5-Cylinder Diesel Engine (AXD AXE BLJ BNZ BPC)

Service
Workshop Manual
Transporter 2004 ➤
Transporter 2010 ➤
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg K0058982120

Transporter 2004 ➤ , Transporter 2010 ➤
4-cylinder injection engine (2.0 l engine) - Edition 09.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . ..V.ol.ks. w. a.g.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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2 Safety information is.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a.ra.nt. . . . . . . . . . . . . . . . . . . . . . . .
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2.1 Safety precautions
aut when working on the cooling system . . . . o. r .a . . . . . . . . . . . . . . . . . . . .
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2.2 Safety measures
ss when working on fuel supply . . . . . . . . . . . . . .c . . . . . . . . . . . . . . . . . . . . 3
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2.3 Safety precautions when working on injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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2.4 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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3.1 Rules for cleanliness when working on fuel supply system/injection system . . . . . . . . . . . . 7
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3.2 General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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3.3 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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1.2 Assembly overview - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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1.3 Assembly overview - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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1.4 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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1.5 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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1.6 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.7 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.2 Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.3 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.3 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.1 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.2 Removing and installing toothed belt, 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.3 Checking semi-automatic toothed belt tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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3.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3.3 Removing and installing camshaft AG. Vooil seal
lkswagen A.G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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3.4 Removing and installing olkswcamshaft . . . . . . . . . .es. n.o.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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3.5 Removing and rinstalling
ise valve stem seals . . . . . . . . . .ra.nt.e . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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3.6 Checking hydraulic
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4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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4.1 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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4.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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1.4 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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2 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

2.1 Assembly overview - oil filter/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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2.2 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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2.3 Measuring oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
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1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
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1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . m 85

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1.2 Coolant hose schematic diagram, 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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1.3 Coolant hose schematic diagram for vehicles with an additional heat exchanger, 2010 ►
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1.4 Coolant hose schematic diagram for vehicles with an additional heat exchanger in countries
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with hot to very hot climates, 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.5 Coolant hose schematic diagram, vehicles with auxiliary heater, 2010 ► . . . . . . . . . . . . . . 89
1.6 Coolant hose schematic diagram for vehicles with additional heat exchanger and auxiliary
heater, 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.7 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.8 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.2 Assembly overview - Y thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.4 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2.5 Testing Y-thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.2 Assembly overview - radiator, radiator fan, 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.3 Assembly overview - radiator cowl with radiator fan V7 and right radiator fan V35 . . . . . . . 111
3.4 Assembly overview - radiator cowl with radiator fan V7 , 2010 ► . . . . . . . . . . . . . . . . . . . . 112
3.5 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.6 Removing and installing radiator cowl with radiator fan V7 , 2010 ► . . . . . . . . . . . . . . . . . . 114
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

1 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.2 Assembly overview - lower part of intake manifold with fuel rail . . . . . . . . . . . . . . . . . . . . 119
3 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
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3.1 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

3.2 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.3 Checking quantity injected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.1 Checking fuel pressure regulator and holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.1 Removing and installing engine (motor) control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 129
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.2 Separating exhaust pipes from silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2 Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.1 Assembly overview - emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.1 Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
4 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
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4.2 Assembly overview - secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.3 Checking combination valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.2 Removing and installing spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.3 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
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Contents iii
satelettronica
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iv Contents
00 – Technical data
1 Identification
(VRL013433; Edition 09.2019)
⇒ “1.1 Engine number/engine data”, page 1
1.1 Engine number/engine data

The engine number -arrow- (“engine code” and “serial number”)
can be found at the joint between engine and gearbox.
The engine number consists of up to 9 characters (alphanumeric).
The first part (maximum 3 characters) makes up the “engine
code”, and the second part (6 characters), the “serial number”. If
more than 999,999 engines were produced with the same code
letters, the first of the six digits is replaced bygean letter.
AG. Volkswagen AG
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In addition, there is a sticker on the toothed
db
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code” and “serial number”. or
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The engine code is also included
a on the vehicle data sticker.
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Codes AXA AXA
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Manufactured 09.03 … 09.09 09.09 ►
is n
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Exhaust emissions fulfil EU 4 standard EU 5 standard
spec
EU 2 dep. on vap. press. 1) EU 2 dep. on vap. press. 1)
urposes, in part or in wh
t to the co
Displacement l 2.0 2.0
Power kW at rpm 85/5200 85/5200
Torque Nm at rpm 170/2700 … 4700 170/2700 … 4700
rrectne
Bore ∅ mm 82.5 82.5
Stroke mm 92.8 92.8 ss o
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Compression ratio 10.5 10.5

inform
mer
Injection system Motronic ME 7.5 Motronic ME 7.5

atio
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Ignition system Motronic ME 7.5 Motronic ME 7.5

o
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RON 95 unleaded 95 unleaded

thi
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Firing order 1-3-4-2 1-3-4-2

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Catalytic converter yes yes

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Exhaust gas recirculation yes yes
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Secondary air system yes yes
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Lambda regulation yes yes
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Electronic power control yes yes
Knock control yes yes
Number of valves per cylinder 2 2
Leakage diagnosis system no no
1) Dependent on vapour pressure
1. Identification 1
2 Safety information
⇒ “2.1 Safety precautions when working on the cooling system”,
page 2
⇒ “2.2 Safety measures when working on fuel supply”,
page 3
⇒ “2.3 Safety precautions when working on injection system”,
page 4
⇒ “2.4 Safety precautions when working on ignition system”, page
5
2.1 Safety precautions when working on the

cooling system
WARNING
The cooling system is under pressure when thewaengine

gen AG is hot! n AG doe
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olks s no
Danger of scalding by steam and hot coolant.
V t gu
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is nte
or
Cover filler cap on expansion tankauwith
th a cloth and open care‐ eo
ra
fully to release pressure. ss c
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Caution
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Observe the following during all assembly work, particularly in
ole,
the engine compartment due to the restricted space:
spec
t to the co
♦ Route lines of any kind and cables so that original routing
is restored.
♦ Ensure that there is sufficient clearance to all moving or
hot components. rrectness o
cial p
f inform
mer
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2 Rep. gr.00 - Technical data

Note
♦ Cooling system is pressurized when engine is warm. If nec‐

essary, release pressure before carrying out repairs.
♦ Hose connections are secured with spring-type clips. In case
of repair, only use spring-type clips.
♦ For fitting spring-type clips, hose clamping pliers - VAS 6340-
or
♦ we recommend hose clip pliers - VAS 6362- .
♦ When installing coolant hoses, route stress-free so that they
do not come into contact with other components (observe
markings on coolant connection and hose).
♦ The arrows on the coolant pipes and on the ends of the coolant
hoses must align with each other.
2.2 Safety measures when working on fuel

supply
satelettronica
Note agen
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Hose connections are secured with couplings or spring-type
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or clamp-type clips. auth eo
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♦ Always renew clamp-type clips with spring-type clips. ce
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♦ Fuel hoses on engine must be secured with spring-type clips
itte
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only. The use of crimp-type or screw-type clips is not permis‐
erm
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♦ Hose clip pliers - VAS 6340- are recommended to install

h re
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spring-type clips.
spec
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WARNING
rrectness of i
Observe the following points during all installation work, in par‐

ticular in the engine compartment, due to the space limitations:
l purpos
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
nform
ercia
fluid and vacuum) and electrical wiring in their original po‐

m
sitions.
at
om
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or
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When removing and installing fuel gauge sender or fuel pump
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(fuel delivery unit) from a full or partly full fuel tank, observe the
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WARNING
Fuel supply lines are under pressure! Wrap a cloth around the
connection before loosening hose connections. Then release
pressure by carefully pulling hose off connection.
2. Safety information 3
♦ Even before work starts, the extraction hose of a fume extrac‐

tion system which is switched on must be placed in the vicinity
of the assembly opening of the fuel tank to extract any escap‐
ing fumes. If no exhaust gas extraction system is available, a
radial fan with a displacement greater than 15 m3/h can be
used providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
♦ For safety reasons, fuses SD14 and SD30 must be removed
from fuse holder before fuel system is opened because fuel
pump can be activated by door contact switch in driver door.
♦ Fuses SD14 and SD30 -arrows- are located in electronics box
fuse holder in engine compartment.
2.3 Safety precautions when working on in‐

jection system
WARNING
Fuel system is under pressure! Before opening the system,
satelettronica
place a cloth around the connection. Then release pressure by
carefully loosening the connection.
To prevent injuries to persons and/or damage to the injection and

ignition system, the following must be observed:
AG. Volkswagen AG d
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♦ Do not touch or disconnect ignition cables when the engine is

running or being turned at starter speed.
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
♦ For safety reasons, if the battery has not been disconnected,
fuse No. SD 14 and SD 30 -arrows- must be removed from
electronics box fuse holder in the engine compartment before
fuel system is opened. Otherwise fuel pump will be activated
by driver door contact switch or ignition switch when switching
on.
WARNING

sitions.
♦ Ensure that there wis gsufficient
en AG. V clearance
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Note the sfollowing
s if testers and measuring instruments havec to
be used during a road test:
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♦ Test and measuring instruments must always be secured to

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rear seat and operated by a second person from this location.

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If test and measuring instruments are operated from front pas‐

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senger seat and the vehicle is involved in an accident, there is a

ole,
possibility that the person sitting in this seat may receive serious
spec
injuries when the airbag is triggered.

t to the co
– When work is completed, clear event memory of engine con‐

trol unit since faults will have been registered as a result of
removing fuses ⇒ Vehicle diagnostic tester.
rrectne
2.4 Safety precautions when working on ig‐

ss o
cial p
nition system
inform
mer
To prevent injuries to persons and/or damage to the injection and

atio
m
ignition system, the following must be observed:

o
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i
or
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♦ Do not touch or disconnect ignition cables when the engine is

te
sd
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running or being turned at starter speed.

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♦ Switch off ignition before connecting or disconnecting injection

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and ignition system wiring as well as test instrument cables.
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♦ If the engine is to be turned at starter speed without starting:
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2. Safety information 5
– Pull fuses SD 22 and SD 25 out of fuse holder in engine com‐

partment.
Note
Removing the fuses interrupts voltage supply to the injectors and

the ignition transformer.
Note the following if testers and measuring instruments have to

be used during a road test:
♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person from this location.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident,G.there olkswis
aga
possibility that the person sitting in this seat may w en A V serious
agreceive
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injuries when the airbag is triggered. by Vo gu
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– When work is completed, clear uthe tho event memory of the en‐
r tee
or
gine control unit since faults will
ss have been recorded as a
a ac
result of removing the fuse ⇒ Vehicle diagnostic tester.
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3 Repair instructions
⇒ “3.1 Rules for cleanliness when working on fuel supply system/
injection system”, page 7
⇒ “3.2 General notes on injection”, page 7
⇒ “3.3 General notes on ignition system”, page 7
3.1 Rules for cleanliness when working on

fuel supply system/injection system
When working on the fuel supply/injection system, pay careful at‐
tention to the following “5 rules”:
Volkswagen AG
♦ Thoroughly clean all joints and surrounding areas before dis‐agen
AG. does
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♦ Place removed parts on a clean surface and coverho them over.
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Use lint-free cloths only. ss
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♦ Carefully cover opened components or seal them if repairs

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cannot be carried out immediately.
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♦ Install clean components only. Do not remove replacement
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h re
toolboxes).
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♦ If system is open, do not work with compressed air. Do not
t to the co
move the vehicle.
3.2 General notes on injection
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♦ Fuel hoses in engine compartment must be secured only with
l purpos
spring-type clips which conform to production standard. The

use of crimp-type or screw-type clips is not permissible.
nf
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♦ The battery must be disconnected only with ignition switched
rm
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off. If a coded radio is installed, ascertain code before discon‐
atio
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necting battery.
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♦ For trouble-free operation of electrical components, a voltage
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of at least 11.5 V is necessary.
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♦ Do not use sealants containing silicone. Particles of silicone

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drawn into the engine will not be burnt in the engine and dam‐
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♦ If, after fault finding, repairs or component tests, the engine
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starts, runs for a short period and then stops, then the fault Prote AG.
may be that the immobilizer is blocking the engine control unit.
In this case, the control unit might need to be adapted ⇒ Ve‐
hicle diagnostic tester.
♦ Certain tests may lead to a fault being detected by the control
unit and stored. Therefore, after completing all the checks and
repairs, read the event memory and clear it if necessary ⇒ Ve‐
♦ Vehicles with an airbag are fitted with a crash fuel shut-off. It
reduces the danger of a fire in a crash as the fuel pump is
switched off via the fuel pump relay.
♦ When driver door is opened, fuel pump is activated for 2 sec‐
onds to generate pressure in fuel system. This improves the
quality of the start behaviour.
3.3 General notes on ignition system

♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
3. Repair instructions 7
n AG. Volkswagen AG do
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♦ Certain tests may lead bto y Va fault being detected by the control
olk ot g
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unit and stored. Therefore,
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tho memory and clear it if necessary ⇒ Ve‐ e or
hicle diagnostic
ss tester.
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♦ If, after fault finding, repairs or component tests, the engine
pt
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starts, runs for a short period and then stops, then the fault
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may be that the immobilizer is blocking the engine control unit.
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In this case, the control unit might need to be adapted ⇒ Ve‐
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Safety precautions ⇒ page 5 .
spec
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Test data, spark plugs ⇒ page 139
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AG. Volkswagen AG d
10 – Removing and installing engine
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1 Removing and installing engine
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⇒ “1.1 Removing engine”, page 9
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⇒ “1.2 Securing engine to assembly stand”, page 16
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⇒ “1.3 Installing engine”, page 16
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1.1 Removing engine
hole
spec
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Special tools and workshop equipment required
♦ Lifting tackle - 2024A- / lifting tackle - 2024B-
rrectness of i
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♦ Engine support - T10229A- with studs - T10229A/1-
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♦ Engine and gearbox support - VAS 6095-
1. Removing and installing engine 9

♦ Workshop hoist - VAS 6100-
♦ Drip tray for workshop hoist - VAS 6208-
satelettronica
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♦ Torque wrench 6-50Nm - V.A.G 1331- tho tee
or
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♦ Torque wrench 40-200Nm - V.A.G 1332A-
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10 Rep. gr.10 - Removing and installing engine

♦ Engine bung set - VAS 6122-
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♦ Engine and gearbox jack - VAS 6931- s
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♦ Spring-type clip pliers - VAS 6362-
inform
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♦ Removal lever - 80 - 200-
♦ Commercially available stepladder

♦ Safety glasses
♦ Safety gloves
♦ Container for removed parts - V.A.G 1698-
♦ Grease - G 000 100-

♦ Cable tie
Note
olkswagen AG
en AG. V
♦ The battery earth must be disconnected
olks
wag for the remaining pro‐
does
no
cedure. Before doing so, check
ed
by whether a coded radio is fitted guar
V t
an
in the vehicle. Then obtain
ho
r anti-theft coding first if necessary.
is tee
t or
au
♦ The engine is removed
ss downwards with gearbox.
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♦ All cable ties which are opened or cut through when engine is
pt
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removed must be replaced in the same position when engine

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♦ Leave ignition key in ignition lock to prevent steering lock from
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engaging.
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♦ It is advisable to remove the front wheels before beginning
es, in part or in w
engine removal. The vehicle can then be lowered on the lifting
t to the co
platform until the splash plates for the brake discs are just
above the floor. This provides a more ergonomic working po‐
sition regarding the accessibility of engine compartment com‐
rrectness of i
ponents.
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satelettronica
♦ To prevent damage to removed components, place them in
the container for removed parts - V.A.G 1698- .
nform
ercia
– Before removing, read event memories of all control units

m
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⇒ Vehicle diagnostic tester.
on in
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– With ignition switched off, disconnect battery earth strap.
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♦ Route lines of any kind and cables so that original routing
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is restored.
hot components.
WARNING
The fuel line is under pressure.

Fuel poses danger of injury to eyes and skin.
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.

– Pull off supply hose -3- and return hose -2- (with blue mark).
Collect escaping fuel with a cleaning cloth.
– Pull off breather hose -1- (with white mark).
Note
To do this, press down release button on hose coupling.
– Seal lines so that fuel system is not contaminated by dirt.

Observe rules for cleanliness ⇒ page 7 .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Body front; Noise insulation .
WARNINGgen AG. Volkswagen AG d

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The coolingrisedsystem is under pressure when the engine
ara
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tho eo
Dangerau of scalding by steam and hot coolant. ra
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Cover filler cap on expansion tank with a cloth and open care‐ ce
e
satelettronica
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fully to release pressure. an

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– Open and close coolant expansion tank cap to release pres‐

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sure in cooling system.
hole
spec
– Drain coolant ⇒ page 92 .

es, in part or in w
t to the co
– Remove throttle valve module/air mass meter connecting

hose ⇒ page 116 .
rrectness of i
– Pull coolant hoses -3- and -4- off throttle valve control module.
l purpos
– Pull crankcase breather hose -7- off cylinder head cover.

– Pull hose -8- off crankcase breather on connecting pipe to oil
nf
ercia
filter bracket.
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atio
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– Open retainers and lay complete hose guide -9- to side.

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– Pull connecting hose to solenoid valve 1 - N80- off line -5-.

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– Pull vacuum hose off brake servo.

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– Disconnect all electrical wiring from gearbox, alternator and
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starter and lay to side.
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– Pull off or disconnect all other electrical connections as nec‐
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essary from engine and lay to side.
agen
Prote AG.
– Detach all connecting, coolant and vacuum hoses/lines from

engine.
– Remove poly V-belt ⇒ page 22 .
– Unbolt power-assisted steering vane pump at ancillaries
bracket and place to one side; hoses remain connected ⇒
Running gear, axles, steering; Rep. gr. 48 ; Hydraulic power-
assisted steering; Removing and installing vane pump .
– Remove air conditioning compressor from ancillaries bracket
and secure it to one side so that refrigerant lines and hoses
are not strained: ⇒ Heating, air conditioning; Rep. gr. 87 ; Air
conditioning compressor bracket .

– Unclip line from slave cylinder of hydraulic clutch at connection

-arrow- (pull clip): ⇒ Power transmission; Rep. gr. 30 ; Clutch
mechanism; Assembly overview - hydraulic system .
– Remove selector mechanism from gearbox ⇒ Power trans‐
mission; Rep. gr. 34 ; Selector mechanism .
– Unclip selector cable.
– Remove drive shafts from gearbox ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shafts .
– Remove front exhaust pipe ⇒ page 132 .
– Remove front torque reaction support ⇒ page 18 .
– Secure threaded pin - T10229A/1- -1- in position shown to en‐

gine support - T10229A- -2-.
– Then, insert engine support - T10229A- -2- in holes at rear of
cylinder block -3-, and tighten nut -4- hand-tight.
satelettronica
– Secure engine support - T10229A- hand-tight at front of cyl‐
inder block with bolts -arrows-.
– Then, tighten all bolts on engine support - T10229A- and on
cylinder block to 50 Nm. olkswage es n
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– Guide engine support - T10229A- onto mounting pins -2- on

spec
engine and gearbox jack - VAS 6931- . Raise engine slightly.

es, in part or in w
t to the co
– Move engine to 0° position for removal by turning the adjuster

screw -1-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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AG. Volkswagen AG d
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2004 ➤ , Transporter 2010 ➤
h
aut
4-cylinder injection engine
r a (2.0 l engine) - Edition 09.2019
c
ss
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le
un
– Unbolt engine side of assembly mounting from above
pt
an
d
-arrows-.
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ility
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spec
es, in part or in w
t to the co
rrectness of i
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nform
– Unbolt gearbox side of assembly mounting -arrows-.
mercia
– Carefully lower engine with gearbox.
a
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tion in
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Note
s
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Engine with gearbox must be guided carefully when lowering to
en
ng
t.
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prevent damage to bodywork.
Co
op
satelettronica
C py
t. rig
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by
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Prote AG.

1.2 Securing engine to assembly stand

Procedure
Secure engine to engine and gearbox support - VAS 6095- to
carry out repairs.
– Unbolt gearbox. When doing this, always secure engine to
workshop hoist .
Note
Never disconnect the gearbox from the engine if either the gear‐
box or the engine is stilled secured ton Athe
wage
G. Vengine
olkswagesupport
n AG d
oes -
T10229A- . y Volks not
gu
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– Attach lifting tackle
ut - 2024A- as follows, and lift off
h engine and or
ac
sa
gearbox jack - sVAS 6931- using workshop hoist.
ce
le
un
pt
Pulley end: 1st hole in hook rail at position 1
an
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itte
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Flywheel end: 4th hole in hook rail at position 7
erm
ab
ility
ot p
satelettronica
wit
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WARNING
h re
ole,
spec
Use locking pins -arrows- to secure hooks and locating pins.
t to the co
rrectne
Note
ss
♦ The positions marked 1…4 on the bar must be towards the

o
cial p
pulley end.
inform
mer
♦ The holes in the hook rails are counted up from the hook.
atio
om
n
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i
or
– Secure engine on engine and gearbox support - VAS 6095- .

thi
te
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1.3 Installing engine

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Install in reverse order of removal, observing the following: C py
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WARNING Prote
cted AG.
agen

♦ Route all the various lines (e.g. for fuel, hydraulics, coolant
and refrigerant, brake fluid and vacuum) and electrical ca‐
bles in their original positions.
hot components.
– Check clutch release bearing for wear and renew if necessary.

– Lightly lubricate clutch release bearing, release bearing guide
sleeve and splines on input shaft with grease ⇒ Vehicle diag‐
nostic tester.
– Check whether dowel sleeves for centring engine/gearbox
have been fitted in cylinder block. If not, fit them.

n AG. V4-cylinder injection
olkswagen AG engine (2.0 l engine) - Edition 09.2019
lkswage does
not
Vo gu
– Hook intermediate plate by
ed onto sealing flange and slide onto ran
a
ris
dowel sleeves -arrows-.
utho tee
or
a ac
ss
– When swinging engine/gearbox assembly in, ensure that there
ce
e
is clearance between drive shafts.
nl
pt
du
an
itte
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– After installing, align engine mountings free of stress by rock‐
erm
ab
ing engine.
ility
ot p
wit
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– Join connector of line to hydraulic clutch slave cylinder of
h re
clutch: ⇒ Rep. gr. 30 ; Clutch operation; Assembly overview
hole
spec
- Hydraulic system .
es, in part or in w
t to the co
– Fit selector mechanism on gearbox ⇒ Power transmission;
Rep. gr. 34 ; Selector mechanism .
– Clip in gear selector cables.
rrectness of i
– Install air conditioner compressor ⇒ Heating, air conditioning
l purpos
system; Rep. gr. 87 ; Air conditioning compressor .

– Install vane pump for power-assisted steering ⇒ Running
nform
ercia
gear, axles, steering; Rep. gr. 48 ; Hydraulic power-assisted

m
at
steering; Removing and installing vane pump .
om
ion
c
in t
– Install drive shafts: ⇒ Running gear, axles, steering; Rep. gr.
or
his
e
satelettronica
40 ; Drive shaft; Removing and installing drive shafts .
at
do
priv
c
– Install front exhaust pipe ⇒ page 132 .
um
for
en
ng
t.
yi
– Install poly V-belt ⇒ page 22 .
Co
Cop py
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– Install noise insulation ⇒ General body repairs, exterior; Rep.
ht
pyri by
Vo
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gr. 66 ; Body - front; Noise insulation .
c by lksw
cted agen
Prote AG.
– Add coolant ⇒ page 92 .
– Carry out road test and read all event memories ⇒ Vehicle
diagnostic tester.
Observe applicable safety measures when carrying out a road
test ⇒ page 4 .
Specified torques
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 18
♦ ⇒ “1.1 Assembly overview - poly V-belt drive”, page 19
♦ ⇒ “2.1 Assembly overview - emission control”, page 132
♦ ⇒ “1.1 Assembly overview - silencers”, page 130
♦ Noise insulation; Assembly overview - noise insulation ⇒
Noise insulation; Rep. gr. 66 ; Assembly overview - noise in‐
sulation .
Bolted connection Specified torque
Nuts and bolts M6 10 Nm
M8 20 Nm
M10 45 Nm
M12 60 Nm

2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 18
2.1 Assembly overview - assembly mount‐

ings
Engine mounting
Specified torque
Component Specified torque
Bolt -A- 50 Nm +90°
Bolt -B- 50 Nm +90°
AG. Volkswagen AG d
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Front support mounting with torque reaction support
rised ara
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Specified torque aut ra
ss c
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nl
satelettronica
pt
du
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itte
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Bolt -A- 50 Nm +90°
erm
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ility
Bolt -B- 20 Nm +90°
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Bolt -C- 90 Nm +180°
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Rear support mounting with torque reaction support
l purpos
Specified torque
nform
ercia
Bolt -A- 20 Nm +180°

m
at
om
io
Bolt -B- 20 Nm +90°
n
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or
Bolt -C- 50 Nm +90°

his
ate
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Bolt -D- 50 Nm +90°

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Gearbox mounting
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Specified torque
Bolt -A- 50 Nm +90°
Bolt -B- 50 Nm +90°

13 – Crankshaft group
AG. Volkswagen AG d
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1 Cylinder block (pulley end) ol not
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⇒ “1.1 Assembly overview
aut
h - poly V-belt drive”, page 19 eo
ra
ss c
⇒ “1.2 Assembly overview - cylinder block (pulley end)”,
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le
un
pt
page 20
an
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⇒ “1.3 Assembly overview - cylinder block”, page 21
rm
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⇒ “1.4 Removing and installing poly-V belt”, page 22
wit
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⇒ “1.5 Removing and installing bracket for ancillaries”,
hole
spec
page 24
es, in part or in w
t to the co
⇒ “1.6 Renewing crankshaft oil seal - belt pulley end”,
page 24
rrectness of i
⇒ “1.7 Removing and installing sealing flange on pulley end”,
page 26
l purpos
1.1 Assembly overview - poly V-belt drive
satelettronica
nform
mercia
1 - Poly V-belt
a
com
tion in
❑ Mark direction of rota‐
r
te o
tion before removing
thi
s
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❑ Check for wear
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❑ Do not kink en
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❑ Removing and installing Cop py
t. rig
⇒ page 22 opyri
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2 - Bolt Prote
cted AG.
agen
❑ Renew after removal

❑ 10 Nm +90°
3 - Belt pulley and vibration
damper
❑ Can only be installed in
one position, holes are
offset.
❑ Note position when in‐
stalling toothed belt
⇒ page 49 .
4 - Bolt
❑ 25 Nm
5 - Tensioning element
6 - Alternator
7 - Ancillary bracket
8 - Bolt
❑ Observe tightening se‐
quence ⇒ page 24
❑ 45 Nm
9 - Banjo bolt
❑ 30 Nm
10 - Seal
1. Cylinder block (pulley end) 19

11 - Pressure line
12 - Vane pump
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 48 ; Hydraulic power-assisted steer‐
ing .
13 - Pulley
1.2 Assembly overview - cylinder block (pulley end)
1 - Bolt agen
AG. Volkswagen AG d
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❑ 10 Nm by Vo gu
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2 - Engine mounting uthor eo
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3 - Toothed belt guard s
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❑ Upper part
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4 - Toothed belt guard
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❑ Centre part
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satelettronica
h re
5 - Nut
hole
spec
❑ 20 Nm
es, in part or in w
t to the co
6 - Washer
7 - Tensioning pulley
rrectness of i
❑ Checking semi-auto‐
matic toothed belt ten‐
l purpos
sioner ⇒ page 59
8 - Toothed belt
nf
ercia
or
❑ Mark direction of rota‐
m
m
atio
tion before removing
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c
❑ Check for wear

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❑ Do not kink
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❑ Removing and installing
o
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f
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⇒ page 49
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9 - Bolt
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❑ 20 Nm
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❑ Rear
11 - O-ring
12 - Coolant pump
❑ Check for ease of move‐
ment.
❑ Observe installation position
❑ Removing and installing ⇒ page 104
13 - Bolt
❑ 15 Nm
14 - Crankshaft pulley
15 - Bolt
❑ Use counterhold - 3415- to loosen and tighten.
❑ Do not additionally oil or grease thread and shoulder.
20 Rep. gr.13 - Crankshaft group

❑ Turning further can be done in several stages.
❑ The turning further angle can be checked using a commercial protractor e.g. Hazet 6690.
❑ 90 Nm +90°
❑ Lower part
17 - Bolt
❑ Insert with locking fluid ⇒ Electronic parts catalogue (ETKA)
❑ 10 Nm
18 - Belt pulley and vibration damper
❑ Can only be installed in one position, holes are offset.
❑ Note position when installing toothed belt ⇒ page 49 .
19 - Bolt
❑ 10 Nm +90° n AG. Volkswagen AG do
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20 - Bolt byV
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❑ 45 Nm ir se tee
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1.3 Assembly overview - cylinder block
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1 - Connector
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❑ For knock sensor 1 -
hole
spec
G61- .
es, in part or in w
t to the co
2 - Knock sensor 1 - G61-
3 - Bolt
rrectness of i
❑ 20 Nm
l purpos
4 - Line
G66- .
nf
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orm
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6 - Piston fitting tool

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7 - Oil dipstick
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❑ Engine oil ⇒ page 80 .

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8 - Coolant pipe t. Cop py
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9 - Bolt yri
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❑ 40 Nm cted agen
Prote AG.
10 - Bracket
❑ For ignition transformer
- N152- .
11 - Bolt
❑ 15 Nm
12 - Nut
❑ 10 Nm
13 - Bolt
❑ 20 Nm

14 - Bracket
15 - O-ring
16 - Bolt
❑ 10 Nm
17 - Oil filter bracket
❑ Assembly overview ⇒ page 81 .
18 - Bolt
❑ 15 Nm +90°
19 - Seal
AG. Volkswagen AG d
❑ Renew after removal agen oes
olksw not
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20 - Bolt orise nte
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❑ 15 Nm aut ra
ss c
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21 - Engine speed sender - G28-

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itte
22 - O-ring
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ility
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23 - Union
h re
hole
spec
24 - Bolt
es, in part or in w
❑ 15 Nm
t to the co
25 - Thermostat
❑ Checking: heat thermostat in water.
rrectness of i
❑ Begins to open at approx. 85°C
l purpos
❑ Ends at approx. 105°C.

❑ Opening lift min. 7 mm
nf
ercia
or
❑ Note installation position ⇒ page 105
m
m
atio
m

o
n in
or c
thi
26 - Bolt
te
sd
iva
❑ Observe tightening sequence ⇒ page 24 o

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❑ 45 Nm
en
ng
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27 - Ancillary bracket
C py
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❑ Observe tightening sequence ⇒ page 24
p by
o Vo
by c lksw
cted agen
28 - Cylinder block
Prote AG.
❑ Removing and installing sealing flange and flywheel ⇒ page 30 .

❑ Removing and installing crankshaft ⇒ page 32 .
❑ Dismantling and assembling pistons and conrods ⇒ page 35
1.4 Removing and installing poly-V belt

♦ Special wrench - T10241-
♦ Twist drill (∅: 4 mm)
Removing
– Mark running direction of poly V-belt.

– To slacken poly V-belt, swing in -direction of arrow- using

open-jaw spanner - T10241- .
– Lock tensioner with a twist drill (∅: 4 mm).
– Remove poly V-belt.
Installing
Install in reverse order of removal, observing the following:
Note
♦ Before installing the poly V-belt, ensure that all sub-assem‐

blies (alternator, air conditioner compressor and vane pump)
are securely mounted.
♦ When fitting poly V-belt, check direction of belt rotation and
proper seating of belt in belt pulleys.
♦ For vehicles without air conditioning, put poly V-belt over al‐
ternator last.
satelettronica
♦ For vehicles with air conditioning, put poly V-belt over air con‐
ditioner compressor last.
After completing repair, always:

– Start engine and check belt running
Belt drive without air conditioner compressor
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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Belt drive with air conditioner compressor

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spec
t to the co
rrectness o
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23
AG.
1. Cylinder block (pulley end)
1.5 Removing and installing bracket for an‐

cillaries
Procedure
– Place ancillary bracket on cylinder block (observe dowel
sleeve between ancillary bracket and cylinder block).
– Tighten ancillary bracket as shown in following tightening se‐
quence:
1- Bolt -A- 45 Nm
2- Bolt -B- 45 Nm
3- Bolt -C- 45 Nm
4- Bolt -D- 45 Nm
5- Bolt -E- 45 Nm
6- Bolt -F- 45 Nm
1.6 Renewing crankshaft oil seal - belt pulley end
satelettronica
Special tools and workshop
equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
ss c
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nl
pt
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ility
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es, in part or in w
t to the co
rrectness of i
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Prote AG.
♦ Seal puller - 3203-

♦ Counter-hold tool - 3415-

♦ Assembly tool - T10053-
♦ Torque wrench (5 … 50 Nm) - V.A.G 1331-
Removing
– Remove toothed belt ⇒ page 49 .
– Remove crankshaft pulley. by locking the toothed-belt pulley
using counterhold - 3415- .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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pt
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ility
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spec
– To guide oil seal extractor - 3203- , screw centre bolt into
es, in part or in w
crankshaft by hand to stop.
t to the co
– Unscrew inner part of oil seal extractor - 3203- 9 turns (approx.
20 mm) from the outer part and lock in position with the knurled rrectness of i
screw.
– Oil threaded head of seal extractor.
l purpos
nf
ercia
orm
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– Position oil seal extractor - 3203- . Screw forcibly as far as

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possible into oil seal.

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– Loosen knurled screw and turn inner part against crankshaft C py
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until the oil seal is pulled out.
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Installing Prote
cted AG.
agen
Note
Do not be additionally oil or grease the oil seal sealing lip.
– Remove oil residues from crankshaft journal with a clean cloth.

– Fit guide sleeve - T10053/1- onto crankshaft journal.

– Slide seal over guide sleeve - T10053/1- onto crankshaft jour‐
nal.
– Press seal in with fitting sleeve - T10053- and bolt - T10053/2-

to stop.
satelettronica
– Install crankshaft pulley. by locking the toothed-belt pulley us‐
ing counterhold - 3415- .
AG. Volkswagen AG d
agen oes
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Note byV
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Thread and shoulder must
aut
h be free of oil and grease.
ra
ss c
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le
– Install and tension toothed belt ⇒ page 49 .

un
pt
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ility
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ole,
spec
Specified torques
t to the co
♦ ⇒ “1.2 Assembly overview - cylinder block (pulley end)”, page

20
rrectne

s

s o
sulation .
cial p
f inform
mer
1.7 Removing and installing sealing flange on pulley end

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om
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equipment required
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es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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Cop py
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cted agen
Prote AG.
♦ Counter-hold tool - 3415-

Not illustrated:
♦ Silicone sealant ⇒ Electronic parts catalogue (ETKA)

♦ Hand drill with plastic brush attachment
♦ Scraper
♦ Safety glasses
Removing
– Remove toothed belt ⇒ page 49 .

– Remove crankshaft pulley. by locking the toothed-belt pulley

using counterhold - 3415- .
– Drain engine oil.
– Remove sump ⇒ page 77 .
– Unbolt front sealing flange.
– Remove sealing flange; if necessary, loosen using light blows
with a rubber headed hammer.
– Remove sealant residues from cylinder block with a flat scra‐
per.
– Cover oil seal with a clean cloth.
– Remove residual sealant on sealing flange using a rotating gen AG

. Volkswagen AG
does
swa
plastic brush (wear eye protection). yV
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– Clean sealing surfaces. They must be free of oil and grease.
thoris
eo
au ra
Installing ss c
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Note
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♦ Observe use-by-date of sealant.
spec
es, in part or in w
♦ The sealing flange must be installed within 5 minutes of ap‐
t to the co
plying the silicone sealant.
♦ Before applying sealant bead, cover the sealing surface of the
rrectness of i
sealing ring with a clean cloth.
l purpos
♦ Sealant bead -arrows- must not be wider than 2…3 mm, be‐
cause otherwise excess sealant can enter sump and clog
strainer in oil pump suction pipe as well as drip onto crankshaft
nf
ercia
o
oil seal.
rm
m
atio
om
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– Cut off nozzle on tube at front marking (∅ of nozzle approx.
thi
te
3 mm).
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– Apply silicone sealant bead as shown to clean sealing surface cu

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of sealing flange.
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.
– Fit sealing flange immediately and lightly tighten all bolts.
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Prote AG.
Note
♦ When fitting sealing flange with oil seal installed use guide
sleeve - T10053/1- .
♦ Leave the sealant to dry for approx. 30 minutes after assem‐
bly. Only then fill with engine oil.
♦ Thread and shoulder must be free of oil and grease.
– Tighten sealing flange securing bolts diagonally and alternate‐

ly.
– Remove excess sealant.
– Install sump ⇒ page 77 .

– Install crankshaft pulley. by locking the toothed-belt pulley us‐

ing counterhold - 3415- .
Install toothed belt and adjust the valve timing ⇒ page 49 .
Specified torques
20
♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 76
sulation .
satelettronica
AG. Volkswagen AG d
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2 Cylinder block, gearbox end

⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
page 30
2.1 Assembly overview - cylinder block, gearbox end
1 - Bolt
❑ Use counterhold - 3415-
to loosen and tighten.
❑ Do not additionally oil or
grease thread and
shoulder.
❑ Turning further can be
done in several stages.
❑ The turning further an‐
gle can be measured
using a commercially
available protractor e.g.
satelettronica
Hazet 6690.
❑ 90 Nm +90°
2 - Crankshaft pulley
3 - Bolt
❑ 15 Nm
4 - Seal lkswage es n
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❑ Do not additionally oil or ir se
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grease the oil seal seal‐ utho
or
ing lip. ss
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❑ Before installing, re‐

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move oil residue from
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crankshaft journal using
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a clean cloth.
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❑ Renewing ⇒ page 26
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5 - Sealing flange
spec
es, in part or in w
❑ Must seat on dowel

t to the co
sleeves.
❑ Remove sump in order
to remove and install.
rrectness of i
❑ Insert with silicone seal‐

l purpos
ant ⇒ Electronic parts catalogue (ETKA) .

nf
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6 - Cylinder block
m
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❑ Removing and installing crankshaft ⇒ page 32 .

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❑ Dismantling and assembling pistons and conrods ⇒ page 35

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7 - Bolt
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❑ 60 Nm +90° Cop py
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8 - Flywheel p by
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❑ Lock with counterhold - 3067- to remove and install.
agen
Prote AG.
9 - Adapter
❑ Must seat on dowel sleeves.
❑ Do not damage or bend when assembling.

10 - Sealing flange with oil seal

❑ Renew only as complete unit
❑ Remove sump in order to remove and install.
❑ Do not additionally oil or grease the oil seal sealing lip.
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
❑ Use support sleeve supplied when installing.
❑ Only remove supporting sleeve after sealing flange has been slid onto crankshaft journal.
lkswage es n
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2. Cylinder block, gearbox end 31

3 Crankshaft
⇒ “3.1 Assembly overview - crankshaft”, page 32
⇒ “3.2 Removing and installing sender wheel”, page 34
⇒ “3.3 Crankshaft dimensions”, page 34
3.1 Assembly overview - crankshaft
Note
Before removing the crankshaft, prepare a suitable surface for

storing the crankshaft so that it is not placed down on the sender
wheel ⇒ Item 8 (page 33) and the sender wheel is not damaged.
1 - Oil pump
❑ With 12 bar pressure re‐ AG. Volkswagen AG d
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❑ Before installing, check
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that both dowel sleeves hor eo
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for centring oil pump on ss a ra
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cylinder block are fitted.
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⇒ page 80
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❑ 15 Nm
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spec
3 - Sprocket
es, in part or in w
t to the co
❑ For oil pump drive.
4 - Bearing shells 1, 2, 3, 4 and
5
rrectness of i
❑ Classification for order‐
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ing spare parts

⇒ page 33 .
nf
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❑ For bearing cap without
or
oil groove.
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❑ for cylinder block with oil

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❑ To measure radial clear‐
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Prote AG.
ance, tighten to 65 Nm
but not further.
❑ 65 Nm +90°
6 - Bearing cap
❑ Bearing cap 1: belt pul‐
ley end.
❑ Bearing cap 3 with recesses for thrust washers
❑ Bearing shell retaining lugs in cylinder block and bearing caps must align.
7 - Bearing shell 3
❑ Classification for ordering spare parts ⇒ page 33 .
❑ For bearing cap without oil groove.

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❑ for cylinder block with oil groove olks es n
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❑ Do not interchange used ir se bearing shells (mark).
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8 - Sender wheel ss
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❑ For engine speed sender - G28-
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❑ Renew if damaged
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❑ Always renew sender wheel if securing bolts have been unscrewed
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9 - Bolt
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spec
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❑ 10 Nm + 90°
10 - Thrust washer
rrectness of i
❑ For bearing cap 3
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❑ Note fixing arrangement

11 - Crankshaft
nform
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❑ Axial clearance, new: 0.07 … 0.23 mm, wear limit: 0.30 mm

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❑ Measure radial clearance with Plastigage , new: 0.01…0.04 mm: wear limit: 0.15 mm.
com
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❑ Do not rotate crankshaft when checking radial clearance
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❑ Crankshaft dimensions ⇒ page 34 .
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12 - Thrust washer
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❑ For cylinder block, bearing 3
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Identification of crankshaft upper bearing Prote AG.
Upper bearing shells of the proper thickness are allocated to the

cylinder block in the factory. Coloured dots are used to identify
the thickness of the bearing shells.
Letters on the lower sealing surface of the cylinder block indicate
which bearing thickness is to be used at each position.
S = black
R = red
G = yellow
Note
♦ Arrow points in direction of travel.

♦ If the colour code is not embossed or no longer readable, use
middle value bearing shell (red).
♦ Lower bearing shells for the crankshaft are supplied with col‐
our mark yellow as spare parts.
3. Crankshaft 33
3.2 Removing and installing sender wheel

Removing and installing sender wheel
– Renew sender wheel -2- each time bolts -1- are loosened.
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♦ The second time the bolts are tightened, the contact points in
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the sender wheel for the countersunk heads are deformed so
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much that the bolt heads seat on the crankshaft -3-, -arrows-
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and the sender wheel is loose under the bolts.
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♦ The sender wheel can only be installed in one position, as the
h re
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holes are offset.
spec
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t to the co
3.3 Crankshaft dimensions
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(Dimensions in mm)
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Honing dimen‐ Crankshaft Conrod

sion main journal ∅ journal ∅
satelettronica
nf
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Basic dimension 54.00 -0.017 47.80 -0.022
orm
-0.037 -0.042
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Stage I 53.75 -0.017 47.55 -0.022
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Stage II 53.50 -0.017 47.30 -0.022
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Stage III 53.25 -0.017 47.05 -0.022
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4 Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 35
⇒ “4.2 Piston and cylinder dimensions”, page 37
⇒ “4.3 Checking pistons and cylinder bores”, page 37
4.1 Assembly overview - pistons and conrods
1 - Piston rings
❑ Offset gaps by 120°
❑ Use piston ring pliers to
remove and install.
❑ “TOP” faces towards
piston crown.
❑ Checking ring gap
⇒ page 36 .
❑ Checking ring-to-groove
clearance ⇒ page 36 .
satelettronica
2 - Piston ksw
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❑ Mark installation ed posi‐
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tion and cylinder num‐ tee
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❑ Arrow on piston crown
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points to belt pulley end.

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❑ Install using piston ring

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clamp.
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❑ Checking ⇒ page 37
h re
hole
3 - Piston pin
spec
es, in part or in w
❑ If difficult to remove,
t to the co
heat piston to 60°C.

❑ Remove and install us‐
rrectness of i
ing drift - VW 222- .

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4 - Retaining ring
5 - Conrod bolt
nform
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6 - Connecting rod
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❑ Renew as set only.

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❑ Mark cylinder allocation

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-A- with coloured pen.

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❑ Installation position:
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Marking -B- faces to‐

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7 - Bearing shell
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❑ Do not interchange used bearing shells.
❑ Ensure firm seating
❑ Axial clearance, new: 0.10 … 0.35 mm, wear limit: 0.4 mm
❑ Measure radial clearance using Plastigage; new: 0.01 to 0.05 mm; wear limit: 0.12 mm. Do not rotate
crankshaft when checking radial clearance.
8 - Cylinder block
❑ Checking cylinder bores ⇒ page 37 .
❑ Piston and cylinder dimensions ⇒ page 37 .
4. Pistons and conrods 35

9 - Conrod bearing cap

10 - Nut
❑ Oil threads and contact surface
❑ To measure radial clearance, tighten to 30 Nm but not further.
❑ 30 Nm +90°
Checking piston ring gap
AG. Volkswagen AG d
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♦ Feeler gauge
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– Insert ring at right angles from above and push down into cyl‐
hole
spec
inder approx. 15 mm from bottom end of cylinder.
es, in part or in w
t to the co
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.20 … 0.40 0.8
rrectness of i
2nd compression ring 0.20 … 0.40 0.8
l purpos
Oil scraper ring 0.25 … 0.50 0.8
nform
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Checking ring-to-groove clearance

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♦ Feeler gauge
– Clean annular groove before check.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.06 … 0.09 0.20
2nd compression ring 0.05 … 0.08 0.20
Oil scraper ring 0.03 … 0.06 0.15

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4.2 Piston and cylinder dimensions
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Honing dimen‐ Piston ∅ Cylinder bore ∅
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Basic dimension mm 82.4652) 82.51
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Stage I mm 82.9652) 83.01
spec
es, in part or in w
2) Dimensions not including graphite coating (thickness 0.02 mm). The graphite
t to the co
coating will wear down.
4.3 Checking pistons and cylinder bores
rrectness of i
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♦ External micrometer 75…100 mm
nform
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Checking piston
m
at
– Measure pistons approx 10 mm from the lower edge of skirt,
om
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at 90° to the piston pin axis.
n
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Deviation from nominal dimension: max. 0.04 mm

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AG.
♦ Cylinder gauge 50 … 100 mm

Checking cylinder bores
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-. Difference between actual
and nominal diameter max. 0.08 mm.
Note
Do not measure cylinder bores when cylinder block is mounted

on engine and gearbox support - VAS 6095- , as measurements
may be incorrect.
4. Pistons and conrods 37

15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Assembly overview - cylinder head”, page 38
⇒ “1.2 Removing and installing cylinder head”, page 40
⇒ “1.3 Checking compression”, page 45
1.1 Assembly overview - cylinder head
Note
♦ When installing an exchange cylinder head with fitted cam‐

shaft, the contact surfaces between the bucket tappets and
the cam must be oiled before installing the cylinder head cov‐
er.
♦ Do not remove the plastic packing pieces for protecting the
open valves until immediately before fitting cylinder head.
satelettronica
♦ If the cylinder head is renewed, all the coolant in the system
must also be renewed.
1 - Cap n AG. Volkswagen AG do

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2 - Seal ir se
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❑ Renew au if damaged
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3 - Connection hose
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❑ For crankcase ventila‐

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4 - Nut
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❑ 10 Nm
h re
hole
spec
5 - Retainer
es, in part or in w
t to the co
6 - Gasket for cylinder head

cover
rrectness of i
❑ Before fitting gasket,

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coat transitions be‐

tween bearing cap and
cylinder head with seal‐
nform
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ant - D 454 300 A2- .

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7 - Oil deflector
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8 - Cylinder head bolt

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❑ Remove and install Pol‐

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ydrive cylinder head
Co
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key - 3452- . p by
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❑ Observe sequence for
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loosing and tightening
⇒ page 40
9 - Plug
❑ With seal
38 Rep. gr.15 - Cylinder head, valve gear

❑ 15 Nm
10 - Seal
11 - Union
12 - Bolt
❑ 10 Nm AG. Volkswagen AG d
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14 - Bolt horis
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❑ 20 Nm ss a c
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15 - Cylinder head gasket
pt
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❑ After renewing, renew entire coolant.
ility
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❑ Note installation position: identification: part number must be readable from inlet side.
h re
hole
16 - Bolt
spec
es, in part or in w
❑ 15 Nm
t to the co
satelettronica
rrectness of i
18 - Toothed belt
❑ Mark direction of rotation before removing
l purpos
❑ Check for wear

❑ Do not kink
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19 - Cylinder head
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❑ After renewing, renew entire coolant.
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❑ Check for distortion ⇒ page 39 .
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20 - Cylinder head cover t. C rig
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Checking cylinder head for distortion

♦ Straight edge
♦ Feeler gauge
Max. permissible distortion: 0.1 mm
1. Cylinder head 39
1.2 Removing and installing
Vol
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Special tools and workshop s au
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equipment required s
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t to the co
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cial p
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mer
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satelettronica
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Prote AG.
♦ Guide pin - 3450/2A-

♦ Removal tool - 3450/3-
♦ Special wrench - 3452-
♦ Drip tray - V.A.G 1306- discontinued, drip tray for workshop
hoist - VAS 6208-

♦ Use hose clip pliers - VAS 6340-
♦ Contour blade set - VAS 852 005- (not illustrated) or commer‐

cially available CERAN surface scraper
Removing
Note
satelettronica
♦ All cable ties which are opened or cut through when cylinder
head is removed must be replaced in the same position when
cylinder head is installed.
G. Volkswagen
♦ Note safety precautions before starting
lksw
ainstallation
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⇒ page 3 . db
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♦ Observe rules for cleanlinessho ⇒ page 7.
tee
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– With ignition switched off, disconnect battery earth strap.

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– Drain coolant ⇒ page 92 . y li

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t to the co
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sitions.
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hot components.
nf
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♦ Fuel system is under pressure! Before opening the sys‐

m
m
atio
tem, place a cloth around the connection. Then release

om
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pressure by carefully loosening the connection.

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1. Cylinder head 41
– Pull off breather hose -1- (with white mark).
Note
To do this, press down release button on hose coupling. agen

AG. Volkswagen AG d
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– Seal lines so that fuel system is not contaminatedrised by dirt. nte
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Observe rules for cleanliness ⇒ page 7 . ss a ra
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ce
– Remove throttle valve module/air mass meter connecting le
un
pt
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hose ⇒ page 116 .
d
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– Pull pressure line off combination valve and unclip from guide.
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filter bracket.
satelettronica
rrectness of i
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– Open retainers and lay complete hose guide -9- to side.

– Unclip Lambda probe before catalytic converter connector
nform
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-1- from retainer.

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– Pull connector -2- off throttle valve control module.
com
tion in
– Pull connector -6- off exhaust gas recirculation valve.
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– Pull off vacuum hose (on side of upper part of intake manifold).
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– Pull off vacuum hose to brake servo.

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– Remove exhaust gas recirculation connecting pipe. Unscrew
C py
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upper part of intake manifold from intake manifold support.
rig ht
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Then remove upper part of intake manifold ⇒ page 117 . by c lksw
cted agen
Prote AG.
– Block off intake ports in lower part of cylinder head with a clean
cloth.
– Pull all coolant hoses off cylinder head.
– Pull off or disconnect all other electrical cables and hoses as
necessary from cylinder head and lay to one side.
– Pull pressure line -arrow- off combination valve.

– Release pressure line from retainers.
– Remove front exhaust pipe ⇒ page 132 .
– Remove toothed belt guard upper part.
– Remove tensioning element for poly V-belt.

– Set camshaft pulley to marking for TDC No. 1 cylinder by turn‐

ing crankshaft. Marking on camshaft pulley must align with
arrow on cylinder head cover.
– Release tensioning roller and remove toothed belt from cam‐
shaft pulley.
– Turn crankshaft back slightly.
– Remove cylinder head cover.
– Loosen cylinder head bolts using special wrench, long reach

- 3452- in sequence given and then remove completely.
– Carefully remove cylinder
gen AG
. Vhead.
olkswagen AG
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Note ris
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The cylinder head must be guided carefully to prevent damage.
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satelettronica
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itte
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ility
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1. Cylinder head 43
Installing
Note
♦ Do not use sandpaper, grinding wheels, abrasive or scour

pads or any other sanding or abrasive media.
♦ Sealing surface (see photo) must not project.
♦ Discolouration (dark spots, see photo) need not be removed.
♦ When removing the sealant residue, make sure no loose par‐
ticles get into the open channels of the engine.
♦ Ensure that all adjacent workspaces are clean, and that none
of the above mentioned sanding or abrasive media are used.
♦ Using unauthorised sanding or abrasive media may lead to
secondary damage such as, for example, damage to the tur‐
bocharger or the conrod bearings.
AG. Volkswagen AG d
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– Only remove sealant residue from cylinder head and cylinder

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block using scraper - VAS 852 005- or a commercially availa‐

ility
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• The sealing surfaces must not be damaged.

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• There must be no oil or coolant in the bolt pockets.

t to the co
• Do not remove new cylinder head gasket from packaging until

it is ready to be fitted.
rrectness of i
• If a new cylinder head is installed, contact surfaces between

roller rocker fingers and running surface of cam must be oiled.
l purpos
– Remove any loose remains using a lint-free cloth.

nform
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– If crankshaft has been turned in the meantime, position no. 1

cylinder piston to TDC and then turn crankshaft back slightly.
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– To centre, screw guide pins - 3450/2A- into outer threaded

holes on the exhaust side.
Note
The tolerance of the centring holes is reduced in the upper area.

Therefore, check that the guide pins can be removed upwards
before fitting the cylinder head. If necessary, knurling of guide
pins may be ground off slightly.
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– Place new cylinder head gasket by V in position. Inscription (Part t gua
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– Fit cylinder head, screwau in 8 remaining cylinder head bolts and ac
ss
tighten by hand.
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– Remove guide pins through bolt holes using the removal tool
an
itte
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- 3450/3- . To do this, turn removal tool anti-clockwise until pins
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are free.
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– Now insert both remaining cylinder head bolts and tighten
h re
these also hand-tight.
hole
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– Tighten cylinder head in sequence as follows:
Stage Tighten
rrectness of i
1 – Tighten to 40 Nm using torque wrench.
l purpos
2 – Turn 90° further (1/4 turn) using a rigid wrench.

3 – Turn 90° further (1/4 turn) using a rigid wrench.
nform
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Note ion
c
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ate
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When camshaft is turned, crankshaft must not be at TDC. Valves

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and/or piston crown may otherwise be damaged.

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– Install upper part of intake manifold.
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py Vo
– Install toothed belt and adjust valve timing ⇒ page 49 .
co lksw
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– Fill with new coolant ⇒ page 92 .
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 38
♦ ⇒ “2.1 Assembly overview - intake manifold”, page 117
♦ ⇒ “2.1 Assembly overview - emission control”, page 132
1.3 Checking compression
1. Cylinder head 45
agen
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lkswalgengine)
en AG
do - Edition 09.2019
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♦ Spark plug socket - 3122 B-
♦ Puller - T10029-
♦ Compression tester - V.A.G 1763- with adapter - V.A.G
1763/6-
Test specification:
• Engine oil temperature min. 30°C
• Voltage supply OK.

– Pull fuses SD 22 and SD 25 out of fuse holder in engine com‐

partment.
Note
Removing the fuses interrupts voltage supply to the injectors and

the ignition transformer.

hose ⇒ page 116 .
satelettronica
AG. Volkswagen AG d
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1. Cylinder head 47
Seal hose ends with, for example, hose clamps up to 25 mm
- 3094- . wage
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– Pull crankcase breather hose
ed -7- off cylinder head cover.
by ara
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– Pull hose -8- off crankcase
au
th breather on connecting pipe to oil eo
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filter bracket. ss c
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– Open retainers, and lay entire hose guide -9- to side.
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-1- from retainer.
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t to the co
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– Remove connecting pipe for exhaust gas recirculation and un‐

bolt upper part of intake manifold from intake manifold support.
nf
ercia
Then remove upper part of intake manifold ⇒ page 117 .
satelettronica
orm
m
– Pull off spark plug connector using assembly tool - T10029- .
atio
om
n in
c
– Unscrew spark plugs with spark plug socket - 3122 B- .

or
thi
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sd
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– Check compression using compression tester - V.A.G 1763-

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and adapter - V.A.G 1763/6- .
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Using compression tester ⇒ operating instructions .
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– Have starter actuated by a second mechanic.

– Operate starter until tester shows no further pressure in‐
crease.
Compression pressures:
New Wear limit Difference between
bar pressure bar pressure cylinders
bar pressure
10.0 … 13.0 8.0 max. 3.0
– When work is completed, clear the event memory of the en‐
gine control unit since faults will have been recorded as a
result of removing the fuse ⇒ Vehicle diagnostic tester.
Specified torques

2 Toothed belt drive

⇒ “2.1 Removing and installing toothed belt”, page 49
⇒ “2.2 Removing and installing toothed belt, 2010 ►”, page 53
⇒ “2.3 Checking semi-automatic toothed belt tensioner”,
page 59
2.1 Removing and installing toothed belt
satelettronica
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♦ Support bracket - V.A.G 10-222A- with adapter - 10-222A/23-
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♦ Torque wrench (5 … 50 Nm) - V.A.G 1331- cted agen
Prote AG.

♦ Pin wrench - T10020-
2. Toothed belt drive 49

Removing
Note
♦ Note safety precautions before starting installation work

⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 7 .
– Remove bulkhead on left and right ⇒ General body repairs,

exterior; Rep. gr. 50 ; Plenum chamber bulkhead
en AG. V
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– Unbolt right cover and batteryy V cover from lock carrier ⇒ Gen‐
o ot g
ua
db
eral body repairs, exterior;
ris Rep. gr. 63 ; Bumper .
e ran
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– Remove throttle valve
ss
a module/air mass meter connecting ra
c
hose ⇒ page 116 .
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– Unbolt power-assisted steering vane pump from ancillaries
ility
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bracket and put to one side; hoses remain connected: ⇒ Run‐
wit
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ning gear, axles, steering; Rep. gr. 48 ; Vane pump .
h re
ole,
satelettronica
spec
– Remove poly V-belt tensioning element ⇒ Item 5 (page 19) .
t to the co
– Remove upper toothed belt guard.
rrectne
arrow on cylinder head cover -arrows-.
s
– Unclip caps on suspension turret.
s o
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f inform
mer
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c
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– Fit adapter - 10-222A/23- -1- on foremost suspension strut rig ht
py by
turret and on lock carrier -arrows-. co Vo
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– Bolt support bracket - V.A.G 10-222A- to respective adapter -

10-222A/23-
– Attach engine to lifting eyewaon
gencylinder head,
AG. Volkswagen Ausing
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– Remove securing bolts from assembly mounting to engine
satelettronica
bracket and assembly mounting to body -arrows- and com‐
nf
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pletely remove assembly mounting.
rm
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♦ The assembly mounting may only be removed if the engine is
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supported with support bracket - V.A.G 10-222A- !

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♦ The engine bracket must be loosened only when the assembly
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– Unbolt engine bracket from cylinder block -arrows- and re‐

move.

– Remove vibration damper/belt pulley.

– Remove centre and lower toothed belt guards.
– Mark direction of rotation of toothed belt.
– Loosen tensioning roller and remove toothed belt.
Installing
Conditions
• The engine must be no more than warm to touch.
• The pistons cannot be positioned at TDC.
• Before tensioning toothed belt, turn tensioning roller on ec‐
centric to stop five times in both directions using 2-hole pin
wrench -T10020- .
Note
When camshaft is turned, crankshaft must not be at TDC. Valves
satelettronica
and/or piston crown may otherwise be damaged.
AG. Volkswagen AG d
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– Align mark on camshaft toothed belt pulley Vwith
olks mark on cyl‐
w oes
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– Place toothed belt on crankshaft toothed
au
th belt pulley and cool‐ ra
ant pump (observe direction of rotation).
ss c
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– Install lower and middle toothed belt guard and the vibration
du
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damper/belt pulley ⇒ page 20 .
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t to the co
– Set engine to TDC No. 1 cylinder.

rrectness of i
– Fit toothed belt to tensioning roller and camshaft toothed belt

l purpos
pulley.
– Before tensioning toothed belt, turn tensioning roller on ec‐
nform
ercia

wrench - T10020- .
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AG. Volkswagen AG d
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not Transporter 2004 ➤ , Transporter 2010 ➤
by gu
ed 4-cylinder ara injection engine (2.0 l engine) - Edition 09.2019
nte
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– Tension
ss a
toothed belt. To do this, turn pin wrench - T10020-
c on
eccentric to left (-direction of arrow-) as far as stop.
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– Then reduce tension on toothed belt until notch -1- and pointer
itte
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-2- align (use a mirror).
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ility
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– Tighten securing nut.
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– Turn crankshaft 2 full revolutions in engine direction of rotation
hole
spec
until engine is again at TDC No. 1 cylinder. It is important that
es, in part or in w
the last 45° rotation (1/8 turn) is performed without interruption.
t to the co
– Check tension of toothed belt again, specification: pointer and
notch align with each other.
rrectness of i
l purpos
– Using securing bolts -arrows-, mount engine bracket on cylin‐

der block and tighten securing bolts.
nform
mercia
at
om
Note
ion
c
in t
or
his
e
Before installing assembly mounting, tighten all engine bracket

at
do
riv
bolts to specified torque.

p
cum
or
satelettronica
f
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ng
t.
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Cop py
t. rig
gh ht
pyri by
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by c lksw
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– Install assembly mounting between engine and body and tight‐

en new securing bolts.
– Bolt engine assembly mounting to engine bracket. Bring con‐
tact surfaces together using support bracket - V.A.G 10-222A-
and tighten threaded connections.
gear, axles, steering; Rep. gr. 48 ; Hydraulic power-assisted
steering .
– Install poly V-belt tensioning element.
– Install upper toothed belt guard.
– Install throttle valve module/air mass meter connecting hose
⇒ page 116 .
– Install bulkhead on left and right ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Bulkhead; Assembly overview - bulkhead .
– Install right cover and battery cover on lock carrier ⇒ General
body repairs, exterior; Rep. gr. 63 ; Bumper
Specified torques
20
2.2 Removing and installing toothed belt, 2010 ►


equipment required
AG. Volkswagen AG d
agen oes
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rig ht
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♦ Support bracket - 10 - 222 A-

♦ Adapter - 10 - 222 A /3-
♦ Adapter - 10 - 222 A /16-
♦ Adapter - 10 - 222 A /23-
♦ Torque wrench - V.A.G 1331-

AG. Volkswagen AG d
agen oes
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by Vol
Transporter 2004 gu ➤ , Transporter 2010 ➤
ara
d
orise 4-cylinder injection engine (2.0 l engine)
nte
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- Edition 09.2019
th
au ra
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♦ Pin wrench - T10020-
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Removing
nf
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♦ Note safety precautions before starting installation work

t
sd
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⇒ page 3 .
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If necessary, equip adapter - 10 - 222 A /23- with adapter - 10 -
ht
pyri by
Vo
222 A /23-1- .
co lksw
by
cted agen
Prote AG.
– Unbolt right cover and battery cover from lock carrier ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 63 ; Bumper .
hose ⇒ page 116 .
– Remove poly V-belt tensioning element ⇒ Item 5 (page 19) .
– Remove upper toothed belt guard.
ing crankshaft. Marking on camshaft sprocket must align with
– Unclip caps on suspension turret.
– Bolt support bracket - V.A.G 10-222A- to respective adapter -
10-222A/23-

– Position support bracket - 10 222 A- together with adapter -

10 - 222 A /23- and adapter - 10 - 222 A /23-1- as shown.
– Attach engine to lifting eye on cylinder head, using additional

hook - 10-222A/2- .
satelettronica
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– Remove securing bolts from assembly mounting to engine

un
pt
bracket and assembly mounting to body -arrows- and com‐

an
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pletely remove assembly mounting.

rm
ab
pe
ility
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Note
hole
spec
es, in part or in w
♦ The assembly mounting may only be removed if the engine is

t to the co
supported with support bracket - V.A.G 10-222A- !

♦ The engine bracket must be loosened only when the assembly
rrectness of i
mounting has been removed.

l purpos
– Unbolt engine bracket from cylinder block -arrows- and re‐

nform
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move.
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by
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Prote AG.

– Remove vibration damper/belt pulley.

– Remove centre and lower toothed belt guards.
– Mark direction of rotation of toothed belt.
– Loosen tensioning roller and remove toothed belt.
Installing
Conditions
• Before tensioning toothed belt, turn tensioning roller on ec‐
wrench -T10020- .
Note
When camshaft is turned, crankshaft must not be at TDC. Danger
satelettronica
of damage to valves and piston crowns.
– Align mark on camshaft toothed belt pulley with mark on cyl‐

inder head cover.
– Place toothed belt on crankshaft toothed belt pulley and cool‐
ant pump (observe direction of rotation).
. Volkswagen AG
gen AG d
– Install lower andVol
ksmiddle
wa toothed belt guard
oes and the vibration
not
damper/belted
bypulley ⇒ page 20 . gu
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ole,
spec
– Now fit toothed belt onto tensioning roller and camshaft

sprocket.
t to the co
– Before tightening toothed belt, turn tensioning roller on eccen‐

tric to stop five times in both directions using pin wrench -
rrectne
T10020- .
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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cum
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fo
en
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
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Prote AG.

– Tension toothed belt. To do this, turn pin wrench - T10020- on

eccentric to left (-direction of arrow-) as far as stop.
– Then reduce tension on toothed belt until notch -1- and indi‐
cator -2- align (use mirror).
– Tighten securing nut.
– Turn crankshaft 2 full revolutions in direction of rotation until
engine is again at TDC No. 1 cylinder. It is important that the
last 45° rotation (1/8 turn) is performed without interruption.
– Check toothed belt tension again. Specification: pointer and
notch align with each other.
– Using securing bolts -arrows-, mount engine bracket on cylin‐

der block, and tighten securing bolts.
Note
Before installing assembly mounting, tighten all engine bracket

bolts to specified torque.
satelettronica
– Install assembly mounting between engine and body and tight‐
en new securing bolts.
– Fit engine assembly mounting to engine bracket by bringing
contact surfaces together using support bracket - V.A.G
10-222A- and tighten ⇒ page 18 .
gear, axles, steering; Rep. gr. 48 ; Hydraulic power-assistedgen AG. Volkswagen AG d
steering . Vol
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not
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– Install poly V-belt tensioning element. ed nte
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th
– Install poly V-belt ⇒ page 22 . au ra
c
ss
ce
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nl
– Install upper toothed belt guard.

pt
du
an
itte
y li
– Install throttle valve module/air mass meter connecting hose

erm
ab
⇒ page 116 .
ility
ot p
wit
, is n

h re

hole
spec
es, in part or in w
– Install right cover and battery cover on lock carrier ⇒ General

t to the co
body repairs, exterior; Rep. gr. 63 ; Bumper .

Specified torques
rrectness of i

l purpos

20
nf
ercia

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n in
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co lksw
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2.3 Checking semi-automatic toothed belt

tensioner
Conditions for testing
• The retainer -arrow- must engage in the notch.
Test sequence
AG. Volkswagen AG d
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olksw not
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– Press ut toothed belt with force using your thumb. Theorpointer
ho e
-2-ss must move.
a ac
ce
le
– Release toothed belt and turn crankshaft 2 full revolutions in

un
pt
satelettronica
an
d
direction of rotation until engine is again at TDC No. 1 cylinder.

itte
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It is important that the last 45° rotation (1/8 turn) is performed ab

ility
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– The tensioning roller must return to its initial position. (Notch
ole,
spec
-1- and pointer -2- align again.)

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Note
rrectne
Use a mirror for test.

ss o
cial p
f inform
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rig ht
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by lksw
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Prote AG.

3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 60
⇒ “3.2 Measuring axial play of camshaft”, page 63
⇒ “3.3 Removing and installing camshaft oil seal”, page 63
⇒ “3.4 Removing and installing camshaft”, page 65
⇒ “3.5 Removing and installing valve stem seals”, page 68
⇒ “3.6 Checking hydraulic compensation elements”, page 71
3.1 Assembly overview - valve gear

AG. Volkswagen AG d
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♦ Cylinder heads which have cracks
s aut between the valve seats or ra
c
between a valve seat insert and
s the spark plug thread can be
ce
e
used further without reducing service life, provided the cracks

nl
pt
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1 - Bolt
❑ 100 Nm
2 - Camshaft pulley
❑ With rotor for Hall send‐
er.
3 - Seal
❑ Do not additionally oil or
grease the oil seal seal‐
ing lip.
❑ Before installing, re‐
move residual oil from
camshaft journal using a
clean cloth.
⇒ page 63
4 - Woodruff key
❑ Check for firm seating
5 - Nut
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❑ Runout: max. 0.01 mm
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❑ Identification and valve timing ⇒ page 62 .

❑ Checking axial clearance ⇒ page 63 .
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9 - Cotters
10 - Valve spring plate
❑ Top
11 - Valve springs
❑ Cylinder head removed: Remove and install using valve spring compressor - 2037- .
12 - Valve stem seal
❑ Renewing ⇒ page 68
3. Valve gear 61
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❑ Reworking sealing surface ⇒ page 62 .
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❑ Valve dimensions ⇒ page 75
❑ Do not rework; only lapping-in is permitted.
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Reworking cylinder head sealing surface

Cylinder head reworking dimension: a = at least 132.8 mm
nform
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Installation position of camshaft bearing caps
Note that bearing caps are not symmetrical. Before installing
camshaft, fit bearing caps and determine installation position.
Camshaft identification, valve timing

Identification
♦ Cam base diameter: a = 34 mm ∅
♦ Can be identified by numbers and letters stamped between
inlet and exhaust cams.
No. 1 cylinder -arrow 1- 50 P
Valve timing at 1 mm opening lift
Inlet opens ATDC 6.2°
Inlet closes ABDC 42.45°
Exhaust opens BBDC 35.8°
Exhaust closes BTDC 0.45°

3.2 Measuring axial play of camshaft

♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge
Checking camshaft axial clearance
Test sequence
– Check with bucket tappets removed and first and last bearing
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♦ Seal puller - 2085-

♦ Counterhold - 3415- with pins - 3415/1-
3. Valve gear 63

Removing
hose ⇒ page 116 .
shaft pulley.
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ing counterhold - 3415- with pins - 3415/1- (first
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– Unscrew inner part of oil seal extractor - 2085- 2 turns (approx.
hole
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3 mm) from the outer part and lock in position with the knurled
es, in part or in w
screw.
t to the co
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– Lubricate threaded head of oil seal extractor, place it in posi‐
l purpos
tion and, exerting firm pressure, screw it into oil seal as far as
possible.
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– Loosen knurled screw and turn inner part against camshaft

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until oil seal is pulled out.

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or
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Do not be additionally oil or grease the oil seal sealing lip.
– Remove oil residues from crankshaft journal with a clean cloth.

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– Set seal in place using guide sleeve - T10071/1-
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– Install camshaft sprocket. To tighten bolt, hold camshaft
rrectne
sprocket using counterhold - 3415- with pins - 3415/1- (bolts
were previously removed -arrows-).
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Install toothed belt and adjust the valve timing ⇒ page 49 .
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3.4 Removing and installing camshaft
3. Valve gear 65

equipment required
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♦ Counterhold - 3415- with pins - 3415/1-

Without illustration:
Sealant - AMV 174 004 01-
Removing
hose ⇒ page 116 .

- 3094- .
filter bracket.
-1- from retainer.
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– Pull off vacuum hose (on sideVof
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not
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– Remove connecting
ss a pipe for exhaust gas recirculation and un‐ c
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Block off intake ports in lower part of cylinder head with a clean
spec
cloth.
es, in part or in w
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ing crankshaft. Marking on camshaft sprocket must align with

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shaft pulley.
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– Remove camshaft. To loosen bolt, hold camshaft sprocket us‐ cted agen
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ing counterhold - 3415- with pins - 3415/1- (first remove bolts
-arrows-).
– Remove Woodruff key from camshaft.
– First remove bearing caps 5, 1 and 3. Loosen bearing caps 2
and 4 alternately and diagonally.
Installing
Condition
3. Valve gear 67
Note
♦ When camshaft is installed, No. 1 cylinder cams must point

upwards. AG. Volkswagen AG d
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offset of gu
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– Lightly coat contact surface of bearing cap 1 with sealant -
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AMV 174 004 01- .
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– Install bearing caps 3, 1 and 5 and also tighten.
– Install cylinder head cover.
rrectness of i
– Install camshaft seal ⇒ page 63 .
l purpos
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– Insert Woodruff key in camshaft.
nform
ercia
– Install camshaft sprocket. To tighten bolt, hold camshaft

sprocket using counterhold - 3415- with pins - 3415/1- (bolts
m
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were previously removed -arrows-).
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– Check coolant level and top up if necessary ⇒ page 92 .
– Install toothed belt and adjust the valve timing ⇒ page 49 .
Specified torques
20
3.5 Removing and installing valve stem seals


equipment required
AG. Volkswagen AG d
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♦ Valve assembly device - 2036-

♦ Puller - 3047 A-
♦ Fitting tool - 3129-
♦ Puller - T10029-
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
3. Valve gear 69
AG. Volkswagen AG d
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♦ Valve lever - VW 541/1A-

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Removing
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(With cylinder head installed)
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– Remove camshaft ⇒ page 65 .
– Remove tappets and place to one side with face downwards.
When doing this, ensure that tappets are not interchanged.
– Pull off spark plug connector using puller - T10029- .
– Unscrew spark plugs using spark plug socket and extension -
3122 B- .
– Set piston of respective cylinder to “bottom dead centre”.

– Fit valve assembly tool - 2036- and adjust mountings to height

of studs.
– Screw pressure hose - VW 653/3- into spark plug thread.
– Connect pressure hose to air pressure source of at least 6 bar.
– Remove valve springs using valve lever - VW 541/1 A- and
press tool - VW 541/5- .
Note
Tight valve cotters can be loosened by tapping lightly on assem‐

bly lever.
– Pull off valve stem seals using puller - 3047A- .

Installing
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– Place theutplastic sleeve -A- supplied on the associated evalve
ho
or
stem. This
ss
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damaged.
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– Place new valve stem seal in fitting tool - 3129- .

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– Oil valve stem seal sealing lip and press carefully onto the
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3.6 Checking hydraulic compensation ele‐

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ments
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♦ Feeler gauge
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♦ Wooden/plastic wedge
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♦ Defective bucket tappets must always be renewed (cannot be
cted agen
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adjusted or repaired).
♦ Irregular valve noise during starting is normal.
Procedure
– Start engine and run until the radiator fan has switched on
once
3. Valve gear 71
– Increase speed for 2 minutes to approx. 2500 rpm.

If hydraulic bucket tappets are still noisy, locate defective tappet
(s) as follows:
hose ⇒ page 116 .
- 3094- .
– Pull crankcase breather hose -7- off cylinder head cover. agen
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– Pull hose -8- off crankcase breather on connecting pipe toeoil db
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filter bracket. h oris nte
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– Pull connecting hose to solenoid valve 1 - N80- off line
ss -5-. c
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m
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– Rotate crankshaft clockwise until cam of tappet to be checked
cop Vo
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– Determine clearance between cam and bucket tappet.

– If play exceeds 0.2 mm, renew bucket tappet. If play is less
than 0.1 mm or there is no play, continue with check as follows:
– Push bucket tappet down lightly with a wooden or plastic

wedge. If when bucket tappet is pushed down, a 0.2 mm feeler
gauge can be pushed between camshaft and bucket tappet,
bucket tappet must be renewed.
Note
When new bucket tappets have been installed the engine must
not be started for about 30 minutes. The hydraulic compensation
elements must settle (otherwise valves will strike pistons).
– Check coolant level and top up if necessary ⇒ page 92 .

Specified torques

AG. Volkswagen AG d
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4 Inlet and exhaust valves
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⇒ “4.1 Reworking valve seats”, page 73
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⇒ “4.2 Checking valve guides”, page 74
h re
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⇒ “4.3 Valve dimensions”, page 75
es, in part or in w
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4.1 Reworking valve seats
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♦ Depth gauge
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♦ Valve seat refacing tool
nform
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Note
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♦ When repairing engines with leaking valves, it is not sufficient
r
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to rework or renew valve seats and valves. There is also a
s
iva
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requirement to check the valve guides for wear. This is par‐
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ticularly important on high mileage engines.
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♦ Valve seats are only to be reworked to the extent required to Cop py
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yield a proper surface appearance. Before beginning to rework
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valve seats, calculate the maximum permissible reworking di‐
cop Vo
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mensions. If the reworking dimension is exceeded, the hy‐ cted agen
Prote AG.
draulic valve clearance compensation can no longer be
guaranteed and the cylinder head must be renewed.
The max. permissible reworking dimension is calculated as fol‐

lows:
– Insert valve and press firmly against seat.
Note
If the valve is to be renewed as part of a repair, use a new valve

for the calculation.
– Measure distance -a- between end of valve stem and upper

edge of cylinder head.
– Calculate maximum permissible reworking dimension from
measured distance -a- and minimum dimension
Minimum dimension: inlet valve 33.8 mm, exhaust valve 34.1 mm
Measured distance -a- minus minimum dimension = maximum
permissible reworking dimension.
Example:
Measured distance -a- 35.1 mm
— Minimum dimension 34.1 mm
= max. perm. rework dimension3) 1.0 mm
3) The max. permissible reworking dimension is shown as dimension “b” in the
illustrations for reworking valve seats.
4. Inlet and exhaust valves 73

Reworking inlet valve seat

Di‐ Inlet valve seat
men‐
sion
∅a mm 39.2
b mm max. perm. rework dimension
c mm 1.8 … 2.2
Z Lower edge of cylinder head
45° Valve seat angle
30° Upper correction angle
Reworking exhaust valve seat

Di‐ Exhaust valve seat
men‐
sion
∅a mm 32.4
∅b mm max. perm. rework dimension
satelettronica
c mm 2.2 … 2.6
Z Lower edge of cylinder head
45° Valve seat angle
30° Upper correction angle
Note
Exhaust valve seat inserts are equipped with an additional narrow . Volkswagen AG
section. When reworking, always ensure that the radius of thekswagen AG does
constriction is not damaged. by Vol not
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4.2 Checking valve guides ss ce
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♦ Universal dial gauge bracket - VW 387-
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♦ Dial gauge
n in
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– Insert new valve in guide. The end of the valve stem must be
flush with the guide. On account of differing stem diameters,
only use inlet valve in inlet guide and exhaust valve in exhaust
guide. gen AG
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– Determinedrock.
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– Cylinder
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4.3 Valve dimensions
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Valve dimensions
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Note
s
Do not rework valves. Only lapping-in is permitted.
s o
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Dimension Inlet valve Outlet valve
mer
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∅a mm 39.5 ± 0.15 32.9 ± 0.15

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∅b mm 6.98 ± 0.007 6.96 ± 0.007
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4. Inlet and exhaust valves 75

17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - sump/oil pump”, page 76
⇒ “1.2 Removing and installing sump”, page 77
⇒ “1.3 Removing and installing oil pump”, page 80
⇒ “1.4 Engine oil:”, page 80
1.1 Assembly overview - sump/oil pump
1 - Bolt
❑ 15 Nm
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3 - Bolt orise nte
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5 - Oil spray jet
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❑ For piston cooling t to the co
6 - Oil dipstick
rrectness of i
❑ Lugs of oil dipstick and

guide tube must align
l purpos
above one another.

❑ The oil level must not be
nf
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above the max. mark

orm
❑ Markings ⇒ page 80 .
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7 - Bolt
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❑ 20 Nm
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8 - Guide tube
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10 - Dowel sleeves
11 - O-ring
12 - Bolt
❑ 15 Nm
13 - Suction line
❑ Clean strainer if soiled
14 - Baffle plate
15 - Bolt
❑ 15 Nm
76 Rep. gr.17 - Lubrication

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16 - Bolt auth or
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18 - Oil drain plug
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❑ 30 Nm
19 - Bolt
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❑ 10 Nm
20 - Oil level/oil temperature sender - G266-
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21 - Seal
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22 - Bolt
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❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
❑ Renewing crankshaft oil seal on belt pulley end ⇒ page 26 .
24 - Chain tensioner with tensioning rail
❑ When installing, pretension spring and fit.
❑ 15 Nm
25 - Chain
26 - Bolt
❑ 20 Nm +90°
27 - Sprocket
28 - Oil pump
❑ With 12 bar pressure relief valve
❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
❑ Renew if running surfaces and gears are scored.
1.2 Removing and installing sump

1. Sump, oil pump 77

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♦ Hand drill with plastic brush attachment
♦ Safety glasses
♦ Scraper
♦ Silicone sealant ⇒ Electronic parts catalogue (ETKA)
Removing
– Drain engine oil.
Note
Please observe disposal instructions!
– Pull 3-pin connector off oil level and oil temperature sender -
G266- . Unclip line from sump.
– Loosen or tighten sump bolts using 10 mm jointed wrench -
3185- . Loosen and tighten only flywheel-end bolts using Allen
key, long reach - T10058- .
– Remove sump. Loosen sump with light blows of a rubber
headed hammer if necessary.
– Remove sealant residues from cylinder block with a flat scra‐
per .

– Remove sealant residues on sump with rotating brush, e.g.

hand drill with plastic brush insert (wear safety goggles).
– Clean sealing surfaces. They must be free of oil and grease.
Installing
Note
♦ Observe use-by-date of sealant.

♦ The sump must be installed within 5 minutes of applying sili‐
cone sealing compound.
♦ The sealant bead must not abe
genthicker,
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– Apply silicone sealant to clean sealing surface of sump, as

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1 - Tighten all sump/cylinder block bolts only very lightly and di‐ cted agen
Prote AG.
agonally.
2 - Tighten sump/gearbox bolts lightly.
3 - Further tighten all sump/cylinder block bolts lightly using di‐
agonal sequence.
4 - Tighten bolts between sump and gearbox.
5 - Tighten diagonally all bolts between sump and cylinder block.
Specified torques
Bolts between sump and gear‐ 45 Nm
box.
1. Sump, oil pump 79

1.3 Removing and installing oil pump

Removing
– Remove sump ⇒ page 77 . AG. Volkswagen AG do
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– Insert dowel sleeves ⇒ Item 10 (page 76) at top of oil pump.
spec
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The chain sprocket can only be fitted in one position on the oil
pump shaft.
– Install oil pan. ⇒ page 77
rrectne
Specified torques
ss
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Bolts between sump and gear‐ 45 Nm
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Engine oil specifications:
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Refer to Maintenance Manual for all current data reference oil

specifications ⇒ Maintenance ; Booklet 18.1 .
Markings on oil dipstick
1 - Min. mark
2 - Max. mark
a - Area of min. mark: top-up with max. 0.5 l of engine oil!
b - Oil level in middle range: can be topped up with engine oil.
c - Area of max. mark: do not add engine oil!

2 Oil filter, oil pressure switch

⇒ “2.1 Assembly overview - oil filter/oil pressure switch”,
page 81
⇒ “2.2 Checking oil pressure and oil pressure switch”,
page 82
⇒ “2.3 Measuring oil consumption”, page 84
2.1 Assembly overview - oil filter/oil pressure switch
1 - Seal
❑ Push on to collar of pipe.
2 - Connecting pipe
❑ For crankcase ventila‐
tion.
3 - Retaining clip
4 - Bolt
satelettronica
❑ 20 Nm
5 - Bracket
6 - Plug
❑ 15 Nm
7 - Seal
❑ If seal is leaking, nip
open and renew.
8 - Oil pressure switch - F1-
❑ 0.9 bar
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12 - Seal
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❑ Fit into lugs on engine oil cooler.

13 - Engine oil cooler
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❑ Coat contact surfaces to oil filter bracket outside the seal with sealing paste - AMV 188 100 02- .
orm
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15 - Oil filter t. Cop py
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❑ Loosen with strap wrench.
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2. Oil filter, oil pressure switch 81

❑ Tighten by hand.
❑ Observe fitting instructions on oil filter
16 - Plug
❑ 40 Nm
17 - Seal
❑ Captive on ⇒ Item 16 (page 82)
18 - Spring
❑ For pressure relief valve, approx. 4 bar
19 - Piston
❑ For pressure relief valve, approx. 4 bar
20 - Seal
21 - Bolt
❑ 10 Nm
satelettronica
2.2 Checking oil pressure and oil pressure switch

equipment required
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♦ Oil pressure tester - V.A.G 1342-

♦ Voltage tester - V.A.G 1527B-
♦ Adapter set - V.A.G 1594C-
• Engine oil level OK.
• Engine oil temperature at least 80°C (radiator fan must have
run once)
Procedure
Note
Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
– Unscrew plug -arrow- from cylinder head.
satelettronica
Note
After the test has been complete, the plug must always be re‐
newed.
AG. Volkswagen AG d
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2. Oil filter, oil pressure switch 83

– Screw sealing plug into tester as shown.

– Screw tester into cylinder head in place of sealing plug.
– Pull connector off oil pressure switch - F1- .
– Connect voltage tester - V.A.G 1527B- to battery positive (+)
and oil pressure switch using cables from auxiliary measuring
set - V.A.G 1594C- . LED must not light up.
– If LED lights up, replace oil pressure switch - F1- .
If LED does not light up:
– Start engine, and increase rpm. At pressure of 0.75…1.05 bar,
LED must light up. Otherwise, renew oil pressure switch.
– Increase engine speed further. At 2000 rpm and an oil tem‐
perature of 80°C, the oil pressure should be between 2.7 and
4.5 bar.
At higher engine speeds, the oil pressure must not exceed 7.0
bar.
If specification is not attained:
– Check suction line strainer for soiling ⇒ Item 13 (page 76) .
satelettronica
Note
Mechanical damage, e.g. to bearings, could also be the cause for

oil pressure being too low.
If no fault is found: agen

AG. Volkswagen AG d
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– Renew oil pump ⇒ page 80 . ed by gu
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If the specification is exceeded: aut
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– Check oil channels.
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– If necessary, replace oil filter bracket with pressure relief valve.

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Specified torques
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2.3 Measuring oil consumption

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♦ Vehicle diagnostic tester
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Procedure
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– Apply handbrake.
nform
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– Manual gearbox: gear lever in neutral.

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– Automatic gearbox: move selector lever to position “N”.

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– Connect ⇒ Vehicle diagnostic tester.

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– Switch on ignition.
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⇒ Vehicle diagnostic tester. C py
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19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 85 n AG. Volkswagen AG do
lkswage es n
⇒ “1.2 Coolant hose schematic diagram, 2010 ►”, page by V86
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⇒ “1.3 Coolant hose schematic diagram for vehicles
utho with an ad‐ tee
or
ditional heat exchanger, 2010 ►”, page 87 ss a ac
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⇒ “1.4 Coolant hose schematic diagram for vehicles with an ad‐
nl
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⇒ “1.6 Coolant hose schematic diagram for vehicles with addi‐
es, in part or in w
tional heat exchanger and auxiliary heater, 2010 ►”, page 90
t to the co
⇒ “1.7 Checking cooling system for leaks”, page 90
⇒ “1.8 Draining and adding coolant”, page 92
rrectness of i
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1.1 Connection diagram - coolant hoses
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1 - Heat exchanger for heater
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2 - 2nd heat exchanger for

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3 - Auxiliary coolant heater

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4 - Circulation pump - V55- Prote
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agen
❑ Fitting location
⇒ page 86
5 - Coolant expansion tank
7 - Radiator/cooler
8 - Coolant pump
9 - Cylinder head/cylinder
block
10 - Throttle valve module -
J338-
11 - Heater coolant shut-off
valve - N279-
❑ Only with auxiliary cool‐
ant heater
12 - Non-return valve
❑ Only with auxiliary cool‐
ant heater
❑ Observe installation po‐
sition
1. Cooling system/coolant 85
Location of circulation pump - V55- .

The circulation pump - V55- -2- is installed at the front left on the
underside of the vehicle.
1.2 Coolant hose schematic diagram, 2010 ►

2 - Expansion tank
3 - Engine oil cooler swage
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4- Radiator for engine coolant
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5- Coolant pump auth or
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6 - Cylinder head ce
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7 - Circulation pump - V55-
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⇒ page 87
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J338-
es, in part or in w
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9 - Intake manifold
rrectness of i
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mercia
at
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86 Rep. gr.19 - Cooling

lkswage es n
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byV uaTransporter 2004 ➤ , Transporter 2010 ➤
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or (2.0 l engine) - Edition 09.2019
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Location of circulation pump - V55- in engine compartment
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1.3 Coolant hose schematic diagram for vehicles with an additional heat ex‐
nform
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changer, 2010 ►
m
at
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⇒ page 103 .
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4 - Expansion tank
6 - Radiator for engine coolant
7 - Coolant pump
8 - Cylinder head
⇒ page 88
J338-
11 - Intake manifold
AG. Volkswagen AG d
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1.4 Coolant hose schematic diagram for vehicles with an additional heat ex‐ orised b ara
nte
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changer in countries with hot to very hot climates, 2010 ►
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3 - Expansion tank
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6 - Coolant pump
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7 - Cylinder head
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⇒ page 89 m
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valve - N279- ht. Cop py
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12 - Non-return valve py by
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1.5 Coolant hose schematic diagram, vehicles with auxiliary heater, 2010 ►
spec
t to the co
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2 - Supplementary heating
ss
❑ Location: on auxiliary
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heater
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4 - Expansion tank
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7 - Coolant pump
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8 - Cylinder head Cop py
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valve - N279-
1.6 Coolant hose schematic diagram for vehicles with additional heat exchang‐
er and auxiliary heater, 2010 ►

heater
3 - Supplementary heating
❑ Location: on auxiliary
heater
5 - Expansion tank
8 - Coolant pump
9 - Cylinder head
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J338-
12 - Heater coolant shut-off AG. Volkswagen AG d
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1.7 Checking cooling system for leaks

nform
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m
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♦ Cooling system tester - V.A.G 1274 B-

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♦ Adapter for cooling system tester - V.A.G 1274/8-
satelettronica
Test conditions
• Engine at operating temperature.
WARNING
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The cooling system is under pressure
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Danger of scalding by steam sed band hot coolant. ua
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Cover filler cap on expansion
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ac
ss
fully to release pressure.
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Cop py
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– Open filler cap on coolant expansion tank.

– Screw adapter for cooling system tester - V.A.G 1274/8- into
coolant expansion tank.
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/8- .
– Connect connector - V.A.G 1274 B/1- to cooling system tester
- V.A.G 1274 B- using supplied hose.
– Using hand pump of tester, build up a pressure of approx.
1.0 bar.
DANGER!
Risk of scalding! Before the cooling system tester - V.A.G 1274

B- is disconnected from the connecting hose or the connector
- V.A.G 1274 B/1- , reduction of the pressure is essential. To
do this, press pressure relief valve on cooling system tester -
V.A.G 1274 B- until pressure gauge displays value of »0«.
If the pressure drops:
satelettronica
– Find leaks and rectify.
Check pressure relief valve in cap.

– Fit cooling system tester - V.A.G 1274 B- with adapter for
cooling system tester - V.A.G 1274/9- on cap -1-.
– Build up pressure using hand pump of cooling system tester.
• The pressure relief valve must open at a pressure of 1.4 to
1.6 bar.
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– Renew filler cap, if pressure relief valve does not
wageopen as de‐
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⇒ “1.8.1 Draining and adding coolant”, page 92

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⇒ “1.8.2 Charging the cooling system in the case of emergency”,

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page 98
spec
1.8.1 Draining and adding coolant

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cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


equipment required
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
♦ Refractometer - T10007 A-
ss o
♦ Drip tray for workshop hoist - VAS 6208-

cial p
f inform
♦ Hose clamp pliers - VAS 6340-

mer
atio
m
♦ Coolant system charge unit - VAS 6096-

o
n
c
i
or

thi
te
sd
iva
o
r
Draining
p
cum
r
fo
en
ng
t.
yi Co
op
WARNING C py
t. rig
gh ht
pyri by
Vo
o
The cooling system is under pressure when the engine is hot!
c by lksw
cted agen
Prote AG.
Cover filler cap on expansion tank with a cloth and open care‐

Transporter 2004 ►
– Remove radiator outlet coolant temperature sender - G83-
-arrow-. To do this, pull retaining clip out of radiator flange.
Transporter 2010 ►
– Pull retaining clip -2- towards the front.
– Detach water hose leading to engine -1- from water AGhose
. Volkslead‐
wagen AG
ing to radiator -3-. swagen does
olk no t gu
yV
db ara
rise nte
tho eo
au ra
c
satelettronica
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
Continued for all vehicles
hole
spec
es, in part or in w
– In addition to draining coolant from engine, pull the coolant
t to the co
hose off the engine oil cooler -arrow-.
rrectness of i
Note
l purpos
Please observe disposal instructions!

nform
ercia
Filling
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

n AG. Volkswagen AG do4-cylinder injection engine (2.0 l engine) - Edition 09.2019
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Note
auth or
ac
ss
ce
le
♦ Use only distilled water for mixing coolant additives. The use
un
pt
an
d
of distilled water ensures optimum protection against corro‐

itte
y li
sion.
erm
ab
ility
ot p
♦ The water used for mixing has a major influence on the effec‐
wit
is n
tiveness of the coolant. Since water quality differs from country
h re
ole,
to country and even region to region, it is necessary to set a
spec
standard for the quality of water to be used. Distilled water
fulfils all requirements. Therefore, always use only distilled
t to the co
water when mixing coolant for topping up or renewing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
rrectne
tronic parts catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
s
age could lead to loss of coolant and subsequent severe
s o
damage to the engine.
cial p
f inform
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
mer
rosion damage as well as scaling. Such additives also raise
atio
m
the boiling point of the coolant. For this reason, the cooling
o
n
c
i
or
n
system must be filled all-year-round with coolant additives.
thi
e
satelettronica
t
sd
va
♦ Because of its high boiling point, the coolant improves engine

i
o
pr
cum
r
reliability under heavy loads, particularly in countries with trop‐

fo
en
ng
ical climates.
t.
yi Co
Cop py
♦ The refractometer - T10007A- must be used to determine the
t. rig
gh ht
yri by
current anti-freeze value.
cop Vo
by lksw
cted agen
Prote
♦ Do not reduce the coolant concentration by adding water even
AG.
in warmer seasons and in warmer countries. Frost protection

must be guaranteed down to at least -25°C.
♦ Read off anti-freeze figures for respective replenished coolant
additives.
♦ The temperature read off the refractometer - T10007A- corre‐
sponds the »ice flocculation point«. Flakes of ice may start
forming in the coolant below this temperature.
♦ Never reuse old coolant.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.
Coolant mixture ratio

• Coolant additive (40%) and distilled water (60%) for frost pro‐
tection to -25°C
tection to -36°C
• Coolant additive ⇒ Electronic parts catalogue (ETKA)
Transporter 2004►
– Install coolant temperature sender at radiator outlet - G83- with
a new seal.
Transporter 2010►
– Attach coolant hose to radiator on lower right-hand side. The
quick-release coupling must engage audibly.
Continued for all vehicles

– Connect coolant hose -arrow- to engine oil cooler.
– Install lower engine cover panel.
AG. Volkswagen AG d
agen oes
olksw not
– Fill tank of cooling esystem
byV charge unit - VAS 6096- with gat
ualeast
d ran
8 litres of pre-mixed
thoris coolant in correct mixture ratio. tee
or
au ac
ss
ce
e
nl
Note
pt
du
an
itte
y li
erm
ab
The quantity may vary depending on the equipment level.
ility
ot p
wit
, is n
satelettronica
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
h re
hole
coolant expansion tank -1-.
spec
es, in part or in w
– Install cooling system charge unit - VAS 6096- on adapter -
t to the co
V.A.G 1274/8- .
– Feed vent hose -2- into a small container -3-. rrectness of i
l purpos
Note
nf
ercia
Exhaust air takes a slight quantity of coolant along with it; this
orm
should be collected.
m
atio
om
n in
or c
– Close valves -A- and -B- (turn lever transverse to direction of

thi
te
flow to do this).
sd
iva
o
r
rp
cu
– Connect hose -4- to compressed air.

o
m
f
en
ng
t.
yi Co
• Pressure: 6 to 10 bar. ht. Cop py
rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Open valve -B-; turn lever in direction of flow to do this.

• In cooling system, vacuum is generated by suction jet pump;
needle of gauge must move into green area.
– In addition, open valve -A- briefly by turning lever in direction
of flow until expansion tank hose of cooling system charge unit
- VAS 6096- fills with coolant.
– Close valve -A- again.
– Leave valve -B- open for a further 2 minutes. AG. Volkswagen
agen AG do
lksw cooling system by es n
• Vacuum continues to be generated yin Vothe ot g
ua
the suction jet pump; the needlerof
ise gauge must remain in green
d b ran
tee
range. utho
or
a ac
ss
– Close valve -B-.
ce
le
un
pt
• The needle on the gauge should stop in the green zone. The
an
d
itte
y li
vacuum level in the cooling system is then sufficient for sub‐
rm
ab
sequent filling.
pe
ility
ot
wit
, is n
• If the needle does not reach the green zone, repeat the proc‐
h re
ess.
hole
spec
es, in part or in w
• If vacuum drops, cooling system must be checked for leaks.
satelettronica
t to the co
– Pull off compressed air hose.
– Open valve -A-.
rrectness of i
• The vacuum in the cooling system causes coolant to be ex‐
l purpos
tracted from coolant expansion tank of cooling system charge

unit - VAS 6096- and the cooling system to be filled.
nform
ercia
– Remove cooling system charge unit - VAS 6096- from coolant

m
expansion tank.
a
com
tion in
– Fill coolant up to max. mark.
r
te o
thi
s
iva
– Close coolant expansion tank.

do
r
rp
cum
fo
– If fitted, switch off air conditioning system.

en
ng
t.
yi Co
op
– Start engine and maintain engine speed at approx. 2000 rpm C py
t. rig
for about 3 minutes.
gh ht
pyri by
Vo
co lksw
by
– Then run engine at idling speed until radiator fan cuts in. cted agen
Prote AG.
• Allow engine to cool down to ambient temperature.
WARNING

– Check coolant level and top up as needed.

• The coolant level must be at the max. marking when the en‐
gine is warm.
• When the engine is cold, the coolant level must be between
min. and max. marking.
1.8.2 Charging the cooling system in the case

of emergency
Note
♦ The following steps only apply in the case of a breakdown.

♦ Here, the cooling system is charged without using the cooling
system charge unit - VAS 6096- .
♦ Charging in the case of an emergency is only permissible to
keep the vehicle mobile and does not replace the proper
charging procedure according to the repair manual.
♦ After an emergency charging, the vehicle should be brought
to a workshop as soon as possible where the cooling system
should be filled properly in accordance with the repair manual.
Procedure
WARNING
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
98
cted agen
Prote
Rep. gr.19 - Cooling
AG.
AG. Volkswagen AG d
agen o4-cylinder
es n injection engine (2.0 l engine) - Edition 09.2019
olksw ot g
byV ua
ed ran
ris tee
tho or
ss
Note
au ac
ce
e
nl
pt
♦ Use only distilled water for mixing coolant additives. The use
du
an
itte
of distilled water ensures optimum protection against corro‐
y li
erm
ab
sion.
ility
ot p
wit
♦ The water used for mixing has a major influence on the effec‐
, is n
h re
tiveness of the coolant. Since water quality differs from country
hole
spec
to country and even region to region, it is necessary to set a
es, in part or in w
standard for the quality of water to be used. Distilled water
t to the co
fulfils all requirements. Therefore, always use only distilled
water when mixing coolant for topping up or renewing coolant.
rrectness of i
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
l purpos
reduce corrosion protection substantially. The resulting dam‐

age could lead to loss of coolant and subsequent severe
damage to the engine.
nf
ercia
orm
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
m
atio
m
rosion damage as well as scaling. Such additives also raise

o
n in
c
the boiling point of the coolant. For this reason, the cooling
or
thi
system must be filled all-year-round with coolant additives.
te
sd
a
satelettronica
iv
o
r
♦ Because of its high boiling point, the coolant improves engine

rp
cu
o
m
f
reliability under heavy loads, particularly in countries with trop‐

en
ng
t.
yi
ical climates.
Co
Cop py
ht. rig
♦ The refractometer - T10007A- must be used to determine the
rig ht
py by
o Vo
current anti-freeze value.
by c lksw
cted agen
Prote AG.
♦ Frost protection must be guaranteed down to -25°C as a min‐
imum and, in countries with arctic conditions, down to approx.
-36°C. Increasing the frost protection is permissible only if cli‐
matic conditions require stronger frost protection. It may, how‐
ever, be increased only to a maximum of -48°C. Otherwise,
the cooling effect will be impaired.
♦ Do not reduce the coolant concentration by adding water even
in warmer seasons and in warmer countries. Frost protection
must be guaranteed down to at least -25°C.
♦ Read off anti-freeze figures for respective replenished coolant
additives.
♦ The temperature read off the refractometer - T10007A- corre‐
sponds the ice flocculation point. Flakes of ice may start
forming in the coolant below this temperature.
♦ Never reuse old coolant.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.
Coolant mixture ratio

tection to -25°C
tection to -36°C
• Coolant additive ⇒ Electronic parts catalogue (ETKA)
– Fill a suitable container with pre-mixed coolant observing the
correct mixing ratio.
– Fill the cooling system via the coolant expansion tank up to
max. marking.
– Close coolant expansion tank.
– If fitted, switch off air conditioning system.
– Start engine and maintain engine speed at approx. 2000 rpm

for about 3 minutes.
– Then run engine at idling speed until radiator fan cuts in.
WARNING

– Check coolant level and top up as needed.

• The coolant level must be at the max. marking when the en‐
gine is warm.
. Volkswage
• When the engine is cold, the coolant level
ksw
agen must be between
AG n AG d
oes
not
min. and max. marking. by
Vol
gu
a
ed ran
oris tee
th or
au
satelettronica
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2 Coolant pump, regulation of cooling

system
⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 101
⇒ “2.2 Assembly overview - Y thermostat”, page 103
⇒ “2.3 Removing and installing coolant pump”, page 104
⇒ “2.4 Removing and installing thermostat”, page 105
⇒ “2.5 Testing Y-thermostat”, page 107
2.1 Assembly overview - coolant pump,

gen AG
. Volkswathermostat
gen AG
d
a oes
ksw not
y Vol gu
b ara
ed
1 - Return from heat exchanger horis nte
eo
ut
❑ Coolant hose schematicss a ra
c
diagram for Transporter
ce
e
nl
2004 ► ⇒ page 85 .
pt
du
an
itte
y li
❑ Coolant hose schematic
erm
ab
satelettronica
ility
ot p
2010 ► ⇒ page 86 .
wit
, is n
h re
2 - Manifold
hole
spec
es, in part or in w
3 - Return from 2nd heat ex‐
t to the co
changer
❑ Only if fitted with option‐
al equipment.
rrectness of i
l purpos

2004 ► ⇒ page 85 .
nform
ercia

m
2010 ► ⇒ page 86 . at
om
ion
c
in t
r
4 - Supply to auxiliary coolant

o
his
e
heater (supplementary heater)

at
do
priv

um
for

en
ng
t.
yi Co
2004 ► ⇒ page 85 . t. Cop py
rig
gh ht
pyri by
co Vo
by lksw
cted
2010 ► ⇒ page 86 .
agen
Prote AG.
5 - Return from auxiliary cool‐

ant heater (supplementary
heater)
2004 ► ⇒ page 85 .
2010 ► ⇒ page 86 .
6 - Union
7 - Bolt
❑ 10 Nm
8 - Bolt
❑ 40 Nm
2. Coolant pump, regulation of cooling system 101

9 - Coolant pipe
❑ Coolant hose schematic diagram for Transporter 2004 ► ⇒ page 85 .
10 - O-ring
11 - To lower coolant expansion tank
12 - To bottom of radiator
14 - Bolt AG. Volkswagen AG d
agen
❑ 15 Nm Volksw
oes
not
gu
by ara
d
15 - Union orise nte
eo
th
u ra
16 - O-ring a c
satelettronica
ss
ce
e

nl
pt
du
an
itte
y li
17 - Thermostat
erm
ab
❑ Checking: heat thermostat in water.
ility
ot p
wit
, is n
❑ Begins to open at approx. 87°C
h re
hole
❑ Ends at approx. 105°C.
spec
es, in part or in w
❑ Opening lift min. 7 mm
t to the co
❑ Note installation position ⇒ page 105
rrectness of i
18 - Toothed belt
l purpos
❑ Mark direction of rotation before removing

❑ Check for wear
nf
ercia
o
❑ Do not kink
rm
m
atio
om
n in
or c
19 - Coolant pump
thi
te
sd
a
❑ Check for ease of movement.

iv
o
r
rp
cu

o
m
f
en
ng
t.
yi
Co
Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
21 - Bolt
cted agen
Prote AG.
❑ 20 Nm
22 - Throttle valve module - J338-
23 - To upper coolant expansion tank
24 - Retaining clip
❑ Check for firm seating
25 - Coolant temperature sender - G62-
26 - Supply from heat exchanger

2.2 Assembly overview - Y thermostat agen

AG. Volkswagen AG d
oes
olksw not
byV gu
ara
ed
1 - Housing horis nte
eo
ut ra
❑ Observe mounting posi‐ ss a c
tion relative to housing
ce
le
un
pt
⇒ Item 6 (page 103)
an
d
itte
y li
2 - Seal
erm
ab
ility
ot p
❑ Coat with coolant before
wit
is n
assembling housings
h re
ole,
⇒ Item 1 (page 103) and
spec
⇒ Item 6 (page 103) .
t to the co
3 - Spring
rrectne
• Note installation position:
• Insert into housing with the
ss
“larger” diameter
o
cial p
f
⇒ Item 1 (page 103) .
inform
mer
4 - Thermostat
satelettronica
atio
om
n
• Note installation position:
c
i
or
n thi
te
• Insert with the “cylinder
sd
iva
o
r
side” pointing towards

p
cum
r
fo
housing
en
ng
t.
yi
⇒ Item 1 (page 103) .
Co
Cop py
.
ht rig
rig ht
py by
co Vo
5 - Retaining clip
by lksw
cted agen
Prote AG.
❑ Do not bend or stretch
excessively
6 - Housing
❑ Observe mounting posi‐
tion relative to housing
⇒ Item 1 (page 103)
Mounting position of housing

– The locking lug -1- must engage in the recess -2-.

2.3 Removing and installing coolant pump

equipment required
AG. Volkswagen AG d
agen oes
olksw not
yV gu
satelettronica
d b ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
thi
te
sd
va

i
o
pr
cum
r
hoist - VAS 6208-

fo
en
ng
t.
yi Co
♦ Torque wrench (5 … 50 Nm) - V.A.G 1331- . Cop py
rig
ht ht
rig
♦ Spring-type clip pliers - VAS 5024- discontinued, use hose clip py by
co Vo
pliers - VAS 6340-
by lksw
cted agen
Prote AG.
Removing
Note
♦ Always renew gaskets and seals.

♦ The lower part of the toothed belt guard need not be removed.
♦ The toothed belt stays on the crankshaft toothed-belt pulley.
♦ Cover toothed belt with a cloth to protect it from coolant before
removing coolant pump.


– Remove tensioning element for poly V-belt.
– Remove upper and centre toothed belt guards.
– Remove toothed belt from coolant pump sprocket
⇒ page 49 .
– Unscrew securing bolts -1- from rear toothed belt guard -2-.
– Unscrew coolant pump securing bolts -5- and remove coolant
pump -4-.
Installing
satelettronica
– Moisten new O-ring -3- with coolant.
AG. Volkswagen AG d
Note agen oes
olksw not
byV gu
ara
ed
The coolant pump plug faces downwards. horis nte
eo
aut ra
ss c
– Insert coolant pump -4- into cylinder block and tighten securing
ce
e
nl
pt
bolts -5-.
du
an
itte
y li
erm
– Tighten securing bolts -1- of rear toothed belt guard -2-.
ab
ility
ot p
Install and tension toothed belt ⇒ page 49 .
wit
, is n
h re
– Install poly V-belt tensioning element.
hole
spec
es, in part or in w

t to the co
– Tighten power-assisted steering vane pump to ancillaries
bracket: ⇒ Running gear, axles, steering; Rep. gr. 48 ; Hy‐
rrectness of i
draulic power-assisted steering

l purpos

Specified torques
nform
ercia
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,

m
page 101
at
om
ion
c

in t
or
his
e
20
at
do
priv

um
for
en
ng
t.
yi Co
op
2.4 Removing and installing thermostat
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
hoist - VAS 6208-
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
♦ Spring-type clip pliers - VAS 5024- discontinued, use hose clip
pliers - VAS 6340-
Removing
Note
Always renew gaskets and seals.

– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .

– Pull coolant hose off connection -3-.

– Unscrew securing bolts -4- of connection -3-, and remove
connection -3- together with thermostat -1-.
Installing
– Moisten new O-ring -2- with coolant.

– Fit connection -3- with thermostat -1- into cylinder block.
Note agen
AG. Volkswagen AG d
oes
olksw not
y V gu
b ara
The brace on the thermostat must be almost vertical.
rise
d
nte
tho eo
satelettronica
au ra
s c
– Tighten securing bolts -4-. s
ce
e
nl
pt
du
an
itte
y li
erm
ab
Specified torques
ility
ot p
♦ ⇒ “1.3 Assembly overview - cylinder block”, page 21
wit
, is n
h re
hole
♦ Alternator; Assembly overview - alternator ⇒ Alternator; Rep.
spec
gr. 27 ; Assembly overview - alternator
es, in part or in w
t to the co
2.5 Testing Y-thermostat
rrectness of i
Check
l purpos
– Remove Y-thermostat.
– Pull off securing clip -1-.
nform
ercia
– Pull housing -2- off housing -3- slowly and carefully.

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Check distance -a- from thermostat in cold condition. The dis‐

tance -a- must be at least 5 mm.
– Place thermostat in hot water. The water must be at least 55°
C.
– Check distance -b- from thermostat in hot condition. The dis‐
tance -b- must be at least 11 mm.
– Put spring with small diameter onto thermostat.
– Before assembling, apply coolant to sealing ring -arrow-.
satelettronica
– Observe installation position of housing.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
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– The locking lug -1- must engage in the recess -2-.

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3 Radiator, radiator fan

⇒ “3.1 Assembly overview - radiator/radiator fan”, page 109
⇒ “3.2 Assembly overview - radiator, radiator fan, 2010 ►”,
page 110
⇒ “3.3 Assembly overview - radiator cowl with radiator fan V7 and
right radiator fan V35 .”, page 111
⇒ “3.4 Assembly overview - radiator cowl with radiator fan V7 ,
2010 ►”, page 112
⇒ “3.5 Removing and installing radiator”, page 113
⇒ “3.6 Removing and installing radiator cowl with radiator fan V7 ,
2010 ►”, page 114
3.1 Assembly overview - radiator/radiator fan

lkswage es n
1 - Oil cooler d by Vo ot g
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❑ For tpowerhoris
steering tee
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2 - Bolt ss
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❑ 6 Nm pt
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3 - Cap
erm
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❑ Check using cooling

wit
system tester - V.A.G

, is n
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1274 B- and adapter for

hole
spec
cooling system tester -

es, in part or in w
V.A.G 1274/9-
t to the co
❑ The pressure relief

valve must open at a
pressure of 1.4 to
rrectness of i
1.6 bar
l purpos
4 - O-ring
nf
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m
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5 - Connector
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6 - Bolt
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❑ 3 Nm
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7 - Coolant expansion tank

t.
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op py
❑ Check cooling system t. C rig
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Prote AG.

V.A.G 1274/8-
8 - Rubber mounting
9 - Radiator/cooler
❑ After renewing, renew
entire coolant.
10 - Bolt
❑ 6 Nm
3. Radiator, radiator fan 109

AG. Volkswagen AG d
Transporter 2004 ➤ , Transporter 2010 ➤ olkswagen oes
not
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4-cylinder injection engine (2.0 l engine) e-dEdition
by 09.2019 gu
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11 - Condenser ss
au ra
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ce
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12 - Retaining clip
un
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13 - Washer
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14 - O-ring
h re
hole
spec
es, in part or in w
t to the co
15 - Retaining clip
❑ For radiator outlet coolant temperature sender - G83- .
rrectness of i
16 - Radiator outlet coolant temperature sender - G83-
l purpos
17 - Connector
❑ For radiator outlet coolant temperature sender - G83- .
nform
ercia
18 - Lower coolant hose

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tion in
19 - Upper coolant hose
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op
3.2 Assembly overview - radiator, radiator fan, 2010 ►
C py
t. rig
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Prote
1 - Oil cooler
AG.
❑ For power steering

2 - Bolt
❑ 6 Nm
3 - Cap
❑ Check using cooling
V.A.G 1274/9-
❑ The pressure relief
valve must open at a
pressure of 1.4 to
1.6 bar
4 - O-ring
5 - Connector
6 - Bolt
❑ 3 Nm
7 - Expansion tank
❑ Check cooling system
for leaks using cooling
V.A.G 1274/8-
8 - Rubber mounting
9 - Radiator/cooler
❑ After renewing, renew

entire coolant.
10 - Bolt
❑ 6 Nm
11 - Condenser
12 - Retaining clip
13 - Washer
14 - Lower coolant hose
15 - Upper coolant hose
3.3 Assembly overview - radiator cowl with radiator fan - V7- and right radiator
fan - V35- . AG. Volkswagen
satelettronica
agen AG do
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y Vol ot g
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1 - Radiator fan
ris - V7-
ed ran
tee
ho
❑ Variation
sa
ut depending on or
ac
vehicle equipment.
s
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un
pt
2 - Nut
an
d
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❑ 10 Nm
rm
ab
pe
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3 - Retaining clip
wit
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❑ For cable guide

hole
spec

es, in part or in w
t to the co
4 - Radiator fan support

5 - Radiator fan 2 - V35-
rrectness of i
❑ Variation depending on
vehicle equipment.
l purpos
6 - Bolt
nform
ercia
❑ 6 Nm
m
7 - Bolt
com
tion in
❑ 6 Nm
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8 - Bolt
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❑ 5 Nm
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9 - Bracket t. Cop py
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❑ May not be fitted ac‐
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3.4 Assembly overview - radiator cowl with radiator fan - V7- , 2010 ►
1 - Radiator/cooler
2 - Radiator fan
3 - Bolt
❑ 5 Nm
4 - Bolt AG. Volkswagen AG d
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❑ 5 Nm Volksw
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5 - Retainer tab orise nte
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❑ Must be engaged in ra‐ ss au ra
c
diator.
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an
6 - Radiator fan support
d
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⇒ page 112
ot
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es, in part or in w
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3.5 Removing and installing radiator

equipment required
satelettronica
AG. Volkswagen AG d
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pliers - VAS 6340-

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Removing Cop py
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– Remove front bumper ⇒ General body repairs, exterior; Rep.
Prote AG.
gr. 63 ; Bumpers .
– Move lock carrier to service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐
sition .
– Pull all coolant hoses off radiator.

– Remove securing bolt -2- for oil cooler for power-assisted

steering.
– Unclip oil cooler and lay to one side.
– Remove condenser securing bolts -3-, -6- and -8-.
– Lever condenser out of retainers -4- and -5- and place to side
(refrigerant lines remain connected).
– Remove radiator securing bolt -1- and push rubber mounting
in direction of arrow.
Transporter 2004►
– Disconnect connectors -arrows-.
satelettronica
Transporter 2010►
AG. Volkswagen AG d
– Pull back securing lever -1- onto stop agen oes
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– Push down securing lever -2- and pull off connector orise nte
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nl
– Carefully remove radiator forwards. pt

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Installing
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spec
Specified torques
es, in part or in w
t to the co
♦ ⇒ “3.1 Assembly overview - radiator/radiator fan”, page 109

♦ ⇒ “3.2 Assembly overview - radiator, radiator fan, 2010 ►”,
rrectness of i
page 110
l purpos
♦ ⇒ “3.3 Assembly overview - radiator cowl with radiator fan V7

and right radiator fan V35 .”, page 111
nform
ercia
♦ ⇒ “3.4 Assembly overview - radiator cowl with radiator fan V7 ,

2010 ►”, page 112
m
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3.6 Removing and installing radiator cowl

o
his
ate
do
riv
with radiator fan - V7- , 2010 ►

p
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for
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Removing
n
t.
yi Co
Cop py
t.
– Bring lock carrier into service position ⇒ General body repairs,
rig
gh ht
yri by
exterior; Rep. gr. 50 ; Lock carrier . op Vo
by c lksw
cted agen
Prote AG.

– Removing radiator ⇒ page 113 .

– Undo screws -arrows- and remove fan mounting together with
radiator fan - V7- from radiator.
AG. Volkswagen AG d
agen oes
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– Push back locking lug -arrow-s and
au
t
remove fan mounting to‐ ra
c
gether with radiator fan - V7- from radiator. s
ce
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nl
pt
du
Installing
an
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ab
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satelettronica
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es, in part or in w
t to the co
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– Insert fan mounting together with radiator fan - V7- into the
radiator with the locking lug first -arrow-.
nform
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at
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c
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ate
do
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Cop py
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– Tighten bolts -arrows-.
– Installing radiator ⇒ page 113 .
Specified torques
♦ ⇒ “3.2 Assembly overview - radiator, radiator fan, 2010 ►”,
page 110
♦ ⇒ “3.4 Assembly overview - radiator cowl with radiator fan V7 ,
2010 ►”, page 112

AG. Volkswagen AG d
agen oes
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24 – Mixture preparation - injection
by gu
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1 Air filter
ce
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⇒ “1.1 Assembly overview - air filter housing”, page 116
erm
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1.1 Assembly overview - air filter housing
wit
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spec
1 - Air mass meter - G70-
t to the co
2 - Seal
rrectne
3 - Air filter upper part
s
4 - Filter element
s o
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5 - Rubber mounting
nform
mer
6 - Air filter lower part
atio
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7 - Rubber mounting
c
satelettronica
or
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❑ Clipped into lower part

t
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of air filter
i
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8 - Bolt
t.
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op
❑ 8 Nm
C py
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9 - Air duct cop Vo
by lksw
cted agen
Prote AG.
10 - To throttle valve module -
J338- .
11 - Spring-type clip
12 - To intake manifold
13 - Connection for crankcase
breather
14 - To breather pipe for injec‐
tors ⇒ Item 8 (page 119)
15 - Intake hose
16 - Bolt
❑ 6 Nm
116 Rep. gr.24 - Mixture preparation - injection

2 Intake manifold
⇒ “2.1 Assembly overview - intake manifold”, page 117
⇒ “2.2 Assembly overview - lower part of intake manifold with fuel
rail”, page 119
2.1 Assembly overview - intake manifold
1 - Upper part of intake mani‐

fold agen
AG. Volkswagen AG d
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2 - Bracketed by V ua
ran
ris
❑ Forut
ho hoses for crankcase
tee
or
ss breather
a ac
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3 - Bolt
un
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d
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❑ 25 Nm
y li
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ab
ility
4 - Vacuum hose
ot p
wit
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❑ To fuel pressure regula‐
h re
ole,
tor.
satelettronica
spec
5 - Vacuum hose
t to the co
❑ To connecting pipe for
throttle valve control
module/air mass meter. rrectne
6 - Bolt
ss
❑ 20 Nm
o
cial p
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7 - Bracket
form
mer
8 - Bolt
atio
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❑ 20 Nm
c
i
or
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sd
9 - Connecting pipe
iva
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pr
❑ Between solenoid vale 1

um
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- N80- and throttle valve

t.
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control module Cop py
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10 - Seal py by
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agen
Prote AG.

J338-
❑ Adaptation ⇒ Vehicle di‐
agnostic tester
12 - Bolt
❑ 10 Nm
13 - To throttle valve control module - J338- .
14 - Threaded union
❑ Install using locking fluid - D 000 600 A2-
❑ 45 Nm
15 - Connecting pipe
❑ For exhaust gas recirculation
❑ 40 Nm
2. Intake manifold 117

16 - Exhaust manifold
17 - To brake servo
18 - Intake manifold support
19 - Bolt
❑ 20 Nm
20 - Seal
21 - Vacuum hose
❑ To pressure line for secondary air system.
22 - Connector
23 - Exhaust gas recirculation valve - N18- with exhaust gas recirculation potentiometer - G212-
❑ Adaptation ⇒ Vehicle diagnostic tester
24 - Bolt n AG. Volkswagen AG do
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❑ 20 Nm yV
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25 - Seal ir se tee
tho
or
satelettronica
u
❑ Renew after removal ss
a ac
ce
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nl
26 - Bolt
pt
du
an
itte
❑ 25 Nm
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es, in part or in w
t to the co
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at
om
ion
c
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or
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ate
do
priv
cum
for
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Cop py
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by
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Prote AG.

2.2 Assembly overview - lower part of intake manifold with fuel rail
1 - Cable channel
2 - To pressure line for secon‐
dary air system.
3 - Fuel pressure regulator
4 - O-ring agen
AG. Volkswagen AG d
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❑ Renew after removal d by Vo gu
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5 - Retaining clip utho eo
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a
❑ Check for firm seating ss c
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nl
pt
6 - To intake hose
du
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7 - Breather pipe
ab
ility
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8 - Air hose
wit
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❑ For air shrouded injec‐
hole
spec
tors
satelettronica
es, in part or in w
t to the co
9 - Injector, cylinder 1 - N30- to
injector, cylinder 4 - N33-
❑ Air shrouded.
rrectness of i
l purpos
⇒ page 120
10 - Nut
nform
ercia
❑ 25 Nm
m
at
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11 - Intake manifold lower part
ion
c
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or
12 - Seal
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13 - Bolt
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❑ 25 Nm C py
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14 - Retaining clip cop Vo
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❑ Ensure correct seating Prote AG.
on injector and fuel rail
15 - Bracket
16 - Bolt
❑ 20 Nm
17 - Union for fuel return line
18 - Union for fuel supply line
19 - Fuel distributor
20 - Bolt
❑ 10 Nm
2. Intake manifold 119

3 Injectors
⇒ “3.1 Removing and installing injectors”, page 120
⇒ “3.2 Checking injectors”, page 121 agen
AG. Volkswagen AG d
oes
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⇒ “3.3 Checking quantity injected”, yV
bpage 124
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3.1 Removing and installing injectors
h
aut ra
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Removing
un
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ab
hose ⇒ page 116 .
ility
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– Pull coolant hoses -3- and -4- off throttle valve module, and
h re
seal hose ends with, for example, hose clamps up to 25 mm -
ole,
spec
3094- .
t to the co
filter bracket.
rrectne
satelettronica
ss o
cial p
f inform
mer
-1- from retainer.
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fo
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t.
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op
– Pull off vacuum hose to brake servo. C py
t. rig
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p by
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by c lksw
bolt upper part of intake manifold from intake manifold support. Prote
cted AG.
agen
Note
cloth.
WARNING
The fuel system is pressurised! Before opening the system,


– Pull off connectors on all injectors.
– Loosen securing bolts of fuel rail.
– Pull hose off vent pipe for air shroud injectors
⇒ Item 8 (page 119) .
– Lift off fuel rail with injectors.
– Pull off retaining clip, and remove injector from fuel rail.
Installing
– Renew the O-rings at all opened connections. agen
AG. Volkswagen AG d
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V gu
– Lubricate the O-rings lightly with clean engine oil. ed by ara
nte
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– Make sure that the injectors are installed in the correct
aut posi‐
h
ra
tions. ss c
ce
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nl
pt
– Ensure retaining clips are properly seated.
du
an
itte
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erm
– Position fuel rail together with secured injectors against lower
ab
satelettronica
ility
part of intake manifold, and press into place evenly.
ot p
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hole
spec
– Check coolant level after completion of work ⇒ page 92 .
es, in part or in w
t to the co
Specified torques
rrectness of i
♦ ⇒ “2.2 Assembly overview - lower part of intake manifold with
l purpos
fuel rail”, page 119
3.2 Checking injectors
nf
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orm
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3. Injectors 121
Special tools and workshop n AG. Volkswagen AG do

equipment required lkswage es n
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satelettronica
com
tion in
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Cop py
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Prote AG.
♦ Remote control - V.A.G 1348/3 A-

♦ Adapter line - V.A.G 1348/3 - 2-
♦ Injection rate tester - V.A.G 1602-
♦ Adapter set - V.A.G 1594 C-
WARNING



• The fuel pressure must be OK. Checking ⇒ page 126 .
• Fuses SD14 and SD30 -arrows- must be removed from their
sockets.
Procedure
– Remove throttle valve control module/air mass meter con‐
necting hose.
- 3094- .
filter bracket.
satelettronica
AG. Volkswagen AG d
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by
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– Open retainers and lay complete hose guide -9- touthside.
o r eo
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– Unclip Lambda probe before catalytic converters connector
ce
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-1- from retainer.

nl
pt
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Note
nform
ercia
♦ Block off intake ports in lower part of cylinder head with a clean
cloth.
m
at
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ion
c
♦ Do not disconnect fuel hoses.

in t
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ate
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– Pull off connector to the injectors.

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– Pull hose off vent pipe for air shroud injectors

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t.
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op
⇒ Item 8 (page 119) . C py
t. rig
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– Loosen securing bolts of fuel rail. op Vo
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Prote
– Lift off fuel rail with injectors.
AG.
3. Injectors 123
– Connect remote control - V.A.G 1348/3 A- with adapter cable

- V.A.G 1348/3-3- to terminal of fuse 30b -enlargement-.
– Insulate second, free flat connector of adapter cable -
V.A.G 1348/3-3- -arrow- using commercially available insulat‐
ing tape.
– Connect battery positive terminal clamp of remote control -
V.A.G 1348/3 A- to positive terminal -+- of battery.
Note
♦ This step serves only to have the fuel pump running when the
engine is stopped.
♦ If injectors are renewed, clear event memory ⇒ Vehicle diag‐
nostic tester.
♦ Always renew seals.
– Check injectors for leaks (visual check). No more than 1 to 2

drops per minute must escape from each valve when fuel
pump is running.
satelettronica
If the fuel loss is greater:
– Separate connection between fuse socket 30b and battery
positive (+), and renew leaking injector ⇒ page 120 .
Specified torques
3.3 Checking quantity injected

gen AG
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d wa oes
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Conditions for testing byV gu
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• The fuel pressure must tho be OK. Checking ⇒ page 126 . eo
au ra
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• Upper part of intake manifold removed.
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pt
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• Injectors installed in fuel rail and fuel line connected.

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sockets.
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Test sequence
hole
spec
– Place injector to be tested into measuring glass of injection

es, in part or in w
t to the co
quantity tester - V.A.G 1602- .

rrectness of i
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orm
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Prote AG.

– Connect fuse socket 30b and battery -+- using cables from
auxiliary measuring set - V.A.G 1594 C- .
Note
This step serves only to have the fuel pump running when the
engine is stopped.
lkswage es n
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– Connect a contact of injector to be tested to engine earth using
spec
satelettronica
test leads from auxiliary measuring set - V.A.G 1594 C- .
es, in part or in w
t to the co
– Connect second injector contact to remote control - V.A.G
1348/3 A- using adapter cable - V.A.G 1348/3 - 2- .
rrectness of i
– Connect crocodile clip to battery (+).
l purpos
– Operate remote control - V.A.G 1348/3 A- for 30 seconds.

– Repeat check on other injectors. Use new measuring beakers.
nform
ercia
– After all injectors have been activated, place measuring beak‐

m
at
ers on a level surface and compare the quantity injected.

om
io
Specification: 85…105 ml per injector

n
c
in t
or
his
e
When checking the quantity injected, check the spray pattern as

at
do
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well. The spray patterns must be the same for all injectors.
p
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If the measured values of one or more injectors are above or be‐

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low the prescribed specifications: C py
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– Renew defective injector ⇒ page 120 .
p by
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– Check coolant level after completion of work.
Prote AG.
Note
♦ If injectors are renewed, clear event memory ⇒ Vehicle diag‐

nostic tester.
♦ Always renew seals.
Specified torques
3. Injectors 125
4 Senders and sensors

⇒ “4.1 Checking fuel pressure regulator and holding pressure”,
page 126
4.1 Checking fuel pressure regulator and holding pressure

equipment required
satelettronica
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♦ Pressure gauge - V.A.G 1318-

mer
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♦ Adapter - V.A.G 1318/9-

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♦ Adapter set - V.A.G 1318/17-

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♦ Connector - V.A.G 1318/23-

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♦ Remote control - V.A.G 1348/3 A-

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Note
♦ The fuel pressure regulator regulates the fuel pressure to ap‐

prox. 3 bar.
♦ Observe safety precautions ⇒ page 4 .

sockets.
WARNING

Test sequence
satelettronica
– Separate fuel supply line -3- plug-in connector. Collect escap‐
ing fuel with a cleaning cloth. agen AG. Volkswagen AG do
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t to the co
– Connect pressure tester - V.A.G 1318- with adapter - V.A.G

1318/9- , double union - 1318/23- and adapter set - V.A.G
1318/17- as shown.
rrectness of i
– Open shut-off tap of pressure tester. The handle points in di‐

l purpos
rection of flow.
– Start engine and allow to idle.
nform
ercia
– Measure fuel pressure. Specification: approx. 2.5 bar.

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tion in
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4. Senders and sensors 127

– Pull vacuum hose -arrow- off fuel pressure regulator.

– The fuel pressure must increase to approx. 3 bar.
If specification is not obtained
– Switch off ignition.
– Check fuel delivery rate of fuel pump ⇒ Rep. gr. 20 ; Fuel
pump; Checking fuel system pressurisation pump - G6- .
If reading matches specification: agen
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– Switch off ignition. e d by ara
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– Now check for leaksautand check retention pressure (entire sys‐
h
ra
tem). Observe pressure
ss drop on pressure gauge for this. After c
ce
le
10 minutes there must be a residual pressure of at least 2.0

un
pt
bar.
an
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itte
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If the holding pressure drops below 2 bar:
ility
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– Start engine and allow to idle.
is n
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spec
– After pressure has built up, switch off the ignition. At the same
time, close shut-off tap of pressure tester (handle perpendic‐
t to the co
satelettronica
ular to direction of flow) -arrow-.
– Observe pressure drop on pressure gauge.
rrectne
If the pressure does not drop:
ss
– Check non-return valve of fuel pump ⇒ Rep. gr. 20 ; Fuel
o
cial p
f
pump; Checking fuel system pressurisation pump - G6- .
inform
mer
If the pressure drops again: atio

m
– Check pressure tester for leaks.

o
n
c
i
or
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e
– Check line connections, O-rings on fuel rail and injectors for

t
sd
va
leaks. ⇒ page 121

i
o
pr
cum
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– Check pressure tester for leaks. yi

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Cop py
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If no leak is detected:
ht
pyri by
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– Renew fuel pressure regulator.
cted agen
Prote AG.
Note
Before removing pressure tester, place cleaning cloths again

around the connections to be loosened.

5 Engine control unit

⇒ “5.1 Removing and installing engine (motor) control unit J623
”, page 129
5.1 Removing and installing engine (motor)

control unit - J623-
♦ Vehicle diagnostic tester AG. Volkswagen AG d
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– If engine control unit - J623- was renewed,ut
h learnt values must
or eo
be reset ⇒ Vehicle diagnostic tester, 01
ss a - Systems capable
ra
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of self-diagnosis , 01 - Diesel direction injection
ce
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nl
pt
du
and preglow system EDC 17 , 01 - Engine electronics
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functions , Bringing into operation .
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es, in part or in w
If the adaption values of the injectors cannot be read from the old
t to the co
(defective) engine control unit - J623- , the adaption values must
be entered in the new engine control unit - J623- manually and
adjusted.
rrectness of i
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
l purpos
Removing and installing battery tray .
nform
– Remove electronics box cover ⇒ Electrical system; Rep. gr.
ercia
97 ; Relay carrier, fuse carrier, electronics boxes; Removing

m
at
and installing electronics box .
om
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– Disconnect connectors -2- and -3- from engine control unit -
or
his
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J623- -1-.
at
do
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for
– Pull engine control unit - J623- -1- in -direction of arrow- out of en

ng
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electronics box -2-.
Co
Cop py
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Installing
rig by
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Install in reverse order of removal.
agen
Prote AG.
5. Engine control unit 129

26 – Exhaust system
1 Exhaust pipes and silencers
⇒ “1.1 Assembly overview - silencers”, page 130
⇒ “1.2 Separating exhaust pipes from silencers”, page 130
1.1 Assembly overview - silencers
1 - From front exhaust pipe

2 - Mounting
❑ With retaining ring AG. Volkswagen AG d
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3 - Bolt horis nte
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❑ 25 Nm ss a c
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4 - Front silencer
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5 - Coupling point
erm
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❑ During production, front
ot p
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and rear silencers are
is n
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installed as a single
ole,
spec
component. For repairs,
front and rear silencers
t to the co
are supplied separately.
❑ The connection is made
with a clamping sleeve
rrectne
❑ Evenly tighten threaded
connections of clamping
ss
sleeve
o
cial p
f in
❑ Separating front and
form
mer
rear silencers
atio
⇒ page 130 .
om
n
c
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6 - Mounting
thi
te
sd
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7 - Bolt
en
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❑ 60 Nm Cop py
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py by
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1.2 Separating exhaust pipes from silencers

130 Rep. gr.26 - Exhaust system

♦ Chain-type pipe cutter - VAS 6254-
Procedure
Note
♦ After working on the exhaust system, ensure that the system

is not under stress and that there is sufficient clearance to the
bodywork. If necessary, loosen double and single clamps and
satelettronica
align silencer and exhaust pipe so that sufficient clearance is
maintained to the bodywork and the support rings are evenly
loaded. AG. Volkswagen n AG do
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♦ Renew seals, gaskets and
y Vself-locking nuts.
olks ot g
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– Separate front silencer
ut
h
-1- at right angles at coupling point (at or
ac
sa
point marked allsround with point indentations or at a measured
ce
le
point on silencers with no marked coupling point).

un
pt
an
d
itte
– Centre repair double clamp -2- when installing.

y li
erm
ab
ility
– Align exhaust system free of stress.

ot p
wit
is n
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ole,
For vehicles having silencers with no marking indentations, the

spec
coupling point must be measured.

t to the co
– Measure distance -A- (144 mm) from fold of front silencer.

Mark exhaust pipe at measured point.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
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– Centre repair double clamp -2- when installing.

iv
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pr
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fo
– Align exhaust system free of stress.

en
ng
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op
Specified torque
C py
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rig ht
py by
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cted agen
Prote AG.
Repair double clamp 52 Nm
1. Exhaust pipes and silencers 131

2 Emission control
⇒ “2.1 Assembly overview - emission control”, page 132
2.1 Assembly overview - emission control
1 - Seal
2 - Connecting pipe
❑ For exhaust gas recircu‐ AG. Volkswagen AG d
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3 - Union nut orise nte
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❑ 40 Nm s au ra
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4 - Connector nl
pt
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❑ 6-pin
itte
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5 - Lambda probe before cata‐
ility
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lytic converter - G39-
wit
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satelettronica
h re
❑ Grease only the thread
hole
spec
with high-temperature
es, in part or in w
paste - G 052 112 A3- ;
t to the co
high-temperature paste
must not get into the
slots of probe body.
rrectness of i
❑ 55 Nm
l purpos
7 - Connecting pipe
nf
ercia
or
❑ For secondary air sys‐
m
m
atio
tem
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8 - Union nut
thi
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sd
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❑ 40 Nm
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9 - Threaded union
en
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❑ 35 Nm C py
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10 - Seal
p by
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cted
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11 - Front exhaust pipe with

catalytic converter
12 - Nut
❑ 25 Nm
13 - Connector
❑ 4-pin
❑ The connector is located beneath right underbody panel.
14 - Lambda probe after catalytic converter - G130-
❑ Grease only thread with high-temperature paste - G 052 112 A3- ; high-temperature paste must not get
into slots in probe body
❑ 55 Nm
15 - Double clamp
❑ 52 Nm

AG. Volkswagen AG d
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eo 2004 ➤ , Transporter 2010 ➤
ut
ss a 4-cylinder injection engine
ra
c (2.0 l engine) - Edition 09.2019
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16 - To front silencer
an
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17 - Bolt
ab
pe
ility
❑ 25 Nm
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18 - Mounting for front exhaust pipe
hole
spec
es, in part or in w
t to the co
19 - Catalytic converter
20 - Nut
rrectness of i
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❑ 25 Nm
nform
mercia
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satelettronica
C py
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pyri by
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Prote AG.
2. Emission control 133

3 Exhaust gas recirculation

⇒ “3.1 Assembly overview - exhaust gas recirculation”,
page 134
3.1 Assembly overview - exhaust gas recirculation
1 - Upper part of intake mani‐

fold
2 - Threaded union
❑ Install using locking fluid
- D 000 600 A2-
❑ 45 Nm
AG. Volkswagen AG d
3 - Union nut lksw
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❑ 40 Nm d by ara
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4 - Connecting pipe auth
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5 - Union nut
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satelettronica
❑ 40 Nm
d
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ab
pe
ility
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7 - To pressure line for secon‐
, is n
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dary air system.
hole
spec
8 - Connector
es, in part or in w
t to the co
9 - Bolt
❑ 20 Nm
10 - Exhaust gas recirculation rrectness of i
l purpos
valve - N18- with exhaust gas

recirculation potentiometer -
G212-
nform
ercia
❑ Adaptation ⇒ Vehicle di‐

m
agnostic tester
com
tion in
11 - Seal
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s
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n AG. Volkswagen AG o
4-cylinder injection wage (2.0 l engine) -dEdition
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l es n
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4 Secondary air system ss
au ra
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nl
⇒ “4.1 Function”, page 135
pt
du
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⇒ “4.2 Assembly overview - secondary air system”, page 135
erm
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ility
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⇒ “4.3 Checking combination valve”, page 136
wit
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4.1 Function
hole
spec
es, in part or in w
During a cold start, air is temporarily blown from the secondary
t to the co
air system into the exhaust ports. This produces an oxygen rich
exhaust gas, causing afterburning and reducing the heat-up
phase of the catalytic converter.
rrectness of i
4.2 Assembly overview - secondary air system l purpos
nf
ercia
1 - Combination valve
orm
m
atio
2 - Union nut
om
n in
c
❑ 40 Nm
or
thi
te
sd
a
3 - Connecting pipe
iv
satelettronica
o
r
rp
cu
o
m
4 - Threaded union
f
en
ng
t.
yi Co
❑ 45 Nm Cop py
t. rig
gh ht
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5 - O-ring p by
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cted
agen
Prote AG.
6 - to exhaust gas recirculation

valve - N18- with exhaust gas
recirculation potentiometer -
G212-
7 - Pressure hose
8 - Bracket
9 - Filter
10 - Secondary air pump motor
- V101-
11 - Bracket
12 - Bolt
❑ 10 Nm
13 - Washer
14 - Nut
❑ 10 Nm
15 - Subframe
16 - Bolt
❑ 25 Nm
17 - Union
❑ For combination valve
18 - Bolt
❑ 20 Nm
19 - Seal
4. Secondary air system 135

4.3 Checking combination valve

• Hose connections must be leak-free.
Note
Do not use compressed air during the following check!
– Pull pressure hose -arrow- off combination valve.

– Slide auxiliary hose onto combination valve.
– Blow into auxiliary hose using light pressure. Combination
valve must be closed.
– Blow into auxiliary hose using strong pressure. Combination
valve must open.
If the combination valve does not open, or is constantly open:
– Renew combination valve.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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un
pt
an
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itte
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ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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en
ng
t.
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Cop py
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pyri by
Vo
co lksw
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cted agen
Prote AG.

28 – Ignition system
1 Ignition system
⇒ “1.1 Assembly overview - ignition system”, page 137
⇒ “1.2 Removing and installing spark plugs”, page 138
⇒ “1.3 Test data, spark plugs”, page 139
1.1 Assembly overview - ignition system
1 - Ignition cable
❑ 4 to 8 kΩ
❑ With suppression con‐
nector and spark plug
connector.
❑ Check for continuity.
❑ Pull off spark plug con‐
satelettronica
nector using assembly
tool - T10029- .
2 - Ignition transformer - N152- n AG. Volkswagen AG do
lkswage es n
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❑ Markings for H.T. ca‐ d byV ua
ran
bles: A = Cylinder 1, B = ir se tee
ho
Cylinder 2, C = Cylinder aut or
ac
3, D = Cylinder 4 ss
ce
le
un
pt
3 - Bolt
an
d
itte
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❑ 10 Nm
rm
ab
pe
ility
4 - Connector
ot
wit
, is n
h re
❑ For ignition transformer
hole
- N152- .
spec
es, in part or in w
t to the co
6 - Connector rrectness of i
❑ 2-pin
❑ For knock sensor I -
l purpos
G61-
7 - Bolt
nform
ercia
❑ 20 Nm
m
a
com
tio
8 - Knock sensor II - G66-

n in
r
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thi
9 - Connector
s
iva
do
r
❑ 3-pin
rp
cum
fo
en
g

n
t.
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G66- Cop py
t. rig
gh ht
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10 - Spark plug p by
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cted
❑ 25 Nm
agen
Prote AG.
❑ Type and electrode gap ⇒ page 139 .

11 - Connector
❑ 3-pin
❑ for Hall sender - G40-
12 - Bolt
❑ 10 Nm
1. Ignition system 137

13 - Bolt
❑ 100 Nm
14 - Camshaft pulley
❑ With rotor for Hall sender.
❑ Assembly overview ⇒ page 60 .
15 - Hall sender - G40-
16 - Bracket
1.2 Removing and installing spark plugs

satelettronica
AG. Volkswagen AG d
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h
aut ra
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nl

pt
du
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itte
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erm
ab
ility
ot p
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia

orm
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atio
om
n in
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thi
te
sd
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Cop py
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Prote AG.
138 Rep. gr.28 - Ignition system

♦ Spark plug connector pliers - V.A.G 1922-
AG. Volkswagen AG d
agen oes
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un
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ility
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, is n
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hole
spec
es, in part or in w
Removing
t to the co
– Detach connectors of injection valves -2-.
rrectness of i
– Pull off spark plug cable -1- using assembly tool - T10029- .
For the 3rd cylinder, use the spark plug connector pliers -
l purpos
V.A.G 1922- if necessary.

– Fit spark plug socket - 3122 B- onto spark plugs and unscrew
nform
ercia
them.
satelettronica
m
a
– Remove spark plugs with spark plug socket - 3122 B- .
com
tion in
r
Installing
te o
thi
s
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fo
– Carefully screw in and tighten spark plugs using spark plug

en
ng
t.
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socket - 3122 B- . t. Cop py
rig
gh ht
– Connect spark plug cables in accordance with the firing order yri
p by
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⇒ page 139 .
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Prote AG.
– Connect injector connectors together.
Specified torques
♦ ⇒ “1.1 Assembly overview - ignition system”, page 137
1.3 Test data, spark plugs

Engine code AXA
Firing order 1-3-4-2
Spark plugs 4)
VW/Audi 101 000 033 AA
Manufacturer's designation BKUR 6 ET-10
Electrode gap 0.9 to 1.1 mm
Specified torque 25 Nm
4) Current specifications as well as spark plug change intervals: ⇒ Data sheets

for exhaust emissions test
1. Ignition system 139

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Service Department. Technical Information

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Copyright © 2019 Volkswagen AG, Wolfsburg K0058982120

2.3 Safety precautions when working on injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.4 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

4.1 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

2 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

2.2 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

2.3 Measuring oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . m 85

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

3.1 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

1.1 Engine number/engine data

Exhaust emissions fulfil EU 4 standard EU 5 standard

Compression ratio 10.5 10.5

Injection system Motronic ME 7.5 Motronic ME 7.5

Ignition system Motronic ME 7.5 Motronic ME 7.5

RON 95 unleaded 95 unleaded

Firing order 1-3-4-2 1-3-4-2

Catalytic converter yes yes

2.1 Safety precautions when working on the

The cooling system is under pressure when thewaengine

the engine compartment due to the restricted space:

2 Rep. gr.00 - Technical data

♦ Cooling system is pressurized when engine is warm. If nec‐

2.2 Safety measures when working on fuel

♦ Hose clip pliers - VAS 6340- are recommended to install

Observe the following points during all installation work, in par‐

fluid and vacuum) and electrical wiring in their original po‐

♦ Ensure that there is sufficient clearance to all moving or

♦ Even before work starts, the extraction hose of a fume extrac‐

2.3 Safety precautions when working on in‐

Fuel system is under pressure! Before opening the system,

To prevent injuries to persons and/or damage to the injection and

4 Rep. gr.00 - Technical data

♦ Do not touch or disconnect ignition cables when the engine is

Observe the following points during all installation work, in par‐

♦ Test and measuring instruments must always be secured to

rear seat and operated by a second person from this location.

If test and measuring instruments are operated from front pas‐

senger seat and the vehicle is involved in an accident, there is a

injuries when the airbag is triggered.

– When work is completed, clear event memory of engine con‐

2.4 Safety precautions when working on ig‐

To prevent injuries to persons and/or damage to the injection and

ignition system, the following must be observed:

♦ Do not touch or disconnect ignition cables when the engine is

running or being turned at starter speed.

♦ Switch off ignition before connecting or disconnecting injection

– Pull fuses SD 22 and SD 25 out of fuse holder in engine com‐

Removing the fuses interrupts voltage supply to the injectors and