1.8T 5V (Awm)

Page 1 of 3
00-1
Technical data
Engine number
The engine number ("Engine code number" and "serial number") is on the
left rear of the cylinder block.
Additionally, there is a sticker on the toothed belt guard with "Engine

code" and "Serial number".
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The engine code is also included on the vehicle data sticker.
Note:
Furthermore, the engine code is stamped onto the front engine lifting eye
(visible after removal of engine cover).
file://C:\DOCUME~1\Bear\LOCALS~1\Temp\triCODIP.htm 11/21/2002
Page 2 of 3
00-2
Engine data
Code letters AWM

Production 04.2000 >
Capacity ltrs. 1.781
Output kW at rpm 125/5900
Torque Nm at rpm 225/1950 - 5000
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Bore diameter mm 81.0
Stroke mm 86.4
Compression 9.3
RON 95 1)
Injection-/Ignition system Bosch Motronic
Knock control yes
On Board Diagnositc (OBD) yes
Oxygen sensor control yes
Catalytic converter yes
Charging yes
1)Regular unleaded petrol RON 91 can be used

but will cause a slight loss of power.
Page 3 of 3
00-3
Code letters AWM

Exhaust gas recirculation system no
Intake manifold changeover no
Camshaft timing control yes
Secondary air inlet yes
Valve timing
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with 1 mm valve lift and 0 mm valve
clearance
Inlet opens after TDC 18
Inlet closes after BDC 28
Exhaust opens before BDC 28
Exhaust closes before TDC 8
Technical data Page 1 of 3
01-1
Technical data
Engine number
The engine number ("Engine code number" and "serial number") is on the
left rear of the cylinder block.
Additionally, there is a sticker on the toothed belt guard with "Engine

code" and "Serial number".
cardiagn.com
The engine code is also included on the vehicle data sticker.
Note:
Furthermore, the engine code is stamped onto the front engine lifting eye
(visible after removal of engine cover).
http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.GE06.01.1 11/21/2002
01-2
Engine data
Code letters AWM

Production 04.2000 >
Capacity ltrs. 1.781
Output kW at rpm 125/5900
Torque Nm at rpm 225/1950 - 5000
cardiagn.com
Bore diameter mm 81.0
Stroke mm 86.4
Compression 9.3
RON 95 1)
Injection-/Ignition system Bosch Motronic
Knock control yes
On Board Diagnositc (OBD) yes
Oxygen sensor control yes
Catalytic converter yes
Charging yes
1)Regular unleaded petrol RON 91 can be used

but will cause a slight loss of power.
01-3
Code letters AWM

Exhaust gas recirculation system no
Intake manifold changeover no
Camshaft timing control yes
Secondary air inlet yes
Valve timing
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with 1 mm valve lift and 0 mm valve
clearance
Inlet opens after TDC 18
Inlet closes after BDC 28
Exhaust opens before BDC 28
Exhaust closes before TDC 8
Engine, disassembling and assembling Page 1 of 47
13-1
Engine, disassembling and

assembling
Lock carrier, moving into service
position
Special tools and equipment
Special tool 3369
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13-2
1 - 45 Nm
2 - 45 Nm
3 - 10 Nm
4 - 10 Nm
5 - Bore
For special tool 3369
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6 - Hole in lock carrier
7 - Bore in fender panel
13-3
Removing
- Remove sound insulation Fig. 1, Page

13-6
- Remove front bumper:
Repair Manual, Body Exterior, Repair Group 63
- Remove lower air duct hose to charge air cooler
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Fig. 2, Page 13-6
- Remove air duct between lock carrier and air
filter Fig. 3, Page 13-7
- Remove retaining clips (if installed) for wiring
harness on left at radiator shroud.
13-4
- Remove bolt -2- and screw in special tool 3369.

- Screw in special tool 3369 into bore -5-.
- Remove bolts -1- and -3-.
- Remove bolts -4- and pull lock carrier out as far
as it will go.
- Secure lock carrier with suitable M6 bolts in hole
-6- (lock carrier) and hole -7- (fender panel).
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13-5
Installing
Installation is carried out in the reverse order of

removal; note the following:
- When lock carrier has been installed, check that

wiring next to radiator is correctly routed.
- Adjust limit stop for torque reaction support
Fig. 4, Page 13-7 .
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- Install front bumper.
- Adjust headlights.
Repair Manual, Electrical Equipment, Repair

Group 94
13-6
Fig. 1 Remove front sound insulation

- Remove sound insulation -arrows-.
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Fig. 2 Remove air duct hose
- Remove air duct hose to bottom left charge air cooler from lock carrier -
arrow-.
13-7
Fig. 3 Remove air duct between lock carrier and air filter
- Remove bolts -arrows-.
- Remove air ducts -1- and -2-.
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Fig. 4 Adjust stop for torque reaction support
- Attach limit stop for torque reaction support to rest on rubber buffer for
torque reaction support under its own weight, and tighten bolts -arrows-
to 28 Nm.
13-8
Ribbed belt drive for power steering pump,

Generator and viscous fan
Note:
Mark the direction of rotation with chalk or felt pen

before removing the ribbed belt. If the belt rotates in
the wrong direction when it is reinstalled, belt
breakage may result. Ensure that the belt is
properly seated on the pulleys when installing.
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1 - 10 Nm.
2 - Fan wheel
For viscous fan
Removing and installing Page 13-21 .
3 - Circlip
For viscous fan bearing
13-9
4 - Ribbed V-belt
Check for wear
Routing of ribbed belt Fig. 2, Page
13-17
5 - Bolt (special type)
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Always replace
Use only genuine bolts
Parts List
Torque: 10 Nm + 90 (1/4 turn)

6 - Vibration damper
With pulley for ribbed belt
Can only be installed in one position Fig.
1, Page 13-17
7 - Pulley
For viscous fan
13-10
8 - 23 Nm
9 - Tensioner for ribbed belt
Turn with open end spanner to loosen
ribbed belt Page 13-18 .
Hold in position by inserting a suitable pin
or Allen key in holes.
10 - 46 Nm
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11 - Mounting
For viscous fan
12 - Bracket
For Generator, power steering pump and
viscous fan
13 - 23 Nm
13-11
14 - Generator
Removing:
- Disconnect battery Ground strap
- Remove air duct hose to charge air
cooler.
- Loosen ribbed belt and take belt off
Generator Page 13-18 .
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- Remove viscous fan and put into radiator
cowl.
- Remove electrical wiring from Generator.
- Loosen connections for Generator from
top and bottom and remove Generator.
Installing:
- To facilitate attachment of Generator
slightly drive back thread bushing for
securing bolt at bracket.
13-12
15 - 45 Nm
16 - Support
For intake manifold
17 - 20 Nm
18 - 52 Nm
Apply D 000 600 when installing
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Bolts have different lengths. For positions
and tightening sequence Page 13-33
19 - 23 Nm
20 - Power steering pump
Removing and installing:
Repair Manual, Suspension, Wheels, Steering,

Repair Group 48
21 - 23 Nm
13-13
22 - Pulley
For power steering pump
Installation position: Open side faces to
front of vehicle
23 - 23 Nm
24 - Ribbed bolt - 28 Nm
25 - Viscous coupling
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Removing and installing Page 13-21
13-14
Ribbed belt drive for air conditioner -

assembly overview
CAUTION!
The air conditioner refrigerant circuit must not

be opened.
Note:
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before removing the ribbed belt. If the belt rotates in
the wrong direction when it is reinstalled, belt
breakage may result. Ensure that the belt is
1 - Bracket
13-15
2 - Air conditioner compressor

Do not loosen or disconnect refrigerant
hoses or lines.
After removing compressor from
mountings, secure to chassis side member
with wire or similar. Do not leave
compressor suspended on refrigerant
hoses.
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3 - Dowel sleeve
Check sleeve is correctly seated in bracket
4 - 33 Nm
5 - Bracket
For A/C compressor
6 - Tensioner
For ribbed belt
Removing and installing ribbed belt
Page 13-18
13-16
7 - Washer
8 - 23 Nm
9 - Ribbed V-belt
Check for wear
Do not kink
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Routing of ribbed belt Fig. 2, Page
13-17
10 - Washer
11 - 25 Nm
12 - Retaining clip
13 - 20 Nm
13-17
Fig. 1 Installing vibration damper

Lock carrier must be in service position Page 13-1 .
Ribbed belt must be removed Page 13-18 .

Always replace bolts. Only use original type bolts to install the
vibration damper.
Parts List
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The vibration damper can only be installed in one position. The hole -
arrow- in the vibration damper must fit over the projection on the toothed
belt sprocket.
- Tighten bolts of vibration damper to 10 Nm + 90 (1/4 turn).
Fig. 2 Ribbed belt routing
13-18
Ribbed belt, removing and installing
Note:
Mark the direction of rotation with chalk or felt

pen before removing the ribbed belt. If the belt
rotates in the wrong direction when it is refitted,
belt breakage may result. Ensure that the belt is
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Removing
- Loosen bolts securing ribbed belt tensioning roller for A/C compressor -
arrows-.
13-19
- Turn tensioner in direction of arrow to loosen ribbed belt.

- Remove ribbed belt from Generator and release tensioner.
Note:
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When the lock carrier is in the service position, the ribbed belt tensioner
can be secured to prevent it from turning by inserting a suitable pin or
Allen key -arrow- into the holes.
13-20
Installing
- Attach ribbed belt to pulleys from crankshaft and

vane pump and, if necessary, pull up with
auxiliary tool.
- Swivel tensioner for ribbed belt in direction of arrow.

- Install ribbed belt over Generator pulley last. Release tensioner.
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- Check that ribbed belt is properly seated.
- Fit ribbed belt for A/C compressor.
Ribbed belt routing Fig. 2, Page 13-17
- Attach torque wrench at "7 o'clock position" as illustrated to hex on

tensioner and pretension to 30 Nm.
- While tensioning, tighten bolts -A- to 23 Nm.
- Start engine and check belt running.
13-21
Viscous fan, removing and installing
Removing
Lock carrier must be in service position

Page 13-1 .
- To loosen ribbed belt, turn tensioner in direction of arrow.
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- Remove ribbed belt from Generator pulley.
- Secure pulley for viscous fan with pin punch -1- and remove using
Allen key -2-.
- Remove viscous fan.
13-22
Installing

- Install ribbed belt Page 13-20 .
- Install lock carrier Page 13-1 .
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Tightening torque
Component Nm
Viscous fan to bearing 45
13-23
Bearing for viscous fan, removing and

installing
Special tool 3301

Special tool 3350
Special tool 3367
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13-24
Removing

Page 13-1 .
- Remove air duct hose -1-.
Note:
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Connector -2- remains plugged in.
- Turn tensioner in direction of arrow to loosen ribbed belt.

13-25
Allen key -2-.
- Remove viscous fan from mounting.
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- Remove intake pipe support -arrows-.
13-26
- Remove circlip -arrow- from bearing bushing using angled circlip pliers.
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- Remove bearing from housing with nut from assembly mounting 3301,
bolt 3367/3 and pipe 3350.
13-27
Installing
Installation is carried out in the reverse order;

note the following:
- Press in bearing with tool 3367 and nut from assembly mounting 3301.
- Install circlip in housing for viscous fan using angled circlip pliers.
- Install viscous fan Page 13-21 .
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13-28
Bracket for Generator, power steering

pump and viscous fan, removing and
installing
Removing
- Observe or obtain radio anti-theft code on

vehicles with coded radio.
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- Disconnect Ground strap at battery with ignition
switched off.
- Remove cover from power steering fluid

reservoir.
- Mark connectors -1 to 5- and remove from bracket.
13-29
- Unclip connector bracket at ABS unit console and lift up to remove.
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Note:
13-30
- To loosen ribbed belt, turn tensioner in direction of arrow.

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Allen key -2-.
- Remove viscous fan from mounting and put in front of radiator cowl.
- Remove wiring from rear of Generator.
- Loosen connections for Generator from top and bottom and remove
Generator.
13-31
- Remove tensioner for ribbed belt from

bracket.
- Remove pulley from power steering pump.
- Unbolt power steering pump, move clear to one

side and tie in place. Do not open hydraulic
connections.
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- Remove intake pipe support -arrows-.
13-32
- Unbolt bracket for Generator, steering pump and viscous fan -bolts 1 to
6-.
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13-33
Installing

- Install bolts -1 to 6- with locking fluid "D 000 600" and tighten bolts
diagonally.
1, 2 - Bolt M10 x 85
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3 to 6 - Bolt M10 x 45
- To help install Generator knock back bushing on bottom securing bolt
slightly.
- Remove viscous fan Page 13-21 .
- Install ribbed belt Page 13-20 .
- After connecting battery, enter anti-theft code for radio.
Radio operating instructions
- Close windows fully using window switches.
13-34
- Actuate all window switches again for at least

one second in the "close" direction to activate
the automatic open/close function.
- Set clock to correct time.
Tightening torques
Component Nm
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Bracket for Generator, power steering
pump and viscous fan to cylinder block
52
1)
Support for intake manifold

to intake manifold 20
to bracket 20
Power steering pump to bracket 23
Pulley to coolant pump 23
Generator at bracket
M8 23
M10 46
Ribbed belt tensioner to bracket
23
Viscous fan to bearing 45
1) Install with locking fluid D 000 600 A2
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13-35
Toothed belt drive
Note:

before removing the toothed belt. If the belt rotates
in the wrong direction when it is reinstalled, belt
breakage may result.
1 - Toothed belt guard - lower
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To remove, unbolt vibration damper
2 - 10 Nm
3 - Toothed belt guard - center
Unbolt tensioner before removing center
section of toothed belt guard
13-36
4 - Toothed belt guard - top

When installing, engage carefully in center
toothed belt guard
5 - Toothed belt
Mark direction of rotation with chalk or felt
pen before removing.
Check for wear
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Removing Page 13-40
Install (adjust valve timing) Page 13-44
6 - Idler roller
7 - 27 Nm
8 - 65 Nm
Counter hold with 3036 to loosen and
tighten
13-37
9 - Camshaft sprocket
For exhaust camshaft
Take off toothed belt before removing and
installing Page 13-40
Installation position Fig. 1, Page
13-39
10 - Tensioner
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11 - Washer
12 - Tensioner for toothed belt
13 - O-ring
Always replace
Lightly coat with coolant G 012 A8 D before
installing
14 - Coolant pump
13-38
15 - 15 Nm
16 - Crankshaft sprocket
Contact surface between sprocket and
crankshaft must be free of oil.
Can only be installed in one position.
17 - 90 Nm + 1/ turn (90 ) further
4
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Always replace
Do not use oil
Counter hold with 3415 to loosen and
tighten
Fasten counterhold 3415 Fig. 2,
Page 13-39
18 - 15 Nm
19 - 25 Nm
13-39
Fig. 1 Location of camshaft sprocket

The narrow web of the camshaft sprocket faces outward -arrows- and
the marking for TDC of cylinder 1 is visible from front.
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Fig. 2 Removing and installing toothed belt crankshaft
- Use counter-hold tool 3415 to loosen and tighten the central bolt.
13-40
Toothed belt, removing and installing
Socket head fastener T10092
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Pin T40011
13-41
Removing
Engine in vehicle.

Page 13-1 .
- Remove engine cover -arrows-.
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- Remove ribbed belt and tensioner for ribbed belt Page 13-18 .
Allen key -2-.
- Remove upper toothed belt guard.
13-42
- Mark direction of rotation of belt with chalk or felt

pen.
- Set crankshaft to markings for TDC of No. 1 cylinder by turning central

bolt on crankshaft sprocket in direction of rotation -arrows-.
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- Unbolt vibration damper.
13-43
- Unbolt lower and center section of toothed belt guard -arrows-.
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- Attach socket head fastener T10092 into the tensioner for toothed belt.
- Only tension pressure piston of tensioner until pressure piston is
secured with pin T40011.
- Take off toothed belt.
13-44
Installing (adjusting valve timing)
Note:
The position of the toothed belt must be set as

described below, even after repairs in which the
belt is only taken off the camshaft sprocket.
When turning the camshaft, the crankshaft must
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not be at TDC at any cylinder. There is a
danger of damage to valves/piston crown.
- Align marking on camshaft sprocket with marking at cylinder head

cover.
- Place toothed belt on crankshaft sprocket (observe direction of
rotation).
- Install toothed belt guard - lower part.
- Secure vibration damper/belt pulley with one bolt (note installation
arrangement).
- Set crankshaft to TDC for cylinder No. 1.
- Install toothed belt onto coolant pump, then tensioning roller, and finally
camshaft sprocket.
13-45
- Unscrew socket head fastener T10092.

- Pull out pin T40011 from tensioner.
The pressure piston of the tensioner for the toothed belt loosens.
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- Turn crankshaft two full turns in direction of rotation (by turning central
bolt on crankshaft sprocket) and check that camshaft and crankshaft
marks align with their reference points.
- Install vibration damper/belt pulley.
- Install toothed belt guard (center and top sections).
- Install ribbed belt and tensioner for ribbed belt Page 13-20 .
13-46
Tightening torques
Component Nm
Lower section of toothed belt guard to
cylinder block
10 1)
Center section of toothed belt guard
to cylinder block
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10 1)
Vibration damper/belt pulley to
crankshaft
10 + 90
2)3)
Ribbed belt tensioner to bracket
23
2) Replace bolts
3) 90 corresponds to a quarter turn
Sealing flanges and flywheel/drive plate, removing and installing Page 1 of 20
13-47
Sealing flanges and

flywheel/drive plate, removing
and installing
Note:
For repairs to the clutch:
Repair Manual, 5 Spd. Manual Transmission
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012/01W Front Wheel Drive, Repair Group 30
Repair Manual, 5 Spd. Manual Transmission

01A All Wheel Drive, Repair Group 30
1 - Sealing flange - front

Must be located on dowel sleeves
2 - 15 Nm
13-48
3 - Sealing ring
Replacing Page 13-51
Do not oil sealing lip of oil seal
4 - Sump
5 - 15 Nm
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6 - Cylinder block
Removing and installing crankshaft
Page 13-67 .
Dismantling and assembling pistons and
conrods Page 13-79 .
7 - Dual-mass flywheel/drive plate
Removing and installing dual mass
flywheel Page 13-62
Removing and installing drive plate
Page 13-64
Can only be installed in one position. Holes
are offset.
13-49
8 - Securing bolt for dual-mass flywheel or

drive plate
Always replace
Tightening torque for dual mass flywheel
Page 13-63
Tightening torque for drive plate (vehicles
with automatic gearbox) Page 13-66
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9 - Intermediate plate
Do not damage/bend when assembling
13-50
10 - 15 Nm
11 - Rear sealing flange with oil seal
With gasket for cylinder block
Do not oil sealing lip of oil seal
Make sure that the sealing lip of the sealing
ring is not folded back or damaged when
installing
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Removal and installation, removing sump
Page 17-11
When installing, push guide sleeve from
repair kit onto crankshaft
13-51
Crankshaft oil seal on pulley end,

replacing
Oil seal extractor 3203

Holding tool 3415
Assembly tool T10053
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13-52
Removing
Engine in vehicle

Page 13-1 .
- Remove toothed belt Page 13-40 .
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- Unbolt stop for torque reaction support -arrows-.
- Remove toothed belt sprocket from crankshaft. To do this, counter hold

sprocket with 3415.
13-53
- Before applying oil seal extractor, thread central

bolt for toothed belt sprocket into crankshaft as
far as it will go.
- Remove inner section of oil seal extractor 3203

one turn out of outer section and lock with
knurled screw.
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- Lubricate threaded head of oil seal extractor, place it in position and
exerting firm pressure, screw it into oil seal as far as possible.
- Loosen knurled screw and turn inner part against crankshaft until the
oil seal is pulled out.
- Clamp flats of oil seal extractor in vice. Remove oil seal with pliers.
- Clean contact surface and sealing surface.
13-54
Installing
Note:
Do not lubricate sealing lip or outer

circumference of seal before pressing in.
- Place guide sleeve T10053/1 onto crankshaft journal.

- Slide oil seal over guide sleeve.
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- Press sealing ring flush with central bolt of toothed belt sprocket and
pressure sleeve from T10053.
13-55
- Replace central bolt for toothed belt sprocket.
- Remove crankshaft toothed belt sprocket. To do this, counter-hold

toothed belt sprocket with 3415.
Note:
Contact surface between sprocket and crankshaft must be free of oil.
Do not oil bolt for crankshaft sprocket.
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- Install toothed belt (adjust valve timing) Page 13-44 .
- Install ribbed belt and tensioner for ribbed belt Page 13-20 .
Tightening torque
Component Nm
Toothed belt sprocket to crankshaft 90 + 90 1)2)
1) Replace bolt
13-56
Front sealing flange, removing and

installing
Special tools, material and equipment
Holding tool 3415
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Electric drill with plastic brush attachment
Protective goggles
Silicone sealant D 176 404 A2
13-57
Removing
Engine in vehicle

Page 13-1 .
- Remove toothed belt Page 13-40 .
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CAUTION!
The air conditioner refrigerant circuit must

not be opened.
- Disconnect A/C compressor from bracket and

secure to body with wire.
- Unbolt bracket for A/C compressor -Item 5 -,

Page 13-15
- Unbolt stop for torque reaction support -arrows-.
13-58
- Remove toothed belt sprocket from crankshaft. To do this, counter hold

sprocket with 3415.
- Remove oil pan Page 17-11
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- Remove bolts -1 to 6-.
- Pry sealing flange loose and remove.
- Carefully remove any remains of sealant from cylinder block.
13-59
- Remove remaining sealant from sealing flange with rotating plastic

brush.
WARNING!
Wear protective glasses.
- Clean sealing surfaces: they must be free of oil and grease.
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Installing
Note:
The sealing flange must be installed within 5 minutes after applying

silicone sealant.
- Cut off nozzle of silicon sealant tube at front marking (diameter of

nozzle = approx. 3 mm).
13-60
- Apply bead of silicone sealant -arrow-onto clean sealing surface of

sealing flange, as illustrated (arrow).
Sealant bead width -arrows-: 2 to 3 mm
Note:
The bead of sealant must not be thicker than 3 mm, otherwise excess
sealant will enter the oil pan and obstruct the strainer in the oil intake line.
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- Install sealing flange immediately, and tighten all bolts lightly.
Note:
Use guide sleeve T10053/1 to attach the sealing flange with sealing ring
installed.
- Tighten sealing flange bolts in diagonal sequence.

- Install oil pan Page 17-23 .
Note:
After assembly, the sealant must dry for approx. 30 min. Only then may
the engine be filled with oil.
13-61
- Install crankshaft oil seal Page 13-54 .
- Install toothed belt (adjust valve timing) Page

13-44 .
- Install bracket for A/C compressor -Item 5 -,

Page 13-15 .
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Tightening torques
Component Nm
Sealing flange to cylinder block 15
Bracket for air conditioner compressor on
cylinder block
33
A/C compressor to bracket 25
13-62
Dual mass flywheel/drive plate,

removing and installing
Dual-mass flywheel
Counter-hold tool 10-201
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Removing
- Reverse position of counter-hold tool 10-201 for loosening/tightening

bolts.
- Mark position of flywheel relative to engine.
- Unbolt flywheel.
13-63
Installing
Installation is carried out in the reverse order or

- Replace bolts.
Tightening torque
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Component Nm
Dual-mass 22.5 mm 60 + 90 2)
flywheel 1)
on crankshaft 43 mm 1) 60 + 180
3)
1) Bolt length
3)180 = 1/2 turn
13-64
Drive plate
Counter hold VW 558

Hex bolt M8 x 45 and two M10 hex nuts
Caliper gauge or depth measure
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Removing
- Secure counter hold tool VW 558 to drive plate with hex bolt M8 x 45 -
Item 2-. Place two M10 hex nuts between counter-hold tool and drive
plate.
- Mark position of drive plate relative to engine.
- Unbolt drive plate.
13-65
Installing
- Place drive plate in position with shim -2- and washer -1-. Lug -arrow-
must face towards torque converter.
- Insert at least 3 old securing bolts and tighten to 30 Nm.
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- Measure distance -a- at three points and calculate average value.
Specified value: 18.9 to 20.5 mm
13-66
If nominal value is exceeded:
- Remove drive plate again and fit without shim -2-. Retighten bolts to 30
Nm.
- Measure distance again.
If specified value is attained:
- Install new bolts and tighten.
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Tightening torque
Component Nm
Drive plate to crankshaft 60 + 90 1)
Crankshaft, removing and installing Page 1 of 12
13-67
Crankshaft, removing and

installing
Note:
When working on the engine, it should be secured

to the engine stand using the engine bracket VW
540 Page 10-27 .
1 - Bearing shell
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For cylinder block with oil groove
Do not interchange used bearing shells
(mark).
Install new bearing plates for cylinder block
with the correct color coding Fig. 2,
Page 13-72
2 - Chain sprocket
For oil pump drive chain
13-68
3 - Bearing shell
For bearing cap without oil groove
(mark).
The crankshaft bearing plates in the
bearing covers are supplied as spare part
with the color coding "yellow"
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4 - Thrust washers
For bearing 3
Different types for cylinder block and
bearing cap
Note locating arrangement
5 - 65 Nm + 1/ turn (90 ) further
4
Always replace
When measuring radial clearance of
crankshaft, tighten to 65 Nm but do not turn
further.
13-69
6 - Bearing cap
Bearing cap 1: Pulley end
Bearing cap 3 with recesses for thrust
washers
Bearing shell retaining lugs (cylinder
block/bearing cap) must be on the same
side
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7 - 10 Nm + 1/ turn (90 ) further
4
Always replace
After each removal of the bolts replace
sensor wheel Fig. 1, Page 13-71
8 - Needle bearing
For vehicles with manual transmission
Pulling out and driving in Page 13-73
13-70
9 - Sensor wheel
For engine speed sensor -G28-
Can only be installed in one position. Holes
are offset
Always replace sensor wheel if securing
bolts have been loosened.
Removing and installing Fig. 1,
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Page 13-71
10 - Crankshaft
Axial clearance new: 0.07 to 00.23 mm,
Wear limit: 0.30 mm
Check radial clearance with Plastigage ,
New: 0.02 to 0.04 mm, Wear limit: 0.15 mm
Do not rotate the crankshaft when checking
the radial clearance.
Crankshaft dimensions Page 13-76
13-71
Fig. 1 Removing and installing sensor wheel
Note:
Always replace sensor wheel -2- if securing bolts -1- have been
loosened..
If the securing bolts are tightened a second time, the seats for the
countersunk bolt heads in the sensor wheel will be distorted to such
an extent that the bolt heads will come into direct contact with the
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crankshaft -3- (-arrows-) and the sensor wheel will only fit loosely
under the bolts.
The mounting holes are asymmetrically spaced, so it is only possible
to install the sensor wheel in one position.
Tightening torque
Component Nm
Sensor wheel to crankshaft 10 + 90 1)2)
1) Replace bolts
13-72
Fig. 2 Allocation of crankshaft bearing plates for cylinder block
The bearing plates with the correct thickness are allocated to the cylinder
block at the factory. Colored dots are used to mark the thickness of the
bearing plates.
Note:
Arrow points in direction of travel.
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The position of each bearing thickness is marked with letters on the lower
sealing area of the cylinder block.
Letter on Color of bearing
cylinder block
S = Black
R = Red
G = Yellow
Note:
The crankshaft bearing cups in the bearing covers are supplied as spare
part with the color coding "yellow".
13-73
Crankshaft needle bearing, removing

and installing
Special tool VW 207 C
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Special tool Kukko 21/1 (Item 1) and Kukko 22/1 (Item 4)
Depth gauge
13-74
Note:
A needle bearing must be installed in the

crankshaft on vehicles with a manual
transmission. Install needle bearing if
necessary.
The needle bearing must not be installed in the

crankshaft on vehicles with an automatic
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transmission. Remove needle bearing if
necessary.
Removing
- Pull out needle bearing with Kukko 21/1 and Kukko 22/1.
13-75
Installing
- Drive in using 207c or centralizing pin 3176.

Lettering on needle bearing must be visible when installed
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Installation depth of needle bearing
Distance a = 1.5 mm
13-76
Crankshaft dimensions
(in mm)
Honing Crankshaft Conrod

dimension bearing journal
main journal
diameter
main journal
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diameter
-0.017 -0.022
Basic 54.00 47.80
dimension
-0.037 -0.042
-0.017 -0.022
1st undersize 53.75 47.55
-0.037 -0.042
-0.017 -0.022
2nd undersize 53.50 47.30
-0.037 -0.042
-0.017 -0.022
3rd undersize 53.25 47.05
-0.037 -0.042
13-77
Chain sprocket, removing and installing
Sleeve 30-100
Two-arm puller, commercially available.
Protective gloves
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Removing
- Remove oil pan Page 17-11 .

- Removing front sealing flange Page 13-56 .
- Disconnect chain wheel of oil pump, remove chain tensioner and chain
-Item 5 -, Page 17-3 .
- Pull chain sprocket off crankshaft with puller -2- (Use a suitable washer
-1- to protect end of crankshaft).
13-78
Installing

WARNING!
Wear protective gloves!
- Heat chain sprocket in heating appliance for
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approx. 15 minutes to 220 C.
Note:
Installation position: wide collar on sprocket

facing toward engine
- Install chain sprocket on end of crankshaft using pliers and push onto
seat on crankshaft with drift sleeve 30-100.
Pistons and connecting rods, disassembling and assembling Page 1 of 8
13-79
Pistons and connecting rods,

disassembling and assembling
Note:
Oil spray jet and pressure relief valve Fig. 6,

Page 13-85
1 - Conrod bolt - 30 Nm + 1/ turn (90 )

4
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further
Always replace
Oil threads and contact surface
To measure radial clearance use old bolt
To measure radial clearance tighten to 30
Nm but not further
13-80
2 - Connecting rod bearing cap

Mark cylinder number -B-
Installation position: Markings -A- face
towards pulley side
3 - Bearing shells
Upper bearing shell with oil bore for piston
bolt lubrication
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13-85
(mark).
Axial clearance New: 0.10 to 0.35 mm,
Wear limit: 0.40 mm
Check radial clearance with Plastigage :
New: 0.01 to 0.05 mm, Wear limit: 0.12
mm. Do not rotate crankshaft when
checking radial clearance
13-81
4 - Connecting rod
Only replace as a set
Mark cylinder number -B-
Installation position: Markings -A- face
toward pulley side
With oil bore for piston pin lubrication
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5 - Circlip
6 - Piston pin
If difficult to remove, heat piston to approx.
60 C
Remove and install with VW 222a
13-82
7 - Piston
Checking Fig. 3, Page 13-84
Mark installation position and cylinder
number.
Arrow on piston crown points to pulley end
Install using piston ring clamp.
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Piston and cylinder dimensions Page
13-86
8 - Piston rings
Offset gaps by 120
Remove and install with piston ring pliers.
"TOP" must face piston crown
Check ring gap Fig. 1, Page 13-83
Check ring to groove clearance Fig. 2,
Page 13-83
13-83
Fig. 1 Checking piston ring gap

- Push ring squarely from above down to approx. 15 mm from bottom
end of cylinder. To do this, use a piston without rings.
Piston ring New Wear limit
Dimensions in mm
1. compression ring 0.20 to 0.40 0.8
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Oil scraper ring 0.25 to 0.50 0.8
Fig. 2 Checking ring to groove clearance

- Clean groove before checking clearance.
Piston ring New Wear limit
Dimensions in mm
Oil scraper ring 0.03 to 0.06 0.15
13-84
Fig. 3 Checking piston

- Measure pistons approx. 10 mm from lower edge of skirt, at 90 to
piston pin axis.
Permissible deviation from nominal dimension: no more than 0.04 mm
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Fig. 4 Checking cylinder bores
Use internal dial gauge 50 to 100 mm

- Take measurements at 3 positions in both lateral direction -A- and
longitudinal direction -B-.
Permissible deviation from nominal dimension: no more than 0.08 mm
13-85
Fig. 5 Location of bearing shell

- Install bearing shells centrally into connecting rod or into connecting
rod bearing cap.
Distance a = 3.0 mm
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Fig. 6 Oil spray jet and pressure relief valve
1 - Oil spray jet (for piston cooling)
2 - Bolt with pressure relief valve - 27 Nm
Opening pressure 1.3 to 1.6 bar
13-86
Piston and cylinder dimensions
Honing Piston Bore

dimension diameter diameter
Basic mm 80.950 1) 81.01
dimension
Oversize mm 81.450 1) 81.51
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1)Dimension without graphite coating (thickness
0.02 mm). The graphite coating on the piston
skirts wears away.
Cylinder head, removing and installing Page 1 of 42
15-1
Cylinder head, removing and

installing
Note:
Always replace the cylinder head bolts.
When performing repairs, replace seals,

gaskets, self-locking nuts and bolts which have
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a specified tightening angle.
The hose connectors and hoses of charge air

system must be free of oil and grease before
assembling.
When installing an exchange cylinder head with

the camshafts installed, the contact surfaces
between bucket tappet and cam running
surface must be oiled after installation of the
cylinder head.
The plastic protectors fitted to protect the open

valves must only be removed immediately
before installing the cylinder head.
When installing a new cylinder head or cylinder

head gasket, drain off all the old coolant and re-
fill with new coolant.
Cylinder heads which have cracks between the

valve seats or between valve seat inserts and
the spark plug thread can be used further
without reducing service life, provided the
cracks do not exceed a maximum of 0.3 mm in
width, or when no more than the first 4 turns of
the spark plug threads are cracked.
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15-2
Part I - Cylinder head components
1 - Cylinder head gasket

Replacing Removing cylinder head,
Page 15-20
Installation position: Part No. to cylinder
head
After replacing, fill with fresh coolant
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2 - Cylinder head
Removing Page 15-20
Check for distortion Fig. 1, Page
15-7
Reworking dimension Fig. 2, Page
15-7
Installing Page 15-28 .
15-3
3 - Oil deflector
Note installation position
4 - Cylinder head bolt
Always replace
Note sequence when loosening Page
15-27
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Note sequence when tightening Page
15-30
5 - Cylinder head cover
6 - Ignition coil
7 - Cap
8 - Gasket
Replace if damaged or leaking
9 - 10 Nm
First tighten inner nuts
Tighten outer nuts diagonally
15-4
10 - Cylinder head cover gasket

Replace if damaged or leaking
Before installing gasket apply "AMV 174
004 01" to sealing points Fig. 3 and
Fig. 4, Page 15-8
11 - Gasket
Always replace
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12 - Combi valve for secondary air inlet
With screw connection
13 - 10 Nm
14 - Coolant flange
With coolant temperature sensor
15 - 10 Nm
16 - O-ring
Always replace
15-5
Part II - Intake manifold components
1 - Gasket
Always replace
2 - 10 Nm
3 - 10 Nm
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4 - O-ring
For injector
Always replace
5 - Fuel rail
With injectors
6 - Top coolant line
7 - 10 Nm
8 - 10 Nm
15-6
9 - O-ring
For top coolant line
Always replace
10 - 10 Nm
11 - Intake manifold
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12 - 20 Nm
13 - Support
For intake manifold
15-7
Fig. 1 Check cylinder head for distortion.

- Use knife edge, straightedge and feeler gauge to measure at several
points.
Max. permissible distortion: 0.1 mm
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Fig. 2 Reworking dimension for cylinder head
Reworking the cylinder head (shaving) is only permitted down to minimum

dimension -a-.
Minimum dimension -a- = 139.20 mm
15-8
Fig. 3 Seal connections between double bearing cap and cylinder

head
- Apply a small quantity of sealant AMV 174 004 01 to sides of joints -
arrows- on upper sealing surface of cylinder head.
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Fig. 4 Seal connections between camshaft adjuster and cylinder
head
15-9
Intake manifold, removing and installing
Removing


switched off.
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- Drain coolant Page 19-4 .
- Disconnect coolant hoses -1- and -3-.

- Unbolt coolant expansion tank -2- (-arrows-).
- Disconnect electrical wiring to coolant level display switch -F66- on
bottom of expansion tank.
15-10
- Unplug vacuum hoses -1 to 3-.

- Disconnect connectors as follows:
4 - on intake air temperature sensor -G42-
5 - for throttle valve control module -J338-
- Remove the air duct hose -6- from throttle valve control module.
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- Remove retaining plate for recirculation valve for turbocharger -N249- -
1- from underneath intake line and secondary air inlet valve -N112 -2- -
arrows-.
Note:
The electrical connectors and vacuum hoses do not have to be

disconnected.
15-11
- Disconnect connector for Camshaft Position sensor -arrow-.
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- Remove retaining bolts for fuel manifold and disconnect vacuum line
from fuel pressure regulator -arrows-.
- Remove fuel manifold together with injectors from intake manifold and
place it on a clean cloth at back of engine compartment.
Note:
Carefully protect the removed injectors from contamination.
15-12
- Disconnect coolant hoses from upper coolant

line.
- Move electrical wiring at top of coolant line

aside.
- Unbolt upper coolant line from intake manifold and coolant flange -
arrows- at back of cylinder head.
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- Remove intake line support -arrows-.
- Disconnect hose -1- to ACF valve on intake line.
- Pull out oil dipstick.
- Remove bracket of guide line for oil dipstick.
15-13
- Remove suction hose from flange and

remove.
Note:
Plug intake ports on cylinder head with clean

cloths.
Installing
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Note:
All cable ties which are released or cut open

when removing must be located in the same
position when installing.
Hose connections and hoses of charge air

system must be free of oil and grease before
assembling.
Replace seals and gaskets.
- Top up coolant Page 19-7 .
- After connecting battery, enter anti-theft code for

radio.
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15-14
- Actuate all power window switches again for at

least one second in the "close" direction to
activate automatic open/close function.
- Perform throttle-valve control module

adaption:
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Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel
Injection & Ignition, Engine Code(s): AWM ,
Repair Group 24
Tightening torques
Component Nm
Intake manifold to cylinder head 10
Support for intake to intake 20
manifold manifold
to bracket 20
Fuel manifold to intake manifold 10
Coolant line to coolant flange 10
Coolant line on intake line 10
Hose clamps for coolant hoses
2
Hose clamps for air duct hoses
3.5
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15-15
Cylinder head cover, removing and

installing
Removing
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- Remove air filter cover -arrow-.
15-16

- Remove air ducts -1- and -2-.
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- Remove line of crankcase vent -1-.
- Disconnect hose of crankcase venting from cylinder head cover.
- Remove line -1- from combination valve for secondary air inlet on
cylinder head cover and from heat shield -3- (engine code ANB only).
- Slightly swivel secondary air inlet line to side.
15-17
- Disconnect Ground wire -2-.

- Disconnect connectors -3-.
- Move lines and hoses aside.
- Remove ignition coils -1-.
- Loosen 2 top retaining clamps for toothed belt guard.
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- Loosen nuts -arrows- for cylinder head cover and remove cylinder head
cover.
15-18
Installing

Note:
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Replace cylinder head cover gaskets if
damaged.


- First tighten inner nuts for cylinder head cover then tighten outer nuts
diagonally.
- Check that upper toothed belt guard is correctly seated.
15-19
Tightening torques
Component Nm
Cylinder head cover to cylinder head 10
Line of crankcase vent to cylinder
headcover
10
Line of secondary air inlet to cylinder head
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cover
10
Hose clamps 2
15-20
Cylinder head, removing
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Pin T40011
15-21
Procedure
Engine in vehicle

Page 13-1 .
Note:
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when removing must be located in the same


switched off.
- Remove intake line Page 15-9 .
- Remove ribbed belt and tensioner for ribbed belt

Page 13-18 .
15-22
- Disconnect connectors as follows:

1 - on ACF valve (in addition, remove ACF valve from air filter housing)
2 - on air mass meter
3 - on solenoid valve for charge pressure control -N75-
- Disconnect hose connections, move wiring aside and remove air filter
housing -arrows-.
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- Disconnect connector -arrow- from camshaft adjuster.
15-23
- Remove line of crankcase vent -1-.

- Remove hose of crankcase venting from cylinder head cover.
- Remove line -1- from combination valve for secondary air inlet on
cylinder head cover and from heat shield -3- (engine code ANB only).
- Slightly swivel secondary air inlet line to side.
- Remove heat shield.
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- Remove bolts -1- and -2- of oil feed line.
- Remove bolts -3- for exhaust turbocharger.
15-24
- Disconnect connector -arrow- at coolant temperature sensor -G2-/-

G62-.
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- Disconnect vacuum hose -arrow- from combination valve.
- Remove bolts -2- and -3- and remove coolant flange.
- Remove bracket -1- for oil feed line.
- Unclip all wiring from cylinder head and move clear to one side.
- Remove coolant hose going to heat exchanger (heater unit) at back of
cylinder head (first release retainers on connecting flange).
15-25
- Remove upper toothed belt guard Page 13-

35 .

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- Attach socket head fastener T10092 into tensioner.
- Only tension pressure piston of tensioner until piston is secured with
pin T40011.
- Remove toothed belt from camshaft sprocket.
15-26
- Disconnec Ground wire -2-.

- Move lines and hoses aside.
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- Loosen nuts -arrows- for cylinder head cover and remove cylinder head
cover.
- Remove both oil deflectors.
15-27
- Loosen cylinder head bolts in correct sequence.

- Remove cylinder head.
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15-28
Cylinder head, installing
Note:
Always replace the cylinder head bolts.
When performing repairs, replace seals,

gaskets, self-locking nuts and bolts which have
a specified tightening angle.
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Secure all hose connections with the correct
hose clips (same as original equipment):
Parts List
If repairing, carefully remove any remains of

gasket material from the cylinder head and
cylinder block. Make sure that no long scores or
scratches are made on the surfaces.
Carefully remove any remaining emery and

abrasive material.
Remove new cylinder head gasket from

packaging, just before installation.
Handle gasket extremely carefully. Damaging
the silicone layer or the indented area will lead

to leaks.
No oil or coolant must be allowed to remain in

the blind holes for the cylinder head bolts in the
cylinder head.
- Before positioning cylinder head, set crankshaft and camshaft to TDC

of cylinder 1.
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15-29
- Loosen bolts -1- and -2- on turbocharger bracket (about 2 full turns
each) to avoid stressing when installing cylinder head.
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- Place cylinder head gasket in position.
Note position of centralizing pins in cylinder block -arrows-.
Check installation position of cylinder head gasket. The Part No.
should be legible from intake side.
- Position cylinder head.
15-30
- Insert cylinder head bolts and tighten by hand.
- Tighten cylinder head bolts in two stages in sequence shown as

follows:
- Tighten using torque wrench:
Stage 1: 40 Nm
- Tighten with rigid wrench:
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Stage 2: 180 (1/2turn) further (2 turns of 90 further is
permissible)
Note:
It is not necessary to retighten cylinder head bolts after repairs have been
performed.
- Tighten exhaust turbocharger to exhaust manifold with new seal and

attach bracket to cylinder block Page 21-45 .
- Install cylinder head cover Page 15-18 .
Note:
Observe all instructions on removing and installing the toothed belt

Page 13-40 .
15-31
- Install ribbed belt and tensioner for ribbed belt

Page 13-20 .
- Install intake line Page 15-13 .
- Replace coolant Page 19-7 .
- After connecting battery, enter anti theft code for
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radio.

activate the automatic open/close function.
- Perform throttle-valve control module

adaption:

Repair Group 24
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15-32
Tightening torques
Component Nm
Support for intake to intake 20
manifold manifold
to bracket 20
Turbocharger to exhaust manifold 35 1)
2)
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Turbocharger bracket to cylinder block
25
Turbocharger bracket to turbocharger
30
2
3.5
1) Replace bolts
2)Coat thread and head attachment area with

high temperature lubricant G 052 112 A3
15-33
Compression, checking
Spark plug spanner 3122 B
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Compression tester VAG VAG 1763
15-34
Test conditions:
Engine oil temperature at least 30 C
Battery voltage at least 12.7 V
Test sequence
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- Switch ignition off.

15-35
- Remove spark plugs with spark plug spanner

3122B.
- Disconnect connectors from all injectors.
- Fully open throttle valve.
- Check compression with compression tester
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VAG VAG 1763.
Note:
Using the compression tester
Operating instructions
- Operate starter until tester shows no further

pressure increase.
Compression pressure values:
New Wear limit Permissible

difference between
cylinders
bar excess
pressure
bar excess bar excess

pressure pressure
9.0 to 14.0 7.5 max. 3.0
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15-36
- Install spark plugs and ignition coils.
Note:
Replace gaskets for ignition coils if damaged.
- Check Diagnostic Trouble Code (DTC)

memory:
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Repair Group 01
Note:
DTCs will have been recorded in the DTC

memory because the connectors have been
unplugged. Check and, if necessary, erase the
DTC memory after completing the test.
Tightening torques
Component Nm
Spark plugs in cylinder head 30
Valve gear, servicing Page 1 of 58
15-37
Valve gear, servicing

Note:
Cylinder heads that have cracks between the

valve seats or between valve seat inserts and
the spark plug thread can be used further
without reducing service life, provided the
cracks do not exceed a maximum of 0.3 mm in
width, or when no more than the first 4 turns of
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the spark plug threads are cracked.
Wait about 30 minutes after installing the

camshafts before starting the engine. Hydraulic
valve compensation elements have to settle
(otherwise valves will strike pistons).
After working on the valve gear, turn the engine

carefully at least 2 rotations to ensure that none
of the valves make contact when the starter is
operated.
Replace all gaskets and seals.
15-38
1 - 65 Nm
Counterhold with 3036 to loosen and
tighten
2 - Camshaft sprocket
Note correct installation position: The
narrow web of the camshaft sprocket faces
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forward and the marking for No. 1 cylinder
is visible from the front Page 15-55
3 - Sealing ring
15-39
4 - Cylinder head
See note Page 15-37
Checking valve guides Page 15-86
Reworking valve seats Page 15-88
Dowel sleeves for bearing caps must be
located in cylinder head.
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Seal joints Fig. 3 and Fig. 4,
Page 15-8
5 - Valve guide
Checking Page 15-86
6 - Valve stem seal
15-40
7 - Valve springs
8 - Valve spring plate
9 - Valve keepers
10 - Hydraulic valve lifter
Checking Page 15-74
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Do not interchange
Store with cam contact surface downward
Before installing check camshaft axial
clearance Page 15-48
Oil contact surface
15-41
11 - Intake camshaft
Check radial clearance with Plastigage
(hydraulic lifters not installed). Wear limit:
0.1 mm
Run-out: no more than 0.035 mm
Checking axial clearance Page 15-48
Removing and installing camshafts
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Page 15-62
12 - Bearing cap for intake camshaft
Dowel sleeves must be located in cylinder
head.
Installation sequence Page 15-67
15-42
13 - Double bearing cap

head
Coat sealing surface lightly with AMV 188
001 02 before installation Page 15-71
Seal connections between double bearing
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cap and cylinder head Fig. 3, Page
15-8
14 - Exhaust camshaft
Check radial clearance with Plastigage
(hydraulic lifters not installed). Wear limit:
0.1 mm
Run-out: no more than 0.035 mm
Checking axial clearance Page 15-48
Removing and installing camshafts
Page 15-62
15-43
15 - Bearing cap for exhaust camshaft

head
Installation sequence Page 15-67
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16 - 10 Nm
17 - 10 Nm
18 - Drive chain
Check for wear
Before removing, mark installation position
Page 15-66
Removing and installing camshaft Page
15-62
15-44
19 - Camshaft adjuster
With solenoid valve for camshaft
adjustment -N205-
Checking Page 15-92
Hold in position with retainer for chain
tensioner 3366 before removing
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Seal sides of joints between camshaft
adjuster and cylinder head Fig. 4 ,
Page 15-8
20 - Metal/rubber gasket
Before installation coat sealing surface
lightly with AMV 188 001 02 Page 15-67
21 - Gasket
Always replace
15-45
22 - Exhaust valve
With sodium filling
Note instructions on scrapping valves with
a sodium filling Page 15-47
Do not rework, only lapping in is permitted
Valve dimensions Fig. 1, Page 15-
47
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23 - Intake valve
Do not rework, only lapping in is permitted
Valve dimensions Fig. 1, Page 15-
47
15-46
24 - Sealing ring
For intake camshaft
25 - Rotor for Camshaft Position sensor
Note correct installation position: Insert tab
in notch of camshaft
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26 - Washer
With cone
27 - 25 Nm
28 - Housing for Camshaft Position sensor -
G40-
29 - 10 Nm
15-47
Fig. 1 Valve dimensions
Note:
Intake and exhaust valves must not be reworked. Only lapping in is

permitted.
Dimension Intake valve Exhaust valve
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Diameter -a- mm 26.80 to 27.00 29.80 to 30.00
Diameter -b- mm 5.95...5.97 5.94 to 5.95
-c- mm 104.84 to 105.34 103.64 to 104.14
45 45
CAUTION!
Worn exhaust valves with sodium filling must not be disposed of

until they have been treated as follows:
The valves must be sawn into two sections with a metal saw at a
point between the center of the shaft and the valve head. They
must not come into contact with water while this is done. Then
throw the valves into a bucket of water (not more than ten at a
time). Step back immediately because a chemical reaction occurs
when the sodium filling burns.
After this treatment the valves can be disposed of in the normal
way.
15-48
Camshaft axial clearance, checking
Universal dial indicator bracket VW 387

Dial indicator
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15-49
Test sequence
Perform measurement with hydraulic lifters

removed and with bearing cap at chain sprocket
end and double bearing cap at camshaft
sprocket end installed.
- Attach dial indicator with universal dial indicator

holder VW 387 to cylinder head:
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Intake camshaft
Exhaust camshaft
Wear limit for intake and exhaust camshafts.
Axial clearance: no more than 0.20 mm
15-50
Exhaust camshaft oil seal, replacing

Holding tool 3036
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Pin T40011
15-51
Removing
Cylinder head installed

Page 13-1 .
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- Remove upper toothed belt guard Page 13-35 .
15-52

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- Attach socket head fastener T10092 into tensioner for toothed belt.
Note:
Only tension piston of tensioner until pressure piston is secured with pin
T40011.
- Take toothed belt off camshaft sprocket.
15-53
- Loosen camshaft sprocket (counter hold with

3036).
- Remove camshaft sprocket.
- To guide oil seal extractor, thread securing bolt for camshaft sprocket -
arrow- into camshaft as far as it will go by hand.
- Adjust inner part of oil seal extractor 2085 two turns (approx. 3 mm)
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from outer part and lock in position with knurled screw.
- Lubricate threaded head of oil seal extractor 2085, place it in position

and, exerting firm pressure, screw it into oil seal as far as possible.
- Loosen knurled screw and turn inner part of extractor against camshaft
until oil seal has been extracted.
- Clamp flats of oil seal extractor in vice. Remove oil seal with pliers.
15-54
Installing
Note:
Do not oil sealing lip of oil seal.
- Place guide sleeve T10071/1 onto crankshaft journal.

- Push sealing ring via guide sleeve onto shaft journal.
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- Remove guide sleeve.
- Press in sealing ring with pressure sleeve T10071/3 and bolt T10071/4.
15-55
- Install camshaft sprocket.

Note correct installation position: Narrow web of camshaft sprocket
faces outward -arrows- and marking for No. 1 is visible from front.
- Install securing bolt for camshaft sprocket (use counter hold tool 3036).
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- Align markings on camshaft sprocket with marking on cylinder head
cover.
- Align marking on vibration damper with marking on lower part of
toothed belt guard.
Note:
If a piston is at TDC the valves could strike the piston when turning the
camshaft. To avoid damage to valves and pistons the pistons must not be
at TDC.
15-56
- Install toothed belt (adjust valve timing) Page

13-44 .
Note:
Observe all instructions on removing and

installing the toothed belt Page 13-40 .
Tightening torque
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Component Nm
Camshaft sprocket to camshaft 65
15-57
Intake camshaft seal, replacing
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Installation tool 3241
15-58
Removing

Page 13-1 .
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- Disconnect connector from camshaft position sensor -arrow-.

- Remove sensor housing.
- Remove sensor rotor and washer.
15-59
- Insert camshaft sprocket bolt 2085/1 by hand into camshaft as far as it

will go.
- Adjust inner part of oil seal extractor 2085 two turns (approx. 3 mm)
from outer part and lock in position with knurled screw.
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- Lubricate threaded head of oil seal extractor 2085, place it in position
and, exerting firm pressure, screw it into oil seal as far as possible.
- Loosen knurled screw and turn inner part of extractor against camshaft
until oil seal has been extracted.
15-60
Installing
Note:
Production variations may have the shaft

sealing rings with ring spring or PTFE sealing
rings used at the intake camshaft.
Difference: The regular shaft sealing ring has only one sealing lip -
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arrow 1- which is tensioned by a spring. The PTFE sealing ring has a
thread-like sealing area -arrow 2- but no spring.
When installing, the sealing surface of the PTFE sealing ring must not
be stretched. For this reason it is not permitted to install the PTFE
sealing ring together with the guide sleeve for sealing rings with
spring.
The PTFE sealing rings must be aligned to the rotation direction of the
shaft (see arrow marking on sealing ring). The wrong rotation direction
causes oil leakage.
Installing PTFE sealing ring:
- Check edge of chamfer -arrow- on shaft end of intake camshaft for

burrs or sharp edges. If necessary, smooth edge with an oil stone.
Note:
- Push PTFE sealing ring carefully onto shaft end by hand.
15-61
Installing sealing ring with spring:
Note:
- Place guide sleeve 3241/2 onto camshaft journal.

- Slide oil seal over guide sleeve.
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All models:
- Press in sealing ring with pressure sleeve 3241/1 as far as it will go. To
do this use bolt 3241/3.
- Install camshaft position sensor Page 15-46 .
- Install toothed belt guard (upper section).
Tightening torques
Component Nm
Camshaft position sensor rotor to camshaft 25
Camshaft position sensor housing to cylinder head 10
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15-62
Camshafts and camshaft adjuster,

Holding tool 3036

Retainer for chain tensioner 3366
Tensioning screw T10092
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Guide pin T40011
15-63
Removing

Page 13-1 .
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- Remove combination valve for secondary air inlet Page 26-64 .

15-64

- Remove cylinder head cover Page 15-15 .
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- Thread socket head fastener T10092 into tensioner for toothed belt.
- Tension pressure piston of tensioner until piston is secured with pin
T40011.
- Remove toothed belt from camshaft sprocket.
15-65
- Loosen camshaft sprocket (counter hold with

3036).
- Remove camshaft sprocket.
- Remove camshaft position sensor completely.
- Hold camshaft adjuster in position with retainer for chain tensioner
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3366.
Note:
If the retainer for chain tensioner is tightened excessively, this can

damage the camshaft adjuster.
- Re-check TDC position of camshafts.

Marks on two camshafts must be in line with arrows on bearing
caps.
15-66
- Clean chain and camshaft sprockets opposite

two arrows on bearing caps and mark
installation position with color marks.
Distance between two arrows or color markings are 16 rollers on

drive chain.
Notch on exhaust camshaft is offset slightly toward inside in
relation to chain roller -1-.
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Note:
Do not mark chain with a center punch or by making a notch or similar

marking.
- Remove bearing caps 3 and 5 on intake and exhaust camshafts.

- Remove double bearing cap.
- Remove both bearing caps next to intake and exhaust camshaft chain
sprockets.
- Remove securing bolts for camshaft adjuster.
15-67
- Loosen bearing caps 2 and 4 of intake and exhaust camshafts

alternately and diagonally, and remove.
- Remove intake and exhaust camshafts with camshaft adjuster.
Installing
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- Replace rubber/metal gasket for hydraulic chain tensioner and apply a
thin coat of sealant AMV 188 001 02 to shaded area.
15-68
- Install drive chain on camshaft sprockets as

follows:
When old chain is being re-installed, install so that colored

markings are in line -arrows-.
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When a new chain is being installed, distance between notches -A-
and -B- on camshafts must be 16 rollers on chain. The illustration
shows exact positions of 1st and 16th rollers on sprockets.
Notch -A- is offset slightly toward inside in relation to chain roller -
1-.
- Push camshaft adjuster between drive chain (2nd mechanic required).
15-69
- Position camshafts together with drive chain and

camshaft adjuster on cylinder head.
- Oil running surfaces of both camshafts.
Note:
Dowel sleeves for bearing caps and camshaft
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adjuster must be located in cylinder head.
When installing bearing caps ensure that the

identification mark is readable from the intake
side of the cylinder head.
- Tighten mountings of camshaft adjuster (watch

position of dowel sleeves).
- Tighten bearing caps 2 and 4 of intake and exhaust camshafts in

stages and in diagonal sequence (watch position of dowel sleeves).
- Install two bearing caps next to chain sprockets on intake and exhaust
camshafts.
15-70
- Check correct setting of camshafts:
Two markings on camshafts must be in line with two arrows on

bearing caps -arrows-.
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Distance between two arrows on bearing caps or color markings are
16 rollers on drive chain.
Notch on exhaust camshaft is offset slightly toward inside in relation
to chain roller -1-.
15-71
- Remove holder for chain tensioner 3366.
- Slightly coat shaded area of dual bearing cap with sealant AMV 188
001 02 and install bearing cap (observe position dowel sleeves).
- Install remaining bearing caps (watch position of dowel sleeves).
- Replace sealing rings for intake and exhaust camshafts as of
Page 15-50 .
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- Install camshaft sprocket.
Note correct installation position: Narrow web of camshaft sprocket
faces outward -arrows- and marking for No. 1 is visible from front.
- Install securing bolt for camshaft sprocket (use counter hold tool 3036).
- Install camshaft position sensor Page 15-46 .
- Install cylinder head cover Page 15-18 .
15-72
- Align markings on camshaft sprocket with marking on cylinder head

cover.
- Align marking on vibration damper with marking on lower part of
toothed belt guard.
Note:
When turning the camshaft the crankshaft must not be at TDC. There is a
danger of damage to the valves/piston crown.
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Note:
Page 13-40 .
Wait about 30 minutes after installing the camshafts before starting
the engine. Hydraulic valve compensation elements have to settle
After working on the valve gear, turn the engine carefully at least 2
rotations to ensure that none of the valves make contact when the
starter is operated.
15-73
Tightening torques
Component Nm
Bearing cap to cylinder head 10
Camshaft adjuster to cylinder head 10
Camshaft position sensor rotor to camshaft 25
Camshaft position sensor housing to 10
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cylinder head
Camshaft sprocket to camshaft 65
15-74
Hydraulic valve lifters, checking
Feeler gauge
Wood or plastic wedge
Note:
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Hydraulic valve lifters cannot be adjusted or
repaired.
Irregular valve noise during starting is normal.
Test sequence
- Start engine and let run until coolant

temperature has reached approx. 80 C.
- Increase engine speed to about 2500 rpm for 2

minutes (perform road test if necessary).
Note:
If the irregular valve noises stop but recur

repeatedly during short journeys, a new oil
retention valve must be fitted. Oil retention valve
location: In oil filter bracket -Item 6 -, Page
17-7 .
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15-75
If the hydraulic lifters are still noisy, locate faulty

lifters as follows:
- Remove cylinder head cover Page 15-15 .
- Rotate crankshaft until cams of lifters to be

checked are pointing upward:
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- Vehicles with manual gearbox: push vehicle
forward with 4th gear engaged and ignition
switched off.
- Vehicles with automatic gearbox: remove

sound insulation and turn crankshaft clockwise
by applying wrench to central bolt on
crankshaft sprocket.
- Determine play between cam and lifter.
- Press down lifter with a wooden or plastic wedge. If an 0.20 mm feeler

gauge can be inserted between camshaft and lifter, replace lifter.
- Replacing lifter Removing and installing camshafts and camshaft
adjuster, Page 15-62 .
15-76
Note:


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operated.
15-77
Valve stem seals, replacing
Pressure hose VW 653/3

Spark plug spanner 3122 B
Puller 3364
Installation tool 3365
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Disassembly and assembly tool VAS 5161
15-78
Removing
Cylinder head in vehicle.
- Remove camshafts and camshaft adjuster

Page 15-62 .
Note:
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Ensure that the valve lifters are not
interchanged.
Mark position of valve lifters on rear of lifter with

a waterproof felt-tip pen.
- Remove lifters from guides and put them down

with contact surface downward.
- Remove spark plugs with spark plug spanner

3122B.
- Set piston of appropriate cylinder to bottom dead

center.
- Thread pressure hose VW 653/3 into spark plug threaded hole and
apply constant pressure of at least 6 bar.
15-79
- Install knock journal VAS 5161/3 into valve lifter guide.

- Loosen solid valve keepers on all five valves with a plastic hammer.
Exhaust side
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- Thread catch part VAS 5161/6 with insertion fork VAS 5161/4 onto a
stud of cylinder head.
- Push guide bushing VAS 5161/14 as far as it will go into lifter guide at
valve to be removed.
Installation position: Shaded areas point across to driving direction.
- Push knurled distance ring VAS 5161/17 onto assembly cartridge VAS
5161/8.
15-80
- Push assembly cartridge into guide sleeve.

- Attach pressure fork VAS 5161/2 to catch part VAS 5161/6 and press
assembly cartridge downward.
- At same time turn knurled screw of assembly cartridge toward right
until tips engage in valve keepers.
- Slightly move knurled screw back and forth. This causes valve keepers
to be pressed apart and taken into cartridge.
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- Release pressure fork.
- Remove assembly cartridge with spacer ring, guide bushing, valve
plate and valve spring.
15-81
Intake side:
- Thread catch part VAS 5161/6 with insertion fork VAS 5161/4 onto a
stud of cylinder head.
- Push in guide bush VAS 5161/13 as far as it will go into lifter guide at
valve to be removed.
Installation position: Shaded areas point across to driving direction.
- Push distance ring VAS 5161/17 onto assembly cartridge VAS 5161/8.
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- Push assembly cartridge into guide sleeve.
- Attach pressure fork VAS 5161/2 to catch part VAS 5161/6 and press
assembly cartridge downward.
- At same time turn knurled screw of assembly cartridge towards right
until the tips engage in valve keepers.
- Slightly move knurled screw back and forth. This causes valve keepers
to be pressed apart and taken into cartridge.
15-82
- Release pressure fork.

- Remove cartridge with spacer ring, guide bushing, valve plate and
valve spring.
All models:
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- Use 3364 to pull off valve stem seals.
15-83
Installing
Note:
A plastic sleeve -A- is enclosed with new valve

shaft seals.
- To prevent damage to new valve stem seals -B-, place plastic sleeve -
A- on valve stem.
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- Lightly oil sealing lip of valve stem seal.
- Push valve stem seal onto plastic sleeve.
- Carefully press valve stem seal onto valve guide using presser tool
3365.
- Remove plastic sleeve again.
- If valve keepers were taken out of assembly cartridge they must first be
inserted into tool VAS 5161/18.
Note:
The large diameter of the valve keepers points upward.
15-84
- Press assembly cartridge VAS 5161/8 onto insert tool from top and
take up valve keepers.
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- Insert assembly cartridge VAS 5161/8 into guide bushing VAS 5161/13
or VAS 5161/14 again.
- Push pressure fork down and pull knurled screw with left-hand and
right-hand thread upward. The valve keepers are now installed.
- Take load off pressure fork when knurled screw is still pulled.
- Install valve lifters.
15-85
- Install camshafts and camshaft adjuster Page

15-67
Note:

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operated.
15-86
Valve guides, checking
Universal dial indicator bracket VW 387

Dial indicator
Test sequence
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- Set valve in guide. Valve stem end must be flush with guide.
Note:
Due to the slight difference in stem diameters, ensure that only an intake
valve is used in an intake guide and an exhaust valve in an exhaust
guide.
15-87
- Determine lateral play.
Wear limit
Intake valve guide Exhaust valve guide

0.80 mm 0.80 mm
Note:
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If the wear limit is exceeded, repeat the
measurement with new valves. Replace valve
guide if wear limit is still exceeded.
If the valve is to be replaced as part of a repair,

use a new valve for the calculation.
15-88
Valve seats, reworking
Note:
If a good seating pattern cannot be obtained by

grinding the valve seats (lapping), they must be
refaced (reworked):
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Depth gauge
Valve seat machining tool
Note:
When repairing engines with leaking valves, it is

not sufficient to reface the valve seats and
replace the valves. The valve guides must also
be checked for wear. This is particularly
important on high mileage engines Page 15-
86 .
Only rework the valve seats as far as is

necessary to ensure a good seating pattern.
Before starting to rework the valve seats,

calculate the maximum permissible reworking
dimension.
If the maximum reworking dimension is

exceeded, the hydraulic lifters will not work
properly and the cylinder head will have to be
replaced.
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15-89
Calculating maximum permissible reworking

dimension
- Insert valve and press firmly against valve

seat.
Note:
If the valve is to be replaced as part of a repair,

use a new valve for the calculation.
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- Measure distance -a- between valve stem end (upper edge) and upper
cylinder head surface -1- with a depth gauge.
- Calculate max. permissible reworking dimension from measured
distance and minimum dimension.
Minimum dimensions
Outer intake valves Central intake valve Exhaust valves
31.0 mm 32.2 mm 31.9 mm
15-90
Measured distance minus minimum dimension =

max. permissible reworking dimension.
Example (for outer intake valve):

Measured distance 31.4 mm
- Minimum dimension -31.0 mm
= max. permissible = 0.4 mm
reworking dim.
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Note:
If the maximum permissible reworking dimension

is 0 mm or less than 0 mm, repeat the
measurement with a new valve. If the measured
result is again 0 mm or less than 0 mm, replace
the cylinder head.
15-91
Rework valve seats
Dim. Intake valve seat

Dia. a mm 26.2
b mm 1.5 to 1.8
Z Lower edge of cylinder head
45 Valve seat angle
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30 Upper correction angle
60 Lower correction angle

Dim. Exhaust valve seat
Dia. a mm 29.0
b mm 1.8
Z Lower edge of cylinder head
45 Valve seat angle
30 Upper correction angle
60 Lower correction angle
Camshaft timing control, checking Page 1 of 7
15-92
Camshaft timing control,

checking
The adjustment of the intake camshaft is
dependent on the engine load and engine speed.
Oil pressure is applied to the camshaft adjuster
(mechanical adjustment device) via the electrical
solenoid valve for camshaft adjustment.
Note:
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Camshaft timing control only becomes active 25
seconds after starting engine.
15-93
Camshaft adjustment solenoid valves,

checking
VAG 1526 A
VAG 1527 B
VAG 1594 A
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VAG 1598/31
15-94
Test requirements:
Vehicle diagnostic, testing and information

system VAS 5051 or VAG 1551 Scan Tool
connected
Test sequence
- Initiate output Diagnostic Test Mode (DTM) and
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activate solenoid valve for camshaft adjuster.
Output Diagnostic Test Mode Display

Camshaft timing control
This valve is actuated (clicks) for approx. one minute if the operation is
not switched to the next component by pressing the key.
If the valve is not actuated (does not click).
- Check internal resistance of solenoid valve for camshaft adjuster.
Checking internal resistance
15-95
- Connect multimeter to valve to measure resistance.

Specified value: 10 to 18
If specified value is not attained:
- Replace solenoid valve for camshaft adjuster.
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- Check power supply.
Checking power supply
Test requirements:
Fuse for solenoid valve for camshaft adjustment OK
Electrical Wiring Diagrams, Troubleshooting & Component Locations

binder
Fuel pump relay OK.
Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel Injection & Ignition,
Engine Code(s): AWM, Repair Group 24
15-96
- Connect voltage tester VAG 1527 B as follows:
Connector Measure to
contact
1 Engine Ground
- Operate starter briefly.

LED should light up.
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If the LED does not light up:
- Check wiring from contact 1 on connector via fuse to fuel pump relay
for open circuit:

binder
- Correct open circuit, if necessary.
If the LED lights up:
- Check actuation.
15-97
Checking actuation
- Connect voltage tester VAG 1527 B to contacts 1 (positive) and 2 of

connector.
- Initiate output Diagnostic Test Mode (DTM) and activate solenoid valve
for camshaft adjuster.
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Camshaft timing control
LED should flash.
If the LED lamp does not flash or if it lights up continuously:
- Connect the VAG 1598/31 test box to wiring harness leading to engine
control module (the engine control module should not be connected):
15-98
- Check for open circuit and short to positive or Ground in following

wiring connection:
Connector Test box VAG 1598/31
Contact
2 115
- If necessary, correct short circuit to Ground or open circuit.
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If the wiring is OK:
- Replace engine control module.
If no fault is found:
- Replace mechanical camshaft adjuster.
Lubrication system components, removing and installing Page 1 of 35
17-1
Lubrication system
components, removing and
installing
Note:
If large quantities of metal shavings or particles

are found in the engine oil when repairing the
engine, all oil passages must be cleaned
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carefully, and the oil cooler replaced in order to
prevent further damage occurring later.
The oil level must not be above max. mark on

dipstick - danger of damage to catalytic
converter!
Oil spray jet and pressure relief valve Fig.

1, Page 17-6
Viscosity grades and oil specifications:
Repair Manual, Maintenance
Oil system capacity:
17-2
Part I - Oil pump/oil pan components
1 - 28 Nm
2 - Limit stop for torque reaction support
3 - Oil pan
Apply silicone sealant D 176 404 A2 before
installing
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4 - Oil pan
With pressure relief valve (12 bar)
Before installation check whether the two
dowel sleeves -Pos. 12 - for the
centralizing of the oil pump/cylinder block
are present
Replace pump if there is scoring on moving
surfaces and gear teeth
Tightening torque for oil pump cover to oil
pump housing: 10 Nm
17-3
5 - Chain sprocket for oil pump

Sprocket can only be installed on oil pump
shaft in one position
6 - 22 Nm
7 - Drive chain for oil pump
Mark direction of rotation before removing
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Check for wear
8 - 15 Nm
9 - Sealing flange - front
Apply silicone sealant D 176 404 A2
Page 13-56
Replacing crankshaft oil seal on pulley end
Page 13-51
17-4
10 - Chain tensioner
Tighten to 16 Nm
Do not disassemble
Pre tension spring and engage before
installing
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If spring is broken replace chain tensioner
complete
11 - Chain sprocket for oil pump
12 - Dowel sleeves
2 pieces
13 - O-ring
Always replace
14 - 16 Nm
15 - Suction pipe
Clean strainer if soiled
17-5
16 - Baffle plate
17 - 16 Nm
18 - 15 Nm
Tighten in stages and in diagonal
sequence
Observe tightening sequence Page 17-
25
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19 - 40 Nm
20 - Sealing ring
Always replace
21 - Oil drain plug, 30 Nm
22 - Gasket
Always replace
23 - 10 Nm
24 - Oil return pipe
From exhaust turbocharger
17-6
Fig. 1 Oil spray jet and pressure relief valve

1 - Oil spray jet (for piston cooling)
2 - Bolt with pressure relief valve - 27 Nm
Opening pressure 1.3 to 1.6 bar
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17-7
Part II - Oil filter bracket components
1 - Screw plug - 40 Nm
2 - Sealing ring
Always replace
3 - Spring
For pressure relief valve, approx. 4 bar
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4 - Piston
For pressure relief valve, approx. 4 bar
5 - Gasket
Always replace
6 - Oil retention valve
Tighten to 8 Nm
Built into oil filter bracket
7 - O-ring
Always replace
Slide on until flush with collar on pipe -Item
9-
17-8
8 - Locking clip
9 - Pipe
For crankcase breather
10 - 20 Nm
Install with locking fluid D 000 600 A2
11 - Bottom coolant pipe
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12 - Screw plug - 15 Nm
13 - Sealing ring
If seal is leaking, cut open and replace
14 - Oil supply pipe
To turbocharger
15 - Banjo bolt - 30 Nm
16 - Seals
Always replace
17-9
17 - Oil pressure switch -F1-, 1.4 bar - 25 Nm

Black insulation
Checking Page 17-30
18 - Sealing ring
If seal is leaking, cut open and replace
19 - 15 Nm + 1/ turn (90 ) further
4
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Always replace
20 - Gasket
Always replace
Engage in projections on oil cooler
21 - Oil filter
Observe change intervals
Observe installation instructions on oil filter

Tighten to 20 Nm
17-10
22 - 25 Nm
23 - Oil cooler
See note Page 17-1
Ensure clearance to adjacent components
Coolant hose connection diagram Page
19-2
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24 - Oil filter bracket
With pressure relief valve, approx. 4 bar
17-11
Oil pan, removing and installing
Support bar 10-222A

Lifting tackle 2024 A
Socket 3249
Workshop crane VAG 1202 A
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Electric drill with plastic brush attachment
Protective goggles
17-12
Removing
Engine in vehicle

Page 13-1 .
- Unbolt bracket for sound insulation -arrow-.
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- Remove air duct hose on bottom left on charge air cooler.
17-13
- Remove seal from plenum chamber cover in direction of arrow.

- Remove plenum chamber cover -1- from front.
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- Remove nut -arrow- from top of left engine mounting.
17-14
- Set up support bar 10-222 A on fender panel flanges.
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- Remove lifting eye from lifting tackle 2024 A.
- Replace pin -1- in center hole on lifting tackle and secure with locking
pin.
- Engage pin on lifting tackle 2024 A on spindle of support bar 10-222 A.
17-15
- Engage lifting tackle 2024 A in front and rear lifting eyes on engine.
CAUTION!
The hooks and locating pins of the lifting tackle must be secured
with locking pins -arrows in illustration-.
- Pretension engine with spindle of support bar, do not lift.

- Drain engine oil.
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- Remove oil return line of exhaust turbocharger from oil pan.
- Disconnect electrical connector -arrow- from oil level sender.
17-16
Vehicles with automatic transmission:
Note:
Observe cleanliness rules when working on the

automatic transmission:
Repair Manual, 5 Spd. Automatic
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Transmission 01V, Repair Group 37
- Remove bolt -3- and disconnect ATF lines from transmission.
Note:
Ignore positions -1- and -2-.
- Remove bracket for ATF lines from engine.

- Move ATF lines aside.
All models:
- Remove stop for torque reaction support -arrows-.
17-17
- Where present unclip operating rod of vehicle level sender from lower
transverse link -arrow-.
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- Cut through cable ties -arrows-. Open retainer for starter cable and
take out electrical wiring.
17-18
- Mark positions of mountings -1- and locating sleeves -2- on left and
right engine mountings (lower).
Note:
Different mounting holes are provided for the different engine versions.
- Remove nut -1- from lower right of engine mounting.

- Completely remove left engine mounting.
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- Support subframe with workshop crane VAG 1202 A.
17-19
- Remove front subframe bolts -2- and -3- (left and right) and loosen
bolts -1-.
Note:
The subframe should be disconnected and lowered at the front only,

otherwise it will be necessary to check the wheel alignment.
Vehicles with manual transmission
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- Loosen nut -arrow- on left transmission mounting until it is flush with
end of bolt (approx. four turns on the thread).
17-20
- Loosen rear bolt -2- on left transmission mounting a few turns; remove
front bolt -1- on left transmission mounting.
All models:
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- Loosen rear bolt -2- on right transmission mounting a few turns;
remove front bolt -1- on right transmission mounting.
17-21
- Lower subframe slowly using workshop crane 1202 A.

- Take out workshop crane VAG 1202 A.
- Remove bolts for oil pan/transmission:
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- Remove M10 bolts -arrows-.
- Loosen bolts -1 to 18- diagonally.
17-22
Note:
Unscrew both rear oil pan bolts -1- and -2- with attachment 3249. Turn the
flywheel on vehicles with a manual transmission -3- until the notch -arrow-
is aligned with the bolt.
- Take off oil pan. If necessary loosen it by striking lightly with a rubber
hammer.
- Carefully remove sealant residues from cylinder block (remove baffle
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plate).
- Remove remaining sealant from oil pan, e.g. with a rotating plastic
brush.
WARNING!
Wear protective glasses.
- Clean sealing surfaces: they must be free of oil and grease.
17-23
Installing

Note:
The oil pan must be installed within 5 minutes

after applying the silicone sealant.
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- Cut off nozzle of tube at front marking (diameter of nozzle approx. 3
mm).
Thickness of sealant bead: 2 to 3 mm
17-24
Note:
The bead of sealant must not be thicker than 3

mm, as otherwise excess sealant will enter the
oil pan and obstruct the strainer in the oil intake
pipe.
- Apply bead of silicone sealant onto clean sealing surface of oil pan, as
illustrated. (Illustration shows position of sealant bead on cylinder
block).
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Note:
Be particularly careful when applying the bead of sealant around the rear
sealing flange (arrows in illustration).
17-25
- Immediately attach oil pan and tighten bolts in

described sequence:
- Tighten bolts -1 to 18- diagonally to 5 Nm.

- Tighten bolts securing oil pan to transmission to 45 Nm.
- Tighten bolts M10 -arrows- to 40 Nm.
- Tighten bolts -1 to 18- tighten diagonally to 15 Nm.
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Note:
When installing the oil pan with the engine removed from the vehicle,
ensure that the oil pan -3- is positioned flush with the intermediate
plate -1- at the flywheel end (i.e. oil pan should protrude dimension "a"
= 0.8 mm from cylinder block with respect to the cylinder block -2-).
After installing oil pan assembly, the sealant must dry for approx. 30
minutes. Only then may the engine be filled with oil.
17-26
- Support subframe with workshop crane VAG 1202 A.

- Installing subframe:
Repair Manual, Suspension, Wheels, Steering, Repair Group 40
- Secure ATF lines.
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Repair Manual, 5 Spd. Automatic Transmission 01V, Repair Group 37
All models:

- Fill engine with oil and check oil level.
- Check ATF level:
17-27
Tightening torques
Component Nm
Oil pan to cylinder block M7 15
M10 40
Oil pan to transmission 45
Limit stop for torque reaction support on oil
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pan
28
Engine mounting to subframe 25
Engine mounting to engine support 25
Transmission support to transmission M10 40
support
Transmission mounting to subframe
M8 25
Oil return pipe to oil pan 10
Oil drain plug 30
3.5
17-28
Oil pump, removing and installing
Removing
- Remove oil pan and baffle plate Page 17-

11 .
- Remove bolt -2-.
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- Remove sprocket wheel from oil pump shaft.
- Remove bolts -1- and -3- and remove oil pump.
17-29
Installing

- Insert dowel sleeves -Item 12 -, Page 17-4 on

top of oil pump.
Oil pump shaft/sprocket wheel location: Can
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only be installed in one position.
- Installing oil pan Page 17-23
Tightening torques
Component Nm
Chain sprocket to oil pump shaft 22
Oil pump to cylinder block 16
17-30
Oil pressure and oil pressure switch,

checking
VAG 1342
VAG 1527 B
VAG 1594 A
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17-31
Test requirements:
Oil level OK.
Engine oil temperature approx. 80 C.
Oil pressure warning lamp -K3- must come

on when ignition is switched on.
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In vehicles with auto check system the "OK"
display must appear (call up symbol).
Testing oil pressure switch
- Disconnect wire from oil pressure switch.
- Remove oil pressure switch and screw in oil pressure tester VAG 1342.
- Thread oil pressure switch -2- intoVAG 1342.
- Connect brown wire -1- of tester to Ground (-).
17-32
- Connect voltage tester VAG 1527 B to oil

pressure switch and positive side of battery (+)
using test leads from VAG 1594 A.
Test lamp should not light up.
- If test lamp lights up, install new oil pressure

switch.
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- Start engine.
Note:
The switching point of the oil pressure switch can

be reached when the engine is cranked on the
starter motor, so watch the tester and the test
lamp while starting the engine.
Black oil pressure switch:
LED must light up at 1.2 to 1.6 bar.
- If test lamp does not light up, install new oil

pressure switch.
17-33
Check oil pressure
- Disconnect wire from oil pressure switch.
- Remove oil pressure switch and screw in oil pressure tester VAG 1342.
- Thread oil pressure switch -2- intoVAG 1342.
- Start engine (engine oil temperature approx. 80 C).
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Oil pressure at idling speed: at least 1.3 bar
Oil pressure at 2000 rpm: 3.5 to 4.5 bar
If specified values are not attained:
- Pressure relief valve or oil pump faulty, replace oil pump Page 17-
28 .
17-34
Engine oil
The engine is filled with a high quality multigrade

oil at the factory. This oil may be used all year
round, except in extremely cold climates.
Viscosity grades and oil specifications
Viscosity grades and oil specifications:
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17-35
Engine oil level, checking
Test requirements:
Engine oil temperature at least 60 C
Vehicle must be level (horizontal)
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Wait a few minutes after switching off engine
to allow oil to flow back into oil pan.
- Pull out dipstick, wipe with a clean cloth and

insert again to stop.
- Pull out dipstick again and read oil level.
Markings on oil dipstick:
a - Oilmust not be topped up.

b - Oil may be topped up. The oil level may rise as far as area -a- after
topping up.
c - Oilmustbe topped up. The oil level is sufficient if somewhere in area -
b- (grooved area) after topping up.
Note:
The oil level must not be above marking -a- on the dipstick.
Cooling system components, removing and installing Page 1 of 38
19-1
Cooling system components,

WARNING!
Hot steam can escape when opening the cap

on the expansion tank: Cover the cap with a
cloth and open carefully.
Note:
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When the engine is warm the cooling system is
under pressure. If necessary release pressure
before beginning repair work.

Parts Catalog
Hose clip pliers VAG 1921 are recommended

when installing spring type clips.
Replace all gaskets and seals.
The arrow markings on the coolant lines and on

the ends of the hoses must be aligned with
each other.
Removing and installing viscous fan Page

13-21 .
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19-2
Cooling system diagram
1 - Radiator
2 - Upper coolant line
3 - Thermostat
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Removing and installing coolant pump
Page 19-12
Checking Page 19-22
4 - Coolant pump
Check for ease of movement
5 - Turbocharger
19-3
6 - Cylinder head/cylinder block

7 - Heating system heat exchanger
8 - Lower coolant line
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9 - Oil cooler
Removing and installing Item 23 ,
Page 17-10
10 - Expansion tank
With filler cap
Testing pressure relief valve in filler cap
Page 19-33
19-4
Cooling system, draining and filling
Adapter 1274/8
Line VAG 1274/10
Drip tray VAG 1306
Hose clamp pliers VAG 1921
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Special tool T10007
19-5
Draining
Note:
Catch drained off coolant in a clean container for

re-use or disposal.
WARNING!
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on the expansion tank: Cover the cap with a
cloth and open carefully.
- Open cover of coolant expansion tank

- Place drip tray VAG 1306 below engine.
- Remove lower coolant hose retaining clip -arrow- and remove coolant
hose from radiator.
19-6
Note:
With bumper and air duct in front of charge air cooler removed, the
coolant can also be drained from the radiator via the drain screw -arrow-.
If necessary use an auxiliary hose.
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- Disconnect lower coolant hose on oil cooler -arrow-, and drain off
remaining coolant.
19-7
Filling
Note:
The cooling system is filled all year round with a

mixture of water and an antifreeze/corrosion
protection agent.
Only use coolant additive G 012 A8 D meeting
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specification TL VW 774 D. Identification color:
red
CAUTION!
G 012 A8 D and other coolant additives

cannot be mixed. Otherwise, serious damage
to the engine may result.
If the fluid in the expansion tank is brown, this

means G 012 A8 D has been mixed with
another type of coolant. In this case, flush out
the cooling system and fill with fresh coolant. To
flush the system, fill it with clean water and run
the engine for about 2 minutes. This should
remove as much of the old coolant as possible.
G 012 A8 D and coolant additives marked

"meeting specification TL VW 774 D" prevent
frost and corrosion damage and stop scaling
while at the same time raising the boiling point
of the coolant. For these reasons the cooling
system must be filled all year round with the

correct anti-freeze and anti-corrosion additive.
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19-8
Because of its high boiling point, the coolant

improves engine reliability under heavy loads,
particularly in countries with tropical climates.
Protection against frost must be assured to

about -25 C (in arctic climatic countries to
about -35 C).
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The coolant concentration must not be reduced
by adding water, even in warmer seasons and
in warmer countries. The anti-freeze ratio must
be at least 40 %.
If greater frost protection is required in very cold

climates, the amount of G 012 A8 D can be
increased, but only up to 60% (this gives frost
protection to about -40 C). Otherwise, frost
protection is reduced again and cooling
effectiveness is also reduced.
Only use clean drinking water for mixing the

coolant.
If radiator, heat exchanger, cylinder head or

cylinder head gasket is replaced, do not reuse
old coolant.
Use special tool T10007 to check frost

protection of coolant additive G012 A8 D in
cooling system.
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19-9
Recommended mixture ratios:
Frost Anti-freeze G Water1)

protection concentration 012A8
to D 1)
-25 C 40% 3.0 l 4.0 l
-35 C 50% 3.5 l 3.5 l
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1)Coolant quantity: 7.0 liters (may vary
depending upon the vehicle equipment)
- Install lower coolant hose and secure.
- Screw adapter VAG 1274/8 onto coolant expansion tank.

- Fit special tool VAG 1274/10 onto adapter.
Note:
To fill expansion tank without special tools, remove expansion tank and
temporarily raise it about 100 mm.
19-10
- Remove seal from plenum chamber cover in direction of arrow.

- Remove plenum chamber cover -1- from front.
- Push back protective cover for coolant hose at connection of heat
exchanger.
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- Release coolant hose to heat exchanger and pull back hose until
bleeder hole in coolant hose -arrow- is no longer covered by
connection.
- Top up coolant until it flows out at bleeder hole in coolant hose.
- Push coolant hose on connection and tighten.
- Install expansion tank cap.
19-11
- Start engine and maintain an engine speed of

about 2000 rpm for approx. 3 minutes.
- Allow engine to run at idling speed until lower

hose on radiator becomes hot.
WARNING!
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on the expansion tank: Cover cap with a cloth
and open carefully.
- Check coolant level and top up if necessary. If

engine is warm, coolant level must be at max.
mark; if cold, between min. and max. marks.
- Stop engine.
19-12
Coolant pump, removing and installing
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Pin T40011
19-13
Removing
Engine in vehicle.

Page 13-1 .
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- Remove ribbed belt and tensioner for ribbed belt
Page 13-18 .
- Secure pulley for viscous fan with pin punch -1- and unfasten using
Allen key -2-.
19-14
- Mark direction of rotation of belt with chalk or felt

pen.
- Remove top and center toothed belt guard

Page 13-35 .

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- Thread socket head fastener T10092 into tensioner for toothed belt.
Note:
Only tension pressure piston of tensioner until the piston is secured with
pin T40011.
19-15
- Take toothed belt off camshaft sprocket and

coolant pump.
Note:
The vibration damper and lower toothed belt

guard do not have to be removed.
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The toothed belt should be left in position on
the crankshaft sprocket.
Before removing the coolant pump, cover

toothed belt with a cloth to protect from coolant.
- Remove coolant pump securing bolts -1- and remove coolant pump -2-.
19-16
Installing

Note:
Always replace seals and gaskets.
- Clean and smooth down sealing surface for O-
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ring as required.
- Lightly coat new O-ring -3- with coolant G 012 A8 D.

- Install coolant pump -2-.
Installation position: Sealing plug in housing faces downward.
- Tighten bolts -1- of coolant pump to 15 Nm.
Note:

Page 13-40 .
19-17

Page 13-20 .
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Tightening torque
Component Nm
Coolant pump to cylinder block 15
Center section of toothed belt guard to
cylinder block
10
1)
Hose clamps for coolant hoses 2
19-18
Coolant thermostat, removing and

installing, checking
Removing
- Observe or obtain radio code on vehicles with

coded radio.
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switched off.
Note:
- Loosen ribbed belt by turning tensioner in direction of arrow.

19-19
- Secure pulley for viscous fan with pin punch -1- and unfasten using
Allen key -2-.
- Remove viscous fan from mounting and place in front of radiator cowl.
- Disconnect wiring from rear of Generator.
- Loosen connections for Generator from top and bottom and remove
Generator.
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- Remove intake line support -arrows-.
19-20
- Release clip and disconnect coolant hose from connection -2-.

- Remove bolts -1- remove connection, O-Ring -3- and coolant
thermostat -4-.
Installing
Installation is carried out in the reverse order of removal; note the

following:
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Note:
- Clean and smooth down sealing surface for O-ring as required.

- Lightly coat new O-ring with coolant G 012 A8 D.
- Insert coolant thermostat.
Installation position: Cross-piece on thermostat should be vertical.
19-21

Page 13-20 .
- After connecting battery, enter anti-theft code for

radio.
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- Close windows fully using power window

switches.

activate automatic open/close function.
19-22
Tightening torques
Component Nm
Connection to cylinder block 15
Support for intake manifold
to intake manifold 20
to bracket 20
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Generator at bracket
M8 23
M10 46
3.5
Check coolant thermostat
- Heat thermostat in water bath.
Starts to Fully open Opening

open travel
approx. 87 C approx. 102 C at least 8 mm
1)
1) cannot be tested
19-23
Lower coolant line, removing and

installing
VAG 1921
Removing
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- Disconnect coolant hoses -1- and -3-.

- Unbolt coolant expansion tank -2- (-arrows-).
- Disconnect electrical wiring to coolant level display switch -F66- on
underside of expansion tank.
19-24
Note:
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- Disconnect heater hose at rear of coolant line -2-. To do this, release
retaining clip on connecting flange.
- Pull off coolant hose to oil cooler -4- at coolant line.
- Remove bolt -3-.
- Push lower coolant line toward rear of vehicle and remove.
- Remove plug -5- if necessary.
19-25
Installing

Note:
- Before installing, clean and smooth down
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sealing surface for O-ring.
- Moisten new O-ring -1- with G 012 A8 D coolant and slide onto coolant
line -2-.
- Push coolant line into opening in cylinder block.
Tightening torques
Component Nm
Coolant line to oil filter bracket 20
2
3.5
19-26
Radiator, removing and installing
VAG 1306
Removing
- Remove front bumper:
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- Remove air cowl in front of charge air cooler -arrows-.
19-27
- Disconnect cooling lines for power steering hydraulic fluid -arrows-.
WARNING!
Hot steam can escape when opening the cap on the expansion tank:
Cover cap with a cloth and open carefully.

- Place drip tray VAG 1306 below engine.
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- Turn drain screw -arrow- on radiator counter-clockwise. If necessary,
install a drain hose on connection.
19-28
- Release coolant hose retaining clip -arrow- and remove coolant hose
from radiator.
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- Disconnect coolant hose from top of radiator -arrow-.
19-29

- Remove air duct -1- and -2-.
Note:
Observe cleanliness rules when working on the automatic transmission:
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- Place drip tray underneath to collect oil.

- Remove ATF lines/hoses from radiator:
- Tie ATF lines to longitudinal member to avoid leakage of fluids.
All models:
CAUTION!
The air conditioner refrigerant circuit must not be opened.
19-30
Note:
To prevent damage to the condenser and

refrigerant lines/hoses, ensure that the lines and
hoses are not stretched, kinked or bent.
- Remove air cowls from radiator -4- (left and right).

- Remove securing bolts -1- and -2- for condenser.
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- Disconnect connector -3- from air conditioner pressure switch -F129-.
- Pull condenser up out of its bracket, pivot toward side and secure to
right-hand front wheel with wire.
Note:
Protect fender panel from damage.
- Release two retaining pins for radiator and pull out upward -arrows-.
- Pivot radiator toward front and lift out.
19-31
Installing

- Install front bumper:
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Repair Manual, Body Exterior, Repair Group
63
- Attach ATF lines.

- Check ATF level:

Tightening torques
Component Nm
Condenser to radiator 10
Cooling lines to radiator 10
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19-32
Cooling system, checking for leaks
VAG 1274
Adapter 1274/8
Adapter 1274/9
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19-33
Test requirements:
Engine at operating temperature.
WARNING!

on the expansion tank: Cover cap with a cloth
and open carefully.
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- Install tester VAG 1274 with adapter VAG 1274/8 onto expansion tank.
- Using hand pump on tester, build up a pressure of approx. 1.0 bar.
- If this pressure is not maintained, locate and repair leaks.
Testing pressure relief valve in filler cap
- Install tester VAG 1274 with adapter VAG 1274/9 onto sealing cover.
- Operate hand pump.
Pressure relief valve must open at a pressure of 1.4 to 1.6 bar.
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Charge air system with turbocharger, checking Page 1 of 17
21-1
Charge air system with

turbocharger, checking
Notes:
For cleanliness rules, see Page 21-44 .

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Parts Catalog
Before performing a check or repair, all hoses

and lines must be checked for tight seating and
leaks.
Always replace seals, gaskets and self-locking

nuts.
21-2
Safety precautions
Note the following points if testers and measuring

instruments have to be used during a road test:
WARNING!
Always attach testers and measuring

instruments to the back seat and have a
second person operate them from there.
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If test equipment were operated from the
front passenger seat, the person sitting there
could be injured if the front passenger airbag
were triggered in the event of an accident.
21-3
Connection diagram for charge air control

and vacuum pressure control
1 - Activated charcoal filter (ACF)

2 - EVAP Canister Purge Regulator valve -
N80-
3 - Non return valve for ACF
Between ACF container and intake line in
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front of exhaust turbocharger
Note position (light side/ dark side) as
shown in Fig; arrow faces in direction of
flow
4 - Air cleaner
With Mass Air Flow (MAF) sensor -G70-
21-4
5 - Turbocharger
Check charge pressure Page 21-8
6 - Combination valve for secondary air inlet
7 - Fuel pressure regulator
8 - To brake servo
9 - Non-return valve
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Between brake servo and intake line
flow
10 - Suction jet pump
21-5
Between brake servo and intake line
flow
12 - Vacuum reservoir
Location: In front left wheel housing
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beneath wheel housing liner
13 - Secondary Air Injection (AIR) Solenoid
valve -N112-
Location: Below intake line
14 - Crankcase breather
21-6
Between ACF container and intake line
flow
16 - From Leak Detection Pump (LDP) -V144-
17 - Charge air cooler
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With Charge Air Pressure sensor -G31-
18 - Throttle Valve Control Module -J338-
19 - Recirculating valve for turbocharger -
N249-
Location: below intake line
With Intake Air Temperature (IAT) sensor -
G42-
21-7
21 - Vacuum unit for charge pressure control

22 - Wastegate Bypass Regulator valve -N75-
Checking Page 21-33
23 - Mechanical air recirculation valve
Checking Page 21-24
24 - Crankcase breather pressure regulating
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valve
25 - Secondary Air Injection (AIR) Pump motor
-V101-
21-8
Turbocharger and charge pressure

regulating valve, checking
Turbocharger tester VAG 1397 A
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VAS 5051 with VAS 5051/1
or
VAG 1551 with VAG 1551/3 A
21-9
Test requirements:

connected.

Injection & Ignition, Engine Code(s): AWM,
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Repair Group 01
All hoses and lines must be checked for

correct seating and leaks.
Diagnostic Trouble Code (DTC) memory has

been checked:

Repair Group 01
Output Diagnostic Test Mode (DTM) has

been performed:

Repair Group 01
Test sequence
WARNING!
Always attach testers and measuring

instruments to the back seat and have a
second person operate them from there.
If test equipment were operated from the

front passenger seat, the person sitting there
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could be injured if the front passenger airbag
were triggered in the event of an accident.
21-10
- Connect T piece and measuring hose of turbocharger tester VAG 1397

A to intake manifold (front).
- Route measuring hose under rear edge of hood and into passenger
compartment via right hand window.
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- Switch on turbocharger tester and set measuring range selector switch
to position -I- (absolute pressure).
- Connect measuring hose to connection -I-.
21-11
Note:
Hose connections must be completely airtight,

otherwise measurements will not be correct.
Ensure that measuring hose is not pinched at

hood or side window.
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Pressing memory key M on turbocharger tester
will store the last measured value until memory
key M is pressed again or tester is switched off.
The decimal point in the display flashes to

indicate that the value is being stored.
If the battery voltage of the turbocharger tester

drops below the minimum level, an arrow will
appear at the top left of the display.
Before checking, drive vehicle quickly for at

least 3 km (choose a safe route that does not
include stopping).
A second mechanic is required to note readings

with the vehicle moving.
21-12
Read measured value block 115

- Read measured value block Display group 115, engine idling.
1 2 3 4
- Accelerate vehicle from 2000 rpm at wide open throttle in third gear,
and observe rev counter.
- At approx. 2500 rpm press print key on VAS 5051 or PRINT key on
VAG 1551 and at same time press recall button -M- on VAG 1397 A.
Note:
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The charge pressure level is measured with turbocharger tester VAG
1397/A. The vehicle diagnostic, measuring and information system VAS
5051 or the VAG 1551 Scan Tool is used to check whether the charge
pressure is being registered by the control module.
Specified value on VAG 1397 A: 1.700 to 1.800 bar
Read measured value block 115

Specified value on VAG 1551 or on VAS 5051 in display zone 4: 1700
1 2 3 4 to 1800 mbar
If specified value not attained table, Page 21-13
21-13
Charge air pressure control malfunctions
Malfunction Possible causes

Charge air pressure below
Wastegate Bypass Regulator valve -N75- faulty checking, Page 21-33
specified value
Hose connection to Wastegate Bypass Regulator valve -N75- faulty Connection
diagram, Page 21-3
Wastegate bypass regulator valve in turbocharger stuck open
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Leak between exhaust turbocharger and intake hose Effects, Page 21-14
Mechanical air recirculation valve faulty checking, Page 21-24
Recirculating valve for turbocharger -N249- faulty checking, Page 21-26
Exhaust turbocharger faulty replacing, Page 21-51
Charge air pressure above Vacuum unit for wastegate bypass regulator valve faulty Replacing exhaust
specified value 1) turbocharger, Page 21-51
Hose connection to vacuum unit for charge air pressure limiter (above -N75-) leaks
Connection diagram, Page 21-3
When in closed position wastegate bypass regulator valve in exhaust turbocharger
sticks replacing exhaust turbocharger, Page 21-51
1) If the charge air pressure is too high the fuel supply will be interrupted in order to protect the engine. This results in misfiring
at high engine speeds.
21-14
Effects of leaks in intake or exhaust

system
Leak downstream of mass air flow sensor
Effect: Loss of power
Possible malfunction sources:
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1 - Connection hoses between mass air flow
sensor and exhaust turbocharger
2 - Connection hose for crankcase vent
3 - Connection hose to mechanical air

recirculation valve
21-15
Leak downstream of exhaust turbocharger
Effect: Charge pressure too low
1 - Connection hoses and line between exhaust

turbocharger and charge air cooler
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2 - Hose between charge air cooler and intake
line
4 - Seal of Charge Air Pressure sensor -G31- (in

charge air cooler)
5 - Sealing between throttle valve control

module and intake line
6 - Sealing between intake line and cylinder

head
Effects of leaks on exhaust side
Effect: Charge air pressure too low, possible

exhaust smell, soot traces in engine
compartment
1 - Exhaust turbocharger /exhaust manifold

connection
2 - Exhaust manifold/cylinder head connection
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Charge pressure leak test with VAG 1687 Page 1 of 34
21-16
Charge pressure leak test with

VAG 1687
Intake system, checking for leaks using
VAG 1687 Diagnostic Tool
Diagnostic trouble codes (DTCs) related to fuel

trim, charge pressure or mass air flow (MAF)
may be caused by:
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Leaking (worn/torn) intake hoses during charge
conditions
Incorrectly torqued or improperly placed clamps

on intake hoses etc. causing leaks during
charge conditions
Check the charge air pressure system using the VAG 1687 Charge air
system tester.
Special tool VAG 1687 Charge air system tester preliminary set-up
- Back off pressure regulator knob -2- of VAG 1687 fully to protect gauge
when shop air supply is applied to assembly.
- Close valve -3- before gauge.

- Close valve -4- after gauge.
The shop air supply line will later be attached to the inlet of VAG 1687.
- Remove female fitting from tester (arrow) and install an appropriate

"male" air fitting that will connect to your shop air supply line (
WARNING!).
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21-17
WARNING!
Use only approved air fittings to adapt shop

air supply line to VAG 1687 tester.
Special tool VAG 1687/1 pressure adapter,

installing (1.8L Turbo)
- Separate intake hose from Mass Air Flow (MAF)

sensor assembly.
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- Insert VAG 1687/1 pressure adapter in intake hose -black arrow- using
existing clamp (as shown).
- Remove crankcase ventilation tube from intake hose at -white arrow-.
Special tool VAG 1687/1 pressure adapter, installing (2.7L BiTurbo)
- Remove upper air cleaner housing and hoses to intake manifold as

necessary
Repair Manual, Maintenance; Air cleaner housing, cleaning; Air cleaner

element, replacing
- Insert VAG 1687/1 pressure adapter in intake hose -white arrow- using
existing clamp (as shown).
- Disconnect engine crankcase ventilation hose from intake manifold -
black arrow-.
-
Plug intake manifold fitting (for crankcase ventilation hose) with
appropriate hose and metal plug using clamps supplied with VAG
1687/1 special tool kit.
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21-18
Note:
To help find small leaks, BEFORE pressurizing

the system fill system with smoke using special
tool KLI9210 and adapter KLI9210/50 as
described on Page 21-18 .
An ultrasonic detector may also be used to

detect extremely small leaks where smoke may
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not be visible.
Special tool KLI9210 (Evaporative system

leak detector), connecting to 1.8L Turbo
- Install optional fitting LKI9210/50 on hose of

special tool KLI9210.
- Connect KLI9210 to VAG 1687/1 adapter (KLI9210 is shown attached

to VAG 1687/1 at arrow on 1.8L Turbo).
Special tool KLI9210 (Evaporative system leak detector), connecting

to 2.7L BiTurbo
- Install optional fitting LKI9210/50 on hose of special tool KLI9210.
-
Connect KLI9210 to VAG 1687/1 adapter (KLI9210 is shown attached
to VAG 1687/1 at arrow on 2.7L BiTurbo).
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21-19
Special tool LKI9210 (Evaporative system

leak detector), preliminary set-up
- Connect smoke generator leads to vehicle

battery.
- Turn valve to test -black arrow-.

- Press smoke generator button to fill system with smoke (see
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instructions printed on tester).
With system filled with smoke:
- Remove smoke generator hose and connect VAG1687 quickly to

prevent smoke from leaking out Page 21-19 .
Special tool VAG 1687, connecting to pressure adapter VAG 1687/1

(1.8L Turbo)
For illustrations purposes VAG is shown lying in the engine compartment.

In practice the tool should be hung from the hood.
- Connect VAG 1687 quickly to prevent smoke from leaking out.
VAG 1687 is shown connected to VAG 1687/1 -black arrow-
Shop air supply will be connected to VAG 1687 -at white arrow-
- Perform pressure test Page 21-21 .
21-20
Special tool VAG 1687, connecting to

pressure adapter VAG 1687/1 (2.7L BiTurbo)
For illustrations purposes VAG is shown lying in

the engine compartment. In practice the tool
should be hung from the hood.
- Connect VAG 1687 quickly to prevent smoke

from leaking out.
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VAG 1687 is shown connected to VAG 1687/1 -black arrow-
Shop air supply will be connected to VAG 1687 -at white arrow-
- Perform pressure test Page 21-21 .
21-21
Performing pressure test:
- With outlet hose -1- of VAG 1687 connected to air pressure adapter:
- Attach shop air supply line to previously installed male fitting Page
21-16 .
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- Open valve -3- between regulator valve and gauge.
- Adjust test pressure up to 0.5 bar ( CAUTION below) by turning
regulator valve -2-.
CAUTION!
DO NOT pressurize the system above 0.5 bar!

Doing so may force oil into the intake system which can damage
the engine.
- Slowly open outlet valve -4- (after gauge) to test hose connections.
- Observe pressure gauge for a drop in pressure.
21-22
Note:
Some pressure will be lost past the throttle plate.
- Readjust test pressure to 0.5 bar ( CAUTION

above) by turning regulator valve -2-.
- Listen for any very large intake leaks.
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If smoke generator was used to fill the system
with smoke:
- Inspect intake system connections for smoke at

leaks.
Note:

detect extremely small leaks where smoke may
not be visible.
- Repair any leaks found.
- Remove tester.
- Remove plug from crankcase ventilation hose.
- Remove air pressure adapter.
With VAS 5051 diagnostic tool connected:
- Erase DTC memory.
If smoke generator was not used to fill the

system with smoke:
- Apply soapy water solution or equivalent to

intake system connections.
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21-23
Note:

detect extremely small leaks.
- Inspect intake system connections for leaks.
- Repair any leaks found.
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- Remove tester.
- Remove plug from crankcase ventilation hose.
- Remove air pressure adapter.
With VAS 5051 diagnostic tool connected:
- Erase DTC memory.
21-24
Mechanical air recirculation valve,

checking
Note:
The mechanical air recirculation valve is

upstream of the exhaust turbocharger. It is
opened via vacuum by the recirculating valve
for turbocharger -N249- under conditions of
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overrun, idling and partial load. This reduces
the charge pressure upstream of the throttle
valve. A high turbocharger speed is thus
maintained.
Check the air recirculation valve if the engine is

not producing full power, or jerking when the
throttle is opened and closed.
Hand vacuum pump VAG 1390
21-25
Test sequence
- Attach vacuum pump VAG 1390 to air recirculation valve.

- Actuate hand vacuum pump.
Air recirculation valve should open -arrow-
- Operate air vent valve on vacuum pump after about 30 seconds.
Air recirculation valve should close -arrow-
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If the air recirculation valve does not open and close as specified, or if the
valve plate does not seal properly when the valve is closed:
- Replace air recirculation valve and attach hose connections with hose
clamps.
21-26
Recirculating valve for turbocharger -

N249-, checking
VAG 1526 A
VAG 1527 B
VAG 1594 A
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VAG 1598/31
- or
21-27
Test requirements:

connected.
Test sequence
Note:
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The recirculating valve for turbocharger -N249-
and the wiring connections are monitored by the
engine control module.
- Read Diagnostic Trouble Code (DTC) memory

of engine control module.
If a DTC relating to the recirculating valve for

turbocharger -N249- is displayed:
- Remove hoses of recirculating valve for turbocharger -N249- (-1-). The

electrical connector remains plugged in.
Note:
The illustration shows bottom view of removed intake line.
21-28
- Connect auxiliary hose to valve connector marked with an arrow.

- Initiate output Diagnostic Test Mode (DTM) and activate recirculating
valve for turbocharger -N249-.
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Output Diagnostic Test Mode Display:
Recircul. valve for turbocharger -N249-
The valve should click ...
... and must open and close (check by blowing into the auxiliary
hose).
If the injector does not click:
- Check internal resistance of valve.
If valve does not open or close properly:
- Replace recirculation valve for turbocharger -N249-.
21-29
- Disconnect connector from recirculation valve for turbocharger -N249-

(-1-).
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- Connect multimeter to injector to measure resistance.
- Replace recirculating valve for turbocharger -N249-.
21-30
Note:
The power supply for the recirculating valve is via

the fuel pump relay.
Test requirements:
Fuse for recirculating valve OK.
cardiagn.com
Electrical Wiring Diagrams, Troubleshooting &
Component Locations binder
Fuel pump relay OK.

Repair Group 24
- Disconnect wiring connector from valve.
contact
1 Engine Ground

The LED must light up.
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21-31
- Check wiring from contact 1 on connector via

fuse to fuel pump relay for an open circuit:

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- Repair open circuit, if necessary.
- Check actuation.
Checking actuation

connector.
- Initiate output Diagnostic Test Mode (DTM) and activate recirculatiing
valve for turbocharger -N249-.
The LED must flash.
21-32
If the LED lamp does not flash or if it lights up

continuously:
- Connect VAG 1598/31 test box to wiring

harness leading to engine control module;
engine control module should not be connected:
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Repair Group 24

wiring connection:
Contact
2 105
- Repair any open/short circuit as necessary.
21-33
Wastegate Bypass Regulator valve -N75-,

checking
VAG 1526 A
VAG 1527 B
VAG 1594 A
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VAG 1598/31
- or
21-34
Test requirements:

connected.
Test sequence
Note:
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The Wastegate Bypass Regulator valve -N75-
and the wiring connections are monitored by the
engine control module.

If a DTC relating to the Wastegate Bypass

Regulator valve -N75 is displayed:
- Disconnect hoses from valve but leave electrical

connector attached.

- Initiate output Diagnostic Test Mode (DTM) and actuate Wastegate
Bypass Regulator valve -N75-.
21-35

-N75- wastegate bypass regulator valve
The valve must click ...
... and must open and close (check by blowing into the auxiliary
hose).
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- Replace Wastegate Bypass Regulator valve -N75-.
- Disconnect connector from valve.

- Replace Wastegate Bypass Regulator valve -N75-.
21-36
Test requirements:
Fuse for wastegate bypass regulator valve

OK
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Fuel pump relay OK.

Repair Group 24
contact
1 Engine Ground

LED must light up.
21-37
- Check wiring from contact 1 on connector via

fuse to fuel pump relay for open circuit:

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- Repair open circuit, if necessary
- Check actuation.
Checking actuation

connector.
- Initiate output Diagnostic Test Mode (DTM) and actuate Wastegate
Bypass Regulator valve -N75-.
LED must flash.

-N75- wastegate bypass regulator valve
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21-38

continuously:

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Repair Group 24

wiring connection:
Contact
2 104
21-39
Charge Air Pressure sensor -G31-,

checking
VAG 1526 A
VAG 1594 A
VAG 1598/31
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- or
21-40
Test requirements:

system VAS 5051 or VAG 1551Scan Tool
connected.
Test sequence
Note:
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The Charge Air Pressure sensor -G31- and the
wiring connections are monitored by the engine
control module.

If a DTC relating to the Charge Air Pressure

sensor -G31- is displayed:
- Disconnect connector -arrow- on charge pressure sender.
21-41
- Connect multimeter between contacts 1 and 3 of connector to measure

voltage.
- Switch ignition on.
Specified value: approx. 5 V
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- Connect VAG 1598/31 test box to wiring harness leading to engine
control module; engine control module must also be connected.
21-42

wiring connections:
contact
1 108
3 98
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Checking signal wire
- Attach connector from charge air pressure sensor.

- Attach multimeter for voltage test to socket 101 and socket 108 of test
box.
- Start engine and run at idling speed.
Specified value: approx. 1.90 V
- Bring engine to speed by spontaneous acceleration.
Specified value: 2.00...3.00 V
21-43
If specified values are not attained:

wiring connection:
contact
4 101
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- Replace Charge Air Pressure sensor -G31-.
Charge pressure system with exhaust turbocharger, servicing Page 1 of 22
21-44
Charge pressure system with

exhaust turbocharger,
servicing
Rules for cleanliness
When working on the exhaust gas turbocharger,

pay careful attention to the following 5 rules:
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Thoroughly clean all unions and the adjacent
areas before disconnecting.
Place removed parts on a clean surface and

cover. Use lint-free cloths.
Carefully cover or seal open components if

repairs cannot be carried out immediately.
Only install clean components: Only remove

replacement parts from packaging immediately
prior to installation. Do not use parts that have
been stored loose (e.g. in tool boxes etc.).
When the system is open: Do not work with

compressed air if this can be avoided. Do not
move vehicle unless absolutely necessary.
21-45
Turbocharger, removing and installing -

Overview
Part I
1 - 30 Nm
Only use original bolt
Parts Catalog
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2 - Gasket
Always replace
3 - Catalytic converter
4 - 30 Nm
Always replace
5 - 30 Nm
6 - 35 Nm
21-46
7 - Oil supply line

Tighten union nut to 23 Nm
From oil filter bracket -Item 24 -, Page
17-10
8 - 3.5 Nm
9 - Heat shield
10 - 23 Nm
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11 - Exhaust manifold
12 - 35 Nm
Always replace
Coat thread and head attachment area with
13 - 10 Nm
21-47
15 - Gasket
Always replace
16 - Coolant return line
Tighten union nut to 30 Nm
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17 - 30 Nm
Always replace
18 - Gasket
Always replace
20 - Coolant supply hose/line
21-48
22 - 10 Nm
23 - Gasket
Always replace
24 - Oil return line
To oil pan
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25 - Gasket
Always replace
26 - 10 Nm
27 - 10 Nm
28 - Turbocharger
Checking Page 21-8
29 - 25 Nm
30 - Bracket
21-49
Part II
1 - Vacuum hose
To Recirculatiing valve for turbocharger -
N249-
2 - Recirculating valve
Checking Page 21-24
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3 - Hose
To recirculating valve
4 - Air duct hose
To connection on turbocharger
5 - Hose
To ACF valve
6 - line
To crankcase vent
7 - 10 Nm
21-50
8 - Hose
To crankcase breather line
9 - Pressure regulating valve
For crankcase breather
10 - Hose
To turbocharger
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11 - Hose
To vacuum unit for charge pressure
regulating valve
12 - Wastegate Bypass Regulator valve -N75-
13 - Angled connector
14 - Hose
To turbocharger
21-51
Turbocharger, removing and installing
Hose clamps 3094
Removing
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21-52
- Loosen bolts securing ribbed belt tensioning roller for A/C compressor -
arrows-. Loosen belt and remove.
CAUTION!
The air conditioner refrigerant circuit must not be opened.
- Disconnect A/C compressor from bracket and secure to body with wire.
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- Remove bracket for exhaust turbocharger -2-.
- Unscrew oil return line -1- from exhaust turbocharger and set aside.
- Loosen air duct hoses -4- and -5- on exhaust turbocharger.
- Remove banjo bolt -3- for pressure line.
21-53
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21-54

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- Disconnect wiring connectors as follows:
2 - on mass air flow sensor
3 - on Wastegate Bypass Regulator valve -N75-
- Move wiring aside and remove air filter housing -arrows-.
21-55
- Remove secondary air inlet line by disconnecting hoses -arrows- and

removing bolts -1-.
- Remove right-hand heat shield on cylinder head.
- Remove hose of vacuum unit for wastegate bypass regulator valve -
N75- on exhaust turbocharger.
- Unbutton sleeve on coolant return hose.
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- Clamp coolant return hose to exhaust turbocharger with hose clamp
3094.
- Loosen hose clamp -4- and remove coolant return hose from exhaust
turbocharger line.
21-56
- Loosen bolts -1- and -3- of oil feed line.

- Remove oil feed line -5- at exhaust turbocharger.
Note:
The isolating element in the exhaust system must not be bent more than
10 or it may be damaged.
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- Remove catalytic converter from exhaust turbocharger -6-.
- Remove exhaust turbocharger from exhaust manifold -2-.
- Swivel exhaust turbocharger to side, loosen mounting angle and banjo
bolt of coolant feed line on exhaust turbocharger.
- Remove exhaust turbocharger.
21-57
Installing

Note:

when removing must be installed in the same
cardiagn.com
Parts Catalog
The hose connectors and hoses must be free of

oil and grease before assembling.

nuts.
- Perform following operating steps before

tightening exhaust turbocharger:
-
Fasten coolant feed line loosely to bracket on
vacuum unit for wastegate bypass regulator
valve.
- Tighten banjo bolt to 35 Nm and then tighten

securing bolt of bracket to 10 Nm.
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21-58
Note:
Fill the exhaust turbocharger with engine oil via

the oil supply connection.
- Install ribbed belt for A/C compressor Page

13-20 .
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- Check oil level Page 17-35 .
Note:
After installing the turbocharger, run engine for

approx. 1 minute at idling speed; do not rev. up
immediately. This ensures the turbocharger is
properly lubricated.
Tightening torques
Component Nm
Coolant feed line to exhaust turbocharger
35
Bracket for coolant feed line to exhaust
turbocharger
10
Turbocharger to exhaust manifold
35 1)
2)
1) Replace bolts

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21-59
Component Nm
Turbocharger bracket to cylinder block 25
Turbocharger bracket to turbocharger 30
Catalytic converter to exhaust 30
turbocharger
Oil return line to turbocharger 10
Oil supply line to turbocharger 23
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Bracket for oil feed line to cylinder head 23
Heat shield to line for secondary air inlet
3.5
Hose clamps for air duct hoses 3.5
21-60
Charge air cooling system components,

Note:
Parts Catalog
cardiagn.com
Before a check or repair all hoses and lines
must be checked for correct seating and leaks.
1 - Air duct
2 - Rubber grommet
3 - Hose
Between charge air cooler and air ducting
in front apron
21-61
4 - Air duct hose

Between intake manifold and charge air
cooler (intercooler)
5 - O-ring
Replace, if damaged
6 - Charge Air Pressure sensor -G31-
7 - 3 Nm
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8 - Rubber grommet
9 - Bracket
Riveted to body
10 - Rubber grommet
21-62
Charge air cooler (intercooler),

Removing

Page 13-1 .
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- Disconnect connector -2- at Charge Air Pressure sensor -G31-.
- Remove air cowl in front of charge air cooler -arrows-.
21-63
- Remove lower air duct hose to charge air

cooler.
- Take out charge air cooler from underneath.
Installing

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Tightening torque
Component Nm
3.5
Exhaust system components, removing and installing Page 1 of 41
26-1
Exhaust system components,

Note:

nuts.
After working on the exhaust system ensure
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that the system is not under stress, and that it
has sufficient clearance from the bodywork. If
necessary, loosen clamps and align mufflers
and exhaust pipes so that sufficient clearance is
maintained to the bodywork at all points and the
mountings are evenly loaded.
The flexible connection in the front exhaust pipe

must not be deflected more than 10 or it may
be damaged..
26-2
Vehicles with front-wheel drive
1 - 25 Nm
2 - Mounting
3 - 25 Nm
4 - Mounting
5 - 25 Nm
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6 - 25 Nm
Replace
7 - 30 Nm
Always replace
8 - Gasket
Always replace
26-3
9 - Turbocharger
Protect from damage by impact
11 - Oxygen sensor - 55 Nm
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Upstream of catalytic converter
Grease only the threads with high-
temperature lubricant G 052 112 A3. The
lubricant must not get into the slots on the
sensor body.
Checking:

Injection & Ignition, Engine Code(s): AWM, Repair
Group 24
26-4
Downstream of catalytic converter
sensor body.
Checking:
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Group 24
13 - Gasket
Always replace
14 - Front exhaust pipe
With flexible connection (de coupling
element)
Do not bend flexible connection more than
10 - otherwise it can be damaged.
Align exhaust system so it is free of stress
before tightening clamp Page 26-34
26-5
15 - Mounting
Individual parts of mounting for manual
transmission Fig. 3, Page 26-16
Individual parts of mounting for automatic 5
speed transmission Fig. 4, Page
26-17
16 - Front clamp
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26-8
Tighten bolted connections evenly.
17 - 40 Nm
18 - Mounting
19 - 25 Nm
26-6
20 - Rear muffler
Rear and center mufflers are one unit as
original equipment. In cases of repair
replace individually
Cutting point Page 26-19
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21 - Rear clamp
For separate replacement of center and
rear mufflers
26-8
Tighten bolted connections evenly.
26-7
22 - 40 Nm
23 - 25 Nm
24 - Mounting
25 - Center muffler
Center and rear mufflers are one unit as
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26-8
Fig. 1 Installation position of front clamp

- Align clamps so that ends of bolts do not protrude over lower edge of
clamp.
Bolted connection facing to the left
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Fig. 2 Installation position of rear clamp
- Install clamp in horizontal position.
26-9
Vehicles with all-wheel drive
1 - Center muffler
Center and rear mufflers are one unit as
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2 - 25 Nm
3 - Mounting
4 - 25 Nm
5 - 25 Nm
Always replace
6 - 30 Nm
Always replace
26-10
7 - Gasket
Always replace
8 - Turbocharger
Protect from damage by impact
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Upstream of catalytic converter
sensor body.
Checking:

Group 24
26-11
Downstream of catalytic converter
sensor body.
Checking:
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Group 24
12 - Gasket
Always replace
13 - Front exhaust pipe
With flexible connection (de coupling
element)
Do not bend flexible connection more than
10 - otherwise it can be damaged.
26-12
14 - Mounting
Individual parts of mounting for manual
Individual parts of mounting for automatic
15 - Front clamp
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26-15
Tighten bolted connections evenly
16 - 40 Nm
26-13
17 - Rear muffler
Rear and center mufflers are one unit as
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18 - Mounting
19 - 25 Nm
20 - 25 Nm
21 - Mounting
26-14
22 - Rear clamp
For separate replacement of center and
rear mufflers
26-15
cardiagn.com
Tighten bolted connections evenly
23 - 40 Nm
24 - Mounting
25 - 25 Nm
26-15
Fig. 1 Installation position of front clamp

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Fig. 2 Installation position of rear clamp
26-16
Fig. 3 Individual parts of mounting for vehicles with manual

transmission
1 - Buffer
2 - Spacer pipe
3 - Washer
4 - Lug, right
5 - Disc
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6 - Bolt - 25 Nm
7 - Spacer
8 - Lug, left
9 - Compression spring
10 - Bolt - 25 Nm
11 - Nut, self-locking - 25 Nm
26-17
Fig. 4 Individual parts of mounting for vehicles with automatic

transmission
1 - Disc
2 - Buffer
3 - Link
4 - Spacer
5 - Bolt - 25 Nm
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6 - Bolt
7 - Disc
8 - Compression spring
9 - Spacer
10 - Nut, self-locking - 25 Nm
26-18
Center and rear mufflers, separating
For individual replacement of the center or rear

muffler, a cutting point is marked on the
connecting pipe.
The cutting point is marked with an indentation

on the outside of the exhaust pipe.
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Body saw VAG 1523 A
Protective goggles
26-19
Vehicles with front wheel drive:
- Cut exhaust pipe at right angles using body saw, e.g. VAG 1523 A, at
position marked -arrow-.
WARNING!
Wear protective goggles.
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- When installing, position clamp centrally over saw cut.
Installation position of clamp -1-: Horizontally, bolted connections

face rear left wheel Fig. 2, Page 26-8
- Ensure exhaust system is aligned stress-free Page 26-34 .
- Tighten bolted connections on clamp evenly to 40 Nm.
26-20
Vehicles with all-wheel drive:
- Cut exhaust pipe at right angles using body saw, e.g. VAG 1523 A, at
position marked -arrow-.
WARNING!
Wear protective goggles.
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- When installing, position clamp centrally over saw cut.
Installation position of clamp -1-: Horizontally, bolted connections

face rear left wheel Fig. 2, Page 26-15
- Ensure exhaust system is aligned stress-free Page 26-37 .
26-21
Exhaust manifold, removing and

installing
Removing
Note:

must not be deflected more than 10 or it may be
damaged.
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- Remove engine cover panel -arrows-.
26-22

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- Remove hose connections, move wiring aside and remove air filter
housing -arrows-.
26-23
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- Loosen bolts -1- and -2- by several turns.
26-24
- Remove front hose from line of crankcase vent -2-.

- Disconnect front hose from line -1- of secondary air inlet.
- Remove heat shield -3-.
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- Remove bolts -1- and -2- of oil feed line.
- Remove bolts -3- for exhaust turbocharger.
- Remove seal between exhaust turbocharger and exhaust manifold.
- Plug opening in suction duct of turbocharger with a clean cloth.
26-25
- Remove all nuts -arrows- on exhaust manifold.

- Remove washers and exhaust manifold.
Installing

following:
Note:
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Always replace seals, gaskets and self-locking nuts.
- Adhere to the following sequence:

Exhaust manifold to cylinder head
Exhaust turbocharger on exhaust manifold
26-26
Tightening torques
Component Nm
Exhaust manifold to cylinder head 30
Turbocharger to exhaust manifold 35 1)
2)
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25
30
Oil feed line to cylinder head 23
Line of crankcase vent to cylinder
head
10
3.5
1) Replace bolts

high temperature lubricant "G 052 112 A3"
26-27
Catalytic converter, removing and

installing
Removing
- Remove heat shield -arrows- above right-hand drive shaft.

- Loosen bolted connection front exhaust pipe/catalytic converter
accessible from below.
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- Remove bolt for transmission bracket to exhaust system -arrow-.
Note:
The flexible connection in the front exhaust pipe must not be deflected
more than 10 to avoid damage.
26-28
- Unbolt coolant expansion tank -2-, -arrows-.

- Disconnect wire to Engine Coolant level (ECL) Warning switch -F66-
and move coolant expansion tank to one side.
Note:
Coolant hoses -1- and -3- do not have to be disconnected.
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- Disconnect wiring connector for oxygen sensors and move wiring
aside.
1 - (brown) to oxygen sensor downstream of catalytic converter -G130-
2 - (black) to oxygen sensor upstream of catalytic converter -G39-
26-29
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26-30

- Disconnect hose connections, move wiring aside and remove air filter
housing -arrows-.
- Loosen bolted connection of front exhaust pipe/catalytic converter
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accessible from above.
- Undo bolts -arrows- of exhaust turbocharger/catalytic converter.

- Remove catalytic converter upward.
26-31
Installing

Note:

nuts.
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- Grease threads of oxygen sensors with high
temperature lubricant G 052 112 A3. Apply
lubricant only to threads of sensors; the lubricant
must not get into the slots on the sensor body.
- Align exhaust system stress-free Page 26-34

or Page 26-37 .
Tightening torques
Components Nm
Oxygen sensor to catalytic converter 55
Catalytic converter to exhaust turbocharger 30
Front exhaust pipe to catalytic converter 25
Front exhaust pipe to mountings on 25
transmission
Heat shield to transmission 23
3.5
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26-32
Front exhaust pipe, removing and

installing
Removing
- Loosen bolted connection of front exhaust

pipe/catalytic converter accessible from above.
- Remove heat shield -arrows- above right-hand drive shaft.
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- Remove crosspiece for underfloor.
- Unbolt transmission bracket for exhaust system -arrow-.
26-33
Note:

must not be deflected more than 10 or it may
be damaged.
- Separate exhaust system at clamp -arrows-.

- Loosen bolted connection of front exhaust pipe/catalytic converter
accessible from below.
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- Remove front exhaust pipe.
Installing

following:
Note:
Always replace seals, gaskets and self-locking nuts.
- Align exhaust system stress-free Page 26-34 or Page 26-37 .
Tightening torques
Components Nm
Front exhaust pipe to catalytic converter 25
Crosspiece for underbody to body 20
Heat shield to transmission 23
26-34
Stress-free alignment of the exhaust

system - Vehicles with front wheel drive
Vehicles without clamp between center

muffler and rear muffler
The exhaust system must be aligned when

cold.
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- Loosen bolted connections on front clamp -Item
16 -, Page 26-5 .
- Push exhaust system toward front of vehicle -arrow- so that rear

mounting of rear muffler is pre-loaded by amount -a- = 9 to 11 mm.
Aligning tailpipes
Align tailpipes so that the distance -a- is the same on both sides.
At the same time, distance -b- must be obtained between the bumper cut-
out and the tailpipe:
Dimension b = min. 24 mm
26-35
Vehicles with clamp between center muffler

and rear muffler

cold.
Note:
It is only necessary to additionally align the

center muffler on vehicles with a clamp installed
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between the center and rear mufflers.
- Loosen bolted connections on front -Item 16 -,

Page 26-5 and rear clamps -Item 21 -, Page
26-6 .
- Push front section of exhaust system toward front of vehicle -arrow-

until preloading at right-hand mounting of center muffler is -a- = 7 to 9
mm.
- Tighten bolts on front clamp -Item 16 -, Page 26-5 evenly to 40 Nm.
26-36
- Push rear part of exhaust system towardsfront of vehicle -arrow- so

that rear mounting on rear muffler is preloaded by -a- = 9 to 11 mm.
- Tighten bolts on rear clamp -Item 21 -, Page 26-6 evenly to 40 Nm.
Aligning tailpipes
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Align tailpipes so that distance -a- is the same on both sides.
At the same time, distance -b- must be obtained between the bumper cut-
out and the tailpipe:
26-37
Stress-free alignment of exhaust system

- Vehicles with all-wheel drive
Vehicles without clamp between centre

silencer and rear silencer

cold.
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- Loosen bolted connections on clamp -Item 15 -,
Page 26-12
- Push rear silencer towards front of vehicle -arrow- so that rear right
mounting on rear silencer is preloaded by a = 9...11 mm.
Aligning tailpipes
- Align tailpipes so that distance -a- is the same on both sides.

- At the same time, distance -b- must be obtained between bumper cut-
out and tailpipe:
26-38
Vehicles with clamp between centre silencer

and rear silencer

cold.
Note:
It is only necessary to additionally align the
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centre silencer on vehicles with clamp fitted
between centre silencer and rear silencer.
- Slacken bolted connections on clamp -Item 15 -,

Page 26-12 and -Item 22 -, Page 26-14 .
- Push exhaust system towards front of vehicle -arrow- so that rear right
mounting on centre silencer is preloaded by a = 7...9 mm.
- Tighten bolts on front clamp -Item 15 -, Page 26-12 evenly to 40
Nm.
26-39
- Push rear silencer towards front of vehicle -arrow- so that rear right
retainer on rear silencer is preloaded by a = 9...11 mm.
- Tighten bolts on rear clamp -Item 22 -, Page 26-14 evenly to 40 Nm.
Aligning tailpipes
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- Align tailpipes so that distance -a- is the same on both sides.
- At the same time, distance -b- must be obtained between bumper cut-
out and tailpipe:
26-40
Checking exhaust system for leaks
- Start engine and run at idling speed.
- Plug tailpipes with cloths or stoppers, etc. until

leakage check is completed.
- Listen for noise at the connection points
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(cylinder head/manifold, manifold/turbocharger,
turbocharger/catalytic converter, etc.) to locate
any leaks.
- Repair any leaks that are found.
Secondary air system Page 1 of 26
26-41
Secondary air system

Secondary air system,
function/components
The secondary air system permits faster warm-up

and thus makes the catalytic converter ready for
operation sooner after cold starting.
Principle
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Due to over-enrichment of the mixture in the cold
start phase, there is an increased amount of
unburned hydrocarbons in the exhaust gas. The
injection of secondary air improves the oxidation in
the catalytic converter and thus reduces emissions.
The heat produced by secondary oxidation reduces
start-up time for the catalytic converter therefore
improving the emission quality in the cold-running
phase.
26-42
Function
During the cold running phase, the engine

control module -6- actuates the secondary air
injection pump -1- via the secondary air
injection pump relay -5-. Air reaches the
combination valve for the secondary air inlet -3-.
Parallel to this the secondary air inlet valve -8-
is actuated, which allows the vacuum to reach
cardiagn.com
the combination valve for secondary air inlet -3-.
The combination valve for secondary air inlet
thus allows the secondary air to enter the
exhaust ducts of the cylinder head -9-.
26-43
1 - Secondary Air Injection (AIR) Pump motor

-V101-
Location Fig. 2, Page 26-45
2 - Air cleaner
3 - Combination valve for secondary air inlet
cardiagn.com
Position (light side/ dark side or direction of
arrow) as shown in illustration, arrow faces
in direction of flow
5 - Secondary Air Injection (AIR) Pump relay -
J299-
26-44
6 - Engine Control Module -J220-

7 - Vacuum reservoir
Location: In front left wheel housing
beneath wheel housing liner
8 - Secondary Air Injection (AIR) Solenoid
valve -N112-
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9 - Cylinder head
26-45
Fig. 1 Installation position Secondary Air Injection (AIR) valve -

N112-
Location: below intake pipe
1 - Recirculating valve for turbocharger -N249- (green connection)
2 - Secondary air injection valve -N112- (brown connection)
Note:
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The illustration shows bottom view of intake pipe.
Fig. 2 Installation position for Secondary Air Injection (AIR)

Pump motor -V101-
Front right in engine compartment beneath air filter housing
26-46
Fig. 3 Installation position Secondary Air Injection (AIR) Pump

relay -J299-
In E-box in plenum chamber
1 - Engine control module
2 - Secondary air pump relay -J299-
3 - Power supply relay for Motronic -J271-
4 - Fuse S130 for secondary air pump
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Fig. 4 Combination valve for secondary air injection
Right rear on cylinder head
26-47
Secondary Air Injection (AIR) Solenoid

valve -N112-, checking
VAG 1526 A
VAG 1527 B
VAG 1594 A
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VAG 1598/31
- or
26-48
Test requirements:

connected.
Test sequence
Note:
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The secondary air injection solenoid valve -
N112- and the wiring connections are monitored
by the engine control module.
- Read out Diagnotic Trouble Code (DTC)

memory of engine control module.
If a DTC relating to the secondary air injection

solenoid valve -N112- is displayed:
- Remove hoses from secondary air injection solenoid valve -N112- (-2-)
but leave electrical connector plugged in.
Note:
The illustration shows bottom view of intake line.
26-49

- Initiate output Diagnostic Test Mode (DTM) and activate secondary air
injection solenoid valve -N112-.
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Output Diagnostic Test Mode Display:
Secondary air injection solenoid valve -N112-
The valve should click ...
... and should open and close (check by blowing into the auxiliary
hose).
- Replace secondary air injection solenoid valve -N112-.
26-50
- Disconnector connector of secondary air injection solenoid valve -

N112- (-Item 2-).
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- Replace secondary air injection solenoid valve -N112-.
26-51
Note:
The power supply for the secondary air injection

solenoid valve -N112- is via the fuel pump relay.
Test requirements:
Fuse for secondary air injection solenoid
cardiagn.com
valve OK.

Fuel pump relay OK.

Repair Group 24
- Disconnect connector from valve.
contact
1 Engine Ground

LED must light up.
cardiagn.com
26-52
- Check wiring from contact 1 on the connector

via the fuse to the fuel pump relay for an open
circuit:

cardiagn.com
- Repair open circuit, if necessary
- Check actuation.
Checking actuation

connector.
injection solenoid valve -N112-.
LED must flash.
26-53

continuously:

cardiagn.com
Repair Group 24

wiring connection:
contact
2 9
26-54
Secondary Air Injection (AIR) Pump relay -

J299- / Secondary Air Injection (AIR) Pump
motor -V101-, checking
VAG 1526 A
VAG 1527 B
cardiagn.com
VAG 1594 A
VAG 1598/31
- or
26-55
Test requirements:

system VAS 5051 or VAG 1551 Scan Tool.
Test sequence
- Initiate output Diagnostic Test Mode (DTM) and

activate Secondary Air Injection Pump relay -
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J299-.
The secondary air injection pump relay-2- (in electronics box of

plenum chamber, left) must respond and secondary air injection pump
motor -V101- must run intermittently.
A - If relay does not respond:
- Check voltage supply of secondary air pump relay Page 26-56 .

- Check actuation of secondary air injection pump relay Page 26-58 .
B - If relay responds but secondary air injection pump motor does not
run:
- Check voltage supply of secondary air injection pump motor Page

26-60 .
26-56
Check voltage supply of secondary air

injection pump relay
- Remove secondary air injection pump relay.
- Connect multimeter as follows to measure voltage.
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3-position relay carrier in E-box in plenum chamber, Measure to
position 2
Contact
8 Engine
Ground
Specified value: approx. battery voltage
- Carry out following tests:
- Check fuse S130 (40 A) in electronics box of plenum chamber, (Pos.

4).
26-57
- Check for open circuit in wiring from battery +

(terminal 30) to fuse S130 for secondary air
injection pump relay (in 3-position in E-box of
plenum chamber, position 2).

cardiagn.com
- Connect multimeter as follows to measure voltage.

position 2
contact
4 Engine
Groung
Specified value: approx. battery voltage
- Check fuse S234 (in fuse box, position 34).

binder
26-58
- Check for open circuit in wiring from

secondary air injection pump relay (in 3-
position relay carrier in E-box of plenum
chamber) via fuse S234 (in fuse box, position
34) to fuel pump relay.

cardiagn.com
Check actuation of secondary air pump relay
- Remove secondary air injection pump relay.

position 2
contact
6 Engine
Ground
injection pump relay.
LED must flash.
26-59
If LED does not flash:

cardiagn.com
Repair Group 24

wiring connection:
3-position relay carrier in E-box in plenum Test box VAG

chamber, position 2 1598/31
Contact
6 66
If no malfunction is found:
- Replace Secondary Air Injection Pump relay -J299-.
26-60
Check voltage supply for secondary air

injection pump motor
cardiagn.com
- Disconnect connector from Secondary Air Injection (AIR) Pump motor -
V101- (-arrow-).
Location: Right front in engine compartment below air filter housing
26-61
- Connect voltage tester VAG 1527 B between contacts 1 and 2.

- Initiate output Diagnostic Test Mode (DTM) and activate Secondary Air
Injection (AIR) Pump relay -J299-.
LED must flash.
If LED does not flash:
cardiagn.com
- Check wiring connection from contact 1 of connector to secondary air
injection pump relay (in 3-pin relay carrier in electronic box (plenum
chamber), for open circuit.

binder
- Check wiring connection of contact 2 of connector to Ground for

open circuit:

binder
If no malfunction is found:
- Replace Secondary Air Injection (AIR) Pump motor -V101-.
26-62
Combination valve for secondary air

inlet, checking function and for leaks
Vacuum hand pump VAG 1390
Test requirements:
cardiagn.com
Vacuum lines and hose connections do not leak.
Vacuum lines not blocked.
Test sequence
26-63
- Remove vacuum hose -arrow- from combination valve.

- Connect hand vacuum pump VAG 1390 to vacuum unit of combination
valve.
cardiagn.com
- Disconnect hose -arrow- to combination valve for secondary air inlet.
- Blow into line with slight pressure (do not use compressed air).
Combi valve must be closed; blowing through must NOT be possible.
- Actuate hand vacuum pump.
Combi valve must open; blowing through must be possible
If the combi valve does not open:
- Replace combination valve Page 26-64 .
26-64
Combination valve for secondary air

inlet, removing and installing
Removing
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- Disconnect hoses -1- and -2- from combination valve.
- Unbolt combination valve -arrows-.
26-65
Installing

Note:
Replace gaskets and seals.
Tightening torque
cardiagn.com
Component Nm
Combination valve for secondary air inlet at
cylinder head
10

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Page 1 of 3

Additionally, there is a sticker on the toothed belt guard with "Engine

Code letters AWM

1)Regular unleaded petrol RON 91 can be used

Code letters AWM

Additionally, there is a sticker on the toothed belt guard with "Engine

Code letters AWM

1)Regular unleaded petrol RON 91 can be used

Code letters AWM

Engine, disassembling and

Special tools and equipment

Special tool 3369

- Remove sound insulation Fig. 1, Page

Repair Manual, Body Exterior, Repair Group 63

- Remove lower air duct hose to charge air cooler

- Remove bolt -2- and screw in special tool 3369.

Installation is carried out in the reverse order of

- When lock carrier has been installed, check that

Repair Manual, Body Exterior, Repair Group 63

Repair Manual, Electrical Equipment, Repair

Fig. 1 Remove front sound insulation

Ribbed belt drive for power steering pump,

Mark the direction of rotation with chalk or felt pen

Torque: 10 Nm + 90 (1/4 turn)

Repair Manual, Suspension, Wheels, Steering,

Ribbed belt drive for air conditioner -

The air conditioner refrigerant circuit must not

2 - Air conditioner compressor

Fig. 1 Installing vibration damper

Ribbed belt must be removed Page 13-18 .

- Tighten bolts of vibration damper to 10 Nm + 90 (1/4 turn).

Fig. 2 Ribbed belt routing

Ribbed belt, removing and installing

Mark the direction of rotation with chalk or felt

- Remove sound insulation -arrows-.

- Turn tensioner in direction of arrow to loosen ribbed belt.

- Attach ribbed belt to pulleys from crankshaft and

- Swivel tensioner for ribbed belt in direction of arrow.

- Attach torque wrench at "7 o'clock position" as illustrated to hex on

Viscous fan, removing and installing

Lock carrier must be in service position

- To loosen ribbed belt, turn tensioner in direction of arrow.

Installation is carried out in the reverse order of

- Install ribbed belt Page 13-20 .

- Install lock carrier Page 13-1 .

Bearing for viscous fan, removing and

Special tools and equipment

Special tool 3301

Lock carrier must be in service position

- Remove air duct hose -1-.

- Turn tensioner in direction of arrow to loosen ribbed belt.

Installation is carried out in the reverse order;

Bracket for Generator, power steering

- Observe or obtain radio anti-theft code on

- Remove cover from power steering fluid

- Mark connectors -1 to 5- and remove from bracket.

- Unclip connector bracket at ABS unit console and lift up to remove.

Connector -2- remains plugged in.