disassembling and assembling
Page 17 / 17
M8x50 to drive plate. Insert three M12 hex nuts between
flywheel lock adapter and drive plate. Installed location of
flywheel retainer: - A - to loosen; - B - to tighten
Installing drive plate.
- Install drive plate using a washer
Item - 8 - .
- Install new bolts and tighten to 30 Nm.
- Using caliper gauge, check distance between drive plate
and cylinder block. Specified dimension - a - : 19.0 to 20.6
mm.
If specification is not obtained:
- Remove drive plate again and insert shim between
crankshaft and drive plate. Tighten bolts again to 30 Nm.
- Tighten bolts to 50 Nm and turn an additional 1 / 4 turn
(90
), (additional rotation may occur in several stages).
Differential shaft
Page 1 / 2
13 - 2
Differential shaft
Note:
„
Secure engine in engine and transmission holder
VAS 6095 when working on engine.
Balance shaft, assembly overview
shaft, assembly overview
13-2, Balance
Balance shaft, assembly overview
Note:
„
It is only possible to remove the balancing shaft
when the engine timing module has been removed
beforehand 13-1, Engine timing module (wheel
cassette), removing and installing .
Differential shaft
„
Thrust washer
„
Main bearing bolt
„
„
„
Page 2 / 2
Note tightening sequence
and torque Topic 13-3 ,
Main bearing bolts,
tightening.
Bearing cap bolt
„
For differential shaft bearing
„
Note tightening sequence
and torque Topic 13-3 ,
Main bearing bolts,
tightening.
Bearing cap
„
With eye for securing oil
pump
„
Bearing shell
„
Balancing shaft
„
Positioning
„
Bearing shell
„
Thrust washer
„
Bearing cap
„
Topic 13-1
Bearing cap with grooves for
thrust washers
Crankshaft
Page 1 / 6
13 - 3
Crankshaft
Caution!
„
Upper section of bearing bracket is bolted to
cylinder with two multi-point socket bolts M8,
which are found in the valley between the
cylinder heads. These bolts must not be
loosened under any circumstances, because it
causes a deformation of the cylinder block which
is no longer reparable.
„
Crankshaft, piston, and connecting rods must
not be replaced! Only removal and installation of
these components is permitted.
Note:
„
Secure engine on engine and transmission holder
VAS 6095 when working on engine.
Crankshaft, assembly overview
assembly overview
13-3, Crankshaft,
Bearing bracket for crankshaft, removing and
installing 13-3, Bearing bracket for crankshaft,
removing and installing
Crankshaft dimensions
13-3, Crankshaft dimensions
Crankshaft, assembly overview
Crankshaft
Page 2 / 6
Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru
огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi
„
„
Bearing bracket
„
Installed in tensioned state
„
Removing and installing
13-3, Bearing bracket for
crankshaft, removing and
installing
Thrust washer
„
„
For lower section of bearing
bracket
Main bearing bolt
„
Note tightening sequence
and torque Topic 13-3 ,
Main bearing bolts,
tightening.
Crankshaft
Page 3 / 6
„
Bearing shell
„
Crankshaft
„
Axial play new: 0.07 to 00.17
mm, Wear limit: 0.37 mm
„
Check radial clearance with
Plastigage 0.03 to 00.08
mm, Wear limit: 0.17 mm
„
Do not turn crankshaft when
measuring radial play
„
Crankshaft dimensions
13-3, Crankshaft
dimensions
„
8 Nm
„
Oil spray jet
„
For piston cooling
„
Bearing shell
„
Cylinder block
„
With upper section of
bearing bracket
„
Cylinder bore, checking
13-6, Checking cylinder
bores
„
Piston and cylinder
dimensions 13-6, Piston
and cylinder dimensions
„
Engine Speed (RPM) Sensor
G28
„
10 Nm
„
Thrust washer
„
For upper section of bearing
bracket
Bearing bracket for crankshaft, removing and installing
Crankshaft
Page 4 / 6
Caution!
Upper section of bearing bracket is bolted to cylinder
with two multi-point socket bolts M8, which are found
in valley between the cylinder heads. These bolts must
not be loosened under any circumstances, because it
causes a deformation of the cylinder block which is no
longer reparable.
Note:
„
Secure engine in engine and transmission holder
VAS 6095 when working on engine.
Special tools, testers and auxiliary items required
„
Tensioning element T10201
„
Torque wrench (5 to 50 Nm) V.A.G 1331
Not illustrated:
„
Removing
Torque wrench (40 to 200 Nm) V.A.G 1332
Crankshaft
Page 5 / 6
- Remove bolts for lower section of bearing bracket.
- Install engine support bridge T10201 on lower section of
bearing bracket as shown.
- Tighten bolts of tensioning device T10201 to 20 Nm.
- Remove lower section of bearing bracket.
Installing
- Place tensioning device T10201 on lower section of
bearing bracket and tighten bolts to 20 Nm.
- Check whether all bearing shells are lying properly in
bearing supports Item - 4 - . Pay attention to thrust
washers Item - 2 - .
- Carefully place lower section of bearing bracket into
cylinder block.
Tightening main bearing bolts
Topic 13-3 .
Tightening main bearing bolts
- Tighten main bearing bolts in three stages in the
tightening sequence shown as follows ( - arrow - points in
driving direction).
„
Tighten using torque wrench:
Crankshaft
Page 6 / 6
Step I = 35 Nm
Step II = 65 Nm
„
Tighten further using a solid wrench:
Stage III = 1 / 2 additional turn (180
)
Crankshaft dimensions
(Dimensions in mm)
Reconditioning
dimension, dimensions in mm
Crankshaft bearing
pins-diameter
-0.032
Basic dimension
Connecting rod bearing
pins-diameter
-0.022
58.00
65.00
-0.047
-0.042
-0.032
-0.022
1st oversize
57.75
64.75
-0.047
-0.042
-0.032
-0.022
2nd oversize
57.50
64.50
-0.047
-0.042
Sealing flanges, seals and vibration damper
Page 1 / 11
13 - 4
Sealing flanges, seals and vibration damper
Note:
„
Secure engine on engine and transmission holder
VAS 6095 when working on engine.
Front sealing flange and vibration damper, assembly
overview 13-4, Front sealing flange and vibration
damper, assembly overview
Sealing ring for crankshaft, vibration damper side,
replacing 13-4, Crankshaft seal (vibration damper side),
replacing
Crankshaft seal (engine timing side), replacing
Crankshaft seal (engine timing side), replacing
Generator shaft seal, replacing
seal, replacing
13-4,
13-4, Generator shaft
Front sealing flange and vibration damper, assembly
overview
Sealing flanges, seals and vibration damper
„
Sealing flange, front
„
„
Must be located on dowel
sleeves
8 Nm
„
Observe tightening
sequence 13-4,
Tightening sequence of bolts
for front sealing flange and
coolant pump cover
„
Coolant pump cover
„
Vibration damper
„
50 Nm plus an additional 1 / 4
turn (90
)
Page 2 / 11
Sealing flanges, seals and vibration damper
„
Washer
„
Seal
„
„
Do not additionally oil or
grease sealing lip of sealing
ring
„
Before installing, remove oil
remains from crankshaft
journal with a clean cloth
„
Replace 13-4, Crankshaft
seal (vibration damper side),
replacing
13 Nm
Tightening sequence of bolts for front sealing flange and
coolant pump cover
- Tighten bolts in the shown tightening sequence to 8 Nm.
Crankshaft seal (vibration damper side), replacing
Special tools, testers and auxiliary items required
Page 3 / 11
Sealing flanges, seals and vibration damper
„
Counter-holder tool T10172
„
Extractor hook T20143/2
Not illustrated:
„
Assembly tool T10196
Work procedure
- Bring lock carrier into service position
Repair Manual, Body Exterior, Repair Group 50, Lock
carrier
.
- Remove vibration damper
Item - 4 - .
Note:
„
Be careful not to damage sealing surface when
removing sealing ring.
Page 4 / 11
Sealing flanges, seals and vibration damper
- Carefully remove old sealing ring from its seat using hook
T20143/2 .
- Before installing, remove oil remains from end of
crankshaft with a clean cloth.
Note:
„
Only remove protective ring from seal immediately
prior to assembly.
- Join assembly sleeve T10196/1 and assembly sleeve
T10196/2 . Slide sealing ring - A - to stop on assembly
sleeve T10196/2 .
- Separate both assembly sleeves.
Page 5 / 11
Sealing flanges, seals and vibration damper
- Place assembly sleeve T10196/2 together with sealing
ring on crankshaft flange and tighten knurled bolts - A hand-tight.
- Press in seal up to stop using pressure sleeve
T1096/3 .
The rest of the assembly is a reverse of the disassembling
sequence.
Crankshaft seal (engine timing side), replacing
Special tools, testers and auxiliary items required
„
Pulling hook T20143/2
Not illustrated:
„
Assembly tool T10207
Requirement:
Page 6 / 11
Sealing flanges, seals and vibration damper
„
Engine removed
„
Transmission separated from engine
Work procedure
Note:
„
Make sure the sealing surface is not damaged when
removing the seal.
- Carefully remove old sealing ring from its seat using hook
T20143/2 .
- Before installing, remove oil remains from end of
crankshaft with a clean cloth.
- Join assembly sleeve T10207/1 and assembly sleeve
T10207/2 . Slide sealing ring - A - to stop on assembly
sleeve T10207/2 .
Page 7 / 11
Sealing flanges, seals and vibration damper
- Separate both assembly sleeves.
- Place assembly sleeve T10207/2 together with sealing
ring on crankshaft flange and tighten knurled bolts - A hand-tight.
- Press in seal up to stop using pressure sleeve
T1207/3 .
The rest of the installation follows the reverse of the
removal procedures.
Generator shaft seal, replacing
Special tools, testers and auxiliary items required
„
Pulling hook T20143/1
Not illustrated:
„
Assembly tool T10208
Page 8 / 11
Sealing flanges, seals and vibration damper
Work procedure
Vehicles with engine code BKW
- Remove fuel filter 20-1, Fuel filter (vehicles with engine
code BKW), removing and installing .
Vehicles with engine codes BWF
- Remove bypass flap with cooler for Exhaust Gas
Recirculation (EGR) 26-2, Bypass flap with cooler for
Exhaust Gas Recirculation (EGR) (vehicles with engine
code BWF), assembly overview .
Continuation for all vehicles
- Remove generator
Repair Manual, Electrical Equipment, Repair Group 27,
Generator
.
Note:
„
Make sure the sealing surface is not damaged when
removing the seal.
- Carefully remove old sealing ring from its seat using hook
T20143/1 .
- Remove oil residue on input shaft for generator using a
clean cloth.
Page 9 / 11
Sealing flanges, seals and vibration damper
- Press inner part of sealing ring toward outside as shown.
- Screw guide sleeve T10208/1 hand-tight onto input shaft
for generator and carefully slide sealing ring - A - on up to
stop.
Page 10 / 11
Sealing flanges, seals and vibration damper
- Position pressure piece T10208/2 and press in inner part
of sealing ring up to stop.
- Position pressure piece T10208/3 and press in outer part
of sealing ring up to stop.
The rest of the assembly is basically a reverse of the
disassembling sequence.
Page 11 / 11
Control housing
Page 1 / 3
13 - 5
Control housing
Note:
„
Secure engine on engine and transmission holder
VAS 6095 when working on engine.
Control housing, assembly overview
housing, assembly overview
Control housing, assembly overview
„
Engine timing module
„
Removing and installing
13-1, Engine timing module
(wheel cassette), removing
and installing
13-5, Control
Control housing
„
Control housing
„
„
Insert with silicone sealant D
176 501 A1
13-5, Sealant
bead on control housing
20 Nm
„
Observe tightening
sequence 13-5,
Tightening sequence of bolts
for control housing
„
20 Nm
„
Seal
„
„
Do not additionally oil or
grease sealing lip of sealing
ring
„
Before installing, remove oil
remains from crankshaft
journal with a clean cloth
„
Replace 13-4, Crankshaft
seal (engine timing side),
replacing
Drive plate
„
„
Page 2 / 3
Removing and installing
13-1, Drive plate, removing
and installing
50 Nm plus an additional 1 / 4
turn (90
„
)
Replace
„
Washer
„
13 Nm
Control housing
Sealant bead on control housing
- Apply sealant bead onto clean sealing surface of the
control housing as shown.
Tightening sequence of bolts for control housing
- Tighten bolts in the illustrated tightening sequence to 20
Nm.
Page 3 / 3
Piston and connecting rod
Page 1 / 7
13 - 6
Piston and connecting rod
Caution!
Crankshaft, piston, and connecting rods must not be
replaced! Only removal and installation of these
components is permitted.
Note:
„
Secure engine on engine and transmission holder
VAS 6095 when working on engine.
Piston and connecting rod, assembly overview
Piston and connecting rod, assembly overview
Checking piston position at TDC
at TDC, checking
Piston and cylinder dimensions
cylinder dimensions
13-6,
13-6, Piston position
13-6, Piston and
Piston rings, cylinder bores and piston positioning
13-6, Piston rings, cylinder bores and piston positioning
Piston and connecting rod, assembly overview
Piston and connecting rod
„
„
Connecting rod bolt, 30 Nm plus
an additional 1 / 4 turn (90 )
„
Replace
„
Lubricate threads and
contact surface
„
Use old bolt to measure
radial play
Connecting rod bearing cap
„
„
Note installation position
Bearing shell
„
Note installation position
„
Note version: Upper bearing
shell (to piston) made of
Page 2 / 7
Piston and connecting rod
wear-resistant material,
identification: Black line on
contact surface in area of
separating point
„
„
Do not interchange used
bearing shells
„
Insert bearing shells in
center
„
Check for secure seating
„
Axial play wear limit: 0.37
mm
„
Measure radial clearance
with Plastigage: Wear limit:
0.08 mm. Do not turn
crankshaft when checking
radial clearance
Connecting rod
„
Mark matching cylinder arrow A -
„
Location: Markings - arrows
B - point to vibration damper
side
„
Circlip
„
Piston
„
With combustion chamber
„
Mark installed position and
cylinder allocation
„
Installed position and
allocation, piston/cylinder
Topic 13-6
„
Directional arrow on piston
head points to intake side
„
Install with piston ring
compressor
„
Checking piston position at
TDC 13-6, Piston position
at TDC, checking
„
Piston and cylinder
Page 3 / 7
Piston and connecting rod
dimensions 13-6, Piston
and cylinder dimensions
„
„
„
Cylinder bore, checking
13-6, Checking cylinder
bores
Piston pin
„
If difficult to move, heat
piston to 60 C
„
Removing and installing
using a drift VW 222 A
Piston rings
„
Offset gaps by 120
„
Use piston ring pliers for
removal and installation
„
"TOP" faces toward piston
crown
„
Checking ring gap
13-6,
Checking piston ring gap
„
Check piston ring groove
clearance 13-6, Checking
ring to groove clearance
Piston position at TDC, checking
It is not possible to measure piston projection position
using workshop equipment. Due to the connecting rod
principle for cylinder head bolts in conjunction with the
aluminum cylinder block results in a compression of the
cylinder block which cannot be reproduced when cylinder
head is removed. For this reason, a new cylinder head
gasket with the same index number ( 15-1, Tightening
sequence of bolts for cylinder head cover ) must be
installed when replacing the cylinder head gasket.
Piston and cylinder dimensions
Note:
„
No repair sizes are provided!
Page 4 / 7
Piston and connecting rod
Page 5 / 7
Honing dimension
Basic dimension
mm
Piston diameter
Cylinder bore diameter
80.97
81.01
Piston rings, cylinder bores and piston positioning
Checking piston ring gap
Special tools, testers and auxiliary items required
„
Feeler gauge
Test sequence
- Push piston ring squarely from above down to approx. 15
mm from bottom end of cylinder.
Piston ring
dimensions in mm
New
Wear limit
1. Compression ring
0.20 to 0.40
1.0
2. Compression ring
0.30 to 0.50
1.0
Oil scraping ring
0.25 to 0.50
1.0
Checking ring to groove clearance
Piston and connecting rod
Page 6 / 7
Special tools, testers and auxiliary items required
„
Feeler gauge
Test sequence
- Clean ring groove before checking.
Piston ring
dimensions in mm
New
Wear limit
1. Compression ring
0.08 to 0.10
0.25
2. Compression ring
0.03 to 0.05
0.25
Oil scraping ring
0.02 to 0.05
0.15
Checking cylinder bores
Special tools, testers and auxiliary items required
„
Internal dial gauge 50 - 100 mm
Test sequence
- Measure bores at 3 locations in both directions - A across engine and - B - in line with crankshaft.
Deviations from nominal dimension: max. 0.05 mm.
Piston: Installed position and allocation,
piston/cylinder
Piston and connecting rod
Pistons are identified on piston head:
„
Pistons 1 through 5: for cylinder bank 1
„
Pistons 6 through 10: for cylinder bank 2
Positioning:
„
Directional arrow on piston head points to intake
side
Page 7 / 7
Cylinder head
Page 1 / 28
15 - 1
Cylinder head
Caution!
Because of the threaded connection of cylinder head
through the aluminum cylinder block into crankshaft
bearing bracket (connecting rod), both cylinder heads
must always be removed. If cylinder head bolts are
loosened or tightened on one side, cylinder block is
warped.
Note:
„
Secure engine on engine and transmission holder
VAS 6095 when working on engine.
„
When installing a replacement cylinder head with
camshaft installed, the contact surfaces between the
lifters and cam lobes must be lubricated before
installing the cylinder head cover.
„
The plastic protectors installed to protect the open
valves must only be removed immediately before
fitting the cylinder head.
„
When cylinder heads are replaced, all coolant must
also be replaced.
Cylinder head, assembly overview
head, assembly overview
15-1, Cylinder
Removing input gear for camshaft 15-1, Camshaft
compensation wheel and input gear, removing and
installing
Valve timing, checking
15-1, Valve timing, checking
Valve timing, adjusting
15-1, Valve timing, adjusting
Cylinder heads, removing and installing
Cylinder heads, removing and installing
Checking compression pressure
pressures, checking
Cylinder head, assembly overview
Note:
15-1,
15-1, Compression
Cylinder head
Page 2 / 28
Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru
огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi
„
Components depicted here correspond to cylinder
bank 1. They are different only as a mirror image of
components for cylinder bank 2.
„
Connecting hose
„
„
On vehicles with engine
code BWF
„
To crankcase ventilation
valve
„
Ensure seated tightly
Sealing sleeve
„
On vehicles with engine
code BWF
„
Replace if damaged
Cylinder head
„
„
„
Bracket
„
On vehicles with engine
code BWF
„
For intake hose between air
filter and intake manifold flap
Acoustic cover
„
„
„
For vehicles with engine
code BWF
Cylinder head cover
„
On vehicles with engine
code BWF
„
Always clean sealing
surfaces of cylinder head
cover with a clean cloth
before setting in place
„
Replace seal together with
cylinder head cover if
damaged or leaking
„
Observe tightening
sequence of bolts 15-1,
Tightening sequence of bolts
for cylinder head cover
Acoustic cover
„
„
Ensure seated tightly
For vehicles with engine
code BKW
Cylinder head cover
„
For vehicles with engine
code BKW
„
Always clean sealing
surfaces of cylinder head
cover with a clean cloth
before setting in place
„
Replace seal together with
cylinder head cover if
Page 3 / 28
Cylinder head
damaged or leaking
„
„
20 Nm
„
„
„
„
Between control housing and
cylinder head
Cylinder head gasket
„
Replace
„
Install new seal of the same
strength 15-1,
Identification of cylinder
head gasket
„
Imprint of replacement part
numbers - A - must be
readable
„
After replacing replace entire
amount of coolant
Cylinder head
„
„
Observe tightening
sequence of bolts 15-1,
Tightening sequence of bolts
for cylinder head cover
Removing and installing
15-1, Cylinder heads,
removing and installing
Cylinder head bolt
„
Replace
„
Observe sequence for
loosening and tightening
15-1, Cylinder heads,
removing and installing ,
Cylinder head, removing and
installing
Sealing sleeve
„
For vehicles with engine
code BKW
„
Replace if damaged
Page 4 / 28
Cylinder head
„
„
Check for secure seating
Connection piece
„
For vehicles with engine
code BKW
„
To crankcase ventilation
valve
„
Check for secure seating
Tightening sequence of bolts for cylinder head cover
- Tighten bolts in the shown tightening sequence to 10
Nm.
Identification of cylinder head gasket
„
Number of holes (specifies thickness of gasket) )
Page 5 / 28
Cylinder head
„
„
Control code (disregard)
Replacement part number
) Cylinder
head gasket is available in three different
strengths, whereby the number of holes indicates the
corresponding strength ETKA (Electronic Parts
Catalog) Always install a new gasket of the same strength
when replacing.
Camshaft compensation wheel and input gear, removing
and installing
Note:
„
After each separation of the gear drive, the position
of the pump pistons in the pump injector units must
be checked after completing assembly and adjusted
if necessary 23-1, Position of pump pistons in
pump injector units, checking and adjusting
Special tools, testers and auxiliary items
Page 6 / 28
Cylinder head
Page 7 / 28
required
„
Torque wrench (5 to 50 Nm) V.A.G
1331
„
Torque wrench (40 to 200 Nm)
V.A.G 1332
„
Puller T10055
„
Multi-point socket T10198
„
Clamping device T10199
„
Wrench T10211
Note:
„
Work sequence described and components depicted
here apply to cylinder bank 1. The difference for
cylinder bank 2 is minimal and is not described
separately for this reason.
Removing
- Remove engine and transmission
removing and installing .
10-1, Engine,
- Remove intake manifold flap and crankcase ventilation
line from respective cylinder.
- Remove acoustic cover and cylinder head cover of the
applicable cylinder head.
- Check rocker arm shaft running surfaces for wear.
- Remove coolant pipe below tandem and fuel pump.
- Remove vibration damper Item - 4 - . For this, use
counterholder T10172 with threading pins T10172/1 .
Cylinder head
- Screw crankshaft locator bar T10195 onto crankshaft
stub. Observe alignment pin while doing so.
- Now carefully rotate crankshaft until the pin of crankshaft
locator bar T10195 inserts into alignment bore.
- Remove corresponding pump 20-1, Tandem pump
and Fuel Pump (FP), removing and installing , Tandem
and fuel pump, removing and installing.
„
Cylinder bank 1: Tandem pump
„
Cylinder bank 2: Fuel Pump (FP)
- Remove oil supply line to exhaust turbocharger.
- Position Wrench T10211 as shown and loosen adapter
ring on pump injection unit central connector.
Page 8 / 28
Cylinder head
- Remove Camshaft Position (CMP) Sensor G40 - C (only on cylinder bank 1).
- Remove outer bearing cap - A - , place clamping device
T10199 on camshaft gear and tighten its bolt to 40 Nm.
- Loosen mounting bolt - B - for camshaft gear using
socket insert T10198 and remove together with tandem
pump drive.
- Loosen bolts on Clamping Device T10199 and remove
it.
- Remove compensating piston - B - for full-floating axle
of compensation linkage.
- Unscrew pull-off head for pump-injector unit from puller
T10055 .
Page 9 / 28
Cylinder head
- Screw puller T10055 into full-floating axle as shown and
pull full-floating axle out of its seat in direction of - arrow , using careful knocking motions.
- Pull out the outer compensation linkage on transmission
side, including its sleeve. If necessary, loosen by hitting
lightly with a plastic hammer.
- Remove camshaft gear.
- Now remove compensation wheel and inner
compensation linkage on engine side.
- Remove diamond disc from camshaft stub.
Installing
Page 10 / 28
Cylinder head
- Clean bearing cap contact surfaces of any sealant
residue.
- Oil compensation linkage sleeve guide surfaces.
Note:
„
If there is marked crimping or deposits on
compensation linkage sleeve guide surfaces, these
must be replaced.
- First engage inner, engine-side compensation linkage A - at bottom (if necessary, guide through compensating
piston hole with finger) and then slide top onto sleeve.
- Place a new diamond disc on camshaft stub.
- Bring lower, transmission-side compensation linkage into
position 15-1, Compensation linkage position and insert
compensation wheel with phase - arrow - in direction of
transmission.
Page 11 / 28
Cylinder head
- When inserting, turn the camshaft gear so marking arrow - on sensor wheel aligns with upper edge of sealing
surface.
- Secure construction by carefully sliding full-floating axle
on by hand with force as even as possible.
Caution!
There is the risk that a linkage may pivot to the side
out of the wheel cassette and will not engage when
full-floating axle is inserted, or it may be distorted
when inserting the full-floating axle.
- Insert guide sleeve in transmission-side compensation
linkage.
- Carefully pull full-floating axle back out of its seat. When
doing so, ensure compensation linkages which have
already been positioned remain in correct location.
- Install transmission-side compensation linkage with
writing toward transmission. When doing so, support if
necessary with light tapping on guide sleeve with a plastic
hammer.
- Control correct seating of compensation linkage with
finger through compensating piston hole.
- Compensation wheel must be aligned so that the holes in
the four linkages and in sprocket are positioned flush
behind one another 15-1, Compensation linkage
position .
Page 12 / 28
Cylinder head
Page 13 / 28
Compensation linkage position
- Lubricate free-floating axle with oil, then carefully slide in
by hand and with as even a force as possible. Correct seat
of full-floating axle faces toward a clear gap to cylinder
head bore - arrow - .
- Before fastening, turn the camshaft gear so that the
marking - arrow - on the sensor wheel aligns with upper
edge of sealing surface.
- Remove tandem or fuel pump drive.
- Position bearing cap flush with cylinder head edge using
Sealant AMV 176 501 and tighten. Tightening torque
Topic 15-1 .
- Install new compensating pistons. Tightening torque
Topic 15-1 .
- Positing Clamping Device T10199 and tighten camshaft
gear bolt. Tightening torque Topic 15-1 .
Torque specifications
Bolted connections
Bolts, nuts
Torque specifications
Cylinder head
Page 14 / 28
M6
10 Nm
M8
20 Nm
M10
45 Nm
M12
60 Nm
Exceptions:
Compensating piston
Bolt for camshaft gear
110 Nm
1st oversize
60 Nm
2nd oversize
150 Nm
Stage III
Bolt for bearing cap
Valve timing, checking
Special tools, testers and auxiliary items
required
1
/ 4 additional turn (90
)
8 Nm plus and additional 1 / 4 turn (90
)
Cylinder head
„
Counter-holder tool T10172
„
Camshaft locator bar T10193 for
cylinder bank 1
„
Camshaft locator bar T10194 for
cylinder bank 2
Work procedure
- Remove noise insulation ( Item - 14 - ) and covers (
Item - 13 - ) from cylinder heads.
- Rotate crankshaft slowly in direction of engine rotation
using counterholder T10172 until camshaft locator bar
T10193 for camshaft for cylinder bank 1 and camshaft
locator bar T10194 for camshaft for cylinder bank 2 can be
inserted into fitting holes as shown.
- Raise vehicle on vehicle platform.
- Check whether marking - arrow A - on vibration damper
aligns with alignment pin - arrow B - .
If markings do not align:
Page 15 / 28
Cylinder head
- Adjust valve timing
Page 16 / 28
15-1, Valve timing, adjusting .
Valve timing, adjusting
Special tools, testers and auxiliary items
required
„
Counter-holder tool T10172
„
Camshaft locator bar T10193 for
cylinder bank 1
„
Camshaft locator bar T10194 for
cylinder bank 2
„
Crankshaft anchor T10195
„
Multi-point socket T10198
Cylinder head
„
Page 17 / 28
Clamping device T10199
Work procedure
- Remove engine and transmission
removing and installing .
10-1, Engine,
- Remove tandem and fuel pumps from cylinder heads
20-1, Tandem pump and Fuel Pump (FP), removing and
installing .
- Remove noise insulation ( Item - 14 - ) and covers (
Item - 13 - ) from cylinder heads.
- Remove acoustic covers and cylinder head cover.
- Turn engine using counterholder T10172 until at least
one camshaft locator bar can be inserted.
- Place clamping device T10199 onto wheel of secured
camshaft and loosen camshaft wheel bolt. Wheel can now
be turned freely on camshaft.
If only one camshaft locator bar could be inserted:
- Turn engine using counterholder T10172 until camshaft
locator bar for other cylinder bank can be inserted.
- Place clamping device T10199 on camshaft gear and
loosen its bolt. Wheel can also now be turned freely on
camshaft.
- Remove vibration damper Item - 4 - . For this, use
counterholder T10172 with threading pins T10172/1 .
Cylinder head
- Screw crankshaft locator bar T10195 onto crankshaft
stub. While doing so, observe alignment pin.
- Carefully rotate crankshaft until pin of crankshaft locator
bar T10195 inserts into alignment bore.
- Place clamping device T10199/1 as shown and tighten
its clamping bolts to 70 Nm.
- Place a torque wrench (40 to 200 Nm) V.A.G 1332 into
square of clamping device and push with 80 Nm in
opposite direction of engine rotation direction to eliminate
play from gear drive.
„
Cylinder bank 1: in direction of - arrow -
„
Cylinder bank 2: against direction of - arrow -
- Maintain specified force and tighten mounting bolt of
camshaft gear to a tightening torque of 50 Nm using socket
T10198 .
- Remove clamping device T10199/1 .
Page 18 / 28
Cylinder head
- Place clamping device T10199 on camshaft gear.
Note:
„
Make sure that clamping device T10199 makes
contact flush on cylinder head.
- Tighten clamping device T10199 bolts to 40 Nm.
- Then tighten camshaft gear using socket T10198 .
Torque specification: 150 Nm plus an additional 1 / 4 turn
(90
).
- Remove clamping device T10199 .
- Remove anchors from camshafts and crankshaft.
- Continue turning crankshaft two rotations in direction of
engine rotation until the crankshaft is again at TDC for
cylinder 1.
- Check whether anchors for camshafts as well as for
crankshaft can be inserted simultaneously.
Cylinder heads, removing and installing
Caution!
Page 19 / 28
Cylinder head
Because of the threaded connection of cylinder head
through the aluminum cylinder block into crankshaft
bearing bracket (connecting rod), both cylinder heads
must always be removed. If cylinder head bolts are
loosened or tightened on one side, cylinder block is
warped.
Special tools, testers and auxiliary items required
„
Counter-holder tool T10172
„
Torque wrench (5 to 50 Nm) V.A.G 1331
Not illustrated:
„
Torque wrench (40 to 200 Nm) V.A.G 1332
„
Container for removed components V.A.G 1698
„
Engine bung set VAS 6122
„
Cable tie
Page 20 / 28
Cylinder head
Page 21 / 28
Removing
- Remove engine and transmission
removing and installing .
10-1, Engine,
- Remove acoustic covers as well as cylinder head covers
from cylinder heads.
- Remove tandem and fuel pumps from cylinder heads
20-1, Tandem pump and Fuel Pump (FP), removing and
installing .
- Set crankshaft to TDC Cylinder 1
checking , check valve timing.
15-1, Valve timing,
- Remove drive gears for camshafts 15-1, Camshaft
compensation wheel and input gear, removing and
installing .
- Remove bolts ( Item - 8 - ) between control housing
and cylinder head of cylinder bank 1 and 2.
- Loosen and remove cylinder head bolts in specified
sequence ( - arrow - points in driving direction).
- Carefully remove cylinder heads with assistance of a
second technician.
Note:
„
The cylinder heads must be carefully guided to
prevent damages.
- Place clean rags into cylinders so that no dirt or emery
cloth particles can get in between cylinder wall and piston.
- Do not allow dirt or abrasive powder to get into coolant
either.
- Carefully clean cylinder head and cylinder block sealing
surfaces. Avoid introducing scratches or scoring (do not
use sandpaper with grit below 100).
Cylinder head
Installing
Note:
„
Always replace cylinder head bolts.
„
Only unpack new cylinder head gasket immediately
prior to installation.
„
Install cylinder head gasket with the same
"thickness" index as the one removed.
„
Handle gasket carefully. Damages to the silicone
layer and in areas of recesses may result in leaks.
- Before installing cylinder heads, position crankshaft to
TDC for cylinder 1.
- Turn back crankshaft in opposite direction of engine
rotation direction until all pistons stand almost evenly below
TDC.
- Set cylinder head gasket in place.
- Install cylinder head according to position of
compensation linkage - arrow - , insert cylinder head bolts
with associated washers and tighten hand-tight.
Caution!
All cylinder head bolts, except number - 1 - , - 2 - , 17 - and - 19 - in tightening sequence must be
installed with notched washers ETKA (Electronic
Parts Catalog)
Page 22 / 28
Cylinder head
Page 23 / 28
- Tighten cylinder heads in sequence indicated, in four
stages as follows ( - arrow - points in driving direction).
„
Tighten using torque wrench:
Step I = 30 Nm
Step II = 60 Nm
„
Tighten further using a solid wrench:
Stage III = 1 / 2 additional turn (180
Step IV = 1 / 2 turn (180
)
)
- Install drive gears for camshafts 15-1, Camshaft
compensation wheel and input gear, removing and
installing .
- Adjust valve timing
15-1, Valve timing, adjusting .
Compression pressures, checking
Note:
„
With this engine, the static compression test requires
a significant amount of work. Therefore it is
recommended to check idle stabilization control
before disassembly Vehicle Diagnosis, Testing
and Information System VAS 5051 or VAS 5052
"Guided Fault Finding; Repair Group 15; partial
systems, boundary conditions" . Only if one or more
cylinder(s) is/are noticeable at this point is the
compression test warranted.
Cylinder head
Special tools, testers and auxiliary items
required
„
Torque wrench (5 to 50 Nm) V.A.G
1331
„
Adapter V.A.G 1381/12
„
Compression tester V.A.G 1763
Not illustrated:
„
Sealing plate T10247
„
Connecting hose VAS 6278
Requirements:
Page 24 / 28
Cylinder head
Page 25 / 28
„
Engine oil temperature min. 30
„
Ignition switched off
C
Work sequence
- Drain coolant
filling .
19-1, Cooling system, draining and
Vehicles with engine code BKW
- Remove fuel filter 20-1, Fuel filter (vehicles with engine
code BKW), removing and installing .
- Seal connection for fuel hoses using sealing plate
T10247 .
- Connect fuel supply line - A - using connecting hose
VAS 6278 to fuel return line - B - .
Vehicles with engine code BWF
- Remove bypass flap with cooler for Exhaust Gas
Recirculation (EGR) 26-2, Bypass flap with cooler for
Exhaust Gas Recirculation (EGR) (vehicles with engine
code BWF), assembly overview .
Continuation for all vehicles
Cylinder head
- Remove upper part of oil filter housing 17-3, Oil filter
housing, assembly overview , Oil filter housing, assembly
overview.
- Remove glow plugs :
„
Vehicles with engine codes BKW and BWF 28-1,
Glow plugs vehicles with engine code BKW, BWF)
removing and installing, checking
- Remove right plenum chamber cover - D - .
- Disconnect small connectors from Engine Control
Modules (ECM).
Note:
„
By disconnecting the small harness connectors for
Engine Control Modules (ECM) the engine is
prevented from starting up even though the starter is
turning. If any DTCs are stored in DTC memory
during start procedure, it is necessary to check and
erase (if required) the DTC memory.
„
After the compression test, check the DTC memory
23-2, Diagnostic Trouble Code (DTC) memory of
Engine control modules (ECM) , checking and
erasing , DTC memory of engine control module
(ECM) , checking and erasing.
Page 26 / 28
Cylinder head
Page 27 / 28
- Screw in adapter V.A.G 1381/12 in place of glow plug at
cylinder to be tested.
- Re-install upper part of oil filter housing 17-3, Oil filter
housing, assembly overview , Oil filter housing,
disassembling and assembling.
- Check compression pressure using compression tester
V.A.G 1763 .
Note:
„
Using the compression tester
instructions .
Operating
- Operate starter until tester shows no further pressure
increase.
Compression pressure:
„
New: 25 to 0.31 bar pressure
„
Wear limit: 19 bar pressure
„
Permissible difference between all cylinders: 5 bar
- Install glow plugs 28-1, Glow plugs vehicles with
engine code BKW, BWF) removing and installing,
checking :
Vehicles with engine codes BKW 28-1, Glow plugs
vehicles with engine code BKW, BWF) removing and
installing, checking
- Fill with coolant
filling .
19-1, Cooling system, draining and
- After all cylinders have been checked and engine has
been completely re-assembled, check DTC memory and
Cylinder head
erase it if necessary 23-2, Diagnostic Trouble Code
(DTC) memory of Engine control modules (ECM) ,
checking and erasing , DTC memory of engine control
module (ECM) , checking and erasing.
Page 28 / 28
Valvetrain
Page 1 / 16
15 - 2
Valvetrain
Note:
„
Secure engine on engine and transmission holder
VAS 6095 when working on engine.
„
Cylinder heads with tears between the valve seats
can continue to be used without reducing service
life, as long as the tears have a width of max. 0.5
mm.
Valve gear, assembly overview
assembly overview
15-2, Valvetrain,
Rework valve seats
15-2, Valve seats, refacing
Check valve guides
15-2, Valve guides, checking
Replacing valve stem oil seals
seals, replacing
15-2, Valve stem
Camshaft, removing and installing
removing and installing
Valvetrain, assembly overview
15-2, Camshaft,
Valvetrain
Page 2 / 16
Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru
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„
20 Nm plus an additional 1 / 4
turn (90
„
„
Replace
„
Observe sequence for
loosening and tightening
15-2, Camshaft, removing
and installing , removing and
installing camshaft
Rocker arm axle
„
„
)
Do not interchange
Bearing cap
„
To install, seal joint surfaces
of outer bearing cap with
sealant AMV 176 501
15-
Valvetrain
Page 3 / 16
2, Seal joint surfaces of
outer bearing caps
„
Valve lifter
„
Do not interchange
„
With hydraulic valve
clearance compensation
„
Place on running surface
when setting down
„
Before installing, check axial
play of camshafts 15-2,
Camshaft, checking axial
play
„
Lubricate contact surface
„
Before removing, remove
bearing caps for camshaft
„
Valve keepers
„
Valve spring plate
„
Outer valve spring
„
„
Inner valve spring
„
„
Replace 15-2, Valve stem
seals, replacing
Diamond disc
„
„
Removing and installing
15-2, Valve stem seals,
replacing , Valve stem seals,
replacing
Valve stem seal
„
„
Removing and installing
15-2, Valve stem seals,
replacing , Valve stem seals,
replacing
Replace
Sleeve
Valvetrain
„
„
„
„
Read "Notes"
„
Reface valve seats 15-2,
Valve seats, refacing
„
„
Topic 15-2
Valves
Valve dimensions
Valve dimensions
15-2,
Pump-Injector Unit
„
„
For linkage mounting
components
Cylinder head
„
„
Page 4 / 16
Removing and installing
23-1, Pump-Injector Unit,
removing and installing
Washer
„
For cylinder head bolts
„
Insert into cylinder head
before assembling bearing
caps
„
Observe "Precautions"
Topic 15-1
Bearing shell
„
Do not interchange used
bearings (mark)
„
Make sure retaining tabs are
engaged properly in bearing
caps and cylinder head
Camshaft
„
Checking axial play 15-2,
Camshaft, checking axial
play
„
Identification, valve timing
15-2, Camshaft
identification, valve timing
Valvetrain
„
„
„
Page 5 / 16
„
Removing and installing
15-2, Camshaft, removing
and installing
„
Checking radial clearance
with Plastigage, Wear limit:
0.11 mm
„
Run-out: max. 0.01 mm
Bearing shell
„
Do not interchange used
bearings (mark)
„
Make sure retaining tabs are
engaged properly in bearing
caps and cylinder head
Cylinder head bolt
„
Replace
„
Observe sequence for
loosening and tightening
15-1, Cylinder heads,
removing and installing ,
Cylinder heads, removing
and installing
„
Before installing, insert
shims Item - 15 - into
cylinder head
8 Nm plus an additional 1 / 4 turn
(90
)
„
Replace
Valvetrain
Camshaft, checking axial play
Special tools, testers and auxiliary items required
„
Dial gauge holder VW 387
„
Dial gauge
Test sequence
Measurement with valve lifters removed and bearing caps
installed:
Cylinder bank 1:
„
Bearing caps 2, 4 and 6 installed
Cylinder bank 2:
„
Bearing caps 9, 11 and 13 installed
Wear limit: max. 0.15 mm
Seal joint surfaces of outer bearing caps
Page 6 / 16
Valvetrain
Page 7 / 16
Special tools, testers and auxiliary items required
„
Sealant AMV 176 501
Work procedure
- Apply sealant AMV 176 501 thinly and evenly on surface
- 1- .
Cylinder bank 1:
„
Seal bearing caps 1 and 7 with sealant AMV 176
501
Cylinder bank 2:
„
Seal bearing caps 8 and 14 with sealant AMV 176
501
Valve dimensions
Note:
„
Valves must not be refaced. Only lapping is
permitted.
Dimension
Intake valve
Exhaust valve
Diameter a
mm
35.950
31.450
Diameter b
mm
6.980
6.956
c
mm
89.950
89.950
45
45
α
Valvetrain
Page 8 / 16
Camshaft identification, valve timing
Identification
„
Base circle of valve cams: a = diameter 52.8 mm
„
Identification by numbers and letters stamped on
face surface of camshaft drive side.
Drive side - arrow Cylinder bank 1
Cylinder bank 2
07Z G
07Z H
Valve timing at 1 mm valve lift
Intake valve opens after TDC
12.0
Intake valve closes after BDC
21.5
Exhaust valve opens before BDC
30.0
Exhaust valve closes before TDC
20.5
Valve seats, refacing
Special tools, testers and auxiliary items required
„
Depth gauge
„
Valve seat refacing tool
Note:
„
When repairing engines with leaking valves, it is not
sufficient to reface or replace valve seats and
valves. It is particularly important to check valve
Valvetrain
Page 9 / 16
guides for wear on engines with longer running
times.
„
Only reface valve seats enough until a perfect
contact pattern is obtained. The maximum
permissible reworking dimension must be calculated
before work is carried out. If the reworking
dimension is exceeded, the function of the hydraulic
lifters can no longer be guaranteed and therefore the
cylinder head should be replaced.
The maximum permissible reworking dimension is
calculated as follows:
- Insert valve and press firmly against seat.
Note:
„
If a valve is to be replaced as part of a repair, use a
new valve for the calculation.
- Measure distance - a - between end of valve stem and
upper edge of cylinder head.
- Calculate max. permissible reworking dimension from
measured distance - a - and minimum dimension.
Minimum dimensions:
„
Intake valve 43.4 mm
„
Exhaust valve 43.2 mm
Measured distance minus minimum dimension = max.
permissible reworking dimension.
Example:
Valvetrain
Page 10 / 16
Measured distance
44.1 mm
Minimum dimension
43.4 mm
Max. permissible reworking dimension*
Refacing intake valve seat
a - Diameter 35.7 mm
b - 1.6 mm
45 - Valve seat angle
Note:
„
The 30 relief milling of the valve seat is always
necessary due to flow ratios in the intake canal.
Refacing exhaust valve seat
a - Diameter 31.4 mm
b - 2.7 mm
45 - Valve seat angle
Valve guides, checking
Special tools, testers and auxiliary items required
0.7 mm
Valvetrain
„
Page 11 / 16
Dial gauge holder VW 387
Not illustrated:
„
Dial gauge
Work sequence
- Insert a new valve into guide. The end of the valve stem
must be flush with the guide. Due to the slight difference in
stem dimensions, make sure that only an intake valve is
used in the intake guide and an exhaust valve in the
exhaust guide.
- Determine tilt clearance. Wear limit: max. 1.3 mm
- If tilt clearance exceeds wear limit, the cylinder head
must be replaced.
Valve stem seals, replacing
Valvetrain
Special tools, testers and auxiliary items
required
„
Valve assembly tool 2036
„
Removal tool 3047 A
„
Valve stem seal driver 3129
„
Valve lever VW 541/1 A
„
Pressure piece VW 541/5
Removing
(With cylinder head installed)
Page 12 / 16
Valvetrain
- Remove camshaft
installing .
Page 13 / 16
15-2, Camshaft, removing and
- Remove valve lifters and place on running surface when
setting down. Be careful not to switch valve lifters.
- Move piston for respective cylinder to Top Dead Center
(TDC) position.
- Insert valve assembly tool 2036 and adjust mounting to
stud height.
- Remove valve springs with valve lever VW 541/1 A and
pressure piece VW 541/5 .
Note:
„
Support valves on piston head while doing this.
- Pull off valve stem seals with valve seal removal tool
3047 A .
Installing
Valvetrain
Page 14 / 16
- Attach plastic sleeves provided - A - to the respective
valve stem. This will help avoid damage to new valve stem
oil seal - B - .
- Insert new valve stem oil seal into valve stem seal driver
3129 .
- Grease lip of valve stem oil seal and carefully slide onto
valve guide.
- Install camshaft
installing .
15-2, Camshaft, removing and
Camshaft, removing and installing
Special tools, testers and auxiliary items required
„
Torque wrench (5 to 50 Nm) V.A.G 1331
„
Sealant AMV 176 501
Removing
- Remove engine and transmission
removing and installing .
- Remove drive gear for camshaft
10-1, Engine,
15-1, Camshaft
Valvetrain
Page 15 / 16
compensation wheel and input gear, removing and
installing .
- Remove rocker arm axles
Item - 2 - .
- Loosen camshaft bearing cap starting from outside
working inward, whereby the bolts of last two bearing caps
must be loosened alternating in diagonal sequence.
Installing
Note:
„
Make sure that no valve is pressed onto piston when
installing the camshaft. Bring pistons evenly to just
below Top Dead Center (TDC) position.
„
Do not interchange run-in connecting rod bearing
shells (mark).
„
When installing camshaft, make sure bearing shell
retaining tabs are seated properly in bearing caps
and cylinder head.
„
Before installing bearing cap, make sure that
washers for cylinder head bolts are inserted in
cylinder head.
- Oil bearing cap contact surfaces.
- Tighten inner two bearing caps alternating in diagonal
sequence and tighten to 8 Nm plus an additional 1 / 4 turn
(90
) (replace bolts).
- Install remaining bearing caps and also tighten to 8 Nm
plus an additional 1 / 4 turn. (90 ) (replace bolts).
Note:
„
Seal joint surfaces of outer bearing caps with sealant
AMV 176 501
15-2, Seal joint surfaces of outer
bearing caps .
- Install rocker arm axles and tighten first the inner and
then outer mounting bolts evenly in diagonal sequence to
tightening torque: 20 Nm plus an additional 1 / 4 turn (90
) turn (replace bolts).
- Re-install drive gear for camshaft
15-1, Camshaft
Valvetrain
Page 16 / 16
compensation wheel and input gear, removing and
installing .
- Adjust valve timing
15-1, Valve timing, adjusting .
- Install acoustic cover as well as cylinder head cover of
respective cylinder.
- Install engine and transmission
removing and installing .
10-1, Engine,
Note:
„
After installing new valve lifters, the engine may not
be started for approx. 30 minutes. The hydraulic
valve lifters have to settle (otherwise valves will
strike the pistons).
Engine oil
Page 1 / 2
17 - 1
Engine oil
Caution!
The oil level must not be above the max. mark - danger
of damage to catalytic converter! Markings on oil
dipstick 17-1, Engine oil level, checking .
Engine oil, draining
Repair Manual, Maintenance
Engine oil specifications
Repair Manual, Maintenance
Oil filling quantities
17-1, Oil filling quantities
Engine oil level, checking
checking
17-1, Engine oil level,
Oil filling quantities
Without oil filter 11.2 L
With oil filter 11.5 L
Engine oil level, checking
Markings on oil dipstick
1 - Max. mark
2 - Min. mark
a - Area above hatched field up to Max. mark: Do not
replenish with engine oil!
b - Oil level within hatched field: Can be replenished with
Engine oil
engine oil
c - Area from Min. mark up to hatched field: Replenish with
max. 0.5 ltr. of engine oil!
Page 2 / 2
Oil pan
Page 1 / 6
17 - 2
Oil pan
Caution!
The oil level must not be above the max. mark - danger
of damage to catalytic converter! Markings on oil
dipstick 17-1, Engine oil level, checking .
Note:
„
If large quantities of metal particles or other deposits
(caused, for example, by partial seizure of the
crankshaft or connecting rod damage) are found in
the engine oil, the oil passages must be cleaned
thoroughly and the oil cooler replaced in order to
prevent further damage from re-occurring.
„
The engine must not be set down on the oil pan
otherwise the liquid gasket between the upper and
lower oil pan will be damaged. To set down the
engine, use frame support T10191 .
„
Secure engine in engine and transmission holder
VAS 6095 when working on engine.
Oil pan, assembly overview
overview
Sealant , applying
17-2, Oil pan, assembly
17-2, Sealant , applying
Oil pan, assembly overview
Lower part of oil pan, assembly overview
pan (lower section), assembly overview
17-2, Oil
Upper part of oil pan, assembly overview
pan (upper section), assembly overview
17-2, Oil
Oil pan (lower section), assembly overview
Oil pan
Page 2 / 6
„
8 Nm
„
8 Nm
„
Oil Level Thermal Sensor G266
„
„
Seal
„
„
Checking Electrical Wiring
Diagrams, Troubleshooting
and Component Locations
binder
Replace
Oil drain plug, 30 Nm
„
If sealing ring is leaking cut
open and replace.
Oil pan
Page 3 / 6
Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru
огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi
„
Oil pan, lower section
„
Clean sealing surface before
installing
„
Insert with sealant AMV 176
501
17-2, Sealant ,
applying
„
Oil tube
„
8 Nm
„
O-ring
„
Replace
Oil pan (upper section), assembly overview
Oil pan
Page 4 / 6
„
8 Nm
„
8 Nm
„
Oil tube
„
Oil pan (upper section)
„
Clean sealing surface before
installing
„
Insert with sealant AMV 176
501
17-2, Sealant ,
applying
„
Note internal oil lines 172, Oil lines in upper section
of oil pan
„
10 Nm
„
Baffle
„
Cylinder block
„
Engine, disassembling and
assembling 13-1, Engine,
disassembling and
assembling
Oil lines in upper section of oil pan
Oil pan
- Insert oil lines - A - as shown in illustration and tighten
bolts - B - to 8 Nm.
Sealant , applying
Special tools, testers and auxiliary items required
„
Sealant AMV 176 501
Work procedure
- Remove sealant residue from pan with a rotating brush,
e.g. a hand drill with a plastic brush attachment (wear eye
protection).
- Clean sealing surfaces. Sealing surfaces must be free of
oil and grease.
Note:
„
Note the expiration date of the sealant .
„
The oil pan must be installed within 5 minutes of
applying sealant .
Page 5 / 6
Oil pan
Page 6 / 6
- Cut tube nozzle at front marking (nozzle diameter approx.
3 mm).
- Apply silicone sealing compound , as shown, to clean oil
pan sealing surface. Sealing compound bead must be:
„
2 to 3 mm thick
„
and run on inside of bolt holes - arrows -
Seal contour for oil pan, lower section
- Apply sealant , as shown, to clean sealing surface of
lower section of oil pan.
Seal contour for oil pan, upper section
- Apply sealant , as shown, to clean sealing surface of
upper section of oil pan.
Oil pump, oil filter housing and oil pressure
Page 1 / 9
17 - 3
Oil pump, oil filter housing and oil pressure
Caution!
The oil level must not be above the max. mark - danger
of damage to catalytic converter! Markings on oil
dipstick 17-1, Engine oil level, checking .
Note:
„
If large quantities of metal particles or other deposits
(caused, for example, by partial seizure of the
crankshaft or connecting rod damage) are found in
the engine oil, the oil passages must be cleaned
thoroughly and the oil cooler replaced in order to
prevent further damage from re-occurring.
„
The engine must not be set down on the oil pan
otherwise the liquid gasket between the upper and
lower oil pan will be damaged. To set down the
engine, use frame support T10191 .
„
Secure engine in engine and transmission holder
VAS 6095 when working on engine.
Oil pump, assembly overview
assembly overview
17-3, Oil pump,
Oil filter housing, assembly overview
housing, assembly overview
17-3, Oil filter
Oil pressure and oil pressure switch, checking
Oil pressure and oil pressure switch, checking
Checking oil pressure at engine face
pressure, checking at front of engine
Oil pump, assembly overview
17-3, Oil
17-3,
Oil pump, oil filter housing and oil pressure
„
8 Nm plus an additional 1 / 4 turn
(90
)
„
Oil return line
„
Gasket
„
„
Replace if damaged
Oil pump
„
Loosening return
connections 17-3,
Loosening return
connections of oil pump
„
To remove, slide slightly in
direction of engine
management side after
loosening all mounts and
remove
Page 2 / 9
Oil pump, oil filter housing and oil pressure
„
10 Nm
„
Baffle plate
„
Slide block
„
Baffle plate
„
20 Nm plus an additional 1 / 4
turn (90
)
Loosening return connections of oil pump
- Pull out securing clamps - A - in direction of - arrow and slide connecting pieces in direction of - arrow B - .
Oil filter housing, assembly overview
Page 3 / 9
Oil pump, oil filter housing and oil pressure
„
Oil filter cover, 25 Nm
„
With bypass valve for oil
filter
„
Loosen and tighten with oil
filter wrench T10192
173, Loosening and tightening
oil filter cover
„
Oil filter element
„
Cap
„
Replace gaskets if damaged
„
Housing upper section
„
8 Nm
„
10 Nm
Page 4 / 9
Oil pump, oil filter housing and oil pressure
„
Gasket
„
Replace if damaged
„
Filler tube
„
Oil cooler
„
Housing lower section
Loosening and tightening oil filter cover
Special tools, testers and auxiliary items required
„
Oil filter wrench T10192
Work procedure
- Loosen and tighten oil filter cover with oil filter wrench
T10192 .
„
Torque specification 25 Nm
Oil pressure and oil pressure switch, checking
Page 5 / 9
Oil pump, oil filter housing and oil pressure
Special tools, testers and auxiliary items
required
„
Oil pressure gauge V.A.G 1342
„
Voltage tester V.A.G 1527 B
„
Connector test set V.A.G 1594 C
Note:
„
Function test and service of visual and acoustic oil
pressure indicator Electrical Wiring Diagrams,
Troubleshooting and Component Locations binder
and Vehicle Diagnosis, Testing and Information
System VAS 5051 or VAS 5052 "Guided Fault
Finding"
Page 6 / 9
Oil pump, oil filter housing and oil pressure
Work sequence
Vehicles with engine codes BKW
- Remove fuel filter 20-1, Fuel filter (vehicles with engine
code BKW), removing and installing .
Vehicles with engine coded BWF
- Remove bypass flap with cooler for Exhaust Gas
Recirculation (EGR) 26-2, Bypass flap with cooler for
Exhaust Gas Recirculation (EGR) (vehicles with engine
code BWF), assembly overview .
Continuation for all vehicles
Note:
„
When removing oil pressure switch, counterhold
banjo bolt so that leaks in the vicinity of the oil line
are prevented.
- Remove oil pressure switch F1 and screw it into oil
pressure gauge V.A.G 1342 .
- Screw oil pressure gauge into banjo fitting in place of oil
pressure switch F1 .
- Connect brown wire of oil pressure gauge to Ground (-).
- Connect diode test lamp of voltage tester V.A.G 1527 B
to B+ and oil pressure switch using adapter cables from
connector test set V.A.G 1594 C . LED must not light up.
Vehicles with engine code BKW
- Install fuel filter 20-1, Fuel filter (vehicles with engine
code BKW), removing and installing .
Vehicles with engine code BWF
- Install bypass flap with cooler for Exhaust Gas
Page 7 / 9
Oil pump, oil filter housing and oil pressure
Recirculation (EGR) 26-2, Bypass flap with cooler for
Exhaust Gas Recirculation (EGR) (vehicles with engine
code BWF), assembly overview .
Continuation for all vehicles
- Start engine and slowly increase engine speed.
- LED must light up at 0.55 to 0.85 bar positive pressure,
otherwise replace oil pressure switch F1 .
- Increase engine speed (RPM) further. At 2000 RPM and
an oil temperature of 80 C, oil pressure must be at least
2.0 bar.
Oil positive pressure must not exceed 7.0 bar at higher
engine speeds.
Oil pressure, checking at front of engine
Special tools, testers and auxiliary items required
„
Oil pressure gauge V.A.G 1342
„
Adapter V.A.G 1342/19
Work sequence
- Remove covers in engine compartment.
- Remove noise insulation (
heads.
Item - 14 - ) from cylinder
Page 8 / 9
Oil pump, oil filter housing and oil pressure
- Remove oil channel sealing plug - A - from cylinder bank
to be tested.
Caution!
The oil channel hole indicates a very low thread depth.
the Adapter VAG1342/19 V.A.G 1342/19 should not be
installed too tightly due to the danger of damaging the
threads.
- Connect oil pressure tester V.A.G 1342 with adapter
V.A.G 1342/19 to oil channel hole.
- Seal test hole for oil pressure switch on oil pressure
tester V.A.G 1342 using engine sealing plug.
- Start engine.
Oil pressure must not reach below a value of 1.4 bar at
1000 RPM and 80 C oil temperature.
Page 9 / 9
Cooling system components
Page 1 / 30
19 - 1
Cooling system components
Caution!
When doing any repair work, especially in the engine
compartment, pay attention to the following due to
clearance issues:
„
Route lines of all types (e.g. for fuel, hydraulic,
additive, coolant and refrigerant, brake fluid,
vacuum) and electrical wiring so that the original
path is followed.
„
To prevent damages to the lines, make sure
there is sufficient clearance to all moving or hot
components.
Note:
„
When the engine is warm the cooling system is
under pressure. If necessary release pressure
before commencing repair work.
„
Hoses are secured with spring-type clips. In cases of
repair only use spring-type clips.
„
The spring-type clip pliers VAS 5024 A are
recommended for installing spring-type clips.
„
When installing coolant hoses, make sure they are
free of stress and do not come into contact with
other components (observe markings on coolant
connections and hoses).
Cooling system components
„
Page 2 / 30
Perform leak test of cooling system using cooling
system tester V.A.G 1274 , adapter V.A.G 1274/8
as well as adapter V.A.G 1274/9 .
Radiator, assembly overview
assembly overview
19-1, Radiator,
Coolant fan, assembly overview
assembly overview
19-1, Coolant fan,
Cooling system components, body side
Cooling system components, body side
19-1,
Cooling system components, on engine and at top
19-1, Cooling system components, on engine and at top
Components of fuel and generator cooling
and generator cooling system components
19-1, Fuel
Component location of After-Run Coolant Pump V51
and Pump for fuel cooler 19-1, After-Run Coolant
Pump V51 and Fuel Cooler Pump V166 , component
location
Coolant thermostat housing, assembly overview
1, Coolant thermostat housing, assembly overview
Coolant pump - assembly overview
pump, assembly overview
19-
19-1, Coolant
Coolant hose connection diagram 19-1, Coolant hose
connection diagram (Vehicles with engine codes BKW)
„
Vehicles with engine code BKW 19-1, Coolant
hose connection diagram (Vehicles with engine
codes BKW)
„
Vehicles with engine code BWF
19-1, Coolant
hose connection diagram, vehicles with engine code
BWF
Cooling system, draining and filling
system, draining and filling
19-1, Cooling
Coolant mixture ratios 19-1, Cooling system, draining
and filling , Coolant, draining and filling
Coolant fan mount, removing and installing
Coolant fan mount, removing and installing
Radiator, removing and installing
removing and installing
19-1,
19-1, Radiator,
Cooling system components
Page 3 / 30
Coolant connection, removing and installing
Coolant connection, removing and installing
Coolant pump, removing and installing
pump, removing and installing
Radiator, assembly overview
„
„
Upper coolant hose
„
Secured to radiator with a
retaining clip
„
Check for secure seating
Radiator
„
Removing and installing
19-1, Radiator, removing
and installing
„
After replacing replace entire
19-1,
19-1, Coolant
Cooling system components
amount of coolant
„
Condenser
„
„
ATF oil cooler
„
„
For air conditioning system
For transmission oil
Oil cooler
„
For power steering oil
„
Lock carrier
„
Bolts, 10 Nm
„
Radiator
Vehicles with engine code
BKW:
„
For generator and fuel
cooling
Vehicles with engine code BWF
„
For fuel cooling
„
Bolts, 10 Nm
„
Rubber bushing
„
Retaining clip
„
Check for secure seat
„
Rubber bushing
„
Engine Coolant Temperature
(ECT) Sensor (on Radiator) G83
„
„
If necessary release
pressure in cooling system
before removing
Lower coolant hose
„
Secured to radiator with a
retaining clip
Page 4 / 30
Cooling system components
„
„
Check for secure seating
Junction piece
„
For coolant hose from
expansion tank
Coolant fan, assembly overview
„
Coolant fan V7
„
Coolant fan mount
„
„
Removing and installing
19-1, Coolant fan mount,
removing and installing
Bolts, 10 Nm
Page 5 / 30
Cooling system components
„
Bolts, 10 Nm
„
Coolant Fan 2 V177
„
Coolant Fan Control (FC) control
module J293
„
Bolts, 10 Nm
Cooling system components, body side
„
„
Cap
„
Check using cooling system
tester V.A.G 1274 and
adapter V.A.G 1274/9
„
Test pressure 1.4 to 1.6 bar
Reservoir
Page 6 / 30
Cooling system components
„
„
Perform leak test of cooling
system with cooling system
tester V.A.G 1274 and
adapter V.A.G 1274/8
„
Depending on optional
equipment, connection may
be sealed with a blanking
plug.
Y-piece
„
„
Note installation position
Coolant hose
„
Fastened to lock carrier
„
Bracket
„
Radiator
Vehicles with engine code
BKW:
„
For generator and fuel
cooling
Vehicles with engine code
BWF:
„
For fuel cooling
Cooling system components, on engine and at top
Page 7 / 30
Cooling system components
„
„
„
Cap
„
Check using cooling system
tester V.A.G 1274 and
adapter V.A.G 1274/9
„
Test pressure 1.4 to 1.6 bar
Reservoir
„
Perform leak test of cooling
system with cooling system
tester V.A.G 1274 and
adapter V.A.G 1274/8
„
Depending on optional
equipment, connection may
be sealed with a blanking
plug.
Coolant pipe
Page 8 / 30
Cooling system components
„
„
To thermostat housing
Coolant pipe
Vehicles with engine code
BKW:
„
To auxiliary water heater
Vehicles with engine code
BWF:
„
„
Coolant hose
„
„
„
To auxiliary water heater
Coolant hose
„
„
To cooler for exhaust gas
recirculation
From heat exchanger
Upper coolant hose
„
Secured to radiator with a
retaining clip
„
Check for secure seating
Lower coolant hose
„
Secured to radiator with a
retaining clip
„
Check for secure seating
Fuel and generator cooling system components
Page 9 / 30
Cooling system components
„
„
„
Reservoir
„
Perform leak test of cooling
system with cooling system
tester V.A.G 1274 and
adapter V.A.G 1274/8
„
Depending on optional
equipment, connection may
be sealed with a blanking
plug.
Cap
„
Check using cooling system
tester V.A.G 1274 and
adapter V.A.G 1274/9
„
Test pressure 1.4 to 1.6 bar
Coolant pipe
Page 10 / 30
Cooling system components
„
„
To Fuel Cooler Pump V166
Coolant pipe
Vehicles with engine code
BKW:
„
To cooler for generator and
fuel cooling Item - 6 -
Vehicles with engine code
BWF:
„
„
To cooler for fuel cooling
Item - 6 -
Coolant hose
Vehicles with engine code
BKW:
„
From cooler for generator
and fuel cooling Item - 6 -
Vehicles with engine code
BWF:
„
„
From cooler for fuel cooling
Item - 6 -
Radiator
Vehicles with engine code
BKW:
„
For generator and fuel
cooling
Vehicles with engine code
BWF:
„
„
For fuel cooling
Coolant hose
„
From fuel cooler pump V166
to radiator Item - 6 -
After-Run Coolant Pump V51 and Fuel Cooler Pump
Page 11 / 30
Cooling system components
V166 , component location
„
After-run coolant pump V51
„
„
Bolted to engine on right
Fuel Cooler Pump V166
„
Bolted to engine on right
„
To Fuel Cooler Pump V166
„
From Fuel Cooler Pump V166
„
Check valve
„
„
Note installation position
From After-run coolant pump
V51
Page 12 / 30
Cooling system components
„
To After-run coolant pump V51
Coolant thermostat housing, assembly overview
Note:
„
The coolant thermostat housing is located in the
lower part of oil filter housing.
„
Routing of coolant hoses to thermostat housing
19-1, Cooling system components, on engine and at
top , Cooling system components - engine side and
top.
„
Oil filter housing - lower section
„
With coolant thermostat
housing
„
Oil filter housing, assembly
Page 13 / 30
Cooling system components
Page 14 / 30
overview 17-3, Oil filter
housing, assembly
overview
„
20 Nm plus an additional 1 / 4
turn (90
„
)
Replace
„
Hex bolt, 10 Nm
„
Bracket
„
Socket head bolt, 10 Nm
„
Map Controlled Engine Cooling
Thermostat F265
„
Connecting piece
„
Gasket
„
„
„
Replace
Coolant thermostat
„
Note installation position
„
Checking: Heat up
thermostat in water
„
Opening begins approx. 80
C
„
Ends approx. 105
„
Opening lift min. 7 mm
C
20 Nm plus an additional 1 / 4
turn (90
„
)
Replace
Coolant pump, assembly overview
Cooling system components
Page 15 / 30
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огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi
„
Seal
„
Replace
„
Coolant drain plug, 40 Nm
„
Coolant pump
„
„
Removing and installing
19-1, Coolant pump,
removing and installing
20 Nm plus an additional 1 / 4
turn (90
)
„
Coolant pump cover
„
8 Nm
„
Observe tightening
sequence 19-1, Coolant
Cooling system components
pump, removing and
installing , Coolant pump,
removing and installing
„
Seal
„
„
Replace
O-ring
„
Replace
Coolant hose connection diagram (Vehicles with engine
codes BKW)
„
Heater unit heat exchanger
„
Auxiliary water heater (auxiliary
heater)
Page 16 / 30
Cooling system components
„
Recirculation Pump V55
„
Fuel cooler
„
Generator
„
Cylinder head/cylinder block
„
Coolant thermostat housing
„
Valve body
„
Radiator
„
Radiator
„
For generator and fuel
cooling
„
Pump for fuel cooler V166
„
After-run coolant pump V51
„
Check valve
„
„
Note installation position
Expansion tank
Coolant hose connection diagram, vehicles with engine
code BWF
Page 17 / 30
Cooling system components
„
Heat exchanger
„
For heater
„
Cylinder head/cylinder block
„
Fuel cooler
„
Radiator
„
For Exhaust Gas
Recirculation (EGR) system
„
Coolant thermostat housing
„
Valve body
„
Pump for fuel cooler V166
„
Radiator
Page 18 / 30
Cooling system components
„
Radiator
„
For fuel cooling
„
After-run coolant pump V51
„
Check valve
„
„
Note installation position
Expansion tank
Cooling system, draining and filling
Special tools, testers and auxiliary items
required
„
Refractometer T10007
Page 19 / 30
Cooling system components
„
Drip tray V.A.G 1306
„
Torque wrench (5 to 50 Nm) V.A.G
1331
„
Spring-type clip pliers VAS 5024
A
„
Adapter V.A.G 1274/8
„
Cooling system charge unit VAS
6096
Draining
Warning!
Hot steam may escape when opening expansion tank.
Wear protective goggles and protective clothing to
prevent damage to eyes and scalding. Cover the cap
with a rag and open very carefully.
- Open cap on coolant expansion tank.
- Remove sound insulation
Repair Manual, Body Exterior, Repair Group 50, Sound
insulation
.
- Remove crossmember
Repair Manual, Body Exterior, Repair Group 63, Front
bumper; Bumper cover, removing and installing; Bumper
carrier - Assembly overview
Page 20 / 30
Cooling system components
- Remove sealing plug - arrow - from radiator.
Note:
„
Observe disposal regulations for coolant!
- Disconnect coolant hoses at coolant regulator housing arrows - to drain coolant from engine.
Filling
Note:
„
Only coolant additive G 12 can be used, in
compliance with TL VW 774 F . Distinguishing
feature: colored violet
„
G 12 and coolant additives marked in accordance
with TL VW 774 F prevent frost and corrosion
damage, scaling and also raise boiling point of
coolant. For this reason the system must be filled all
year round with frost and corrosion protection
additives.
„
Because of its high boiling point, the coolant
improves engine reliability under heavy loads,
Page 21 / 30
Cooling system components
Page 22 / 30
particularly in countries with tropical climates.
„
Protection against frost must be assured to about 25 C (in arctic climatic countries to about -35
C).
„
The coolant concentration must not be reduced by
adding water even in warmer seasons and in
warmer countries. The coolant additive portion must
be at least 40%.
„
If for climatic reasons a greater frost protection is
required, the amount of G 12 can be increased, but
only up to 60% (frost protection to about -40 C), as
otherwise frost protection is reduced again and
cooling effectiveness is also reduced.
„
If radiator, heat exchanger, cylinder head or cylinder
head gasket is replaced, do not reuse old coolant.
„
The refractometer T10007 is recommended for
determining the current anti-freeze density.
Recommended mixture ratios:
Frost protection to
Anti-freeze amount
G 12 1)
Water 1)
-25
C
40%
5.0 l
8.0 l
-35
C
50%
6.5 l
6.5 l
1) The
quantity of coolant can vary depending upon the
vehicle equipment.
Work procedure
Cooling system components
- Install coolant hoses and secure.
- Thread adapter V.A.G 1274/8 on expansion tank.
- Fill coolant circuit using cooling system charge unit VAS
6096
Operating instructions for cooling system charge
unit VAS 6096
Coolant fan mount, removing and installing
Special tools, testers and auxiliary items required
„
Torque wrench (5 to 50 Nm) V.A.G 1331
Removing
- Drain coolant
filling .
19-1, Cooling system, draining and
- Pull off retaining clamps for upper coolant hose, remove
bolt - 1 - .
- Disconnect upper coolant hose from radiator.
- Remove front bumper
Page 23 / 30
Cooling system components
Repair Manual, Body Exterior, Repair Group 63, Front
bumper
- Bring lock carrier into service position
Repair Manual, Body Exterior, Repair Group 50, Lock
carrier
.
- Disconnect harness connectors for radiator fan.
- Disengage retainer - arrows - and remove fan mount
upward.
Installing
Installation is in reverse order of removal. Note the
following:
- The coolant fan mount must engage into mounting points
intended for it.
- Fill with coolant
filling .
19-1, Cooling system, draining and
Radiator, removing and installing
Special tools, testers and auxiliary items required
„
Drip tray V.A.G 1306
Page 24 / 30
Cooling system components
„
Torque wrench (5 to 50 Nm) V.A.G 1331
Removing
- Remove fan mount
and installing .
19-1, Coolant fan mount, removing
- Remove retaining clips on bumper carrier
Repair Manual, Body Exterior, Repair Group 63, Front
bumper; Bumper cover, removing and installing; Bumper
carrier - Assembly overview
- Disengage securing clamps for A/C system condenser
and ATF oil cooler - arrow - .
- Remove upper radiator securing bolts and remove
radiator upward.
Installing
Installation is in reverse order of removal. Note the
following:
- Fill with coolant
filling .
19-1, Cooling system, draining and
Page 25 / 30
Cooling system components
- Electrical connections and routing Electrical Wiring
Diagrams, Troubleshooting and Component Locations
binder
- Install front bumper
Repair Manual, Body Exterior, Repair Group 63, Front
bumper
- Check headlight adjustment and correct, if necessary
Repair Manual, Maintenance
Coolant connection, removing and installing
Special tools, testers and auxiliary items required
„
Drip tray V.A.G 1306
„
Torque wrench (5 to 50 Nm) V.A.G 1331
Removing
- Drain coolant
filling .
19-1, Cooling system, draining and
Page 26 / 30
Cooling system components
- Pull off coolant hoses from coolant connection.
- Disconnect connector from Engine Coolant Temperature
(ECT) Sensor G62 .
- Remove bolts from coolant connection.
- Slide cylinder connecting pieces in direction of - arrow into coolant housing - 1 - .
Installing
Installation is in reverse order of removal. Note the
following:
- Always replace seals - 2 - and gaskets.
- Tighten bolts of coolant housing - 1 - to 8 Nm.
- Fill with coolant
filling .
19-1, Cooling system, draining and
Coolant pump, removing and installing
Special tools, testers and auxiliary items required
Page 27 / 30
Cooling system components
Page 28 / 30
„
Drip tray V.A.G 1306
„
Torque wrench (5 to 50 Nm) V.A.G 1331
Removing
- Remove front bumper
Repair Manual, Body Exterior, Repair Group 63, Front
bumper
- Bring lock carrier into service position
Repair Manual, Body Exterior, Repair Group 50, Lock
carrier
.
- Set crankshaft to TDC Cylinder 1
checking , check valve timing.
- Remove vibration damper
15-1, Valve timing,
Item - 4 - .
Cooling system components
- Drain coolant
filling .
Page 29 / 30
19-1, Cooling system, draining and
- Disconnect coolant hose - 3 - from coolant pipe.
Unscrew mounting bolts - 1 - and - 2 - and fold coolant
pipe toward front.
- Remove coolant drain plugs
- Remove coolant pump cover
Item - 2 - .
Item - 5 - .
- Remove mounting bolts for coolant pump - arrows - and
remove coolant pump.
Note:
„
If coolant pump bolts are not accessibly, attach
vibration damper and turn crankshaft using
counterholder T10172 and threaded pins T10172/1
until bolts are accessible.
Installing
Installation is in reverse order of removal. Note the
following:
- Coat new O-ring with coolant, do not use any other
lubricants.
Cooling system components
- Install coolant pump.
- Tighten coolant pump bolts - arrows - to 20 Nm plus an
additional 1 / - 4 - turn (90 ).
- Tighten coolant pump cover bolts in the shown tightening
sequence to 8 Nm.
- Fill with coolant
filling .
19-1, Cooling system, draining and
Page 30 / 30
Fuel supply system components
Page 1 / 48
20 - 1
Fuel supply system components
Note:
„
Hose connections are secured with couplings or
spring-type or clamp-type clips.
„
Always replace clamp-type clips with spring-type
clips.
„
Fuel hoses at engine must only be secured with
spring-type clips. The use of clamp or screw type
clips is not permitted.
„
The spring-type clip pliers VAS 5024A are
recommended for installing spring-type clips.
Observe safety precautions when working on fuel
supply system 20-1, Safety precautions when working
on fuel supply system
Note rules of cleanliness
20-1, Rules for cleanliness
Fuel tank with attachments, assembly overview
1, Fuel tank with attachments, assembly overview
20-
Fuel filter, assembly overview 20-1, Fuel filter
(vehicles with engine code BKW), assembly overview
„
Vehicles with engine code BKW 20-1, Fuel filter
(vehicles with engine code BKW), assembly
overview
„
Vehicles with engine code BWF
20-1, Fuel filter,
(vehicles with engine code BWF), assembly
Fuel supply system components
Page 2 / 48
overview
Connection diagram of fuel lines and components in
fuel tank 20-1, Connection diagram for fuel lines and
fuel tank components
Connection diagram for fuel hoses in engine
compartment 20-1, Connection diagram for fuel hoses
in engine compartment (vehicles with engine code BKW)
„
Vehicles with engine code BKW 20-1, Connection
diagram for fuel hoses in engine compartment
(vehicles with engine code BKW)
„
Vehicles with engine code BWF
20-1, Fuel hoses
in engine compartment, vehicles with engine code
BKW, connection diagram
Fuel tank, emptying
20-1, Fuel tank, emptying
Fuel delivery unit, fuel gauge sender and suction jet
pump, removing and installing 20-1, Fuel delivery
unit, fuel gauge sensor and suction jet pump, removing and
installing
Fuel tank with attachments, removing and installing
20-1, Fuel tank with attachments, removing and installing
Fuel filter, removing and installing (Vehicles with
engine code BKW) 20-1, Fuel filter (vehicles with
engine code BKW), removing and installing
Check fuel pumps
20-1, Fuel pumps, checking
Tandem and fuel pump, checking
pump and Fuel Pump (FP), checking
20-1, Tandem
Tandem and fuel pump, removing and installing 201, Tandem pump and Fuel Pump (FP), removing and
installing
Accelerator pedal mechanism, assembly overview
20-1, Accelerator pedal mechanism, assembly overview
Safety precautions when working on fuel supply system
Warning!
When doing any repair work, especially in the engine
compartment, pay attention to the following due to
clearance issues:
„
Route lines of all types (e.g. for fuel, hydraulic,
Fuel supply system components
additive, coolant and refrigerant, brake fluid,
vacuum) and electrical wiring so that the original
path is followed.
„
Ensure sufficient clearance to all moving or hot
components.
„
The fuel or fuel lines in fuel system can become
very hot (danger of scalding)!
„
In addition, the fuel system is under pressure!
Before opening the system, place rags around
the connection area and release pressure by
carefully loosening the connection!
„
Wear protective goggles and protective gloves
when working on the fuel system!
Always observe the following when removing and installing
the sender for fuel gauge or the fuel delivery unit from full
or partially filled fuel tanks:
When removing and installing sender for fuel gauge from
full or partially full fuel tanks, the following must be
observed:
„
Before starting work, switch on exhaust extraction
system and place an extraction hose close to the
installation opening of fuel tank to extract escaping
fuel fumes. If no exhaust extraction system is
available, a radial fan (as long as motor is not in air
flow) with a displacement greater than 15 m 3 /h can
be used.
„
Prevent fuel from contacting skin! Wear fuelresistant gloves!
Rules for cleanliness
When working on the fuel supply/injection system, pay
careful attention to the following "7 rules" of cleanliness:
„
Thoroughly clean all connections and the
surrounding area before disconnecting.
„
Place parts that have been removed on a clean
Page 3 / 48
Fuel supply system components
surface and cover them. Do not use fluffy cloths!
„
Carefully cover over opened components or seal, if
repairs are not performed immediately.
„
Only install clean components: Only unpack
replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in
tool boxes etc.).
„
Supplied transport and protective packaging and
sealing caps should only be removed immediately
before installing.
„
When the system is open: Avoid working with
compressed air if possible. Do not move vehicle
unless absolutely necessary.
„
In addition, do not let diesel fuel flow onto coolant
hoses. If necessary, the hoses must be cleaned
again immediately. Replace corroded hoses.
Fuel tank with attachments, assembly overview
Page 4 / 48
Fuel supply system components
Page 5 / 48
Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru
огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi
„
Fuel filler tube
„
Metering line
„
„
Only for vehicles with engine
code BLE (Not available)
Fuel tank
„
Connection diagram of fuel
lines and components in fuel
tank 20-1, Connection
diagram for fuel lines and
fuel tank components
„
Draining
emptying
„
Removing and installing
20-1, Fuel tank with
attachments, removing and
installing
20-1, Fuel tank,
Fuel supply system components
„
„
„
„
Flange
„
Left side
„
Note installed position on
fuel tank 20-1, Installation
position of fuel delivery unit
flange
Locking ring, 145 Nm
„
Use wrench T10202 for
removal and installation
„
Check for secure seating
Fuel delivery unit
„
Left side
„
Removing and installing
20-1, Fuel delivery unit, fuel
gauge sensor and suction jet
pump, removing and
installing , Fuel delivery unit,
fuel gauge sender and
suction jet pump, removing
and installing
„
Check fuel pumps 20-1,
Fuel pumps, checking
Fuel Level Sensor 3 G237
„
Left side
„
Clipped into bottom of tank
„
Removing and installing
20-1, Fuel delivery unit, fuel
gauge sensor and suction jet
pump, removing and
installing , Fuel delivery unit,
fuel gauge sender and
suction jet pump, removing
and installing
„
Checking Electrical Wiring
Diagrams, Troubleshooting
and Component Locations
binder
Page 6 / 48
Fuel supply system components
„
„
Suction jet pump
„
Left side
„
At fuel delivery unit
„
Removing and installing
20-1, Fuel delivery unit, fuel
gauge sensor and suction jet
pump, removing and
installing , Fuel delivery unit,
fuel gauge sender and
suction jet pump, removing
and installing
Protective cover
„
„
„
For bottom of fuel tank
Securing strap
„
Note installation position
„
Check for secure seating
20 Nm plus an additional 1 / 4
turn (90
„
Protective cover
„
„
„
)
For top of fuel tank
Suction jet pump
„
Left side
„
Clipped into bottom of tank
„
Removing and installing
20-1, Fuel delivery unit, fuel
gauge sensor and suction jet
pump, removing and
installing , Fuel delivery unit,
fuel gauge sender and
suction jet pump, removing
and installing
Metering line
„
Only for vehicles with engine
Page 7 / 48
Fuel supply system components
code BLE (Not available)
„
„
„
„
Suction jet pump
„
Right side
„
Removing and installing
20-1, Fuel delivery unit, fuel
gauge sensor and suction jet
pump, removing and
installing , Fuel delivery unit,
fuel gauge sender and
suction jet pump, removing
and installing
Fuel delivery unit
„
Right side
„
Removing and installing
20-1, Fuel delivery unit, fuel
gauge sensor and suction jet
pump, removing and
installing , Fuel delivery unit,
fuel gauge sender and
suction jet pump, removing
and installing
„
Check fuel pumps 20-1,
Fuel pumps, checking
Fuel Level Sensor G
„
Right side
„
Removing and installing
20-1, Fuel delivery unit, fuel
gauge sensor and suction jet
pump, removing and
installing , Fuel delivery unit,
fuel gauge sender and
suction jet pump, removing
and installing
„
Checking Electrical Wiring
Diagrams, Troubleshooting
and Component Locations
binder
Flange
„
Right side
Page 8 / 48
Fuel supply system components
„
„
Note installed position on
fuel tank 20-1, Installation
position of fuel delivery unit
flange
Bracket
„
Only for vehicles with engine
code BLE (Not available)
Installation position of fuel delivery unit flange
Insert sender flange with marking in direction of travel arrow - .
Fuel filter (vehicles with engine code BKW), assembly
overview
Connection diagram for fuel hoses in engine
compartment 20-1, Connection diagram for fuel hoses
in engine compartment (vehicles with engine code BKW)
Coolant hose connection diagram 19-1, Coolant
hose connection diagram (Vehicles with engine codes
BKW)
Page 9 / 48
Fuel supply system components
„
8 Nm
„
Fuel filter cover
„
„
Seal
„
„
Connections for fuel hoses
20-1, Fuel hose
connection
Replace
Fuel filter insert
„
Observe change intervals
Repair Manual, Maintenance
„
Water drain connection
Page 10 / 48
Fuel supply system components
„
„
„
To drain water, extract
approx. 100 cm 3 using
suction pump VAS 5226 .
„
Tighten sealing plug to 3 Nm
Return tube
„
To fuel tank
„
Blue or with blue marking
„
Check for secure seating
Supply tube
„
From fuel tank
„
White or with white markings
„
Check for secure seating
„
Coolant return line
„
Coolant supply line
„
8 Nm
„
3 Nm
„
Flexible Fuel (FF) Sensor G133
„
O-ring, replace
„
Fuel cooler
„
Fuel filter housing
„
Removing and installing
20-1, Fuel filter (vehicles
with engine code BKW),
removing and installing
Page 11 / 48
Fuel supply system components
Fuel hose connection
- Replace seal between connection and fuel filter cover.
- Tighten mounting bolts - arrows - to 8 Nm.
Fuel filter, (vehicles with engine code BWF), assembly
overview
Connection diagram for fuel hoses in engine
compartment 20-1, Fuel hoses in engine compartment,
vehicles with engine code BKW, connection diagram
Coolant hose connection diagram 19-1, Coolant
hose connection diagram, vehicles with engine code
BWF
Page 12 / 48
Fuel supply system components
„
„
Fuel line
„
Between fuel filter cover
Item - 6 - (identification on
connection - RT - ) and fuel
cooler Item - 16 -
„
Blue or with blue marking
„
Ensure seated tightly
Fuel supply line
„
From fuel tank to fuel filter
cover Item - 6 (identification on connection
- VF - )
„
White or with white markings
„
Ensure seated tightly
Page 13 / 48
Fuel supply system components
„
Locking bolt, 5 Nm
„
Seal
„
„
„
To drain water, extract
approx. 100 cm 3 using
suction pump VAS 5226 .
Fuel filter cover
„
Note installation position
„
Only possible to install in
one position
Seal
„
„
Replace
Water drain connection
„
„
Page 14 / 48
Replace
Fuel filter insert
„
Observe change intervals
Repair Manual, Maintenance
„
8 Nm
„
Seal
„
„
Note installation position
„
Replace
Fuel filter
„
„
Item -
Bracket
„
„
Secured to bracket
12 -
For fuel filter Item - 11 and fuel cooler Item - 16 -
50 Nm plus an additional 1 / 4
Fuel supply system components
turn (90
„
„
„
„
Replace
Ensure seated tightly
Fuel return line
„
Blue or with blue marking
„
Ensure seated tightly
Fuel cooler
„
„
)
Coolant hose
„
„
Page 15 / 48
Secured to bracket
12 -
Item -
Fuel return line
„
From connection at fuel line
Item - 3 - to fuel filter
cover Item - 6 (identification on connection
- RF - )
„
Blue or with blue marking
„
Ensure seated tightly
Fuel supply line
„
From fuel filter cover Item
- 6 - (identification on
connection - VM - ) to
connection at fuel line
Item - 2 -
„
White or with white markings
„
Ensure seated tightly
Connection diagram for fuel lines and fuel tank
components
- A - : Left half of tank
- arrow - : Direction of travel
Fuel supply system components
- B - : Right half of tank
„
Supply line for suction jet pump
„
„
Left side
Supply line
Vehicles with engine code
BKW:
„
To fuel filter
Item - 7 -
Vehicles with engine code
BWF:
„
„
To fuel filter
Item - 2 -
Return line
Vehicles with engine code,
Page 16 / 48
Fuel supply system components
Page 17 / 48
BKW:
„
„
From fuel filter
Item - 6 -
Flange
„
Right side
„
Supply line for auxiliary heater
„
Supply line for suction jet pump
„
„
Suction jet pump
„
„
„
„
Right side
Delivery line
„
Black
„
To fuel delivery unit on left
side
Delivery line
„
Black
„
To fuel delivery unit on right
side
Suction jet pump
„
„
Right side
Suction jet pump
„
„
To fuel delivery unit, right
side
Fuel delivery unit
„
„
Right side
Left side
Fuel delivery unit
„
Left side
Fuel supply system components
„
Suction jet pump
„
To fuel delivery unit, left side
Connection diagram for fuel hoses in engine
compartment (vehicles with engine code BKW)
Caution!
When installing fuel lines and hoses, ensure there is
clearance to other components or to body. Contact
can cause leaks.
„
Return line
„
To fuel tank
„
Blue or with blue marking
„
Check for secure seating
Page 18 / 48
Fuel supply system components
„
„
Supply line
„
From fuel tank
„
White or with white markings
„
Check for secure seating
Fuel rail
„
For cylinder bank 2
„
Fuel cooler
„
Test connection
„
„
For cylinder bank 1
„
Tighten sealing plug to 27
Nm
„
Not available on all vehicles
Fuel rail
„
„
„
Tandem pump
„
For cylinder bank 1
„
With vacuum pump
„
Tandem and fuel pump,
checking 20-1, Tandem
pump and Fuel Pump (FP),
checking
„
Tandem and fuel pump,
removing and installing
20-1, Tandem pump and
Fuel Pump (FP), removing
and installing
Fuel Temperature Sensor G81
„
„
For cylinder bank 1
For cylinder bank 1
Fuel filter
Page 19 / 48
Fuel supply system components
„
„
„
Fuel Pump (FP)
„
For cylinder bank 2
„
Tandem and fuel pump,
checking 20-1, Tandem
pump and Fuel Pump (FP),
checking
„
Tandem and fuel pump,
removing and installing
20-1, Tandem pump and
Fuel Pump (FP), removing
and installing
Fuel Temperature Sensor 2 G248
„
„
Removing and installing
20-1, Fuel filter (vehicles
with engine code BKW),
removing and installing
For cylinder bank 2
Test connection
„
For cylinder bank 2
„
Tighten sealing plug to 27
Nm
„
Not available on all vehicles
Fuel hoses in engine compartment, vehicles with engine
code BKW, connection diagram
Warning!
When installing fuel lines and hoses, ensure there is
clearance to other components or to body. Contact
can cause leaks.
Page 20 / 48
Fuel supply system components
„
„
„
Test connection
„
For cylinder bank 2
„
Tighten sealing plug to 27
Nm
„
Not available on all vehicles
Fuel supply line
„
From connection at fuel filter
cover Item - 18 -
„
White or with white markings
„
Ensure seated tightly
Fuel return line
„
To connection at fuel filter
Page 21 / 48
Fuel supply system components
cover
„
„
Blue or with blue marking
„
Ensure seated tightly
Fuel line
„
„
„
„
„
For cylinder bank 1
„
Tighten sealing plug to 27
Nm
Fuel rail
For cylinder bank 1
Tandem pump
„
For cylinder bank 1
„
With vacuum pump
„
Tandem and fuel pump,
checking 20-1, Tandem
pump and Fuel Pump (FP),
checking
„
Tandem and fuel pump,
removing and installing
20-1, Tandem pump and
Fuel Pump (FP), removing
and installing
„
Must not be disassembled
Fuel Temperature Sensor G81
„
„
For cylinder bank 2
Test connection
„
„
Secured to intake manifold
of cylinder bank 2
Fuel rail
„
„
Item - 17 -
For cylinder bank 1 and 2
Fuel Pump (FP)
Page 22 / 48
Fuel supply system components
„
For cylinder bank 2
„
Tandem and fuel pump,
checking 20-1, Tandem
pump and Fuel Pump (FP),
checking
„
Tandem and fuel pump,
removing and installing
20-1, Tandem pump and
Fuel Pump (FP), removing
and installing
„
Must not be disassembled
Fuel tank, emptying
Special tools, testers and auxiliary items required
„
Fuel siphoning unit VAS 5190
„
Wrench T10202
Not illustrated:
Page 23 / 48
Fuel supply system components
„
Torque wrench (40 to 200 Nm) V.A.G 1332
Work procedure
- Read safety precautions before beginning work 20-1,
Safety precautions when working on fuel supply system .
- Open fuel tank flap and remove fuel tank cap.
Note:
„
Secure Ground (GND) wire of fuel extraction unit
VAS 5190 to a bare area of the chassis.
- Slide extraction hose - arrow - of fuel extraction unit
VAS 5190 approx. 170 to 180 cm into fuel filler tube and
extract fuel.
Note:
„
When no more fuel can be extracted, the tank is
emptied only enough for the sender flange to be
opened without danger. The tank may be removed
while containing the remaining fuel. If work must be
performed on the fuel pumps or fuel tank senders,
proceed as follows:
- Fold rear seat bench forward.
Page 24 / 48
Fuel supply system components
- Cut open carpet from point - A - to point - B - in pre-cut
area - arrows - .
- Remove nuts - 1 - for cover. If necessary, remove
anchor plate - 2 - .
- Disconnect harness connector for fuel pump and tank
sensor - 4 - .
- Disconnect return line - 1 - , supply line - 2 - as well as
supply line for auxiliary heater - 3 - from right sensor
flange.
Note:
„
Press in securing ring to disengage the fuel lines.
Page 25 / 48
Fuel supply system components
- Remove locking ring from sensor flange using wrench
T10202 .
- Carefully pry out sensor flange and raise it slightly.
- Insert extraction hose of fuel extraction unit VAS 5190 as
deeply as possible into right or left side of fuel tank and
extract fuel.
- For work on left side of fuel tank, proceed as described
above.
- When disconnecting fuel lines, it is possible that the
securing rings on the hose connections cannot be pressed
in. To do this, insert assembly tool T10118 .
For additional work on components inside of fuel tank,
sensor flanges may remain removed.
If fuel tank needed only to be emptied, install sensor
flanges again.
- Check that sensor flange seals are properly seated.
Note:
„
If seals are swollen with fuel, always replace.
Page 26 / 48
Fuel supply system components
- Insert sensor flange with marking in direction of travel arrow - .
- Tighten left and right locking rings using wrench T10202
to 145 Nm.
Note:
„
Do not interchange supply and return lines (return
line blue - 1 - , supply line black - 2 - ).
„
Ensure fuel hoses are seated securely.
Fuel delivery unit, fuel gauge sensor and suction jet
pump, removing and installing
Special tools, testers and auxiliary items required
„
Torque wrench (40 to 200 Nm) V.A.G 1332
Page 27 / 48
Fuel supply system components
„
Page 28 / 48
Wrench T10202
Requirements
„
The fuel tank must be drained
emptying , emptying fuel tank
20-1, Fuel tank,
„
Connectors and lines for left and right sender
flanges are disconnected
„
Locking rings for left and right sender flanges are
removed
Removing
- Observe safety precautions before performing repair
work 20-1, Safety precautions when working on fuel
supply system .
- Disconnect harness connectors - 1 - and - 2 - , as well
as hose couplings - 3 - , - 4 - and - 5 - below right sensor
flange.
Note:
„
Press in securing ring to disengage the fuel lines.
Fuel supply system components
- Remove sensor flange.
- Unclip black filler hose - arrow - from fuel delivery unit
housing on left and right sides of fuel tank.
- Disconnect fuel supply line from fuel delivery unit - arrow
- on left and right sides of fuel tank to suction jet pumps.
- Disconnect supply and return lines between both fuel
delivery units on left side of fuel tank.
- Unscrew Fuel Pump (FP) unit in bottom of fuel tank by
turning approx. 90 to left.
Note:
„
The fuel pump (FP) unit housing is filled with fuel.
Fuel may run out if the housing is tipped.
- Unclip fuel level sensors on both sides of fuel tank and
pull them out.
- Unclip suction jet pumps from bottom on each side and
remove with a slight turn.
- Pull out hose ends through left and right sender
openings.
Page 29 / 48
Fuel supply system components
Installing
Installation is in reverse order of removal. Note the
following:
„
Connections for fuel lines must engage audibly when
joined.
„
Route fuel hoses kink-free.
„
Make sure fuel hoses are seated securely.
Fuel tank with attachments, removing and installing
Special tools, testers and auxiliary items
required
„
Fuel extraction unit VAS 5190
Page 30 / 48
Fuel supply system components
Page 31 / 48
„
Polydrive key T10202
„
Torque wrench (5 to 50 Nm) V.A.G
1331
„
Torque wrench (40 to 200 Nm)
V.A.G 1332
„
Engine/transmission jack V.A.G
1383 A
Removing
Note:
„
Read safety precautions before beginning work
20-1, Safety precautions when working on fuel
supply system .
„
The fuel tank must be drained
emptying , emptying fuel tank.
20-1, Fuel tank,
Vehicles with engine code BKW
- Remove middle and rear mufflers of exhaust system
26-1, Muffler with mountings (vehicles with engine code
BKW), assembly overview .
Vehicles with engine code BWF
- Remove rear muffler of exhaust system 26-1, Muffler
with mountings (vehicles with engine code BWF),
assembly overview .
Continuation for all vehicles
- Remove rear driveshaft
Repair Manual, Rear Final Drive, Repair Group 39,
Driveshafts, removing and installing
- Remove rear subframe
Repair Manual, Suspension, Wheels, Steering, Repair
Fuel supply system components
Group 42, I - Assembly overview: Subframe, stabilizer bar,
stone impact protection
- Open fuel tank flap and remove fuel tank cap.
- Pull rubber gasket off filler neck.
- Remove securing bolts - 1 - on filler neck and pull off
Ground (GND) wire - 2 - .
- Remove right rear wheelhousing liner
Repair Manual, Body Exterior, Repair Group 66,
Wheelhousing liners
- Unbolt cover plate - arrow - .
Page 32 / 48
Fuel supply system components
- Unclip fuel tank breather lines at securing clip attached
on longitudinal member.
- Remove mounting nut for filling pipe - arrow - in wheel
housing.
- Disconnect fuel pump connectors, on left next to fuel
tank.
- Remove securing straps with covers on left and right
below fuel tank.
- Support fuel tank using engine/transmission jack V.A.G
1383 A and remove tension strap at center of fuel tank.
- Carefully lower fuel tank about 30 cm.
Page 33 / 48
Fuel supply system components
- Grab between fuel tank and vehicle floor and disconnect
fuel lines from sensor flange. When pulling off fuel supply
line, hold a cloth around fuel supply line.
Note:
„
This step eliminates having to cut open the carpeting
in the vehicle interior in the vicinity of sender flange
cover.
- Lower and remove fuel tank.
Installing
Installation is in reverse order of removal. Note the
following:
„
Line connections for metering, ventilation and fuel
lines must engage audibly when joined.
„
Do not interchange supply and return lines (return
line blue or with blue marking - 1 - , supply line
black - 2 - ).
„
Clip in the metering and fuel lines at the fuel tank.
„
Make sure metering, ventilation and fuel hoses are
not kinked when installed.
„
Make sure metering and fuel lines are securely
positioned.
„
If necessary, fill up additive for additive tank
Repair Manual, Maintenance
Page 34 / 48
Fuel supply system components
Fuel filter (vehicles with engine code BKW), removing
and installing
Special tools, testers and auxiliary items
required
„
Hose clamps up to 25 mm dia.
3094
„
Torque wrench (5 to 50 Nm) V.A.G
1331
„
Spring-type clip pliers VAS 5024
A
„
Suction pump VAS 5226
Removing
Page 35 / 48
Fuel supply system components
- Disconnect supply hose - 3 - (white marking) and return
hose - 2 - (blue marking) from fuel filter.
- Connect suction pump VAS 5226 to water drain
connection - arrow - of fuel filter.
- Operate suction pump VAS 5226 until fuel no longer
flows out.
- Remove both mounting bolts - 1 - and remove
connection with fuel lines.
- Open cap on coolant expansion tank.
- Clamp off both coolant hoses - 4 - using hose clamps up
to dia. 25 mm 3094 .
Page 36 / 48
Fuel supply system components
- Disconnect coolant hoses and catch escaping coolant
using a rag.
- Remove both mounting bolts - arrows - and pull fuel
filter slightly toward front.
Note:
„
Be careful not to lose the rubber mount bushing on
the top and bottom of the fuel filter mounting holes.
- Unclip lines at rear side of fuel filter.
- Disconnect harness connector for Flexible Fuel (FF)
Sensor G133 and remove fuel filter.
Installing
Installation is in reverse order of removal. Note the
following:
- Replace seal between connection and fuel filter cover.
- Tighten sealing plug of water drain connection to 3 Nm.
- Fill with coolant
filling .
19-1, Cooling system, draining and
Fuel pumps, checking
Special tools, testers and auxiliary items required
Page 37 / 48
Fuel supply system components
„
Voltage tester V.A.G 1527 B
„
Hand multimeter V.A.G 1526 C or Multimeter V.A.G
1715
Not illustrated:
„
Connector test set V.A.G 1594 C
Requirements
„
The fuses must be OK
„
Battery voltage must be at least 11.5 Volts
„
All electrical consumers such as, lights and rear
window defroster must be switched off
Function and voltage supply, checking
- Fold rear seat bench forward.
- Briefly operate starter. Fuel Pumps (FP) must run
audibly.
Page 38 / 48
Fuel supply system components
- Switch off ignition.
If Fuel Pumps (FP) do not start up:
- Cut floor carpet in pre-cut area - arrows - from points A - to - B - on left and right vehicle sides.
- Remove nuts - 1 - for cover. If necessary, unscrew
anchor plate - 2 - .
Check voltage supply of each individual Fuel Pump (FP) as
follows:
- Disconnect 4-pin harness connector from right flange of
fuel delivery unit.
- Connect diode test lamp V.A.G 1527 B using adapter
Page 39 / 48
Fuel supply system components
cables from connector test kit V.A.G 1594 C to outer
terminals of connector.
- Switch on ignition, LED must light up for approx. 2
seconds.
If LED does not light up:
- Check activation of fuel pump relay and check wires for
open circuit and short circuit Vehicle Diagnosis, Testing
and Information System VAS 5051
LED lights up (voltage supply OK):
- Remove right Fuel Pump (FP) unit 20-1, Fuel delivery
unit, fuel gauge sensor and suction jet pump, removing and
installing .
- Check if electrical wiring between flange and fuel pump is
connected and has continuity.
If no open circuits are found:
- Right fuel pump is faulty. Replace fuel delivery unit 201, Fuel delivery unit, fuel gauge sensor and suction jet
pump, removing and installing .
- Repeat test on left fuel delivery unit.
Current pick-up of fuel pumps, checking
- Check current consumption of each fuel pump separately
as follows:
- Connect current clamp of multimeter V.A.G 1715 to the
wire of the 4-pin connector contact - 1 - - arrow - from
wiring harness to right fuel delivery unit.
- Start engine and let run at idle speed.
- Measure Fuel Pump (FP) current draw: Specification:
max. 8 amperes.
Page 40 / 48
Fuel supply system components
If current draw is exceeded:
- Right fuel pump is faulty. Replace fuel delivery unit 201, Fuel delivery unit, fuel gauge sensor and suction jet
pump, removing and installing .
- Repeat test on left fuel delivery unit.
Tandem pump and Fuel Pump (FP), checking
Note:
„
The tandem pump delivers fuel for cylinder bank 1
and Fuel Pump (FP) delivers fuel for cylinder bank
2.
Special tools, testers and auxiliary items required
„
Torque wrench (5 to 50 Nm) V.A.G 1331
„
Pressure Gauge VAS 5187 with Adapter Set VAS
5187/6
Not illustrated:
„
Vehicle Diagnostic, Testing and Information System
Page 41 / 48
Fuel supply system components
Page 42 / 48
VAS 5051 A with diagnostic cable
„
Adapter Set VAS5187/6
Requirements
„
Coolant temperature must be at least 85
C.
„
Pump-injector units OK
„
Fuel filter and fuel lines must not be blocked
Work sequence
Vehicles with test connections (engine code BKW)
- Connect pressure gauge VAS 5187 to test connection
for cylinder bank 1 - 1 - or to test connection for cylinder
bank 2 - 2 - .
Vehicles with test connections (engine code BWF)
- Connect test unit for tandem pump VAS 5187 to test
connection for cylinder bank 1 - 1 - or to test connection
for cylinder bank 2 - 2 - .
Fuel supply system components
Vehicles without test connections (engine code BKW)
- Remove fuel filter 20-1, Fuel filter (vehicles with engine
code BKW), removing and installing .
- Connect test unit for tandem pump VAS 5187 to supply
line for cylinder bank 1 - 1 - or to supply line for cylinder
bank 2.
- Install fuel filter 20-1, Fuel filter (vehicles with engine
code BKW), removing and installing .
Continuation for all vehicles
Connect vehicle diagnosis, testing and information system
VAS 5051 as follows:
- Open cover - 1 - (if equipped) and connect the connector
of the diagnostic cable to the Data Link Connector (DLC).
- Start engine and run at idle speed.
- On Vehicle diagnostic, testing, and information system ,
select operating mode "Vehicle Self Diagnosis" . Then, go
into engine control module (ECM) J623 with address word
"01 - Engine electronics" .
- Press diagnostic function "08 - Read measuring value
blocks" .
Page 43 / 48
Fuel supply system components
- Enter "display group 1" via number keypad and confirm
input by pressing Q button.
- Read idle RPM in "display field 1" .
- Increase engine speed to 1500 RPM.
- Observe pressure displayed on pressure gauge.
Specification: at least 7.5 bar.
- Press
key twice.
- Press function "06 - End output" .
If specification is not obtained:
- Replace tandem pump or Fuel Pump (FP) 20-1,
Tandem pump and Fuel Pump (FP), removing and
installing .
Note:
„
After removing pressure gauge for tandem pump ,
tighten supply line and sealing plug to 27 Nm.
Tandem pump and Fuel Pump (FP), removing and
installing
Caution!
The tandem pump must not be disassembled under
any circumstances because it can cause the vacuum
part to malfunction. The result would be brake booster
failure.
Special tools, testers and auxiliary items required
„
Torque wrench (5 to 50 Nm) V.A.G 1331
Page 44 / 48
Fuel supply system components
„
Page 45 / 48
Spring-type clip pliers VAS 5024 A
Removing
Note:
„
Work sequence for removing and installing tandem
pump is described. Work sequence for Fuel Pump
(FP) is identical up to disconnecting the vacuum
line.
Vehicles with engine code BKW
- Remove fuel filter 20-1, Fuel filter (vehicles with engine
code BKW), removing and installing .
Vehicles with engine code BWF
- Remove bypass flap with cooler for Exhaust Gas
Recirculation (EGR) 26-2, Bypass flap with cooler for
Exhaust Gas Recirculation (EGR) (vehicles with engine
code BWF), assembly overview .
Continuation for all vehicles
- Remove intake manifold
removing and installing .
23-1, Intake manifold,
Fuel supply system components
- Disconnect vacuum line - 1 - from brake booster of
tandem pump - 5 - .
- Disconnect central connector for Pump-Injector Units - 3
- .
- Disconnect fuel hose - 2 - at tandem pump - 5 - .
- Remove mounting bolts - arrows - .
- Remove tandem pump - 5 - from cylinder head.
- Pull tandem pump - 5 - slightly upward, unscrew fuel
hose - 4 - and remove tandem pump.
Installing
Installation is in reverse order of removal. Note the
following:
Note:
„
Make sure that the tandem pump coupling has
proper seating in camshaft.
„
Tandem pump seals must always be replaced.
- Connect fuel line - 4 - with new sealing rings to tandem
pump - 5 - and tighten banjo bolt to 25 Nm.
- Install tandem pump and tighten mounting bolts - arrows
- .
Torque specification:
„
M6: 8 Nm
„
M8: 20 Nm
Page 46 / 48
Fuel supply system components
- Connect fuel hose - 2 - and vacuum line - 1 - to tandem
pump.
- Connect central connector for Pump-Injector Units.
Vehicles with engine code BKW
- Install fuel filter 20-1, Fuel filter (vehicles with engine
code BKW), removing and installing .
Vehicles with engine code BWF
- Install bypass flap with cooler for Exhaust Gas
Recirculation (EGR) 26-2, Bypass flap with cooler for
Exhaust Gas Recirculation (EGR) (vehicles with engine
code BWF), assembly overview .
Continuation for all vehicles
- Install intake manifold
and installing .
23-1, Intake manifold, removing
- Perform test drive and check DTC memory 23-2,
Diagnostic Trouble Code (DTC) memory of Engine control
modules (ECM) , checking and erasing , DTC memory of
Engine Control Module (ECM) , checking and erasing.
Note:
„
By disconnecting the central connection for the
pump-injector unit, DTCs will be stored. Check the
DTC memory and erase, if necessary.
Accelerator pedal mechanism, assembly overview
Page 47 / 48
Fuel supply system components
„
Bracket
„
Connector
„
Black, 6-pin
„
10 Nm
„
Throttle position (TP) sensor
G79
„
Not adjustable
„
Remove footwell cover to
remove sensor
Page 48 / 48
Charge air system with turbocharger
Page 1 / 9
21 - 1
Charge air system with turbocharger
Observe safety precautions
precautions .
Note rules of cleanliness
21-1, Safety
21-1, Rules for cleanliness
Observe installation of hose connections with
connector couplings 21-1, Hose connections with
connector couplings, installing
Turbocharger, assembly overview
Turbocharger, assembly overview
21-1,
Charge air cooler, assembly overview 21-1, Charge
air cooler components, assembly overview
Safety precautions
Caution!
When doing any repair work, especially in the engine
compartment, pay attention to the following due to
clearance issues:
„
Route lines of all types (e.g. for fuel, hydraulic,
additive, coolant and refrigerant, brake fluid,
vacuum) and electrical wiring so that the original
path is followed.
„
To prevent damages to the lines, make sure
there is sufficient clearance to all moving or hot
components.
Observe the following if test and measuring instruments
are required during a test drive:
„
Test and measuring instruments must be secured to
rear seat and operated by a 2nd person from this
location.
If test and measuring instruments are operated from the
front passengers seat and the vehicle is involved in an
accident, there is a possibility that the person sitting in this
seat may receive serious injuries when the airbag is
triggered.
Warning!
Secure Scan Tool (ST) on the rear seat and operate it
Charge air system with turbocharger
from there by second technician.
Rules for cleanliness
When working on turbocharger, carefully observe the
following "7 rules" of cleanliness:
„
Thoroughly clean all connections and surrounding
area before disconnecting.
„
Place parts that have been removed on a clean
surface and cover them. Do not use fluffy cloths!
„
Carefully cover over opened components or seal, if
repairs are not performed immediately.
„
Only install clean components: Only unpack
replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in
tool boxes etc.).
„
Supplied transport and protective packaging and
sealing caps should only be removed immediately
before installing.
„
During repair, clean oil from connections and hose
ends.
„
When the system is open: Avoid working with
compressed air if possible. Do not move vehicle
unless absolutely necessary.
Hose connections with connector couplings, installing
Caution!
Connector coupling sealing ring can be damaged if
securing clamp is in locked position when installing.
This would result in a leak. Follow assembly
instructions.
Removing
Page 2 / 9
Charge air system with turbocharger
- Release connection coupling by pulling securing clip arrow - . Separate hose/tube without assistance from
tools.
Installing
- When replacing sealing ring, lay ring in charge air hose
groove. Ensure gasket is completely seated in groove all
the way around.
- Oil sealing surfaces and sealing ring.
- Bring securing clip into release position - 1 - .
- Slide charge air hose into clutch as far as stop.
- Bring securing clip into lock position - 2 - and then press
charge air hose back again.
- Check for correct seating and proper locking of connector
by pulling on hose.
Page 3 / 9
Charge air system with turbocharger
Page 4 / 9
Turbocharger, assembly overview
Note:
„
Various hose connections are secured.
„
Charge air system must be properly sealed.
„
Replace self-locking nuts.
„
Before screwing on oil supply line, fill turbocharger
with engine oil at connecting tube.
„
After installing turbocharger, let engine run at idle for
approx. 1 minute and without increasing engine
speed. This ensures that Turbocharger is
lubricated.
„
Components depicted here correspond to cylinder
bank 2. They are different only as a mirror image of
components for cylinder bank 1.
Observe safety precautions
precautions .
Observe rules for cleanliness
cleanliness .
21-1, Safety
21-1, Rules for
Charge air system with turbocharger
Page 5 / 9
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„
„
To connecting pipe
„
Vehicles with engine code
BKW Item - 12 -
„
Vehicles with engine code
BWF Item - 11 -
Exhaust manifold
„
„
Exhaust manifold, assembly
overview 26-1, Exhaust
manifold, assembly
overview
Turbocharger Intake
Temperature Sensor , 45 Nm
„
Only on vehicles with engine
code BWF
Charge air system with turbocharger
Cylinder bank 1:
„
Turbocharger (TC) Intake
Temperature Sensor G507
Cylinder bank 2:
„
Turbocharger (TC) Intake
Temperature Sensor 2
G499
„
Securing clamp, 8 Nm
„
Turbocharger
„
„
Can only be replaced when
engine is removed from
engine compartment 10-1,
Engine, removing and
installing , Engine, removing
and installing
„
Tighten oil supply line to 23
Nm
To front exhaust pipe with
catalytic converter
„
Vehicles with engine code
BKW Item - 7 -
„
Vehicles with engine code
BWF Item - 11 -
„
40 Nm
„
Servo motor for turbocharger
„
Component of the
turbocharger cannot be
replaced
Cylinder bank 1:
„
Turbocharger (TC) 1 Servomotor V280
Cylinder bank 2:
„
Turbocharger (TC) 2 Servomotor V281
Page 6 / 9
Charge air system with turbocharger
„
Seal
„
Replace
„
Before installing, check
sealing surfaces for
contamination and clean if
necessary
„
8 Nm
„
Connecting pipe
„
To charge air tube
„
„
„
Item - 8 -
Sealing sleeve
„
Replace if damaged
„
Check for secure seating
Connecting pipe
„
From crankcase ventilation
valve
Charge air cooler components, assembly overview
Note:
„
Various hose connections are secured.
„
If necessary, use lubricant (water without additive) to
assist assembly. Do not use lubricants containing
oil.
„
Charge air system must be properly sealed.
„
With connector couplings, follow the installation
instructions closely 21-1, Hose connections with
connector couplings, installing .
„
Components depicted here correspond to cylinder
bank 2. They are different only as a mirror image of
Page 7 / 9
Charge air system with turbocharger
Page 8 / 9
components for cylinder bank 1.
Observe safety precautions
precautions .
Note rules of cleanliness
„
Air duct
„
8 Nm
„
Spacer bushing
„
Air charge cooler
„
21-1, Safety
21-1, Rules for cleanliness
To remove, remove bumper
cover
Repair Manual, Body Exterior, Repair
Group 63, Front bumper
Charge air system with turbocharger
„
O-ring
„
Replace if damaged
„
3 Nm
„
Charge Air Pressure Sensor G31
with Intake Air Temperature (IAT)
Sensor G42
Cylinder bank 1:
„
Charge Air Pressure Sensor
G31 with Intake Air
Temperature (IAT) Sensor
G42
Cylinder bank 2:
„
Charge Air Pressure Sensor
2 G447 with Intake Air
Temperature (IAT) Sensor 2
G299
„
Charge air pipe
„
Retaining clip
„
„
Check for secure seat
To intake manifold
„
Vehicles with engine code
BKW Item - 1 -
„
Vehicles with engine code
BWF Item - 15 -
„
Connecting hose
„
8 Nm
„
From connecting pipe
„
Item - 11 -
Page 9 / 9
Diesel-Direct Fuel Injection System, servicing
Page 1 / 28
23 - 1
Diesel-Direct Fuel Injection System, servicing
Note:
„
Engine control modules for Diesel-Direct fuel
injection system are equipped with a DTC memory.
Before and after repairs or adjustment work, DTC
memory must be checked 23-2, Diagnostic
Trouble Code (DTC) memory of Engine control
modules (ECM) , checking and erasing ; DTC
memory of Engine Control Modules (ECM) ,
checking and erasing.
23-1, Safety
Observe safety precautions
precautions .
Note rules of cleanliness
23-1, Rules for cleanliness
Intake manifold, removing and installing
manifold, removing and installing
23-1, Intake
Intake connection, assembly overview 23-1, Intake
connection (vehicles with engine code BKW), assembly
overview
„
Vehicles with engine code BKW 23-1, Intake
connection (vehicles with engine code BKW),
assembly overview
„
Vehicles with engine code BWF
23-1, Intake
connection (vehicles with engine code BWF),
assembly overview
Air filter, assembly overview
overview
23-1, Air filter, assembly
Pump-injector unit, assembly overview
injector unit, assembly overview
23-1, Pump-
Pump-injector unit, removing and installing
Pump-Injector Unit, removing and installing
O-rings for pump-injector unit, replacing
rings for pump-injector unit, replacing
23-1,
23-1, O-
Safety precautions
Caution!
When doing any repair work, especially in the engine
Diesel-Direct Fuel Injection System, servicing
compartment, pay attention to the following due to
clearance issues:
„
Route lines of all types (e.g. for fuel, hydraulic,
additive, coolant and refrigerant, brake fluid,
vacuum) and electrical wiring so that the original
path is followed.
„
To prevent damages to the lines, make sure
there is sufficient clearance to all moving or hot
components.
Observe the following if test and measuring instruments
are required during a test drive:
„
Test and measuring instruments must be secured to
rear seat and operated by a 2nd person from this
location.
If test and measuring instruments are operated from the
front passengers seat and the vehicle is involved in an
accident, there is a possibility that the person sitting in this
seat may receive serious injuries when the airbag is
triggered.
Warning!
Secure Scan Tool (ST) on the rear seat and operate it
from there by second technician.
To reduce the risk of personal injury and/or damage to the
fuel injection and glow plug system, always observe the
following:
„
Only disconnect and reconnect wires for glow plug
and fuel injection systems, including test leads,
when ignition is turned off.
„
Obtain radio code for radios with anti-theft coding
before disconnecting battery.
„
The battery must only be disconnected and
connected with the ignition switched off, otherwise
the Engine Control Modules (ECM) could be
damaged.
Rules for cleanliness
Page 2 / 28
Diesel-Direct Fuel Injection System, servicing
When working on the fuel supply/injection system, pay
careful attention to the following "7 rules" of cleanliness:
„
Thoroughly clean all connections and the
surrounding area before disconnecting.
„
Place parts that have been removed on a clean
surface and cover them. Do not use fluffy cloths!
„
Carefully cover over opened components or seal, if
repairs are not performed immediately.
„
Only install clean components: Only unpack
replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in
tool boxes etc.).
„
Supplied transport and protective packaging and
sealing caps should only be removed immediately
before installing.
„
When the system is open: Avoid working with
compressed air if possible. Do not move vehicle
unless absolutely necessary.
„
In addition, do not let diesel fuel flow onto coolant
hoses. If necessary, the hoses must be cleaned
again immediately. Replace corroded hoses.
Intake manifold, removing and installing
Requirements:
Vehicles with engine code BKW
„
Fuel filter unit removed 20-1, Fuel filter (vehicles
with engine code BKW), removing and installing
Vehicles with engine code BWF
„
Bypass flap with cooler for Exhaust Gas
Recirculation (EGR) removed 26-2, Bypass flap
with cooler for Exhaust Gas Recirculation (EGR)
(vehicles with engine code BWF), assembly
overview
Page 3 / 28
Diesel-Direct Fuel Injection System, servicing
Continuation for all vehicles
„
Upper part of oil filter housing removed 17-3, Oil
filter housing, assembly overview , Oil filter housing Assembly overview
Note:
„
Components depicted here correspond to cylinder
bank 2. They are different only as a mirror image of
components for cylinder bank 1.
„
In order to be able to remove intake manifold without
disassembling the fuel rail, intake manifold bolts
must be completely removed.
„
Cylinder head
„
Removing and installing
15-1, Cylinder heads,
Page 4 / 28
Diesel-Direct Fuel Injection System, servicing
removing and installing ,
Cylinder heads, removing
and installing
„
Gasket
„
„
Replace
Intake manifold
Intake connection - Assembly
overview:
„
Vehicles with engine code
BKW 23-1, Intake
connection (vehicles with
engine code BKW),
assembly overview
„
Vehicles with engine code
BWF 23-1, Intake
connection (vehicles with
engine code BWF),
assembly overview
„
20 Nm
„
Fuel rail
„
8 Nm plus an additional 1 / 4 turn
(90
)
„
„
Seal
„
„
„
Replace
Replace
Connecting piece
„
Long
„
For supply
„
Remove and install using
pliers VAS 6275
Connecting piece
„
Short
Page 5 / 28
Diesel-Direct Fuel Injection System, servicing
„
„
For return
„
Remove and install using
pliers VAS 6275
Glow plug , 15 Nm
Cylinder bank 1
„
Glow plugs 1 through 5 Q10
to Q14
Cylinder bank 2
„
Glow plugs 6 through 10
Q15 to Q19
Removing and installing,
checking:
„
Vehicles with engine codes
BKW and BWF 28-1,
Glow plugs vehicles with
engine code BKW, BWF)
removing and installing,
checking
Intake connection (vehicles with engine code BKW),
assembly overview
Note:
„
When engine is switched off, the intake connection
is closed for approx. 3 seconds and then opens
again. This reduces the stop jolt.
„
Components depicted here correspond to cylinder
bank 2. They are different only as a mirror image of
components for cylinder bank 1.
Page 6 / 28
Diesel-Direct Fuel Injection System, servicing
„
Intake connection with intake
flap motor
Cylinder bank 1:
„
Intake Flap Motor V157
Cylinder bank 2:
„
„
8 Nm
„
Seal
Intake Flap Motor 2 V275
„
Replace
„
Before installing, check
sealing surfaces for
contamination and clean if
necessary
Page 7 / 28
Diesel-Direct Fuel Injection System, servicing
„
EGR Vacuum Regulator
Solenoid Valve N18
„
„
Intake manifold
„
„
Checking mechanically
26-2, Exhaust Gas
Recirculation (EGR) valve
(vehicles with engine code
BKW), checking
Removing and installing
23-1, Intake manifold,
removing and installing
Gasket
„
Replace
„
Note installation position
„
20 Nm
„
From exhaust manifold
„
Item - 2 -
„
Connecting pipe
„
Bracket
For connecting pipe
Item - 9 -
Intake connection (vehicles with engine code BWF),
assembly overview
Note:
„
When engine is switched off, the intake connection
is closed for approx. 3 seconds and then opens
again. This reduces the stop jolt.
„
Components depicted here correspond to cylinder
bank 2. They are different only as a mirror image of
components for cylinder bank 1.
Page 8 / 28
Diesel-Direct Fuel Injection System, servicing
„
Test connection bracket
„
Cylinder bank 1
Item - 6 -
„
Cylinder bank 2
Item - 1 -
„
8 Nm
„
Seal
„
„
Replace
„
Before installing, check the
sealing surfaces for
contamination and clean if
necessary
Gasket
„
Replace
Page 9 / 28
Diesel-Direct Fuel Injection System, servicing
„
„
Note installation position
To the bypass flap
Item - 16 -
„
„
Connecting pipe
„
20 Nm
„
From the bypass flap
Item - 17 -
„
„
Bracket
For connecting pipe
-
„
Connecting pipe
„
Connecting pipe
„
8 Nm
„
From exhaust manifold
„
„
Item - 10
Item - 2 -
Intake connection with intake
flap motor
Cylinder bank 1:
„
Intake Flap Motor V157
Cylinder bank 2:
„
„
Intake Flap Motor 2 V275
EGR Vacuum Regulator
Solenoid Valve with EGR
Potentiometer
Cylinder bank 1:
„
EGR Vacuum Regulator
Solenoid Valve N18 with
EGR Potentiometer G212
Cylinder bank 2:
Page 10 / 28
Diesel-Direct Fuel Injection System, servicing
„
Exhaust Gas Recirculation
(EGR) valve 2 N213 with
Exhaust Gas Recirculation
(EGR) Position Sensor
G466
If the Exhaust Gas
Recirculation (EGR) valve with
EGR Potentiometer is replaced,
then do the following:
- Switch ignition on and off.
- Then wait for one minute
for the control module
after-run.
- Start engine and let run at
idle for at least 1 minute.
- Then, check the DTC
memory of the engine
control module (ECM)
23-2, Diagnostic Trouble
Code (DTC) memory of
Engine control modules
(ECM) , checking and
erasing , DTC memory of
engine control module
(ECM) , checking and
erasing.
If a fault is stored in DTC
memory:
- Repeat work procedure.
„
Intake manifold
„
Removing and installing
23-1, Intake manifold,
removing and installing
Air filter, assembly overview
Note:
Page 11 / 28
Diesel-Direct Fuel Injection System, servicing
„
The spring-type clip pliers VAS 5024 A are
recommended for installing spring-type clips.
„
Components depicted here correspond to cylinder
bank 2. They are different only as a mirror image of
components for cylinder bank 1.
„
Line connection to compressor for air suspension
23-1, Line connection to compressor for air
suspension
Page 12 / 28
Diesel-Direct Fuel Injection System, servicing
„
Lower section of air filter
„
Filter element
„
Upper section of air filter
„
Securing pins
„
„
Removing and installing
23-1, Removing and
installing securing pins
O-ring
„
Replace if damaged
„
Intake manifold
„
Mass air flow (MAF) sensor
Cylinder bank 1:
Page 13 / 28
Diesel-Direct Fuel Injection System, servicing
„
Mass air flow (MAF) sensor
G70
Cylinder bank 2:
„
Mass Air Flow (MAF) Sensor
2 G246
„
6 Nm
„
Spring-type clip
„
Use pliers for spring-type
clamps VAS 5024 A to
remove and install
„
Transition piece
„
Connecting pipe
„
Connecting hose
„
To turbocharger
Removing and installing securing pins
Removing
- Using an appropriate socket, turn securing pins until
markings - A - on pins and - B - on housing align.
- Remove pins upward.
Installing
- Press pins into holes up to stop and twist them approx.
180 using an appropriate socket.
Page 14 / 28
Diesel-Direct Fuel Injection System, servicing
Line connection to compressor for air suspension
- Using a screwdriver - C - , pry off green sealing ring - 1
- from line flange - 3 - .
- Press securing sleeve - 2 - in direction of - arrow - and
disconnect line - B - from air filter connection - A - .
Pump-injector unit, assembly overview
Note rules of cleanliness
23-1, Rules for cleanliness
Note:
„
Always replace seals and O-rings.
Page 15 / 28
Diesel-Direct Fuel Injection System, servicing
„
20 Nm plus an additional 1 / 4
turn (90
„
)
Replace
„
Lock nut, 30 Nm
„
Adjustment screw
„
„
Replace with each
separation from ball pin
Rocker arm axle
„
With rocker arm
„
Removing and installing
23-1, Pump-Injector Unit,
removing and installing ,
removing and installing
Page 16 / 28
Diesel-Direct Fuel Injection System, servicing
Pump-Injector Unit
„
Tension block
„
12 Nm plus an additional 3 / 4
turn (270
„
„
„
„
Removing and installing
23-1, Pump-Injector Unit,
removing and installing
„
Replace ball pins when
separating from adjusting
screw
O-ring
Replace 23-1, O-rings for
pump-injector unit,
replacing
Heat protection seal
„
„
Replace
Pump-Injector Unit
„
„
)
Replace
Circlip
Pump-Injector Unit, removing and installing
Page 17 / 28
Diesel-Direct Fuel Injection System, servicing
Special tools, testers and auxiliary items
required
„
Dial gauge holder VW 387
„
Multi-point socket 3410
„
Multi-point socket T10054
„
Puller T10055
„
Torque wrench (5 to 50 Nm) V.A.G
1331
Not illustrated:
„
Gauge T10210
Page 18 / 28
Diesel-Direct Fuel Injection System, servicing
„
Dial gauge
Removing
- Remove acoustic cover and cylinder head cover of the
applicable cylinder head.
- Rotate crankshaft until cam pair of respective PumpInjector Unit to be installed and removed face upward
simultaneously.
- Loosen lock nuts of adjustment bolts - 1 - and unscrew
adjustment bolts as far until respective rocker arm makes
contact at plunger spring of Pump-Injector Unit.
- Loosen bolts - 2 - for rocker lever shaft from the outside
toward the inside, using the socket insert 3410 and
remove the rocker lever shaft.
- Loosen mounting bolt - 3 - for tension block using socket
insert T10054 and remove tension block.
- Pry out connector from Pump-Injector Unit using a
screwdriver. In order to avoid canting, support opposite
side of connector with light finger pressure.
Page 19 / 28
Diesel-Direct Fuel Injection System, servicing
- Insert puller T10055 in place of tension block into side
slit of pump-injector unit.
- Using careful knocking motions, pull Pump-Injector Unit
upward out of its cylinder head seat.
Installing
Note:
„
Install a new pump-injector unit, and also replace the
corresponding adjustment bolt in rocker arm.
„
For every procedure that requires adjustment of the
pump-injector unit, the adjustment screw in the
rocker lever and the ball pin of the pump-injector unit
must be replaced.
„
New Pump-Injector Units are shipped with O-rings
and heat protection seal.
- Install pump-injector unit again, replace O-rings and heat
protection seal 23-1, O-rings for pump-injector unit,
replacing .
- Before installing Pump-Injector Unit, check that the three
sealing rings, heat protection seal and securing ring are
seated properly.
Note:
„
Sealing rings must not be twisted on themselves.
Page 20 / 28
Diesel-Direct Fuel Injection System, servicing
- Oil sealing rings and insert Pump-Injector Unit with great
care into cylinder head seat.
- Drive Pump-Injector Unit in using uniform pressure into
cylinder head seat until stop.
- Insert tension block into lateral slot of Pump-Injector Unit.
Note:
„
If Pump-Injector Unit does not stand at right angle to
tension block, securing bolt can loosen and thereby
cause damage to Pump-Injector Unit / cylinder head.
Align pump-injector unit as follows:
- Screw new bolt into tension block so far that the pumpinjector unit can still be lightly turned.
- Insert gauge T10210 between thrust bearing and PumpInjector Unit as shown.
- Turn pump-injector unit against gauge by hand.
- Re-align pump-injector unit if necessary and tighten
securing bolt as follows: 12 Nm plus an additional 3 / 4 turn
(270 ) further (additional rotation can occur in several
stages).
- Install rocker arm axle and tighten new mounting bolts as
follows.
- Tighten first inner and then both outer bolts by hand.
Then, in the same sequence to 20 Nm plus an additional
1 / turn (90
) further.
4
Page 21 / 28
Diesel-Direct Fuel Injection System, servicing
- Place a dial gauge as shown onto adjustment screw of
pump-injector unit.
- Rotate crankshaft in direction of engine rotation until
rocker arm roller stands at camshaft point.
„
Roller side - arrow A - is positioned at highest
point
„
Dial gauge - arrow B - is positioned at lowest point
- Remove dial gauge .
- Thread adjusting screw into rocker arm against spring
force of pump-injector unit until significant resistance is
detected (pump-injector unit is positioned at stop).
- Turn back adjustment bolt from stop approx. 180
- Hold adjustment bolt in this position and tighten lock nut
to 30 Nm.
- Connect connector of the pump-injector unit and install
cylinder head cover and acoustic cover.
Position of pump pistons in pump injector units,
checking and adjusting
Page 22 / 28
Diesel-Direct Fuel Injection System, servicing
Special tools, testers and auxiliary items
required
„
Clamping device T10199
„
Socket XZN16 T10198
„
Crankshaft anchor T10195
„
Multi-point socket T10336
„
Dial gauge holder VW 387
„
Dial Gauge Set, 4-part VAS 6341
Requirement:
Page 23 / 28
Diesel-Direct Fuel Injection System, servicing
„
Engine removed
Work procedure
- Remove acoustic cover and cylinder head cover of the
applicable cylinder head.
- Remove fuel or tandem pump from respective cylinder
head 20-1, Tandem pump and Fuel Pump (FP),
removing and installing .
- Rotate engine with Counterhold Tool Touareg V10
T10172 to TDC 15-1, Valve timing, checking and
remove vibration damper
13-4, Front sealing flange and
vibration damper, assembly overview .
- Install Camshaft Tool T10195 .
- Position dial gauge from Dial Gauge Set, 4-part VAS
6341 using Dial Gauge Holder VW 387 and approx. 1 mm
pre-tension as shown on pump injector unit spring seat.
- Remove Camshaft Tool T10195 pin and rotate engine
opposite engine rotation direction until dial gauge needle
no longer moves.
- Set dial gauge to "0" .
- Now turn motor again in direction of rotation to TDC and
Page 24 / 28
Diesel-Direct Fuel Injection System, servicing
Page 25 / 28
insert camshaft tool securing pin.
- Read out value on dial gauge.
Specified values
„
Engine code BKW: 5.18 mm
0.1 mm
„
Engine code BWF: 4.95 mm
0.1 mm
If specified value is not achieved:
- Complete engine.
If specification is not obtained:
- Remove outer bearing cap - A - , place clamping device
T10199 on camshaft gear and tighten its bolt to 40 Nm.
- Loosen camshaft gear bolt - B - using Socket XZN16
T10198 .
- Rotate camshaft with Socket T10336 until specified
value is reached.
- Tighten camshaft to 150 Nm and repeat measurement.
- If specified value is now reached, tighten camshaft gear
threaded connection an additional 90 .
- Reinstall cylinder head cover
15-1, Tightening
sequence of bolts for cylinder head cover as well as
acoustic cover.
O-rings for pump-injector unit, replacing
Special tools, testers and auxiliary items required
Diesel-Direct Fuel Injection System, servicing
„
Assembly sleeve T10056
Removing
- Remove pump-injector unit
removing and installing .
23-1, Pump-Injector Unit,
- Pry off old O-rings from Pump-Injector Unit extremely
carefully.
- Above all, make sure that no burrs develop at O-ring
seat.
Installing
Note:
„
Always use assembly sleeves T10056 for installing
O-rings. Not using them may cause the O-rings to be
damaged during installation.
„
O-rings without distinguishing color markings are
gradually introduced. Ensure the correct allocation of
O-rings to grooves: ring strength decreases in
direction toward injector.
„
Avoid rolling movements when sliding on O-rings. Orings must not be twisted on itself in the seat of
Pump-Injector Unit.
- Pull off heat protection seal together with securing ring.
- Clean seating surfaces for O-rings on Pump-Injector Unit
very carefully.
Page 26 / 28
Diesel-Direct Fuel Injection System, servicing
Page 27 / 28
Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru
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- Insert assembly sleeve T10056/1 up to stop on PumpInjector Unit.
- Slide upper, thicker O-ring carefully on assembly sleeve
and into seat of Pump-Injector Unit.
- Remove assembly sleeve.
- Insert assembly sleeve T10056/2 up to stop on PumpInjector Unit.
- Slide center, thinner O-ring carefully onto assembly
sleeve and into seat of pump-injector unit.
- Remove assembly sleeve.
- Insert assembly sleeve T10056/3 up to stop on Pump-
Diesel-Direct Fuel Injection System, servicing
Injector Unit.
- Slide lower O-ring carefully on assembly sleeve and into
seat of Pump-Injector Unit.
- Remove assembly sleeve.
- Slide on a new heat protection seal together with
securing ring.
- Install pump-injector unit
removing and installing .
23-1, Pump-Injector Unit,
Page 28 / 28
Engine Control Modules (ECM)
Page 1 / 5
23 - 2
Engine Control Modules (ECM)
Note:
„
Engine control modules for Diesel-Direct fuel
injection system are equipped with a DTC memory.
Before and after repairs or adjustment work, DTC
memory must be checked 23-2, Diagnostic
Trouble Code (DTC) memory of Engine control
modules (ECM) , checking and erasing ; DTC
memory of Engine Control Modules (ECM) ,
checking and erasing.
Observe safety precautions
precautions .
23-1, Safety
DTC memory of Engine control modules (ECM) ,
checking and erasing 23-2, Diagnostic Trouble Code
(DTC) memory of Engine control modules (ECM) ,
checking and erasing
Adapting functions and components
and adapting components
23-2, Functions
Engine Control Modules (ECM) , removing and
installing 23-2, Engine Control Modules (ECM) ,
removing and installing
Diagnostic Trouble Code (DTC) memory of Engine
control modules (ECM) , checking and erasing
Special tools, testers and auxiliary items required
„
Vehicle Diagnostic, Testing and Information System
VAS 5051 A with diagnostic cable
Work procedure
Engine Control Modules (ECM)
Connect vehicle diagnosis, testing and information system
VAS 5051 A as follows:
- Open cover - 1 - (if equipped) and connect connector of
diagnostic cable to the Data Link Connector (DLC).
- Start engine and run at idle speed.
Only when engine does not start:
- Switch ignition on.
Selecting operating mode:
- Press button on display for "Vehicle Self-Diagnosis" .
Selecting vehicle system:
- Press "01 - Engine electronics" on display to check
Engine Control Module (ECM) J623 for cylinder bank 1, or
"11 - Engine electronics 2" on display to check Engine
Control Module (ECM) 2 J624 for cylinder bank 2.
The control module identification with code - 2 - of engine
control module , as well as chassis number and
immobilizer identification number will be indicated on the
display.
Note:
Page 2 / 5
Engine Control Modules (ECM)
„
A print-out is available. Press Print button if
required.
Selecting diagnosis function:
- Press button "02 - Check DTC memory" on display.
- If no DTC is stored in engine control module "0
malfunction(s) detected" is displayed.
- If DTCs are stored in engine control module , these are
shown one below the other on the display.
- Press
key.
- Press button "05 - Erase DTC memory" on display.
- Press function "06 - End output" .
Functions and adapting components
Special tools, testers and auxiliary items required
„
Vehicle Diagnostic, Testing and Information System
VAS 5051 A with diagnostic cable
Work procedure
Connect vehicle diagnosis, testing and information system
VAS 5051 A as follows:
Page 3 / 5
Engine Control Modules (ECM)
- Open cover - 1 - (if equipped) and connect connector of
diagnostic cable to the Data Link Connector (DLC).
On Vehicle diagnostic, testing, and information system
VAS 5051 A , select "Guided Fault Finding" .
After all control modules have been checked:
- Press "Go to" button.
- Select "Function/component selection" .
- Select "powertrain" .
- Select "engine code" .
- Select "01-Systems capable of self-diagnosis" .
- Select "engine management system" .
- Select "Functions" .
- Select "Function or component" .
Engine Control Modules (ECM) , removing and installing
Caution!
This vehicle is equipped with two Engine Control
Modules (ECM) which cannot be visually distinguished
from each other. If engine control modules are
installed interchanged, the DTC memories are not
detected. Therefore it is recommended to mark the
engine control modules , as well as their
corresponding harness connectors, before removing
in order to prevent interchanging the engine control
modules .
- Before removing Engine Control Modules (ECM) , the
control module identification and with it also the coding of
the previous control module must be checked 23-2,
Diagnostic Trouble Code (DTC) memory of Engine control
Page 4 / 5
Engine Control Modules (ECM)
modules (ECM) , checking and erasing ; DTC memory of
Engine Control Module (ECM), checking and erasing.
Work procedure
- Switch off ignition.
- Remove right plenum chamber cover - D - .
- Release and disconnect connector of engine control
module - 1 - and/or - 2 - .
- Remove old control module and install new control
module.
- Verify old coding and code new control module 23-2,
Functions and adapting components ; Adapting functions
and components.
- Check DTC memory of new Engine Control Module
(ECM) and erase if necessary 23-2, Functions and
adapting components ; DTC memory of Engine Control
Module (ECM) , checking and erasing.
- Perform test drive.
- Again, check engine control module DTC memory.
Page 5 / 5
Exhaust system components, removing and installing
Page 1 / 18
26 - 1
Exhaust system components, removing and
installing
Special tools, testers and auxiliary items required
„
Ring spanner 7-piece set 3337
Caution!
When doing any repair work, especially in the engine
compartment, pay attention to the following due to
clearance issues:
„
Route lines of all types (e.g. for fuel, hydraulic,
additive, coolant and refrigerant, brake fluid,
vacuum) and electrical wiring so that the original
path is followed.
„
To prevent damages to the lines, make sure
there is sufficient clearance to all moving or hot
components.
Note:
„
After exhaust system repairs, make sure exhaust
system is not under stress and that it has sufficient
clearance from the body. If necessary, loosen
double clamps and clamp and align exhaust pipe so
that sufficient clearance is maintained to the body
and support rings carry uniform loads.
„
Always replace self-locking nuts.
„
Do not use sealants containing silicone. Particles of
silicone drawn into the engine, will not be burned in
Exhaust system components, removing and installing
the engine and damage the oxygen sensor .
Exhaust manifold, assembly overview
manifold, assembly overview
26-1, Exhaust
Front exhaust pipe with catalytic converter and
attachments, assembly overview 26-1, Front exhaust
pipe with catalytic converter and attachments (vehicles with
engine code BKW), assembly overview
Muffler with mountings, assembly overview:
„
Vehicles with engine code BKW 26-1, Muffler with
mountings (vehicles with engine code BKW),
assembly overview
„
Vehicles with engine code BWF
26-1, Muffler with
mountings (vehicles with engine code BWF),
assembly overview
Exhaust manifold, assembly overview
Note:
„
Components depicted here correspond to cylinder
bank 2. They are different only as a mirror image of
components for cylinder bank 1.
Page 2 / 18
Exhaust system components, removing and installing
„
Cylinder head
„
Exhaust manifold
„
„
Can only be replaced when
engine is removed from
engine compartment 10-1,
Engine, removing and
installing , Engine, removing
and installing
Turbocharger (TC) Intake
Temperature Sensor , 45 Nm
„
Only on vehicles with engine
code BWF
Cylinder bank 1:
„
Turbocharger (TC) Intake
Temperature Sensor G507
Page 3 / 18
Exhaust system components, removing and installing
Cylinder bank 2:
„
„
Turbocharger (TC) Intake
Temperature Sensor 2
G499
To turbocharger
Item - 5 -
„
„
Spacer piece
„
23 Nm
„
Replace
„
Observe tightening
sequence 26-1,
Tightening sequence of nuts
for exhaust manifold
„
4.5 Nm
„
Heat shield
„
To connecting pipe
„
„
Vehicles with engine code
BKW Item - 12 -
„
Vehicles with engine code
BWF Item - 11 -
Gasket
„
Replace
„
Note installation position
Page 4 / 18
Exhaust system components, removing and installing
Tightening sequence of nuts for exhaust manifold
- Tighten nuts in the tightening sequence shown as
follows:
„
Pre-tighten all nuts to 5 Nm
„
Then tighten all nuts to 23 Nm
Front exhaust pipe with catalytic converter and
attachments (vehicles with engine code BKW), assembly
overview
Note:
„
Components depicted here correspond to cylinder
bank 2. They are different only as a mirror image of
components for cylinder bank 1.
Page 5 / 18
Exhaust system components, removing and installing
„
Turbocharger
„
„
Turbocharger, Assembly
overview 21-1,
Turbocharger, assembly
overview
Gasket
„
Replace
„
25 Nm
„
25 Nm
„
Connector
„
For Heated oxygen sensor
(HO2S) and Oxygen sensor
(O2S) heater
Page 6 / 18
Exhaust system components, removing and installing
Cylinder bank 1:
„
Connector (black)
Cylinder bank 2:
„
„
Connector (brown)
Heated Oxygen Sensor (HO2S) ,
50 Nm
„
Can only be replaced with
the engine removed 10-1,
Engine, removing and
installing
„
Grease only threads with
High-temperature lubricant G
052 112 A3 (anti-seize
compound). Hightemperature lubricant G 052
112 A3 must not get into
slots on sensor body.
„
To remove, use ring wrench
for oxygen sensor 3337
Cylinder bank 1:
„
Oxygen sensor G39
Cylinder bank 2:
„
„
Heated Oxygen Sensor
(HO2S) 2 G108
Front exhaust pipe with catalytic
converter
„
Can only be replaced with
the engine removed 10-1,
Engine, removing and
installing
„
Catalytic converter
„
Suspended mount
„
Bracket
Front exhaust pipe with catalytic converter, particle filter
and attachments, vehicles with engine code BLE and
Page 7 / 18
Exhaust system components, removing and installing
BWF, Assembly overview
Note:
„
Components depicted here correspond to cylinder
bank 2. They are different only as a mirror image of
components for cylinder bank 1.
„
Turbocharger
„
„
Gasket
„
„
Turbocharger - Assembly
overview 21-1,
Turbocharger, assembly
overview
Replace
25 Nm
Page 8 / 18
Exhaust system components, removing and installing
„
Heated Oxygen Sensor (HO2S) ,
50 Nm
„
Can only be replaced with
the engine removed 10-1,
Engine, removing and
installing
„
Grease only threads with hot
bolt paste G 052 112 A3
(anti-seize compound). Hot
bolt paste G 052 112 A3
must not get into slots on
sensor body.
„
To remove, use ring wrench
for oxygen sensor 3337
Cylinder bank 1:
„
Oxygen sensor G39
Cylinder bank 2:
„
„
Heated Oxygen Sensor
(HO2S) 2 G108
Pre-Particle Filter Temperature
Sensor , 45 Nm
Cylinder bank 1:
„
Pre-Particle Filter
Temperature Sensor G506
Cylinder bank 2:
„
„
Particle Filter Intake
Temperature Sensor 2
G498
Pressure line
„
Ensure seated tightly
Cylinder bank 1:
„
To exhaust pressure sensor
1 G450
Cylinder bank 2:
„
To exhaust pressure sensor
2 G451
Page 9 / 18
Exhaust system components, removing and installing
„
To rear muffler
Item - 9 -
„
„
Transmission crossmember
„
Suspended mount
„
Particle filter
„
„
„
after replacing, the
adaptation of the soot load
measurement must be set to
"0" Vehicle Diagnosis,
Testing and Information
System VAS 5051
Front exhaust pipe with catalytic
converter
„
Can only be replaced when
engine is removed from
engine compartment 10-1,
Engine, removing and
installing , Engine, removing
and installing
„
with engine code BWF with
metering pump connecting
pieces at catalytic converter
26-1, Post-injection
metering pump, engine code
BWF
Bracket
Post-injection metering pump, engine code BWF
Metering pumps are secured on subframe and inject diesel
fuel behind catalytic converters. The goal is to increase the
exhaust temperature in order to burn the particle filter.
- 1 - : Bank 2 Particle Filter Post-Injection Metering
Pump V337
Page 10 / 18
Exhaust system components, removing and installing
Page 11 / 18
- 2 - : Bank 1 Particle Filter Post-Injection Metering
Pump V336
Metering pumps, securing
„
- A - : Bolts, tightening torque 9 Nm
„
- B - : To cylinder bank 2 catalytic converter
Metering pumps, connecting line
„
- C - : From fuel tank
„
- D - : To cylinder bank 1 catalytic converter
Metering pumps, connecting line
Metering Pumps for Post-injection in Particle Filter
Metering pumps, connecting line
26-1,
26-1,
Exhaust system components, removing and installing
The metering pump fuel line is secured directly behind the
catalytic converter in order to utilize its exhaust
temperature.
Muffler with mountings (vehicles with engine code BKW),
assembly overview
„
Double clamp
Page 12 / 18
Exhaust system components, removing and installing
Threads M8:
„
Fasten evenly to 25 Nm
Threads M10:
„
Fasten evenly to 40 Nm
„
Center muffler
„
Suspended mount
„
25 Nm
„
Rear muffler
„
„
As standard, center and rear
mufflers are installed as a
single component. In cases
of repair, the center and rear
muffler are supplied
individually and with a
double clamp for connecting.
„
Cut through connecting pipe
with body repair saw V.A.G
1523A at right angles at
separating point 26-1,
Separating points between
center muffler and rear
muffler
End pipe
„
„
„
„
Align in bumper cutout
Clamp
„
Fasten to 60 Nm
„
Note installation position
Dimension - a - = approx. 10 mm
„
Exhaust system must be
cold
„
Arrow points in direction of
travel
Repair double clamp
Page 13 / 18
Exhaust system components, removing and installing
„
„
„
„
„
Double clamp viewed in
direction of travel
„
Note installation position
Repair double clamp
„
Double clamp viewed in
direction of travel
„
Note installation position
Dimension - a - = approx. 4 mm
„
Exhaust system must be
cold
„
Arrow points in direction of
travel
Double clamp
„
Bolt heads must point toward
transmission
„
Note installation position
Suspended mount
Separating points between center muffler and rear muffler
Special tools, testers and auxiliary items required
„
Body repair saw V.A.G 1523A
Page 14 / 18
Exhaust system components, removing and installing
Work procedure
- Separate connecting pipes at a right angle between
center muffler and rear muffler at the locations marked with
a groove:
„
Dimension - a - approx. 510 mm
„
Dimension - b - approx. 535 mm
Muffler with mountings (vehicles with engine code BWF),
assembly overview
„
Suspended mount
„
„
Right, in driving direction
Particle filter
„
Right, in driving direction
Page 15 / 18
Exhaust system components, removing and installing
Item - 10 „
Double clamp
„
Right, in driving direction
Threads M8:
„
Fasten evenly to 25 Nm
Threads M10:
„
„
Particle filter
„
„
Fasten evenly to 40 Nm
Left, in driving direction
Item - 10 -
Double clamp
„
Left, in driving direction
Threads M8:
„
Fasten evenly to 25 Nm
Threads M10:
„
Fasten evenly to 40 Nm
„
25 Nm
„
Suspended mount
„
„
Left, in driving direction
Repair double clamp
„
Left, in driving direction
Threads M8:
„
Fasten evenly to 25 Nm
Threads M10:
„
Fasten evenly to 40 Nm
„
Rear muffler
„
Suspended mount
Page 16 / 18
Exhaust system components, removing and installing
„
„
„
„
„
„
„
„
Left, in driving direction
End pipe
„
Left, in driving direction
„
Align in bumper cutout
Dimension - a - = approx. 10 mm
„
Exhaust system must be
cold
„
Arrow points in direction of
travel
Clamp
„
Fasten to 60 Nm
„
Note installation position
Dimension - a - = approx. 4 mm
„
Exhaust system must be
cold
„
Arrow points in direction of
travel
End pipe
„
Right, in driving direction
„
Align in bumper cutout
Repair double clamp
„
Double clamp viewed in
direction of travel
„
Note installation position
Repair double clamp
„
Double clamp viewed in
direction of travel
„
Note installation position
Page 17 / 18
Exhaust system components, removing and installing
„
„
Double clamp
„
Bolt heads must point toward
transmission
„
Note installation position
Suspended mount
„
„
Right, in driving direction
Repair double clamp
„
Right, in driving direction
Threads M8:
„
Fasten evenly to 25 Nm
Threads M10:
„
„
Fasten evenly to 40 Nm
Separating point
„
For repairs
„
Marked by two grooves
around circumference of
respective exhaust pipe
„
At factory, exhaust pipe and
rear mufflers are installed as
a single component.
Replacement exhaust pipe
and rear muffler are supplied
separately, with replacement
double clamp for connecting
joint
„
Cut through exhaust pipes
with body repair saw V.A.G
1523A at right angles at
separating point
Page 18 / 18
Exhaust Gas Recirculation (EGR) system
Page 1 / 18
26 - 2
Exhaust Gas Recirculation (EGR) system
Observe safety precautions
precautions .
Note rules of cleanliness
26-2, Safety
26-2, Rules for cleanliness
Exhaust Gas Recirculation (EGR), assembly overview:
„
Vehicles with engine code BKW 26-2, Exhaust
Gas Recirculation (EGR) (vehicles with engine code
BKW), assembly overview
„
Vehicles with engine code BWF
26-2, Exhaust
Gas Recirculation (EGR) (vehicles with engine code
BWF), assembly overview
Bypass flap with cooler for Exhaust Gas Recirculation
(EGR) - Assembly overview (Vehicles with engine code
BWF) 26-2, Bypass flap with cooler for Exhaust Gas
Recirculation (EGR) (vehicles with engine code BWF),
assembly overview
Connection diagram for vacuum hoses:
„
Vehicles with engine code BKW 26-2, Vacuum
hose connection diagram (vehicles with engine code
BKW)
„
Vehicles with engine code BWF
26-2, Vacuum
hose connection diagram (vehicles with engine
codes BWF)
Exhaust Gas Recirculation (EGR) valve (vehicles with
engine code BKW) , checking 26-2, Exhaust Gas
Recirculation (EGR) valve (vehicles with engine code
BKW), checking
Safety precautions
Caution!
When doing any repair work, especially in the engine
compartment, pay attention to the following due to
clearance issues:
„
Route lines of all types (e.g. for fuel, hydraulic,
additive, coolant and refrigerant, brake fluid,
vacuum) and electrical wiring so that the original
Exhaust Gas Recirculation (EGR) system
path is followed.
„
To prevent damages to the lines, make sure
there is sufficient clearance to all moving or hot
components.
Rules for cleanliness
When working on the exhaust gas recirculation (EGR)
system, pay careful attention to the following "7 rules" of
cleanliness:
„
Thoroughly clean all connections and the
surrounding area before disconnecting.
„
Place parts that have been removed on a clean
surface and cover them. Do not use fluffy cloths!
„
Carefully cover over opened components or seal, if
repairs are not performed immediately.
„
Only install clean components: Only unpack
replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in
tool boxes etc.).
„
Supplied transport and protective packaging and
sealing caps should only be removed immediately
before installing.
„
During repair, clean oil from connections and hose
ends.
„
When the system is open: Avoid working with
compressed air if possible. Do not move vehicle
unless absolutely necessary.
Exhaust Gas Recirculation (EGR) (vehicles with engine
code BKW), assembly overview
Note:
„
Exhaust gas recirculation is controlled by Engine
Control Module (ECM) J623 and Engine Control
Page 2 / 18
Exhaust Gas Recirculation (EGR) system
Page 3 / 18
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Module (ECM) 2 J624 via EGR Vacuum Regulator
Solenoid Valve N18 (electro-pneumatic) and EGR
Valve 2 N213 (electro-pneumatic) to the mechanical
exhaust gas recirculation valves.
„
The mechanical EGR valve with cone-shaped valve
plunger makes different opening diameters possible
at different valve lift.
„
Components depicted here correspond to cylinder
bank 2. They are different only as a mirror image of
components for cylinder bank 1.
„
Intake connection with intake
flap motor
Cylinder bank 1:
„
Intake Flap Motor V157
Exhaust Gas Recirculation (EGR) system
Cylinder bank 2:
„
„
8 Nm
„
Seal
„
„
Replace
„
Before installing, check the
sealing surfaces for
contamination and clean if
necessary
EGR Vacuum Regulator
Solenoid Valve
„
„
Intake Flap Motor 2 V275
Checking mechanically
26-2, Exhaust Gas
Recirculation (EGR) valve
(vehicles with engine code
BKW), checking
Intake manifold
„
Removing and installing
23-1, Intake manifold,
removing and installing
„
20 Nm
„
Gasket
„
Replace
„
Note installation position
„
8 Nm
„
Exhaust manifold
„
Exhaust manifold, assembly
overview 26-1, Exhaust
manifold, assembly
overview
„
8 Nm
„
20 Nm
Page 4 / 18
Exhaust Gas Recirculation (EGR) system
„
Connecting pipe
Exhaust Gas Recirculation (EGR) (vehicles with engine
code BWF), assembly overview
Note:
„
Activation of the Exhaust Gas Recirculation (EGR)
system occurs from Engine Control Module (ECM)
J623 and Engine Control Module 2 J624 via the
EGR Potentiometer G212 and the EGR Position
Sensor G466 .
„
Components depicted here correspond to cylinder
bank 2. They are different only as a mirror image of
components for cylinder bank 1.
„
Bypass flap with cooler for Exhaust Gas
Recirculation (EGR), assembly overview 26-2,
Bypass flap with cooler for Exhaust Gas
Recirculation (EGR) (vehicles with engine code
BWF), assembly overview .
Page 5 / 18
Exhaust Gas Recirculation (EGR) system
„
Test connection bracket
„
Cylinder bank 1:
Item - 6 -
„
Cylinder bank 2:
Item - 1 -
„
8 Nm
„
Seal
„
„
Replace
„
Before installing, check the
sealing surfaces for
contamination and clean if
necessary
Gasket
„
Replace
Page 6 / 18
Exhaust Gas Recirculation (EGR) system
„
„
Note installation position
To the bypass flap
Item - 16 -
„
„
Connecting pipe
„
20 Nm
„
From the bypass flap
Item - 17 -
„
„
Bracket
For connecting pipe
-
„
Connecting pipe
„
Connecting pipe
„
8 Nm
„
To turbocharger
„
„
Item - 5 -
Exhaust manifold
„
„
Item - 10
Exhaust manifold, assembly
overview 26-1, Exhaust
manifold, assembly
overview
Intake connection with intake
flap motor
Cylinder bank 1:
„
Intake Flap Motor V157
Cylinder bank 2:
„
„
Intake Flap Motor 2 V275
EGR Vacuum Regulator
Solenoid Valve with EGR
Potentiometer
Page 7 / 18
Exhaust Gas Recirculation (EGR) system
Cylinder bank 1:
„
EGR Vacuum Regulator
Solenoid Valve N18 (electropneumatic) with EGR
Potentiometer G212
Cylinder bank 2:
„
EGR Valve 2 N213 (electropneumatic) with Exhaust
Gas Recirculation (EGR)
Position Sensor G466
If EGR Vacuum Regulator
Solenoid Valve is replaced with
EGR Potentiometer , you must
then:
- Switch ignition on and off.
- Then wait for one minute
for the control module
after-run.
- Start engine and let run at
idle for at least 1 minute.
- Then, check the DTC
memory of the engine
control module (ECM)
23-2, Diagnostic Trouble
Code (DTC) memory of
Engine control modules
(ECM) , checking and
erasing , DTC memory of
engine control module
(ECM) , checking and
erasing.
If a DTC is stored in DTC
memory:
- Repeat work procedure.
„
Intake manifold
„
Removing and installing
23-1, Intake manifold,
removing and installing
Page 8 / 18
Exhaust Gas Recirculation (EGR) system
Bypass flap with cooler for Exhaust Gas Recirculation
(EGR) (vehicles with engine code BWF), assembly
overview
Note:
„
Hose connections are secured with either springtype or clamp-type clips.
„
Always replace clamps.
„
The spring-type clip pliers VAS 5024 A are
recommended for installing spring-type clips.
„
Exhaust Gas Recirculation (EGR), assembly
overview 26-2, Exhaust Gas Recirculation (EGR)
(vehicles with engine code BWF), assembly
overview .
Page 9 / 18
Exhaust Gas Recirculation (EGR) system
„
8 Nm
„
Vacuum tube
„
Vacuum line
„
„
For cylinder bank 2
„
Ensure seated tightly
„
To Exhaust Gas
Recirculation (EGR) Cooler
Switch-Over Valve 2 N381
„
Connection diagram for
vacuum hoses 26-2,
Vacuum hose connection
diagram (vehicles with
engine codes BWF)
Vacuum hose
Page 10 / 18
Exhaust Gas Recirculation (EGR) system
„
„
For cylinder bank 1
„
Ensure seated tightly
„
To Exhaust Gas
Recirculation (EGR) Cooler
Switch-Over Valve N345
„
Connection diagram for
vacuum hoses 26-2,
Vacuum hose connection
diagram (vehicles with
engine codes BWF)
Coolant hose
„
Between cooler for Exhaust
Gas Recirculation (EGR)
and bypass flap
„
Ensure seated tightly
„
40 Nm
„
Coolant hose
„
Ensure seated tightly
„
Use pliers for spring-type
clamps VAS 5024 A to
remove and install
„
5 Nm
„
Coolant line
„
Bracket
„
For coolant pipe
„
20 Nm
„
Coolant hose
Item - 9 -
„
Ensure seated tightly
„
Use pliers for spring-type
clamps VAS 5024 A to
remove and install
„
To heat exchanger for heater
unit
Page 11 / 18
Exhaust Gas Recirculation (EGR) system
„
„
„
„
„
„
Vacuum actuator
„
For cylinder bank 1
„
Check operation with hand
vacuum pump V.A.G 1390
at vacuum connection
Connecting pipe
„
For cylinder bank 1
„
from EGR Vacuum
Regulator Solenoid Valve
N18 (electro-pneumatic) with
EGR Potentiometer G212
Item - 16 -
Connecting pipe
„
For cylinder bank 1
„
To connecting pipe of
exhaust manifold Item 11 -
Connecting pipe
„
For cylinder bank 2
„
From EGR Valve 2 N213
(electro-pneumatic) with
Exhaust Gas Recirculation
(EGR) Position Sensor
G466
Item - 16 -
Connecting pipe
„
For cylinder bank 2
„
To connecting pipe of
exhaust manifold Item 11 -
Gasket
„
Replace
„
Note installation position
Page 12 / 18
Exhaust Gas Recirculation (EGR) system
„
„
Bracket
„
For bypass-flap
-
„
Fastened to cylinder block
Bypass-flap
„
„
„
Remove and install together
with cooler for exhaust gas
recirculation ( Item - 25 )
Vacuum actuator
„
For cylinder bank 2
„
Check operation with hand
vacuum pump V.A.G 1390
at vacuum connection
Ball pin, 3 Nm
„
Fastened to flange of
generator
„
Rubber bushing
„
Bracket
„
„
For cooler for Exhaust Gas
Recirculation (EGR) Item
- 25 -
Cooler for Exhaust Gas
Recirculation (EGR)
„
„
Item - 20
Remove and install together
with bypass flap ( Item 20 - )
Coolant hose
„
Ensure seated tightly
„
Use pliers for spring-type
clamps VAS 5024 A to
remove and install
Page 13 / 18
Exhaust Gas Recirculation (EGR) system
„
From coolant pipe
Vacuum hose connection diagram (vehicles with engine
code BKW)
„
EGR Vacuum Regulator
Solenoid Valve N18 (electropneumatic)
„
„
EGR Vacuum Regulator
Solenoid Valve (mechanical)
„
„
For cylinder bank 1
For cylinder bank 1
EGR Vacuum Regulator
Solenoid Valve (mechanical)
Page 14 / 18
Exhaust Gas Recirculation (EGR) system
„
„
For cylinder bank 2
EGR Valve 2 N213
„
For cylinder bank 2
„
Filter
„
Vacuum line
„
„
Between tandem pump and
brake booster
„
Check for secure seating
Tandem pump
„
Component location:
Cylinder bank 1
„
For fuel and vacuum supply
„
Must not be disassembled
Vacuum hose connection diagram (vehicles with engine
codes BWF)
Page 15 / 18
Exhaust Gas Recirculation (EGR) system
„
Vacuum actuator
„
„
For cylinder bank 1
Vacuum actuator
„
For cylinder bank 2
„
Vacuum tube
„
Exhaust Gas Recirculation
(EGR) Cooler Switch-Over Valve
N345
„
„
For cylinder bank 1
„
Component location: at right
rear wheelhousing
Exhaust Gas Recirculation
Page 16 / 18
Exhaust Gas Recirculation (EGR) system
(EGR) Cooler Switch-Over Valve
2 N381
„
„
„
For cylinder bank 2
„
Component location: at right
front wheelhousing
Tandem pump
„
Component location:
Cylinder bank 1
„
For fuel and vacuum supply
„
Must not be disassembled
From brake booster
Exhaust Gas Recirculation (EGR) valve (vehicles with
engine code BKW), checking
Special tools, testers and auxiliary items required
„
Hand vacuum pump V.A.G 1390
Work sequence
- Remove connecting hose charge air pipe/intake
manifold.
Note:
„
With connector couplings, follow the installation
instructions closely 21-1, Hose connections with
connector couplings, installing .
- Disconnect vacuum hose at EGR vacuum regulator
solenoid valve.
Page 17 / 18
Exhaust Gas Recirculation (EGR) system
- Connect hand vacuum pump with additional equipment
V.A.G 1390 to valve.
- Operate hand vacuum pump and observe diaphragm rod.
Diaphragm rod must move in direction of - arrow - .
- Disconnect hose of hand vacuum pump from EGR valve.
Diaphragm rod must move back in opposite direction of arrow - into output position.
Page 18 / 18
Glow plugs
Page 1 / 4
28 - 1
Glow plugs
Glow plugs , removing and installing, checking:
„
Vehicles with engine codes BKW and BWF 28-1,
Glow plugs vehicles with engine code BKW, BWF)
removing and installing, checking
Glow plugs vehicles with engine code BKW, BWF)
removing and installing, checking
Visual characteristics of ceramic sheathed element glow plugs
Caution!
Ceramic sheathed element glow plugs are susceptible
to shock and bending. For this reason, do not use
sheathed element glow plugs which have dropped
(even from a height of approx. 2 cm) under any
circumstances, even if no visible damage can be
detected. Installation instructions must be performed
in sequence, otherwise there is a danger the plug
breaks and will cause damage to engine.
Visual characteristics of ceramic sheathed element glow
plugs
A - Ceramic sheathed element glow plugs, phased
stepping on tip (see magnified area), white color coding
arrow
B - Metal glow plugs, green color coding arrow
Ceramic sheathed element glow plugs, removing, installing
and checking 28-1, Ceramic sheathed element glow
plugs, removing, installing and checking .
Glow plugs
Ceramic sheathed element glow plugs, removing,
installing and checking
Special tools, testers and auxiliary items
required
„
„
„
„
Flex wrench 3220
Torque wrench (5 to 50 Nm) V.A.G
1331
Portable multimeter V.A.G 1526
A
Connector test set V.A.G 1594 C
Not illustrated:
Page 2 / 4
Glow plugs
„
Page 3 / 4
Pliers 6275
Requirements
„
Engine is cold
„
Ignition is switched off
Work procedure
Note:
„
Observe visual characteristics of ceramic sheathed
element glow plugs 28-1, Visual characteristics of
ceramic sheathed element glow plugs .
„
When removing and installing, do not cant ceramic
sheathed element glow plugs. Remove components
which hinder installation.
- Remove intake manifolds 23-1, Intake manifold,
removing and installing , Intake manifold, removing and
installing.
- Disconnect connectors from ceramic sheathed element
glow plugs using pliers 6275 .
- Remove ceramic sheathed element glow plugs using flex
wrench 3220 .
Installation is in reverse order of removal. Note the
following:
- Clean deposits from cylinder head bore and threads
completely before installing.
Note:
„
Never oil or grease thread of bore in cylinder head
and ceramic sheathed element glow plugs.
- Screw ceramic sheathed element glow plugs into cylinder
head by hand using flex wrench 3220 .
- Tighten ceramic sheathed element glow plugs. Torque
specification: 15 Nm
Caution!
After installing and before first engine start with a cold
Glow plugs
Page 4 / 4
engine, always perform a resistance test at all ceramic
sheathed element glow plugs.
„
Specification: max. 1.0 Ω
- If specified value is exceeded, replace malfunctioning
ceramic sheathed element glow plug.
Note:
„
If the malfunctioning ceramic sheathed element glow
plug is broken, remove all broken pieces from
engine, otherwise they can cause damage to
engine.
Electrical components of transmission control, removing and installing, checking
Page 1 / 27
38-1
Electrical components of
transmission control,
removing and installing,
checking
Safety precautions
WARNING!
Observe the following for all installations,
especially in engine compartment due to lack
of room:
Route lines of all types (e.g. for fuel,
hydraulic, EVAP canister system, coolant
and refrigerant, brake fluid, vacuum) and
electrical wiring so that the original path is
followed.
Watch for sufficient clearance to all moving
or hot components.
Shift selector lever into position -P- and
engage parking brake before working with
the engine running.
If special testing equipment is required during
road test, note the following:
Test equipment must always be secured to the
rear seat and operated from there by a second
person.
Electrical components of transmission control, removing and installing, checking
Page 2 / 27
38-2
If test and measuring equipment is operated
from the passenger seat, the person seated
there could be injured in the event of an accident
involving deployment of the passenger-side
airbag.
Notes:
For the electric components to work properly, a
voltage of at least 11.5 V is required.
Transmission Control Module (TCM) is
equipped with On Board Diagnostic (OBD).
It is possible that the control module will
recognize a malfunction and store a DTC during
some tests. Therefore the following work steps
must be performed in the mentioned sequence
after ending all tests and repairs.
- - Check DTC memory Page ST-23 ,
Diagnostic mode 3: Check DTC Memory,
- - Erase DTC memory
Page ST-28 ,
Diagnostic mode 4: Reset/erase diagnostic
data
- - For completion, generate readiness code
Page ST-50 .
Electrical components of transmission control, removing and installing, checking
Page 3 / 27
38-3
Multi-Function Transmission
Range (TR) Switch, removing
and installing, adjusting
Recommended special tools and
equipment
V.A.G 1331 torque wrench (5 to 50
Nm)
T10173 adjustment tool
Electrical components of transmission control, removing and installing, checking
Page 4 / 27
38-4
Note:
For the sake of illustration, work procedure
shown with transmission removed.
Removing
- Place selector lever in position "P".
- Remove noise insulation panel below
transmission.
- Remove cap nut -4-.
- Remove cover -3- from shift rod.
- Carefully bend hooks of locking washer using a screwdriver.
Note:
If a hook breaks off, replace locking washer
- Now remove nut -2- and locking washer shift rod.
- Disconnect harness connector from Multi
Function Transmission Range (TR) Switc
F125- (arrow -A-).
- Unscrew mounting bolts (arrows -B-) and
remove Multi-Function Transmission Ran
Switch -F125- (arrow -A-) from shift rod.
Electrical components of transmission control, removing and installing, checking
Page 5 / 27
38-5
Installing and adjusting
- Shift the lever/switch rod at the transmiss
N- position.
- Connect Multi-Function Transmission Ra
(TR) Switch -F125- (arrow -A-) on shift ro
- Hand-tighten mounting bolts (arrows -B-)
Multi-Function Transmission Range (TR)
- Place adjustment tool (T10173) on shift ro
- Disengage selector lever cable.
- Rotate Multi-Function Transmission Rang
Switch until tab on connector -arrow 1- en
in groove of adjustment tool.
Electrical components of transmission control, removing and installing, checking
Page 6 / 27
38-6
- Tighten mounting bolts -arrows Bof Multi-Function Transmission
Range (TR) Switch.
Tightening torque: 6 Nm
- Remove adjustment tool (T10173)
from shift rod.
- Hook in selector lever cable.
Rest of installation is performed in
the reverse order of removal.
- Check adjustment of selector
lever cable:
Repair Manual, 6 Spd. Automatic
Transmission 09D All Wheel Drive,
Repair Group 37; servicing shift
mechanism
Electrical components of transmission control, removing and installing, checking
Page 7 / 27
38-7
Multi-Function Transmission Range (TR)
Switch, checking
Recommended special tools and equipment
V.A.G 1526 multimeter or V.A.G 1715
multimeter
V.A.G 1594 connector test kit
Wiring diagram
Test requirements
Respective fuses in fuse box (instrument
panel, right) must be OK:
Electrical Wiring Diagrams and Component
Locations
Control Module with indicator unit in
instrument panel insert -J285- must be OK.
Battery voltage must be at least 11.5 volts.
All electrical consumers such as, for
example, lights and rear window defroster
must be switched off.
Parking brake must be engaged or else
daylight driving lights will be switched on.
Selector lever must be in -P- position.
Ground (GND) connections to transmission
must be OK.
Electrical components of transmission control, removing and installing, checking
Page 8 / 27
38-8
Function test
- Switch ignition on.
- Depress brake pedal and maintain depressed.
- Shift into all selector lever positions.
Selector lever position must correspond to
display of Control Module with indicator unit
in instrument panel insert -J285-.
- Switch ignition off.
If selector lever position does not correspond to
display of Control Module with indicator unit in
instrument panel insert -J285- Check wires according to wiring diagram
Page 38-9 .
Electrical components of transmission control, removing and installing, checking
Page 9 / 27
38-9
Checking wiring
- Connect test box to control module wiring
harness Page ST-10 , connect test box
wiring test.
- Disconnect 10-pin harness connector -ar
to Multi-Function Transmission Range (T
Switch -F125-.
Electrical components of transmission control, removing and installing, checking
Page 10 / 27
38-10
- Check wires between test box
and 10-pin connector to
Transmission Control Module
(TCM) for open circuit according
to wiring diagram.
Terminal 1+socket 47
Terminal 3 + socket 1
Terminal 4 + socket 2
Terminal 5 + socket 22
Terminal 7 + socket 10
Terminal 9 + socket 36
Terminal 10 + socket 21
Wire resistance: max. 1.5
- Also check wires for short circuit
to each other.
Specified value:
If no malfunctions are found in
wires:
- Check adjustment of MultiFunction Transmission Range
(TR) Switch -F125- Page 38-3 ,
Multi-Function Transmission
Range (TR) Switch, removing and
installing, adjusting.
- Check adjustment of selector
lever cable:
Repair Manual, 6 Spd. Automatic
Transmission 09D All Wheel Drive,
Repair Group 37; servicing shift
mechanism
Electrical components of transmission control, removing and installing, checking
Page 11 / 27
38-11
- Erase DTC memory of Transmission Control
Module (TCM) Page ST-28 , Diagnostic mode
4: Reset/erase diagnostic data.
- Generate readiness code
Page ST-50 .
If no malfunctions are detected in wires and
adjustments of selector lever cable and MultiFunction Transmission Range (TR) Switch are
OK:
- Replace Multi-Function Transmission Range
(TR) Switch -F125- Page 38-3 , MultiFunction Transmission Range (TR) Switch,
removing and installing, adjusting.
- Erase DTC memory of Transmission Control
Module (TCM) Page ST-28 , Diagnostic mode
4: Reset/erase diagnostic data.
- Generate readiness code
Page ST-50 .
Electrical components of transmission control, removing and installing, checking
Page 12 / 27
38-12
Sensor for transmission RPM, checking
Recommended special tools and equipment
V.A.G 1526 multimeter or V.A.G 1715
multimeter
V.A.G 1594 connector test kit
Wiring diagram
Test requirements
Respective fuses in fuse box (instrument
panel, right) must be OK:
Electrical Wiring Diagrams and Component
Locations
Battery voltage must be at least 11.5 volts.
Ground (GND) connections to transmission
must be OK.
Selector lever must be in -P- position.
Ignition switched off.
Electrical components of transmission control, removing and installing, checking
Page 13 / 27
38-13
Checking wiring
- Connect test box to control module wiring
harness Page ST-10 , connect test box
wiring test.
- Disconnect 8-pin harness connector -arro
- Check wires between test box and 8-pin
connector to Transmission Control Modu
(TCM) for open circuit according to wiring
diagram.
Terminal 3 + socket 51
Terminal 4 + socket 39
Wire resistance: max. 1.5
- Also check wires for short circuit to each
Specified value:
Electrical components of transmission control, removing and installing, checking
Page 14 / 27
38-14
If no malfunctions are found in wires:
- Replace Sensor for transmission RPM -G182-.
- Erase DTC memory of Transmission Control
Module (TCM) Page ST-28 , Diagnostic mode
4: Reset/erase diagnostic data.
- Generate readiness code
Page ST-50 .
Electrical components of transmission control, removing and installing, checking
Page 15 / 27
38-15
Sender for transmission output RPM
checking
Recommended special tools and equipm
V.A.G 1526 multimeter or V.A.G 1715
multimeter
V.A.G 1594 connector test kit
Wiring diagram
Test requirements
Respective fuses in fuse box (instrumen
panel, right) must be OK:
Electrical Wiring Diagrams and Component
Locations
Battery voltage must be at least 11.5 vo
Ground (GND) connections to transmiss
must be OK.
Selector lever must be in -P- position.
Ignition switched off.
Checking wiring
- Connect test box to control module wiring
harness Page ST-10 , connect test box
wiring test.
- Disconnect 8-pin harness connector -arro
Electrical components of transmission control, removing and installing, checking
Page 16 / 27
38-16
- Check wires between test box
and 8-pin connector to
Transmission Control Module
(TCM) for open circuit according
to wiring diagram.
Terminal 5 + socket 38
Terminal 6 + socket 50
Wire resistance: max. 1.5
- Also check wires for short circuit
to each other.
Specified value:
If no malfunctions are found in
wires:
- Replace Sender for transmission
output RPM -G195-.
- Erase DTC memory of
Transmission Control Module
(TCM) Page ST-28 , Diagnostic
mode 4: Reset/erase diagnostic
data.
- Generate readiness code
ST-50 .
Page
Electrical components of transmission control, removing and installing, checking
Page 17 / 27
38-17
Transmission Fluid Temperature
Sensor, checking
Recommended special tools and equipment
V.A.G 1526 multimeter or V.A.G 1715
multimeter
V.A.G 1594 connector test kit
Wiring diagram
Test requirements
Respective fuses in fuse box (instrument
panel, right) must be OK:
Electrical Wiring Diagrams and Component
Locations
Battery voltage must be at least 11.5 volts.
Ground (GND) connections to transmission
must be OK.
Selector lever must be in -P- position.
Ignition switched off.
Electrical components of transmission control, removing and installing, checking
Page 18 / 27
38-18
Test sequence
- Disconnect 8-pin harness
connector -arrow 3-.
Checking resistance
- Measure resistance of
Transmission Fluid Temperature
Sensor-G93- between terminals 1
+ 2 at connector to sensor:
ATF
temperature
Specified
value
37.0 to 51.0
K
approx. -30
C
approx. 10
C
5.0 to 8.0 K
approx. 25
C
3.0 to 5.0 K
approx. 110
C
230.0 to 265.0
approx. 145
C
100.0 to 120.0
If one of the specified values is not
obtained:
- Replace Transmission Fluid
Temperature Sensor -G93-.
- Erase DTC memory of
Transmission Control Module
(TCM) Page ST-28 , Diagnostic
mode 4: Reset/erase diagnostic
data.
- Generate readiness code
ST-50 .
Page
Electrical components of transmission control, removing and installing, checking
Page 19 / 27
38-19
If specified values are obtained:
- Check wires according to wiring diagram
Page 38-19 .
Checking wiring
- Connect test box to control module wiring
harness Page ST-10 , connect test box
wiring test.
- Check wires between test box and 8-pin
connector to Transmission Control Modu
(TCM) for open circuit according to wiring
diagram.
Terminal 1+socket 45
Terminal 2+socket 8
Wire resistance: max. 1.5
- Also check wires for short circuit to each
Specified value:
If no malfunctions are found in wires:
- Replace Transmission Control Module (T
J217- Page 38-29 .
Electrical components of transmission control, removing and installing, checking
Page 20 / 27
38-20
Solenoid valves in valve body, checking
Recommended special tools and equipment
V.A.G 1526 multimeter or V.A.G 1715
multimeter
V.A.G 1594 connector test kit
Wiring diagram
Test requirements
Respective fuses in fuse box (instrument
panel, right) must be OK:
Electrical Wiring Diagrams and Component
Locations
Selector lever must be in -P- position.
Ground (GND) connections to transmission
must be OK.
Ignition switched off.
Electrical components of transmission control, removing and installing, checking
Page 21 / 27
38-21
Test sequence
- Disconnect 14-pin harness
connector -arrow 2- to solenoid
valves (Solenoid Valve 1 -N88- to
Solenoid Valve 6 -N93-, Solenoid
Valve 9-N282-, Solenoid Valve 10
-N283-).
Electrical components of transmission control, removing and installing, checking
Page 22 / 27
Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru
огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi
38-22
Checking resistance
- Check resistances of solenoid valves
at connector to the solenoid valves:
Component
Connector
Specified
value
Terminal
Solenoid
Valve 1 N88-
1+Ground
(GND)
transmission
10.0 to
16.0
Solenoid
Valve 2 N89-
2+Ground
(GND)
transmission
10.0 to
16.0
Solenoid
Valve 3 N90-
7+8
4.0 to 8.0
Solenoid
Valve 4 N91-
11+12
4.0 to 8.0
Solenoid
Valve 5 N92-
3+4
4.0 to 8.0
Solenoid
Valve 6 N93-
13+14
4.0 to 8.0
Solenoid
Valve 9 N282-
5+6
4.0 to 8.0
Solenoid
Valve 10 N283-
9+10
4.0 to 8.0
Note:
Resistance value is valid at approx. 20
C. At higher temperatures, resistance
value increases.
Electrical components of transmission control, removing and installing, checking
Page 23 / 27
38-23
If one of the specified values is not obtained:
- Replace the respective solenoid valve.
- Erase DTC memory of Transmission Control
Module (TCM) Page ST-28 , Diagnostic mode
4: Reset/erase diagnostic data.
- Generate readiness code
Page ST-50 .
If specified values are obtained:
- Check wires according to wiring diagram
Page 38-23 .
Checking wiring
- Connect test box to control module wiring
harness Page ST-10 , connect test box for
wiring test.
- Check wires between test box and 14-pin
connector to Transmission Control Module
(TCM) for open circuit according to wiring
diagram.
Wire resistance: max. 1.5
Component
Connector
Test box
Solenoid Valve 1 N88-
Terminal 1
Socket
41
Solenoid Valve 2 N89-
Terminal 2
Socket
15
Solenoid Valve 3 N90-
Terminal 7
Socket
30
Terminal 8
Socket
18
Electrical components of transmission control, removing and installing, checking
Page 24 / 27
38-24
Component
Connector
Test box
Solenoid Valve 4 -N91-
Terminal
11
Socket 5
Terminal
12
Socket
43
Terminal 3
Socket
42
Terminal 4
Socket 6
Terminal
13
Socket
31
Terminal
14
Socket
17
Terminal 5
Socket
16
Terminal 6
Socket
32
Terminal 9
Socket 4
Terminal
10
Socket
44
Solenoid Valve 5 -N92-
Solenoid Valve 6 -N93-
Solenoid Valve 9 N282-
Solenoid Valve 10 N283-
- Also check wires for short circuit to each
other.
Specified value:
If no malfunctions are found in wires:
- Replace Transmission Control Module (TCM) J217- Page 38-29 .
Electrical components of transmission control, removing and installing, checking
Page 25 / 27
38-25
Sender for hydraulic pressure, checking
Recommended special tools and equipment
V.A.G 1526 multimeter or V.A.G 1715
multimeter
V.A.G 1594 connector test kit
Wiring diagram
Test requirements
Respective fuses in fuse box (instrument
panel, right) must be OK:
Electrical Wiring Diagrams and Component
Locations
Battery voltage must be at least 11.5 volts.
Ground (GND) connections to transmission
must be OK.
Selector lever must be in -P- position.
Ignition switched off.
Electrical components of transmission control, removing and installing, checking
Page 26 / 27
38-26
Checking wiring
- Connect test box to control module wiring
harness Page ST-10 , connect test box
wiring test.
- Disconnect 8-pin harness connector -arro
Electrical components of transmission control, removing and installing, checking
Page 27 / 27
38-27
- Check wires between test box
and 8-pin connector to
Transmission Control Module
(TCM) for open circuit according
to wiring diagram.
Wire resistance: max. 1.5
Component
Connector
Test
box
Sender 1 for
hydraulic
pressure,
automatic
transmission
-G193-
Terminal 7
Socket
24
Sender 2 for
hydraulic
pressure,
automatic
transmission
-G194-
Terminal 8
Socket
25
- Also check wires for short circuit
to each other.
Specified value:
If no malfunctions are found in
wires:
- Replace the respective sender for
hydraulic pressure:
Repair Manual, 6 Spd. Automatic
Transmission 09D All Wheel Drive,
Repair Group 38
- Erase DTC memory of
Transmission Control Module
(TCM) Page ST-28 , Diagnostic
mode 4: Reset/erase diagnostic
data.
- Generate readiness code
ST-50 .
Page