Engine ATD

Service 5
Workshop Manual
FABIA 2000 ³
1.9/74 TDI Engine, Mechanics
Edition 08.00
Engine code ATD
Service Department. Technical Information Printed in Czech Republic

S00.5313.00.20
5 Service
The Workshop Manual is intended only for use within the Organisation Škoda. Printed in Czech Republic
It is not permitted to pass it on to other persons. S00.5313.00.20
© ŠKODA AUTO a. s.
FABIA 2000 ³ 1.9/74 TDI Engine, Mechanics
List of Supplements to Workshop Manual

FABIA 2000 ³
1.9/74 TDI Engine, Mechanics
Edition 08.00
Supple-
Edition Subject Article Number
ment
08.00 Basic Edition S00.5313.00.20
1 08.01 Modifications in Rep. Gr. 13, 17, 20, 21 S00.5313.01.20
2 05.02 Modifications in Rep. Gr. 10, 13, 19, 20, 21 S00.5313.02.20
3 11.03 Modifications in Rep. Gr. 13, 15, 17, 19, 20, 21, 26 S00.5313.03.20
Edition 11.03 List of Supplements

S00.5313.03.20
List of Supplements Edition 11.03

S00.5313.03.20
Table of Contents
00 – Technical Data
Technical data ........................................................................................... 00-1 page 1
10 – Removing and Installing Engine

Removing and Installing Engine .................................................................... 10-1 page 1
- Removing engine ...................................................................................... 10-1 page 1
- Securing the engine to the assembly stand ....................................................... 10-1 page 7
- Installing the engine ................................................................................... 10-1 page 9
- Tightening torques .................................................................................... 10-1 page 11
- Assembly bracket ...................................................................................... 10-1 page 11
13 – Crankgear
Removing and installing V-ribbed belt ............................................................ 13-1 page 1
- Summary of components - Vehicles without air conditioning ................................... 13-1 page 1
- Summary of components - Vehicles with air conditioning ....................................... 13-1 page 2
- Removing the V-ribbed belt .......................................................................... 13-1 page 3
- Installing the V-ribbed belt ........................................................................... 13-1 page 5
Removing and installing, tightening the timing belt ........................................... 13-2 page 1
- Summary of components ............................................................................. 13-2 page 1
- Removing and installing, tightening the timing belt .............................................. 13-2 page 3
Removing and installing sealing flange and flywheel ......................................... 13-3 page 1
- Replacing gasket ring for crankshaft - on the belt pulley side - ................................ 13-3 page 2
- Removing and installing the front sealing flange ................................................. 13-3 page 4
Crankshaft, Piston and Conrod ..................................................................... 13-4 page 1
- Removing and installing crankshaft ................................................................ 13-4 page 1
- Disassembling and assembling piston and conrod .............................................. 13-4 page 2
- Checking piston projection in TDC .................................................................. 13-4 page 5
15 – Cylinder Head, Valve Gear

Removing and installing cylinder head ........................................................... 15-1 page 1
- Summary of components ............................................................................. 15-1 page 1
- Removing and installing cylinder head ............................................................. 15-1 page 3
- Testing compression .................................................................................. 15-1 page 6
Repairing Valve Gear .................................................................................. 15-2 page 1
Camshaft ................................................................................................. 15-3 page 1
- Removing and installing camshaft .................................................................. 15-3 page 1
- Removing and installing gasket ring for camshaft ................................................ 15-3 page 3
Valve Seats/Valves Guide/Valve Stem Seal ...................................................... 15-4 page 1
- Reworking valve seats ................................................................................ 15-4 page 1
- Calculating max. permissible reworking dimension .............................................. 15-4 page 1
- Inspecting valve guides .............................................................................. 15-4 page 2
- Replacing valve stem seals .......................................................................... 15-4 page 2
17 – Lubrication
Removing and installing parts of the lubrication system ..................................... 17-1 page 1
- Disassembling and assembling oil filter holder ................................................... 17-1 page 2
Edition 11.03 Table of Contents I

S00.5313.03.20
Removing and Installing Oil Pan ................................................................... 17-2 page 1

Testing oil pressure and oil pressure switch .................................................... 17-3 page 1
19 – Cooling
Parts of cooling system - Summary of components ........................................... 19-1 page 1
- Parts of the cooling system fitted to body ......................................................... 19-1 page 2
- Parts of cooling system engine side ................................................................ 19-1 page 3
- Connection diagram for coolant hoses ............................................................. 19-1 page 4
- Draining and filling up coolant ....................................................................... 19-1 page 4
- Checking the coolant system for tightness ........................................................ 19-1 page 6
Removing and Installing Radiator, Coolant Pump, Coolant Regulator .................... 19-2 page 1
- Removing and installing radiator .................................................................... 19-2 page 1
- Removing and installing coolant pump ............................................................ 19-2 page 2
- Removing and installing coolant regulator ........................................................ 19-2 page 3
20 – Fuel Supply
Removing and installing parts of the fuel supply - Part 1 .................................... 20-1 page 1
- Fuel tank with component parts - Summary of components .................................... 20-1 page 1
- Safety precautions when working on the fuel supply system ................................... 20-1 page 2
- Rules of cleanliness ................................................................................... 20-1 page 3
- Repairing the fuel filter ................................................................................ 20-1 page 4
- Removing and installing the fuel delivery unit/fuel gauge sender unit ........................ 20-1 page 5
- Removing and installing the fuel gauge sender from the fuel delivery unit .................. 20-1 page 6
- Testing fuel pump ..................................................................................... 20-1 page 6
Removing and installing parts of the fuel supply - Part 2 .................................... 20-2 page 1
- Removing and installing the fuel tank .............................................................. 20-2 page 1
- Removing and installing fuel cooler ................................................................ 20-2 page 2
- Inspecting tandem pump ............................................................................ 20-2 page 2
- Removing and installing the tandem pump ........................................................ 20-2 page 4
Repairing the accelerator control .................................................................. 20-3 page 1
- Summary of components ............................................................................ 20-3 page 1
21 – Turbocharging
Charge-air system with exhaust turbocharger - Part 1 ........................................ 21-1 page 1
- Removing and installing exhaust turbocharger with component parts ........................ 21-1 page 1
- Removing and installing parts of the charge air cooling ......................................... 21-1 page 3
- Removing and installing charge-air cooler ........................................................ 21-1 page 3
- Connection diagram for vacuum hoses for vehicles ³ 10.01 .................................. 21-1 page 5
- Connection diagram for vacuum hoses for vehicles 11.01 ³ .................................. 21-1 page 6
Charge-air system with exhaust turbocharger - Part 2 ........................................ 21-2 page 1
- Rules of cleanliness ................................................................................... 21-2 page 1
- Remove exhaust turbocharger ...................................................................... 21-2 page 1
- Checking charge pressure control .................................................................. 21-2 page 2
26 – Exhaust System
Removing and installing parts of the exhaust system ........................................ 26-1 page 1
- Aligning exhaust system free of stress ............................................................. 26-1 page 2
- Replacing front or rear silencer ..................................................................... 26-1 page 2
- Checking the exhaust system for leaks ............................................................ 26-1 page 2
Table of Contents Edition 11.03

II S00.5313.03.20
Exhaust gas recirculation system .................................................................. 26-2 page 1

- Removing and installing parts of the exhaust gas recirculation system ...................... 26-2 page 1
- Test mechanical exhaust gas recirculation valve ................................................. 26-2 page 2
Edition 11.03 Table of Contents III

S00.5313.03.20
Table of Contents Edition 11.03

IV S00.5313.03.20
FABIA 2000 ³ 1.9/74 TDI Engine, Mechanics 00
00 – Technical Data
00-1 Technical data

Engine number
The engine number („engine identification characters“
and „serial number“) is located in the front at the engine/
gearbox joint -arrow-.
In addition, a sticker with the „engine identification char-
acters“ and „serial number“ is affixed to the toothed belt
guard.
The engine identification characters are also indicated on
the vehicle data sticker.
Engine characteristics
Identification characters ATD

Manufactured 02.00 ³
Exhaust limits conforming to EU -3
Displacement l 1,896
Power output kW at rpm 74/4000
Torque Nm at rpm 240/1800-2400
Bore ∅ mm 79,5
Stroke mm 95,5
Compression ratio 19,0
Firing order 1-3-4-2
min. CN 49
Catalytic converter yes
Exhaust gas recirculation yes
Turbocharging yes
Charge air cooler yes
Edition 08.00 Technical data 00-1 page 1

S00.5313.00.20
00 FABIA 2000 ³ 1.9/74 TDI Engine, Mechanics
Technical data Edition 08.00

00-1 page 2 S00.5313.00.20
10 – Removing and Installing Engine
10-1 Removing and Installing

Engine
Special tools, test and measuring equipment and
auxiliary items required
♦ Workshop crane (e.g. -V.A.G 1202 A-)
♦ Catch pan (e.g. -V.A.G 1306-)
♦ Torque wrench
♦ Engine/gearbox jack (e.g. -V.A.G 1383 A-)
♦ Engine mount -T10012-
♦ Distance sleeve -T30010-
♦ Extension -10-222 A/7-
♦ Engine / gearbox mount -MP 1-202-
♦ Assembly stand -MP 9-101-
♦ Lifting device -MP 9-201-
♦ Pliers for spring strap clips
♦ Snap hook
♦ Grease -G 000 100-
♦ Hot screw paste -G 052 112 A3-
♦ Wire
♦ Adhesive tape
Removing engine
Note
♦ The engine is removed towards the front together with
the gearbox.
♦ Supporting points on the lift platform ⇒ Inspection
and Maintenance.
♦ The hose connections are secured with screw-type
clips, spring-type clips or clamp-type clips. Always re-
place warm-type clamps with spring strap clips or
screw clamps.
♦ Fuel hoses at the engine must only be secured with
spring-type clips. The use of clamp-type or screw-type
clips is not allowed.
♦ Use pliers for spring strap clips to fit the spring strap
clips.
♦ Pay attention to the correct assignment of the connec-
tors, if necessary mark.
♦ If the battery is disconnected and reconnected, carry
out certain additional operations ⇒ Electrical System;
Rep. Gr. 27.
Procedure
– On models fitted with a coded radio set, pay attention
to the coding; determine if necessary.
Edition 05.02 Removing and Installing Engine 10-1 page 1

S00.5313.02.20
– Disconnect the battery-earth strap with the ignition off.

– Remove noise insulation -arrows-.
– Remove drive shaft to the right ⇒ Running gear;
Rep. Gr. 40.
– Unscrew the drive shaft to the left of the gearbox
flange.
– Raise drive shaft on the left and secure.
– Remove front exhaust pipe with catalyst ⇒ Chapter
26-1.
– Remove front bumper ⇒ Body work; Rep. Gr. 63.
S10-0114
– Screw out screw -3-.

– Remove charge-air pipe at bottom -1- with connecting
hose -2- -arrows-.
– Remove charge-air routing from charge-air cooler
⇒ Chapter 21-1.
– Unbolt the pendulum support -arrows-.

– Place a catch pan under the engine.
– Open the cap on the coolant expansion bottle.
Removing and Installing Engine Edition 05.02

10-1 page 2 S00.5313.02.20
– Turn the drain plug -arrow- on the radiator to the left
and draw backwards, if necessary fit auxiliary hose
onto connection.
A10-0118
– Also detach the front coolant hose at bottom of oil

cooler -arrow- and allow remaining coolant to drain
off.
S10-0116
– Remove engine cover:

Pull the front engine cover upwards with a sudden mo-
tion -arrow A- and pull the cover out of the rear attach-
ment -arrow B-.
– Remove air filter with intake hose ⇒ 1.9/74 TDI En-

gine - Fuel Injection; Rep. Gr. 23.
– Remove battery and battery tray ⇒ Electrical System;
Rep. Gr. 27.
– Unscrew the generator cables from the battery cover
and remove the wiring loom from the holder.
– Remove the coolant hoses from the radiator.
– Removing the lock carrier ⇒ Body work; Rep. Gr. 50.
For vehicles with air conditioning

Instructions and work procedures ⇒ Heating, Air Condi-
tioning; Rep. Gr. 87.
– Before removing the lock carrier:

S00.5313.02.20
♦ Drain refrigerant.
♦ Disconnect the high and low pressure lines on the 1
couplings.
♦ Remove high-pressure line from the compressor.
For all vehicles

– Disconnect the coolant hose -1- from the pipe. 3
– Disconnect the fuel-intake hose -3- and the fuel-return
hose -2- from the pipes.
2
S10-0148
– Remove charge-air pipe at the top -1- with connecting

hose -2- -arrows-.
– Pull off the coolant hose from the expansion bottle at
the bottom.
– Disconnect the vacuum hose to the vacuum reservoir
at the connecting piece.
– Remove the vacuum hose -1- from the intake manifold

flap vacuum unit.
– Pull off the vacuum hose -2- from the exhaust gas so- 2 1
lenoid valve -N18-.
S10-0146

10-1 page 4 S00.5313.02.20
– Remove the coolant intake hose -3- from the supports
-4-.
– Remove the coolant return hose -2- from the heat ex- 3
changer connection fittings -1-. 4
– Pull off vacuum hose -6- from tandem pump -5-.
5
1 6
S10-0150
– Unplug connector -1- from the engine control unit.

– Disconnect the plug connections -2- and -3- and re-
move from bracket.
– Unclip cable clip -4- -arrows-.
1
2 3
S10-0117
– Remove Bowden cable support -arrows-.

– Pull out slave cylinder line -A- from the holder on the
gearbox.
S10-0152

S00.5313.02.20
– Detach selector cable -1- with relay lever, for this step
remove circlip -arrow A- from the relay lever. 1
– Remove the shift cable -2- with the gearbox shift lever,
for this step unscrew nut -arrow B-. 6
– Raise control cables and secure. B A
– Disconnect plug -3- from the reversing light switch
-F4-. 5
– Release earth strap -4- from the frame side rail.
2
3
– Unplug connector -5- and the cable -6- from the start-
er.
4
S10-0153
– Remove slave cylinder -B-, lay aside and secure with

wire. Do not open line system.
Note
Do not depress the clutch pedal.
A30-0048
– Disconnect the plug connections -2- and -3- under the

starter and remove from bracket.
2
3
S10-0151

10-1 page 6 S00.5313.02.20
– Hook on lifting device -MP 9-201- with extension
-10-222A/7- and snap hook -A-, as shown in the fig- MP 9-201
ure, hang up and take up the weight of the engine/
gearbox assembly. 10-222A/7
Caution!
Use securing pins on the hooks and rig pins to pre-
vent release.
S10-0155
– Unscrew the engine mounting from the engine sup-

port bracket -arrows-.
Note
If the engine/gearbox unit drops when the screws are re- m
ax
leased raise it up again.
in
m
S10-0149
– Unscrew the gearbox mount from the gearbox support

bracket -arrows-.
The note on unscrewing the engine mounting also ap-
plies for the gearbox mount.
– Carefully lower the engine with gearbox and pull out

carefully towards the front.
Note
Carefully guide the engine and gearbox during withdraw-
al. Ensure adequate clearance to other neighbouring
components.
Securing the engine to the assembly S10-0120

stand
To perform the assembly work the engine must be se-
cured to the assembly stand -MP 9-101-.
Note
When measuring the cylinder bore (⇒ Chapter 13-4) the
engine must not be fixed to the assembly stand.

S00.5313.02.20
Procedure
– Position the engine mount -T10012- in the engine/
gearbox jack.
– Fix engine mount -T10012- to the cylinder block using
fixing nuts and bolts M10 with a tightening torque of
40 Nm.
– Raise the engine and gearbox with the engine/gear-
box jack.
– Dismantle the lifting device -MP 9-201-.
T10012
V.A.G 1383A N10-0056
– With a lifting device bring the engine/gearbox unit to

the work bench.
– Lower the engine/gearbox unit in such a way that the
gearbox is positioned on the support.
T 10012 V.A.G 1383/A

N10-0148
– Remove cover plate -A- for flywheel behind the right

flange shaft -arrows-.
– Unplug the connector from the speedometer sender
-G22-.
– Remove engine/gearbox connecting screws. A
– Press gearbox from engine.
V34 - 3005

10-1 page 8 S00.5313.02.20
– Hook on lifting device -MP 9-201- and lift out of en-
gine/gearbox jack using the workshop crane. MP 9-201
Caution! 8
7
Use securing pins on the hooks and rig pins to pre- 5 6
vent release.
12 3 4
S10-0175
– Unscrew Engine mount -T10012-.
– Attach engine to the assembly stand -MP 9-101- with
the engine / gearbox mount -MP 1-202 - and distance MP 1-202
sleeves -T30010-. (The figure shows the 1.9 l/47 kW
SDI engine; the fixing system is the same).
Installing the engine
Note T30010
♦ Always replace the seals and gaskets during assem-
bly work.
♦ Always replace self-locking nuts.
♦ Coat stud bolts of exhaust manifold with hot bolt paste
-G 052 112 A3- before installing.
S10-0123
♦ Tightening torques ⇒ 10-1 page 11.
♦ Assembly bracket ⇒ 10-1 page 11.
Procedure
Installation is performed in the reverse order. Pay atten-
tion to the following points:
– Check whether the dowel sleeves for centering the

engine/gearbox are present in the cylinder block; in-
sert if necessary.
– Check whether the intermediate plate has been insert-
ed on the sealing flange and rests on the dowel
sleeves -arrows-.
– If necessary check the centering of the clutch driver
disc.
– Inspect clutch release bearing for wear, replace if nec-
essary.
– Grease the drive shaft serration with grease
-G 000 100 -.
– Assemble together the engine with gearbox
⇒ Manual gearbox 02R; Rep. Gr. 34.
– When installing engine/gearbox unit, ensure ade-
quate clearance to neighbouring components. A10-0129

S00.5313.02.20
– Align the engine/gearbox unit free of stress and attach

firmly.
When tightening the bolts for engine and gearbox
mounts, engine and gearbox support brackets must
be resting fully against mount.
Tightening torques ⇒ 10-1 page 11.
– Install the slave cylinder of the hydraulic clutch

⇒ Gearbox 02R; Rep. Gr. 30.
– Adjust the gearshift mechanism and the shift cables
⇒ Gearbox 02R; Rep. Gr. 34.
– Install the right drive shaft and screw the left drive
shaft onto the gearbox ⇒ Chassis; Rep. Gr. 40.
– Install the front exhaust pipe with catalytic converter
and the exhaust system so that they are not under
tension. ⇒ Chapter 26-1.
– Install the lock carrier with component parts ⇒ Body
work; Rep. Gr. 50.
For vehicles with air conditioning

Instructions and work procedures ⇒ Heating, Air Condi-
tioning; Rep. Gr. 87.
– Disconnect the refrigerant lines.

– Replacing dessicator insert.
– Filling the refrigerant circuit.
For all vehicles

– Install front bumper ⇒ Body work; Rep. Gr. 63.
– Electrical connections and proper routing ⇒ Current
Flow Diagrams, Electrical Fault Finding and Fitting Lo-
cations.
– Install the coolant hoses ⇒ Chapter 19-1.
Note
Only re-use drained coolant if none of the following com-
ponents has been replaced: Engine block, cylinder head,
radiator, heat exchanger.
– Top up coolant ⇒ Chapter 19-1.

– Check oil level before starting the engine.
– Interrogate fault memory and erase ⇒ 1.9/74 TDI En-
gine - Fuel Injection; Rep. Gr. 01.
– Perform a test drive.

10-1 page 10 S00.5313.02.20
Tightening torques
Note
♦ Tightening torques apply only for lightly greased,
oiled, phosphatized or blackened nuts and screws.
♦ Other lubricants such as engine and gearbox oil are
allowed. Do not use Molykote.
♦ Do not use degreased parts.
♦ Unless otherwise indicated the following tightening
torques apply:
2
Component Nm 1
Screws/nuts M6 9
M7 13
M8 20
M10 40
M12 70
1
1
Assembly bracket
S10-0154
Engine assembly bracket
1 - 20 Nm + 90° (1/4 turn) - replace
2
2 - 30 Nm + 90° (1/4 turn) - replace
1
Gearbox assembly bracket
1
1 - 50 Nm + 90° (1/4 turn) - replace
2 - 40 Nm + 90° (1/4 turn) - replace
1 S10-0125
Hinged bracket
Note
Position the screws -1- in the elongated holes of the pen-
dulum support in such a way that there is maximum dis-
tance between the gearbox and the assembly carrier.
1 - 30 Nm + 90° (1/4 turn) - replace

2 - 40 Nm + 90° (1/4 turn) - replace
2
S10-0126

S00.5313.02.20

10-1 page 12 S00.5313.02.20
13 – Crankgear
13-1 Removing and installing V-ribbed belt
Summary of components - Vehicles without air conditioning
Note
♦ Mark the rotation direction before removing the V-ribbed belt. Reversing the rotation direction of an already used
belt may destroy it.
♦ Pay attention to the correct position of the V-ribbed belt in the belt pulley when installing it.
1 - 10 Nm + torque a further 1/4

turn (90°)
2 - Vibration damper/belt pulley
T Assembly only possible in 1 2 3 4 5
one position - holes offset
3 - 25 Nm
4 - Tensioner for V-ribbed belt
5 - Bracket
T for generator
T Dowel sleeve for centering
⇒ Fig. 1 in 13-1 page 3
6 - 45 Nm 6
7 - Bracket
T for bottom charge-air pipe
8 - 8 Nm
9 - Generator
7
T to facilitate the positioning of
the generator on the holder
drive the threaded bushings 8
of the retaining screws slight-
ly backwards
10 - 25 Nm 6
11 - V-ribbed belt
T removing ⇒ 13-1 page 3
T installing ⇒ 13-1 page 5
11 10 9
S13-0255
Edition 05.02 Removing and installing V-ribbed belt 13-1 page 1

S00.5313.02.20
Summary of components - Vehicles with air conditioning
Note
♦ Mark the rotation direction before removing the V-ribbed belt. Reversing the rotation direction of an already used
♦ Pay attention to the correct position of the V-ribbed belt in the belt pulley when installing it.

turn (90°)
2 - Vibration damper/belt pulley
T Assembly only possible in
1 2 3 4 5 6
3 - 25 Nm
4 - Generator
T to facilitate the positioning of
the generator on the holder
drive the threaded bushings
of the retaining screws slight-
ly backwards
5 - Tensioner for V-ribbed belt
6 - Bracket
T for generator and AC com- 7
pressor
T Dowel sleeve for centering
⇒ Fig. 1 in 13-1 page 3 9
7 - 25 Nm
8 - 45 Nm
8
9 - Bracket 10
T for bottom charge-air pipe
10 - 8 Nm
11 - 25 Nm
12 - AC compressor 14
13 - Dowel sleeves for AC com-
pressor
T must be present in holder
⇒ item 6 13 12 11
14 - V-ribbed belt
S13-0257
T removing ⇒ 13-1 page 3
T installing ⇒ 13-1 page 5
Removing and installing V-ribbed belt Edition 05.02

13-1 page 2 S00.5313.02.20
Fig. 1: dowel sleeve for centering
– Before installing the bracket check whether the dowel

sleeve -arrow- has been fitted.
Removing the V-ribbed belt

S13-0256
Removing - vehicles without air conditioning
ment -arrow B-.

hose -2- -arrows-.
– Mark the rotation direction of the V-ribbed belt.

S00.5313.02.20
– To slacken the V-ribbed belt turn the tensioning de-

vice in the direction of the arrow.
– Remove V-ribbed belt; first from the generator-belt
pulley.
S13-0220
Removing- vehicles with air conditioning
– Remove the noise insulation.
S10-0114
– Release screw -3-.

– Remove charge-air pipe at the bottom -1- with con-
necting hose -2- -arrows-.
– Mark the rotation direction of the V-ribbed belt.

13-1 page 4 S00.5313.02.20
– Swivel tensioning pulley in -direction of arrow- in order
to slacken the V-ribbed belt.
– Remove V-ribbed belt; first from the air conditioning
compressor belt-pulley.
Installing the V-ribbed belt
Note
♦ Inspect V-ribbed belt ⇒ Inspection and Maintenance.
♦ Before fitting the V-ribbed belt make sure that all as-
semblies (generator and AC compressor) are secure-
ly mounted.
♦ Ensure belt pulley and tensioning pulley run freely.
– Tension the tensioning device and lay the V-ribbed

belt on it; lay it over the generator belt pulley last.
– Start engine and inspect running of belt.

S00.5313.02.20

13-1 page 6 S00.5313.02.20
13-2 Removing and installing,

tightening the timing belt
Summary of components
Note
Before removing the timing belt, mark direction of run-
ning. Reversing the rotation direction of an already used
For vehicles ³ 04.01
1 - Timing belt guard - top part

2 - Timing belt
T before removing mark run-
ning direction
T check for wear
T do not kink
T removing and installing
⇒ 13-2 page 3
turn (45°)
4 - Tensioning pulley
5 - 100 Nm
turn (45°)
7 - Camshaft sprocket
8 - Hub
T with pulse rotor
T to release and tighten use
counterholder -T10051 -
T to remove use extractor
-T10052-
⇒ Chapter 15-3
9 - 10 Nm
10 - Rear timing belt guard
11 - Sealing sleeve
T replace if damaged
12 - Tensioning device for timing
belt
13 - Guide pulley
14 - Coolant pump
T removing and installing ⇒ Chapter 19-2
15 - Timing belt gear - crankshaft
T Contact surface between crankshaft timing belt sprocket and crankshaft must be clean and free of grease
T Fitting position: flats on timing belt sprocket and crankshaft must be aligned
16 - 120 Nm + torque a further 1/4 turn (90°)
T to release and tighten use counterholder -MP 1-310 - or -T30004-
T replace
T do not wet new screws with oil and do not grease them
17 - 15 Nm
18 - 20 Nm
Edition 11.03 Removing and installing, tightening the timing belt 13-2 page 1
S00.5313.03.20
19 - Timing belt guard - bottom part

20 - V-ribbed belt pulley
T with vibration damper
T Assembly only possible in one position - holes offset
22 - Timing belt guard - middle part
23 - 45 Nm
24 - Engine support bracket
For vehicles 05.01 ³
1 - Timing belt guard - top part

2 - Timing belt 1 2 3 4 5 6 7 8 9 10 11
T before removing mark run-
ning direction
T check for wear
T do not kink
⇒ 13-2 page 3
turn (45°) 24
4 - Tensioning pulley
turn (45°)
6 - Camshaft sprocket
7 - 100 Nm
8 - Hub 5
T with pulse rotor
12
T to release and tighten use
counterholder -T10051 - 13
T to remove use extractor
-T10052- 14
⇒ Chapter 15-3 15
9 - 10 Nm 23 9 22
10 - Rear timing belt guard
11 - Sealing sleeve
12 - O-ring
T replace
13 - Coolant pump 21 20 9 19 18 17 16 S13-0399
⇒ Chapter 19-2
14 - 15 Nm
15 - Guide pulley
16 - Timing belt gear - crankshaft
T Contact surface between crankshaft timing belt sprocket and crankshaft must be clean and free of grease
T Fitting position: flats on timing belt sprocket and crankshaft must be aligned
T to release and tighten use counterholder -MP 1-310 - or -T30004-
T replace
T do not wet new screws with oil and do not grease them
Removing and installing, tightening the timing belt Edition 11.03

13-2 page 2 S00.5313.03.20
19 - Timing belt guard - bottom part
20 - V-ribbed belt pulley
T with vibration damper
T Assembly only possible in one position - holes offset
22 - Timing belt guard - middle part
23 - 45 Nm
24 - Engine support bracket
Removing and installing, tightening the

timing belt
♦ Torque wrench
♦ Rig pin for injection pump -MP 1-301- or -3359-
♦ Supporting device -MP 9-200-
♦ Small locking plates -T10008-
♦ Locking device -T10050-
♦ Wrench for tensioning pulleys (e.g. -Matra V 159-,
-T10020-, -Hazet 2587 - or - Stahlwille 127-17-)
♦ Liquid locking material -D 000 600 A2-
Removing
– Remove the V-ribbed belt ⇒ Chapter 13-1.
– Remove the front right wheelhouse liner ⇒ Body
Work; Rep. Gr. 66.
– Removing the V-ribbed belt pulley.
– Remove middle and bottom part of toothed belt guard.
hose -2- -arrows-.
WARNING!
Fuel line is under pressure. Place cleaning cloths
around the connection point before detaching
hose connections. Reduce pressure by carefully
removing the hose.
– Disconnect the fuel feed line -1- and the fuel return-
flow line -2-.
– Remove expansion reservoir and place down to the
front with coolant hoses connected.
S00.5313.03.20
– Install supporting device -MP 9-200- and support the

engine with spindle -A- in fitting position. Allow spindle
-B- to hang loosely.
– Remove engine support -arrows-.
Note
Releasing the pendulum support brings the engine for-
wards and the engine mounting can be removed.
– Unbolt the pendulum support from the gearbox.

– Remove timing belt guard - top part.
– Lower engine approx. 35 mm and release bottom
screw of the engine mounting.
– Raise the engine approx. 45 mm relative to its normal
position and release the top screws of the engine
mounting.
– Swivel out the engine mounting towards the top -ar-
row A- and subsequently pull up at the rear -arrow B-.
– Lower engine again into normal position.
– Position crankshaft on TDC cylinder 1.

13-2 page 4 S00.5313.03.20
Note
Rotate crankshaft until the marking on the top of the
toothed belt sprocket and the arrow on the rear toothed
belt guard are positioned opposite the lugs on the hub of
the impulse rotor -arrows A-.
– Lock hub with locking pin -MP 1-301- or -3359-.

Insert locking pin through the left slot into the hole at
the cylinder head.
– Secure crankshaft toothed belt sprocket with locking

device -T10050-.
Insert locking device from the front of the timing belt
sprocket into the teeth.
To facilitate this step, it is recommended to colour the
TDC marking on the crankshaft timing belt sprocket and
on the locking device -T10050- with white paint -arrows
B-.
Note
♦ The marking on the crankshaft timing belt sprocket
and the marking on the locking device -T10050- must
be positioned opposite -arrows B-. Pin of locking de-
vice must engage in the hole of the sealing flange -ar-
row C-.
♦ Locking device - T10050- must not be used as a coun-
terholder when releasing or tightening the bolts for the
toothed belt gear - crankshaft!
– Mark the rotation direction of the timing belt.

– Insert wrench fully into the hexagon socket bolt and

press in anti-clockwise direction onto the tensioning
pulley -arrow- long enough until it is possible to secure
the toothed belt tensioning device with the locking
plate -T10008-.
– Slacken nut of tensioning pulley.
– Unscrew bolts -1- of toothed belt tensioning device

and remove the tensioning device.
– Remove guide pulley ⇒ item 13 in 13-2 page 1
S00.5313.03.20
– Loosen the fixing nut on the tensioning roller.

– Loosen the eccentric of the tensioning pulley with a
wrench (e. g. -T10020-) anti-clockwise.
– Remove guide pulley ⇒ item 15 in 13-2 page 2
For all vehicles ³
– Remove timing belt.
Installing and tensioning
Note
Tensioning work at the timing belt must only be carried
out when engine is cold.
– Slacken bolts of camshaft sprocket -1- sufficiently so

that the camshaft sprocket can be turned in the area
of the slots.
– Turn camshaft sprocket clockwise in the slots -arrow-
as far as the stop.
– Carefully turn eccentric in clockwise direction with the

wrench for tensioning pulleys -C- sufficiently until the
lug on the eccentric is right in front of stop -B-.
– Fit timing belt onto camshaft sprocket, tensioning pul-
ley, crankshaft timing belt sprocket and onto the tim-
ing belt sprocket of the coolant pump.
– Install the tensioning device for toothed belt.
– Install guide pulley ⇒ item 13 in 13-2 page 1
– Carefully turn eccentric in an anti-clockwise direction
with a wrench for tensioning rollers -C- (the lug on the
eccentric moves toward the stop -A-) until it is possible
to move the locking plate -T10008- away slightly.
– Turn wrench in clockwise direction long enough until
gap size -a- is achieved. (The lug on the eccentric
moves toward the stop -B-).
Specification -a-: 4 ± 1 mm.

13-2 page 6 S00.5313.03.20
Note
♦ Use e.g. a ∅ 4 mm drill bit to adjust gap size -a-.
♦ Gap size -a- becomes smaller after the tensioning pul-
ley is tightened. This fact should therefore be taken
into account when setting with ∅ 4 mm drill bit.
♦ On a warm engine dimension -a- can decrease to 1
mm.
– Hold tensioning pulley in this position and tighten nut

of tensioning pulley as follows:
20 Nm + torque a further 1/8 turn (45°)
– Fit timing belt onto crankshaft timing belt sprocket,

tensioning pulley, camshaft sprocket and onto the tim-
ing belt sprocket of the coolant pump.
– Install guide pulley ⇒ item 15 in 13-2 page 2 A13-0053
– Check the correct catch fitting of the tensioning pulley
in the hole in the rear timing belt guard -arrow-.
– Turn the eccentric of the tensioning pulley with a
wrench (e. g. -T10020-) clockwise in such a way until
the pointer -2- stands in the centre of the gap size of
the base plate.
Note
Ensure that the fixing nut does not turn at the same time.
– Hold the tensioning pulley in this position and tighten

the nut of the tensioning pulley to 20 Nm + torque a
further 45° (1/8 turn).
Note
When tightening the fixing nut, the pointer turns -arrow-
max. 5 mm to the right from the gap of the base plate.
This position must not be corrected, because the toothed
belt settles when running-in.
For all vehicles ³
S00.5313.03.20
– Tighten bolts of camshaft sprocket -1- to tightening

torque of 25 Nm + torque a further 45° (1/8 turn).
Test timing
– Remove locking pin -MP 1-301- or -3359- and locking
device -T10050-.
– Tighten crankshaft two revolutions in the direction of
rotation of engine and position again to TDC of piston
for cylinder 1.
Note
♦ Pin for locking device - T10050 - must engage in the
sealing flange. (Locking device should be inserted just
ahead of TDC on toothed belt sprocket.)
♦ If the crankshaft is positioned after TDC of piston for
cylinder 1 and the pin of the locking device does not
engage in the sealing flange, rotate the crankshaft
back no more than 1/4 revolution and again set the
crankshaft to the TDC of the piston for cylinder 1 by
turning in direction of rotation of engine.
♦ It is not permitted to carry out the correction by turning
in the opposite direction of rotation of the engine in or-
der to insert the locking device.
– After inserting the pin for locking device -T10050-

check and determine whether the hub can be secured
with locking pin -MP 1-301- or -3359-.
If the hub cannot be arrested:
– Remove bolt for locking device from the hole at the

sealing flange and rotate the crankshaft until the hub
can be locked with locking pin.
– Slacken bolts of camshaft sprocket -1-.
– Rotate crankshaft in opposite direction of rotation of
engine long enough until the pin for locking device in
the sealing flange is positioned close to the hole -ar-
row-.
– Rotate crankshaft in direction of rotation of engine
long enough until the pin for locking device engages
in the sealing flange.
– Tighten bolts of camshaft sprocket to a tightening
torque of 25 Nm.
– After inserting the pin for locking device -T10050-

check dimension -a- 4 ± 1 mm and determine whether
the hub can be secured with rig pin - MP 1-301- or
-3359-.
If dimension -a- is not reached:
– Tighten the tensioning pulley.

13-2 page 8 S00.5313.03.20
Hold the tensioning pulley with the wrench, slacken
the nut, and turn the wrench clockwise until dimension
-a- is achieved.
Specification -a-: 4 ± 1 mm.
If nominal dimension -a- is obtained and if the hub can be
arrested:
– Again tighten the nut:


The pointer of the tensioning pulley stands in the centre
or max. 5 mm to the right from the gap of the base plate.
For all vehicles ³
– Remove locking pin and locking device -T10050-.

– Rotate crankshaft on a further two revolutions in direc-
tion of rotation of the engine until the crankshaft is
again positioned at TDC of piston of cylinder 1.
Note
♦ Pin for locking device -T10050- must engage in seal-
ing flange when this is done.
♦ If the crankshaft is positioned after TDC of piston for
cylinder 1 and the pin of the locking device does not
engage in the sealing flange, rotate the crankshaft
back no more than 1/4 revolution and again set the
crankshaft to the TDC of the piston for cylinder 1 by
turning in direction of rotation of engine.
♦ It is not permitted to carry out the correction by turning
in the opposite direction of rotation of the engine in or-
der to insert the locking device.
– Repeat check.
Further installation occurs in reverse order.
Tightening torque of the engine support bracket on the
vehicle body: 45 Nm.
Tightening torque of the engine support and pendulum
support: ⇒ Chapter 10-1.
S00.5313.03.20

13-2 page 10 S00.5313.03.20
13-3 Removing and installing sealing flange and flywheel
Note
♦ Repairing the clutch ⇒ Manual gearbox 02R; Rep. Gr. 30
♦ Secure the engine with engine mount -MP 1-202- and distance sleeves -T30010- on the assembly stand before
performing assembly work.
1 - PTFE gasket ring

T replace ⇒ 13-3 page 3
T only install PTFE gasket ring 2 3
(pay attention to different
versions ⇒ Fig. 1 in 13-3
page 2)
2 - Front sealing flange
T must be positioned on dowel
sleeves
1
⇒ 13-3 page 4
3 - Cylinder block
crankshaft ⇒ Chapter 13-4
T disassembling and assem-
bling pistons and conrod 7
⇒ Chapter 13-4
4 - Flywheel 4
T Assembly only possible in
5
T lock using -MP 1-504- for re-
moving and installing with
the fixture ⇒ Fig. 2 in 13-3
page 2
5 - 60 Nm + torque a further 90°
(1/4 turn)
T replace
6 - Intermediate plate
T must be positioned on dowel
sleeves
T do not damage/bend during 8 7 6
assembly work N13-0488
T hang on the sealing flange
⇒ Fig. 3 in 13-3 page 2
7 - 15 Nm
8 - Sealing flange with PTFE gasket ring
T to remove and install, take off oil pan ⇒ Chapter 17-2
T must be replaced completely
T only install sealing flange with PTFE gasket ring (pay attention to different versions ⇒ Fig. 1 in 13-3 page 2)
T install gasket ring dry, the crankshaft stub must be free of grease
T fit new sealing flange with guide bushing (do not pull guide bushing out of gasket ring before fitting)
Edition 05.02 Removing and installing sealing flange and flywheel 13-3 page 1
S00.5313.02.20
Fig. 1: Gasket ring versions

I II
I Elastomer gasket ring
sealing lip -1-; with garter spring
II PTFE gasket ring
multiple sealing lips -2-; without garter spring
1 2
Note
When installing PTFE gasket ring do not moisten with oil.
The shaft must also be free from oil and grease.
S13-0190
Fig. 2: Lock the flywheel

MP 1-202
– Position the assembly fixture -MP 1-504- on the ring
gear and turn until it rests against spacer bush
-T30010-.
T30010
T30010
MP 1-504
S13-0191
Fig. 3: Installing intermediate plate
– Insert intermediate plate on sealing flange and push

onto the dowel sleeves -arrows-.
Replacing gasket ring for crankshaft - on

the belt pulley side -
♦ Torque wrench
♦ Gasket ring extractor -MP 1-226-
♦ Pressure bushing -T10053-
A10-0129
♦ Guide bushing -T10053/1-
♦ Bolt (M16 x 1.5 x 60) -T10053/2-
♦ Counterholder -T30004- or -MP 1-310 -
Removing and installing sealing flange and flywheel Edition 05.02

13-3 page 2 S00.5313.02.20
Removing
– Remove the timing belt ⇒ Chapter 13-2.
– Remove crankshaft timing belt sprocket. To this end
lock the toothed belt gear with counterholder -T30004-
or -MP 1-310-.
T 30004
Note
When screwing on the counterholder -MP 1-310- place 2
washers between the toothed belt gear and the counter-
holder.
MP 1-310
S13-0166
– Screw the bolt by hand into the crankshaft as far as

the stop.
– Unscrew inner part of the gasket ring extractor
-MP 1-226- nine turns (approx. 17 mm) out of the out-
er part and lock with knurled screw.
A13-0067
– Oil the thread head of the gasket ring extractor

-MP 1-226 -, position and forcefully screw it into the
gasket ring as far as possible.
– Release knurled screw and turn the inner side against
the crankshaft until the gasket ring is pulled out.
Installing
Note
♦ Only fit PTFE gasket rings. Do not fit elastomer gasket
rings with a garter spring.
♦ The sealing lips of the PTFE gasket ring must neither
be oiled nor greased.
S13-0078
MP 1-226
S00.5313.02.20
– Use a clean cloth to remove oil residues on the crank-

shaft journal.
– Insert guide bushing -T10053/1- on the crankshaft
stub.
– Slide gasket ring over the guide bushing onto the
crankshaft stub.
T10053/1 S13-0194
– Press in the gasket ring with pressure bushing

-T10053- and screw -T10053/2- up to the stop.
T10053/2
T10053 S13-0266
– Install timing belt gear on the crankshaft and lock with

counterholder -T30004- or -MP 1-310-.
Note
♦ When screwing on the counterholder -MP 1-310-
place 2 washers between the toothed belt gear and T 30004
the counterholder.
♦ Replace central screw for toothed belt gear - crank-
shaft.
– Tighten new central screw for toothed belt gear -

crankshaft to 120 Nm and turn a further 90° (1/4 turn).
– Install the timing belt ⇒ Chapter 13-2.
Removing and installing the front seal-

ing flange
Special tools, test and measuring equipment and MP 1-310
♦ Torque wrench
♦ Guide bushing -T10053/1-
S13-0166
♦ Counterholder -T30004- or -MP 1-310 -
♦ Hand-held power drill with plastic brush insert

13-3 page 4 S00.5313.02.20
♦ Flat scraper
♦ Silicone sealant -D 176 404 A2-
Removing
T 30004
– Remove crankshaft timing belt sprocket. To this end
lock the toothed belt gear with counterholder -T30004-
or -MP 1-310 -.
Note
When screwing on the counterholder -MP 1-310- place 2
washers between the toothed belt gear and the counter-
holder.
– Drain engine oil.

– Remove oil pan ⇒ Chapter 17-2. MP 1-310
– Unscrew front sealing flange.
– Remove sealing flange, if necessary release by apply-
ing slight blows with a rubber-headed hammer.
– Use a flat scraper to remove sealant residues on the S13-0166
cylinder block.
– Use a rotating plastic brush to remove sealant resi-
dues on the sealing flange (wear protective goggles).
– Clean sealing surfaces, they must be free of oil and
grease.
Installing
Note
♦ Pay attention to the 'use by date' on sealant.
♦ The sealing flange must be installed within 5 minutes
after applying the silicone sealant.
– Cut off nozzle of tube of silicone sealant

-D 176 404 A2- at the front marking (∅ of nozzle ap-
prox. 3 mm).
N17-0019
S00.5313.02.20
– Apply silicone sealant bead to the clean sealing sur-

face of the sealing flange, as shown in the illustration.
Thickness of sealant bead -arrow-: 2…3 mm
Note
The sealant bead must not be thicker than 3 mm other-
wise excess sealant may get into the oil pan and clogg
the strainer in the oil suction pipe.
– Fit sealing flange immediately and lightly tighten all

bolts.
A17-0028
Note
When installing the sealing flange with the gasket ring fit-
ted use guide bushing -T10053/1-:
– Tighten the fixing screws of the sealing flange cross-

wise.
Tightening torque: 15 Nm
– Install oil pan ⇒ Chapter 17-2.
Note
After installing, allow the sealant to dry for about 30 min-
utes. Only then may engine oil be filled in.
– Install the timing belt ⇒ Chapter 13-2.

T10053/1 S13-0194

13-3 page 6 S00.5313.02.20
13-4 Crankshaft, Piston and Conrod

Removing and installing crankshaft
1 - Bearing shells 1, 2, 4 and 5
T for bearing cap without lubri-
cating groove
T for cylinder block with lubri-
cating groove
T do not mix up used bearing
shells (mark)
turn (90°)
T replace
T tighten thread
3 - Bearing caps
T Bearing cap 1: on the belt
pulley side
T Bearing cap 3: with recesses
for thrust washers
T retaining lugs of the bearing
shells of the cylinder block/
bearing cap must be on top
of one another
4 - Bearing shell 3
T for bearing cap without lubri-
cating groove
T for cylinder block with lubri-
cating groove
5 - Thrust washer
T for bearing cap 3
T pay attention to locating ele-
ment
6 - Rotor
T for engine speed sender
-G28-
T replace
8 - Fit pin
T Checking projection from crankshaft ⇒ Fig. 1 in 13-4 page 2
9 - Crankshaft
θ ∅ Crankshaft bearing journal: 54.00 mm
θ ∅ Conrod bearing journal: 47.80 mm
T Axial play when new: 0,07…0.17 mm
Wear limit: 0.37 mm
10 - Thrust washer
T for cylinder block, bearing 3
Edition 11.03 Crankshaft, Piston and Conrod 13-4 page 1

S00.5313.03.20
Fig. 1: Checking projection of fit pin from crank-

shaft
1 2 a
♦ Depth gauge
Test sequence:
– Use depth gauge to inspect projection -a- of dowel pin

when pulse rotor -1- is removed. 3
1 - Pulse rotor
2 - Fixing screw
3 - Projection of the fit pin -3- from crankshaft -a- = 2 2
2.5…3.0 mm N13-0554
Disassembling and assembling piston and conrod

1 - Piston rings
T Offset joint 120°
T use piston ring pliers for re-
moving and installing
T Marking „TOP“ faces up
T inspect gap clearance
⇒ Fig. 2 in 13-4 page 3
T inspect end clearance
⇒ Fig. 3 in 13-4 page 4
2 - Piston
T with combustion chamber
T mark installation position and
matching cylinder
T Installation position and as-
signment of piston/cylinder
⇒ Fig. 5 in 13-4 page 4
T arrow on piston crown faces
towards the belt pulley side
T use piston ring tensioning
strap for installing
T if cracks present on piston
stem - replace piston
T inspect piston projection at
TDC ⇒ 13-4 page 5
θ ∅ Pistons: 79.47 mm
3 - Piston pin
T if stiff, heat piston to 60°C
T use drift -VW 222A- for re-
moving and installing
4 - Circlip
5 - Conrod
T replace as a set only
T mark assignment to cylinder, refer to -A-
T Fitting position: Markings -B- point towards the belt pulley side
6 - Bearing shell
T Check fitting position
T pay attention to different version:
Crankshaft, Piston and Conrod Edition 11.03

13-4 page 2 S00.5313.03.20
Top bearing shell (on piston side) is subject to less stress
Distinguishing feature:
black marking on the contact surface near the separation point
T insert bearing shell in the middle of the conrod bearing cap
T do not mix up used bearing shells (mark)
T check for firm seating
T Axial clearance:
Wear limit: 0.37 mm
7- Cylinder block
T Inspect cylinder block ⇒ Fig. 4 in 13-4 page 4
θ ∅ Cylinder: 79.51 mm
8- Conrod cap
T as a result of the conrod separated in the cracking process, the cover fits only in one position and only to the
relevant conrod
9- Oil injection nozzle
T For piston cooling
T Pay attention to SP No. (right-angle bend)
10 - Pressure relief valve, 27 Nm
T opens at an overpressure of 2.5 to 3.2 bar (0.25 to 0.32 MPa)
T replace without sealant
11 - Conrod bolt, 30 Nm + torque a further 1/4 turn (90°)
T replace
T oil thread and head contact surface
Fig. 2: Inspecting piston ring gap clearance

♦ Feeler gauge
Test sequence
– Push in ring at right angles to the cylinder wall from the

top through to the bottom cylinder opening, about 15
mm from the cylinder edge. To insert use piston with-
out rings.
Piston ring new Wear limit

(mm) (mm)
1. Compression ring 0,20…0,40 1,0
Oil scraper ring 0,25…0,50 1,0

S00.5313.03.20
Fig. 3: Inspect piston ring end clearance

♦ Feeler gauge
– Clean ring groove before inspecting.
Piston ring new Wear limit

(mm) (mm)
Oil scraper ring 0,03…0,06 0,15
V13 - 0687
Fig. 4: Inspecting cylinder bore

♦ Internal precision measuring instrument 50 to 100 mm
Piston dimenston ⇒ item 2 in 13-4 page 2.

Cylinder dimenston ⇒ item 7 in 13-4 page 3.
Test sequence
– Measure at 3 points crosswise in a transverse direc-

tion -A- and lengthwise -B-.
Deviations from specified dimension: max. 0.10 mm
Note
Do not measure the cylinder bore if the cylinder block is
fixed to the assembly stand with the engine mount
-MP 1-202-, as this may result in incorrect measure-
ments.
Fig. 5: Piston fitting position and assignment of

the piston/cylinder

♦ e. g. electric stylus
Procedure
1/2
1/2
3/4
3/4
– Mark installation position and assignment on inside of

piston (not on piston crown), e.g. with an electric sty-
lus.
Pistons in cylinders 1 and 2:
Large piston relief for inlet valve to flywheel side -arrows-
Pistons in cylinders 3 and 4:

13-4 page 4 S00.5313.03.20
Large piston relief for inlet valve to belt pulley side -ar-
rows-
Note
♦ For new pistons the cylinder assignment is colour-
coded on the piston crown.
♦ Pistons in cylinders 1 and 2: Identification 1/2
♦ Pistons in cylinders 3 and 4: Identification 3/4
Checking piston projection in TDC

♦ Measuring tool for piston projection -MP 1-107-
Procedure
– When installing new pistons or a short engine, inspect
the piston projection at TDC. Depending on the piston
projection fit the relevant cylinder head seal in accord-
ance with the table below:
Piston projection over cylin- Marking of bore

der block - top side
0.91 mm…1.00 mm 1
1.01 mm…1.10 mm 2
1.11 mm…1.20 mm 3
Identification of the cylinder head seal

♦ Spare parts No. = -arrow 1-
♦ Control code = -arrow 2- (ignore)
♦ Bore = -arrow 3-
Note
If different values are measured during the piston projec-
tion measurement, the greatest dimension applies for the
seal assignment.

S00.5313.03.20

13-4 page 6 S00.5313.03.20
15 – Cylinder Head, Valve Gear
15-1 Removing and installing cylinder head
Removing and installing toothed belt ⇒ Chap. 13-2
Testing compression pressure ⇒ 15-1 page 6.
Note
♦ When installing a replacement cylinder head with fitted crankshaft moisten the contact surfaces between the buck-
et tappet and the cam slide with engine oil.
♦ Factory-fitted plastic washers intended to protect the open valves must only be removed shortly before inserting
the cylinder head.
♦ If the cylinder head is replaced, the system must be completely filled with fresh coolant.
♦ Reworking of cylinder heads on diesel engines is not allowed.
1 - Cylinder head cover

1 2 3 4 5 6
T before inserting thoroughly
clean the contact surface of
the cylinder head with a
clean cloth.
2 - Pressure control valve
T for crankcase ventilation
12
3 - to exhaust turbocharger
4 - Closing cover
13
T replace seal if damaged
7 14
5 - Sealing cup
6 - Hexagon collar bolt with 8 15
guide bushing, 10 Nm
T first tighten all screws by
9
hand 28 10 11
7 - Gasket for cylinder head cov- 27
er 11
T replace if damaged 17 16
8 - 20 Nm
T
9 - Lifting eye
10 - Central socket connector 26
T for pump-nozzle unit 20 19 18
11 - 10 Nm
12 - from brake servo unit 25
13 - Tandem pump
T for fuel and vacuum supply
⇒ Chap. 20-2 24 23 22 21 19
S15-0164
T inspecting ⇒ 20-2
14 - 25 Nm
15 - intake hose
T from fuel filter ⇒ Chap. 20-1
T white marking
Edition 08.00 Removing and installing cylinder head 15-1 page 1

S00.5313.00.20
T check tightness
T secure with spring band clamps
16 - Return-flow hose
T to fuel filter ⇒ Chap. 20-1
T blue marking
T check tightness
T secure with spring band clamps
17 - Gasket
T replace
18 - 20 Nm
19 - Ball knob screw, 8 Nm
20 - Bracket
T for engine cover
21 - Lifting eye
T with bracket for engine cover
22 - Bracket
T for coolant hose
23 - Cylinder head gasket
T replace
T Pay attention to identification ⇒ Fig. 2 in 15-1 page 3
24 - 20 Nm
25 - Cylinder head
T check for distortion ⇒ Fig. 1 in 15-1 page 2
T removing and installing ⇒ 15-1 page 3
T after replacing, fill entire system with fresh coolant
26 - Glow plug
T 15 Nm
T inspecting ⇒ 1.9/74 TDI Engine, Fuel Injection; Rep. Gr. 28
27 - pump-nozzle unit
T removing and installing ⇒ 1.9/74 TDI engine, Fuel Injection; Rep. Gr. 23
28 - Cylinder head bolt
T replace
T Sequence for loosening and tightening ⇒ 15-1 page 3
T with the camshaft bearing caps removed insert the special washers in the cylinder block before fitting the cyl-
inder head screws ⇒ Chap. 15-2
Fig. 1: Inspecting cylinder head for distortion

♦ Feeler gauge
♦ Knife-edge straightedge
Max. permissible distortion: 0.1 mm
Note
Reworking of cylinder heads on diesel engines is not al-
lowed.
V15 - 0673
Removing and installing cylinder head Edition 08.00

15-1 page 2 S00.5313.00.20
Fig. 2: Cylinder head seal identification
♦ Spare part No. = -arrow 1-
♦ Control code = -arrow 2- (disregard!)
♦ Orifices = -arrow 3-
Note
Cylinder head seals of different thicknesses are fitted de-
pending on the piston projection from the cylinder block.
If only the seal is replaced the new seal must bear the
same identification.
Removing and installing cylinder head

♦ Catch pan (e.g. -V.A.G 1306-)
♦ Lifting device -MP 9-200-
♦ Bracket -T10014-
♦ Torque wrench 5...50 Nm (e.g. -V.A.G 1331-)
♦ Snap hook
♦ Workshop crane
Removing
to the coding; determine if necessary.
– Disconnect the earth strap from the battery with the ig-
nition off.
– Removing engine cover ⇒ Chap. 10-1.
– Remove air filter with intake hose ⇒ 1.9/74 TDI En-
gine, Fuel Injection; Rep. Gr. 23.
– Remove battery and battery tray ⇒ Electrical System;
Rep. Gr. 27.
– Removing charge air pipe at the rear ⇒ Chap. 21-1.
– Unplug connector with glow plugs.
– Remove front exhaust pipe with catalyst -6-.
– Remove hoses -1- and -2- from the exhaust turbo-
charger. First unscrew the charge air pipe at the bot-
tom of the engine bracket - risk of fracture! 1 2
– Unscrew the oil return-flow line -5- on the cylinder
block ⇒ Chap. 21-1. 4
– Release screw -3- of the support, release screw -4- 3
and swivel the support down.
– Remove the vacuum hose -7- from the vacuum unit
for boost-pressure control. 7 5
– Drain coolant ⇒ Chap. 19-1.
6 S21-0022

S00.5313.00.20
– Unscrew the induction pipe from the intake manifold

and lay aside with the hoses connected ⇒ 1.9/74 TDI
Engine - Fuel Injection; Rep. Gr. 23.
1
– Release screws from the cylinder head cover.
5
– Extract the fuel with a manual vacuum pump and ven-
tilation reservoir from the return hose of the tandem 2
pump ⇒ Chap. 20-2.
4
– Remove fuel hoses -1- and -4-.
– Remove coolant hose -5-.
– Remove plug -2- for the central socket connector for 3
the pump-nozzle unit.
– Disconnect plug -3- from the fuel temperature sender
-G81-. S15-0165
– Unscrew the oil feed line on the oil filter holder, the ex-
haust turbocharger and brackets.
– Disconnect coolant hose -1- from T-piece and the
coolant hoses -2- and -3- from the connection fittings.
– Disconnect plug -4- from the coolant temperature
sender -G62-. 1
2 3 4
S15-0166
– Remove the coolant hose -3- from the supports -4-.

– Pull off vacuum hose -6- from tandem pump -5-.
3
– Removing the toothed belt ⇒ Chap. 13-2. 4
– Turn the crankshaft slightly back from the TDC posi-
tion.
– Remove the camshaft timing gear and the hub 2
⇒ Chap. 15-3.
– Removing coolant pump ⇒ Chap. 19-2. 5
– Removing camshaft position sensor -G40- and 1 6
toothed belt guard at rear ⇒ Chap. 13-2.
S10-0150

15-1 page 4 S00.5313.00.20
– Screw holder -T10014- with snap hook -A- into the
front threaded bore of the removed engine support
bracket above the coolant pump and take up engine
MP 9-200
weight with workshop crane -B-.
– Dismantle supporting device -MP 9-200-. B
A
T10014
S15-0167
– Release the cylinder head bolts in the given sequence

and remove.
– Carefully remove the cylinder head.
Note
The assistance of a second mechanic is required to re-
move and install the cylinder head.
Installing
Note
♦ Always replace the cylinder head bolts.
♦ There must be no oil or coolant in the blind holes of the
cylinder head bolts in the cylinder block.
♦ Remove the new cylinder head seal from its wrapping
immediately before fitting.
♦ In the event of repairs carefully remove residual seal-
ant from the cylinder head and cylinder block. Make
sure this does not cause any extended scoring or
scratching. When using emery paper the grain must
not be less than 100.
♦ Carefully remove lubrication and grinding residues.
♦ Treat the new seal with the utmost care. Any damage
will result in leaks.
– Before fitting the cylinder head position the crankshaft

on TDC marking.
– Turn crankshaft back against the running direction of
the engine until all pistons are almost evenly at TDC.
– Check whether the 2 dowel sleeves -1- that guide the
cylinder head are located in the cylinder block, if nec-
esarry insert.
– Position the new cylinder heads. The legend (spare 1 1
part No.) must be legible.
– Position cylinder head, insert new cylinder head bolts
and tighten by hand.
S15-0154

S00.5313.00.20
– Screw down the cylinder head in four stages in the in-

dicated tightening sequence:
1. Pre-tighten with torque wrench:
Stage I = 40 Nm
stage II = 60 Nm
2. Tighten further with a rigid wrench:
Stage III = 1/4 turn (90°)

Stage IV = 1/4 turn (90°)
– After securing the cylinder head or the camshaft tim-

ing gear turn the camshaft in such a way that the cams
for cylinder 1 point upwards evenly.
The further assembly is carried out in reverse order to
disassembly.
– Installing the toothed belt, tightening ⇒ Chap. 13-2.

– Top up coolant ⇒ Chap. 19-1.
gine, Fuel Injection; Rep. Gr. 01.
Testing compression
Test condition
• Engine oil temperature min. 30 °C
♦ Compression pressure gauge, (e.g. -V.A.G 1763-)
♦ Adapter (e.g. -V.A.G 1381/12-)
♦ Flexible-head wrench for glow plugs
Test sequence
– Removing engine cover ⇒ Chap. 10-1.
– Remove central socket connector for pump-nozzle
unit.
– Remove all glow plugs with the flexible-head wrench
for glow plugs.
– Screw in adapter instead of the glow plugs.
– Check compression pressure with the compression
gauge. V.A.G 1381/12
Note
Use of tester ⇒ Operating Instructions.
Zyl bar
– Operate starter until the tester no longer indicates a V.A.G 1763

pressure rise. Zylinder
Compression readings: PRINT
! C
V.A.G1783 N15-0227

15-1 page 6 S00.5313.00.20
new engine Wear limit Pressure difference

between cylinders
2,5…3.1 1.9 MPa max. 0.5 MPa
MPa
– Screw in glow plugs with flexible-head wrench.

– Interrogate fault memory and erase: ⇒ 1.9/74 TDI En-

gine, Fuel Injection; Rep. Gr. 01
Note
Faults are stored when the plug connection is separated
from the pump-nozzle unit.

S00.5313.00.20

15-1 page 8 S00.5313.00.20
15-2 Repairing Valve Gear
Note
Cylinder heads with cracks between the valve seats may continue to be used without any reduction in life provided
these are slight incipient cracks which are not more than 0.5 mm wide.

turn (90°) 1
T replace
2
T Pay attention to tightening
and release sequence
⇒ Chapter 15-3 19
2 - Valve-lever shaft 3
T do not interchange
3 - Cylinder head bolt 4
T Pay attention to tightening
and release sequence 5
⇒ Chapter 15-1
18 6
T before fitting insert washers
⇒ item 4 in the cylinder head 7
4 - Washer 16
T for cylinder head screws 17 8
T insert in cylinder head before
fitting the bearing cap 16 9
5 - Bucket tappets 10
T do not interchange
T with hydraulic valve clear- 11
ance compensation
T lay aside with contact sur-
12
face facing down
13
T before installing check axial
play of the camshaft ⇒ Fig. 1 14
in 15-2 page 2
T oil contact surface
T before removing remove the
camshaft bearing shells 15
6 - Collets N15-0231
7 - Valve spring retainer
8 - Valve spring outside
T removing and installing:
♦ Cylinder head removed: with - MP 1-218-, - MP 1-211-, -MP 1-213-
♦ Cylinder head fitted: ⇒ Chapter 15-4
9 - Valve spring inside
T removing and installing:
♦ Cylinder head removed: with - MP 1-218-, - MP 1-211-, -MP 1-213-
♦ Cylinder head fitted: ⇒ Chapter 15-4
10 - Valve stem seal
T replacing ⇒ Chapter 15-4
11 - Valve guide
T inspect ⇒ Chapter 15-4
T if the wear limit is exceed, replace cylinder head
12 - Unit injector
T removing and installing ⇒ 1.9/74 TDI Engine, Fuel Injection; Rep. Gr. 23
Edition 11.03 Repairing Valve Gear 15-2 page 1

S00.5313.03.20
13 - Cylinder head
T pay attention to note ⇒ 15-2 page 1
14 - PTFE gasket ring
T Do not additionally lubricate or grease the sealing lips of the PTFE gasket ring
T before fitting remove oil residues on the camshaft studs with a clean cloth
T to fit cover slot on the camshaft cone with commercially available adhesive tape (e.g. with Sellotape)
15 - Valves
T Valve dimensions ⇒ Fig. 3 in 15-2 page 3
16 - Bearing shell
T do not mix up used bearing shells (mark)
T check correct fit of the retaining lugs in the bearing caps and cylinder head
17 - Camshaft
T inspecting axial play ⇒ Fig. 1 in 15-2 page 2
T check radial clearance with Plastigage
♦ Wear limit: 0.11 mm
T Slack: max. 0.04 mm
T Identification, timing ⇒ Fig. 4 in 15-2 page 3
18 - Bearing caps
T Fitting sequence ⇒ Chap. 15-3
T seal contact surface of bearing caps 1 and 5 with sealant -AMV 174 004 01- ⇒ Fig. 2 in 15-2 page 3
T replace
Fig. 1: inspect camshaft, axial play
Special tools, test and measuring equipment and MP 3-447

♦ Universal dial gauge holder -MP 3-447-
♦ Dial gauge
Perform measurement with the bucket tappets removed

and the first, third and last bearing cap fitted.
Wear limit: max. 0.15 mm
S15-0168
Repairing Valve Gear Edition 11.03

15-2 page 2 S00.5313.03.20
Fig. 2: Seal contact surface of bearing caps 1 and 5
with sealant -AMV 174 004 01- 1
– Apply a thin layer of sealant -AMV 174 004 01- evenly
to the sealing surfaces -1-.
Note
Make sure no sealant penetrates into the slots -arrows-.
N15-0270
Fig. 3: Valve dimensions
Note
Valves must not be reworked. Only grinding in is permis-
sible.
Di- Inlet valve Exhaust valve

men-
sion
∅a mm 35,95 31,45
∅b mm 6,980 6,956
c mm 89,95 89,95
α ∠° 45 45
Fig. 4: Camshaft identification, timing

Camshaft identification
♦ Base circle of the valve cams: a = ∅ 52.8 mm
♦ Identification with digits and characters stamped in on a
the end face of the cam for outlet valve on 4th cylinder.
Cylinder 4 -arrow- 038 R

or
858 R
N15-0258
Edition 11.03 Repairing Valve Gear 15-2 page 3

S00.5313.03.20
Repairing Valve Gear Edition 11.03

15-2 page 4 S00.5313.03.20
15-3 Camshaft
Removing and installing camshaft
♦ Pressure pad -T10051-
♦ Extractor -T10052-
♦ Torque wrench
♦ Sealant -AMV 174 004 01-
Removing
– Unscrew fixing screws -1- for camshaft sprocket.
– Pull camshaft sprocket off the hub.
– Loosen fixing screw -1- of the hub. 1
Use counterholder -T10051-.
T10051
N15-0271
– Turn bolt attaching the hub out about 2 turns.
– Position extractor -T10052- and align it with the hub
bores. T10052
– Put the hub under tension by uniformly tightening the
extractor until the hub is released from the camshaft
cone.
Note
Hold the extractor firmly using a wrench SW 30.
– Remove the hub from the cone of the camshaft.

– Remove cylinder head cover.
– Remove the valve-lever shafts.
N15-0267
Note
♦ First release the two outer and then the inner fixing
screws.
♦ Mark the valve-lever shafts to avoid mixing them up
and to avoid having to perform a basic setting of the
pump-nozzle units.
– Remove tandem pump ⇒ Chap. 20-2.
Edition 11.03 Camshaft 15-3 page 1

S00.5313.03.20
– First remove bearing caps 5, 1 and 3. Detach bearing

caps 2 and 4 alternately (diagonally across).
Installing
Note
♦ When fitting the camshaft the cams of cylinder 1 must
point upwards.
♦ Do not mix up used bearing shells (mark)
♦ When installing the camshaft, ensure it is correctly lo-
cated in the retaining lugs of the bearing shells in the
bearing caps and the cylinder head.
♦ Before installing the bearing caps make sure the
washers for the cylinder head screws have been in-
serted in the cylinder head.
– Oil the contact surfaces of the bearing shells.

– Tighten bearing caps 2 and 4 alternately crosswise
and tighten to 8 Nm and torque a further 1/4 turn (90°)
(replace screws).
– Install bearing caps 5, 1 and 3 and likewise tighten to
8 Nm and torque a further 1/4 turn (90°) (replace
screws).
Note 1
♦ Seal the separator surfaces of bearing caps 1 and 5 2
with sealant -AMV 174 004 01- ⇒ Chap. 15-2
♦ Bearing cap 5 -1- must fit flush -arrows- with the outer
side of the cylinder head -2-, as this may otherwise
cause leaks on the tandem pump.
– Install camshaft seal ⇒ 15-3 page 3.

– Install valve-lever shafts and first tighten the inside
and then the outside fixing screws evenly and cross-
wise.
Tightening torque: 20 Nm + torque a further 1/4 turn

(90°) S15-0174
– Position hub onto camshaft.

– Tighten fixing screw -1- of the hub. 1
Use counterholder -T10051-.
T10051
N15-0271
Camshaft Edition 11.03

15-3 page 2 S00.5313.03.20
– Push camshaft sprocket onto the hub.
Note
Tooth segment -arrow- of camshaft sprocket must be fac-
ing up.
– Align the camshaft timing gear in middle position in

the elongated holes.
– Insert the fixing screws -1- by hand and clearance free
relatively to the camshaft timing gear.
– Lock hub with locking pin - MP 1-301-.
– Installing the timing belt, tightening ⇒ Chapter 13-2.
– Install tandem pump ⇒ Chap. 20-2.
Note
After installing new bucket tappets, the engine must not
be started for about 30 minutes. The hydraulic clearance
compensation elements must settle (otherwise valves
would strike the pistons).
Removing and installing gasket ring for

camshaft
♦ Inserting device - MP 1-214-
♦ Gasket ring extractor -T30003-
♦ Torque wrench
♦ Screw -M12x65-
Removing
– Remove camshaft sprocket and hub ⇒ 15-3 page 1.
– Turn inner part of gasket ring extractor -T30003- two
turns (approx. 3 mm) out of the outer part and lock
with knurled screw.
– Oil the thread head of the gasket ring extractor, posi-
tion and forcefully screw into the gasket ring as far as T30003
possible.
– Slacken knurled screw and turn inner part of seal ex-
tractor against the camshaft until the seal is pulled out.
Installing
Note
The sealing lips of the PTFE gasket ring must neither be
oiled nor greased.
– Remove oil residue on the camshaft stud with a clean S15-0169

cloth.
Edition 11.03 Camshaft 15-3 page 3

S00.5313.03.20
– Cover the slot on the camshaft cone with commercial-

ly available adhesive tape (e.g. with sellotape).
– Carefully fit seal onto camshaft.
– Press in the gasket ring with inserting device
-MP 1-214- and screw -M12x65- up to the stop. MP 1-214
S15-0170
Camshaft Edition 11.03

15-3 page 4 S00.5313.03.20
15-4 Valve Seats/Valves Guide/

Valve Stem Seal
Reworking valve seats
Note
♦ Do not remill valve. Only grinding in of valves is per-
missible.
♦ inspecting valve guides ⇒ 15-4 page 2. If the wear
limit is exceeded, repeat measurement with new
valves. If the wear limit is again exceed, replace cylin-
der head.
♦ Calculating max. permissible reworking dimension
⇒ 15-4 page 1. If the wear limit is exceeded, repeat
measurement with new valves. If the wear limit is
again exceed, replace cylinder head.
Calculating max. permissible reworking

dimension
– Insert valve and press firmly against the valve seat.
Note
If the valve is replaced when carrying out repair work, use
a new valve for the measurement.
– Measure distance -a- between the end of the valve

stem and the upper face of the cylinder head.
– Calculate max. permissible reworking dimension from
the distance -a- measured and the minimum dimen-
sion.
a
Minimum dimension:
♦ Inlet valve: 43.4 mm
♦ Exhaust valve: 43.2 mm
Measured distance less minimum dimension = max. per-

missible reworking dimension.
Example:
N15-0253
Measured distance 44.1 mm

- Minimum dimension 43.4 mm
= Max. permissible reworking dimen- 0.7 mm
sion
Note
If the max. permissible reworking dimension is 0 mm, re-
peat the measurement with a new valve. If the max. per-
missible reworking dimension is once again 0 mm,
replace cylinder head.
Edition 08.00 Valve Seats/Valves Guide/Valve Stem Seal 15-4 page 1

S00.5313.00.20
Inspecting valve guides

♦ Universal dial gauge holder -MP 3-447-
♦ Dial gauge
Work sequence
– Insert valve into guide. End of valve stem must be
flush with guide.
Because of the different stem diameters only use inlet
valve in inlet guide or outlet valve in outlet guide.
Valve rock: max. 1.3 mm
Note
♦ If the wear limit is exceeded, repeat measurement
with new valves. If the wear limit is again exceed, re-
place cylinder head.
♦ If the valve is replaced when carrying out repair work,
use a new valve for the measurement.
Replacing valve stem seals

• Cylinder head fitted

♦ Assembly lever with pressure plate -MP 1-211-
♦ Assembly device -MP 1-213-
♦ Extractor -MP 1-206-
♦ Insertion tool -MP 1-306-
Removing
– Removing camshaft ⇒ Chap. 15-3.
– Remove bucket tappets (do not interchange) and lay
aside with the contact surface facing down.
– Put the piston of the relevant cylinder in top dead cen-
tre (TDC).
– Insert assembly device -MP 1-213- and adjust bearing
MP 1-213
to stay bolt height.
– Remove valve springs with assembly lever and pres-
sure plate -MP 1-211-.
Note
The valves rest on the piston crown.
MP 1-211 S15-0171
Valve Seats/Valves Guide/Valve Stem Seal Edition 08.00

15-4 page 2 S00.5313.00.20
– Pull off valve stem seals with -MP 1-206-.
To do so press bushing -1- slightly downwards.
MP 1-206
S15-0172
Installing
– To avoid damaging the new valve stem seals insert
plastic bushing -A- on the valve stem. MP 1-306
– Insert valve stem seal -B- in the insertion tool
-MP 1-306-, oil sealing lip and carefully push onto the B
valve guide.
A
Note
♦ After working on the valve gear carefully rotate the en-
gine at least 2 turns to ensure no valve strikes when
the engine is started.
♦ After installing the camshaft, the engine must not be
started for about 30 minutes. The hydraulic clearance
compensation elements must settle (otherwise valves
would strike the pistons). S15-0173
Edition 08.00 Valve Seats/Valves Guide/Valve Stem Seal 15-4 page 3

S00.5313.00.20
Valve Seats/Valves Guide/Valve Stem Seal Edition 08.00

15-4 page 4 S00.5313.00.20
17 – Lubrication
17-1 Removing and installing parts of the lubrication system
Note
♦ If considerable quantities of metal swarf or abrasion is found in the engine oil when carrying out engine repairs,
carefully clean the oil galleries in order to avoid consequential damage and additionally replace the oil cooler.
♦ Testing oil pressure and oil pressure switch ⇒ Chapter 17-3.
♦ The oil level must never exceed the „max“ marking - risk of damage to catalytic converter!
Check oil specifications, capacity and oil level ⇒ Inspection and Maintenance; Chap. 02-3
1 - 15 Nm
2 - 15 Nm
3 - Bracket at top
T For cable to oil level/oil tem-
perature sender
4 - Sprocket
5 - Dipstick 7
T the oil level must not be
above the „max“ marking!
T Inspecting engine oil level
6 - Filler funnel
T Remove for extracting oil
7 - Guide tube
8 - Oil injection nozzle
T For piston cooling
T Pay attention to SP No.
(right-angle bend)
9 - Pressure relief valve, 27 Nm
T opens at 0.25 to 0.32 MPa
overpressure
T replace without sealant
10 - O-ring
T replace
11 - Suction line
T Clean strainer if dirty
12 - Baffle
13 - Oil pan
T Before installing, coat with
silicone sealant
- D 176 404 A2 - ⇒ Chapter
17-2
14 - Oil drain plug, 30 Nm
T with gasket
T replace
15 - 10 Nm
16 - Oil level/oil temperature sensor -G266-
T check ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
17 - Gasket ring
T replace
Edition 11.03 Removing and installing parts of the lubrication system 17-1 page 1
S00.5313.03.20
18 - Oil pump
T With pressure relief valve 1.2 MPa
T Before installing, check whether both dowel sleeves for centering oil pump/cylinder block are present
T If there is any scoring on contact surfaces and gears, replace
19 - Oil pump sprocket
T Fits onto oil pump shaft in one position only
20 - Bracket at bottom
T For cable to oil level/oil temperature sender
21 - 15 Nm
22 - 25 Nm
23 - Oil pump chain
24 - Sealing flange
T Before installing, coat with silicone sealant - D 176 404 A2 - ⇒ Chapter 13-3
T Replacing crankshaft seal ⇒ Chapter 13-3
25 - Chain tensioner, 15 Nm
T When installing, pretension spring and attach
Disassembling and assembling oil filter holder

1 - Screw plug, 25 Nm
2 - Gasket
T replace
3 - Oil cooler
T when installing, move up
against anti-twist lock up to
7 8 9 13
the stop (in direction of tight-
ening)
4 - Gasket
10 11 12
T replace 14
T Insert into lugs on oil cooler
T with gasket
T do not slacken, otherwise re-
place
6 - 0.07 MPa Oil pressure switch 6 15
- F1-
T Brown
T Tighten to 20 Nm
5
T Cut open gasket ring if leak-
ing and replace 4
T inspect ⇒ Chapter 17-3
7 - Oil filter holder 3
T with integrated pressure re- 16
lief valve (0.5 MPa) 2
turn (90°)
1
T replace
T Before tightening, turn in by
hand first
9 - Gasket S17-0053
T replace
Removing and installing parts of the lubrication system Edition 11.03

17-1 page 2 S00.5313.03.20
10 - Gasket ring
T replace
11 - Connection fitting, 30 Nm
12 - Oil feed line
T For exhaust turbocharger
T Tighten to 22 Nm
14 - O-ring
T replace
15 - Oil filter element
T if oil filter changed, replace O-rings ⇒ item 14 and ⇒ item 16
16 - O-ring
T replace
Edition 11.03 Removing and installing parts of the lubrication system 17-1 page 3
S00.5313.03.20
Removing and installing parts of the lubrication system Edition 11.03

17-1 page 4 S00.5313.03.20

Oil Pan
♦ Hinged wrench -3185-
♦ Socket insert -3249-
♦ Hand drill with plastic brush attachment
♦ Flat scraper
♦ Silicone sealant D 176 404 A2
Removing

– Drain engine oil.
– Unbolt oil pan.
Note
Slacken oil pan bolts at flywheel side with hinged wrench
S10-0114
-3185- and unscrew with wrench socket -3249-.
– Remove oil pan, if necessary release by applying

slight blows with a rubber-headed hammer.
– Use a flat scraper to remove sealant residues on the
cylinder block.
– Use a rotating plastic brush to remove sealant resi-
dues on the oil pan (wear protective goggles).
– Clean sealing surfaces. They must be free of oil and
grease.
Installing
Note
♦ The oil pan must be installed within 5 minutes after ap-
plying the silicone sealant.
N17-0012
♦ Use wrench socket -3249- to insert the oil pan bolts at
flywheel side and tighten with hinged wrench -3185-.
– Cut off nozzle tube of the silicone sealant D 176 404

A2 at the front marking (∅ of nozzle approx. 3 mm).
♦ Thickness of sealant bead: 2…3 mm
♦ Run past the area around the bolt holes on the inside
-arrows-.
Note
The sealant bead must not be thicker than 3 mm other-
wise excess sealant may get into the oil pan and clogg
the strainer in the oil suction pipe.
N17-0019
Edition 08.00 Removing and Installing Oil Pan 17-2 page 1

S00.5313.00.20
– Apply silicone sealant to the clean sealing surface of

the oil pan, as shown in the illustration.
Note
Take particular care when applying sealant bead in the
area of the sealing flange at the rear -arrows-.
– Fit on oil pan immediately and tighten the bolts as fol-

lows:
1 - Tighten all the bolts of oil pan/cylinder block slightly.
2 - Tighten the three bolts of oil pan/cylinder block
slightly.
3 - Tighten all the bolts of oil pan/cylinder block slightly
diagonally across. S17-0045
4 - Tighten the three bolts of the oil pan/gearbox fully to
45 Nm.
5 - Tighten all the bolts of the oil pan/cylinder block fully
to 15 Nm diagonally across.
Note
♦ When installing the oil pan with the engine removed,
ensure that the oil pan is flush with the cylinder block
at the flywheel side.
♦ After installing the oil pan, allow the sealant to dry for
about 30 minutes. Only then may engine oil be filled
in.
Removing and Installing Oil Pan Edition 08.00

17-2 page 2 S00.5313.00.20
17-3 Testing oil pressure and

oil pressure switch
♦ Oil pressure tester (e. g. -V.A.G 1342-)
♦ Diode test lamp (e.g. -V.A.G 1527 B-)
♦ Adapter cable set (e.g. -V.A.G 1594 A-)
♦ Current flow diagram
Function of dynamic oil pressure warning system

The oil pressure switch is opened when pressureless and
closed when the switching pressure is reached.
The oil pressure warning is activated for about 10 s after
the ignition is switched on („terminal 15 on“). Activation
delay of oil pressure warning: approx. 3 s Off delay of oil
pressure warning: approx. 5 s
Check warning lamp
After the ignition is switched on and engine not running,
the oil pressure warning lamp in the dash panel insert
must light up for about 3 s and then go out. The check is
ended when the engine is started.
Warning criteria
The visual oil pressure warning (oil pressure warning
lamp flashes) is activated and the audible warning buzzer
sounds 3 times if one of the following conditions exists:
• „Ignition on“, engine not running, oil pressure switch

closed
• Engine speed greater than 1500 rpm, oil pressure
switch open
– At an engine speed above 5000 rpm, the oil pressure

warning is not cancelled; not even if the oil pressure
switch is closed. Oil pressure switch cancelled below
5000 rpm-1.
– If the oil pressure switch is open for only 0.5...3 s at an
engine speed above 1500 rpm, this is stored in the
combination processor of the dash panel insert. If this
condition occurs 3 times when the engine is running,
the oil pressure warning is immediately activated and
is not cancelled below 1500 rpm. The oil pressure
warning is cancelled if the oil pressure switch is closed
for more than 5 s at a speed of more than 1500 rpm,
or at „Ignition off“.
Test conditions
• Engine oil at correct level, inspecting ⇒ Chap. 17-1

• Oil pressure warning lamp (-K3-) must light up for
about 3 s when ignition is switched on.
• Engine oil temperature at least 80 °C (radiator fan
must have cut in once).
Test sequence
Edition 08.00 Testing oil pressure and oil pressure switch 17-3 page 1
S00.5313.00.20
– Unplug connector from oil pressure switch.

– Unscrew oil pressure switch and screw in oil pressure V.A.G 1342
tester (e.g. -V.A.G 1342-).
– Screw oil pressure switch -2- into -V.A.G 1342-.
– Connect brown cable -1- of tester to earth (-).
– Connect diode test lamp (e. g. -V.A.G 1527 B-) to oil
pressure switch -2- and battery positive (+).
The LED must not light up.
+ -
– If the LED lights up, replace the oil pressure switch.
1
– Start engine and slowly increase engine speed. 2
– The LED must light up at 0.055…0.085 MPa over-
pressure, if not, replace oil pressure switch. A17-0025
– Increase engine speed further. At 2000 rpm and an oil
temperature of 80 °C the oil pressure should be at
least 0.2 MPa.
At higher engine speeds the oil pressure must not be low-
er than 0.7 MPa. If necessary, replace oil filter holder to-
gether with pressure relief valve.
Testing oil pressure and oil pressure switch Edition 08.00

17-3 page 2 S00.5313.00.20
19 – Cooling
19-1 Parts of cooling system -

Note
♦ When the engine is warm the cooling system is under
pressure. If necessary reduce pressure before re-
pairs.
♦ The hose connections are secured with spring-type
clips. In the event of repairs only use spring-type clips.
♦ Use pliers for spring strap clips to remove and fit the
spring strap clips.
♦ Always replace seals and gasket rings.
♦ When installing fit the coolant hoses free of stress,
without them touching any other components (pay at-
tention to the marking on the coolant connection and
hose).
Information concerning the mixture ratios ⇒ 19-1 page 5
Edition 11.03 Parts of cooling system - Summary of components 19-1 page 1

S00.5313.03.20
Parts of the cooling system fitted to body

1 - Radiator
⇒ Chapter 19-2
1 2 3
T after replacing fill entire sys-
tem with fresh coolant
4 5 6
2 - O-ring
T replace
7 8
3 - Top coolant hose
T attached to radiator by re- 19
taining clips
G12
T connection diagram for cool-
ant hoses ⇒ 19-1 page 4
4 - Cap 18 17
T check pressure ⇒ 19-1 9
page 6
5 - Connector 10
6 - Double screw, 2 Nm
7 - Air duct scoop 16 5 13
8 - 5 Nm 8
9 - Expansion bottle
T check the coolant system for 11
tightness ⇒ 19-1 page 6 14
T connection diagram for cool- 5 12
ant hoses ⇒ 19-1 page 4 11
10 - Auxiliary fan
T for vehicles with air condi- 8
tioning system or additional 2 15
equipment
11 - Fan holder
12 - Retaining clip 5 8 12 S19-0088
T for fan cable
T check tightness
13 - Fan for radiator
14 - Bracket
T for fan connector
15 - Bottom coolant hose
T attached to radiator by retaining clips
T connection diagram for coolant hoses ⇒ 19-1 page 4
16 - Thermoswitch for radiator fan -F18-, 35 Nm
T for fan
T switching temperatures:
1. Stage
♦ on: 91…97 °C
♦ off: 84…91 °C
2. Stage
♦ on: 99…105 °C
♦ off: 91…98 °C
17 - Bottom radiator bearing
T black
18 - 5 Nm
19 - Top radiator bearing
T white
Parts of cooling system - Summary of components Edition 11.03

19-1 page 2 S00.5313.03.20
Parts of cooling system engine side

1 - 15 Nm
2 - Coolant pump
T check smooth operation 6
11
⇒ Chapter 19-2
3 - O-ring 7
T replace
4 - To expansion reservoir (top) 13
T connection diagram for cool- 12
ant hoses ⇒ 19-1 page 4 8
14
5 - Top coolant pipe 9
T screwed onto the cylinder 5 3 15
head cover 10
6 - Connection fittings 4 16
T for heat exchanger
7 - Distributor part
8 - Sender for the coolant tem- 7
perature -G62- 1
T inspect ⇒ 1.9/74 TDI En- 3
gine, Fuel Injection; 17
Rep. Gr. 28 2
9 - Retaining clip 18
T check for firm seating 3
10 - Gasket ring
T check tightness
T replace 1 19
11 - Distributor part 1
12 - Connection fittings
T on cylinder head 22 21 3 20 S19-0089
13 - 10 Nm
15 - 40 Nm
16 - towards top radiator
17 - Coolant pipe
18 - To the expansion bottle (bottom)
19 - to bottom radiator
T for coolant regulator
21 - Coolant regulator
22 - Oil cooler

S00.5313.03.20
Connection diagram for coolant hoses

1- Radiator
2- Oil cooler
3- Coolant regulator
4- Coolant pump 6 9 10
5- Cylinder block
6- Expansion bottle
7- Top coolant pipe
T at cylinder head cover, with
screw thread
8- Connection fittings 7 8
T on cylinder head
9- Heat exchanger for heating
5
T for heat exchanger
11 - Coolant pipe
12 - Quick coupling
4
3 11
12
2
1
S19-0090
Draining and filling up coolant

Coolant capacity approx. 6.0 litres

♦ Catch pan (e.g. -V.A.G 1306 -)
♦ antifreeze tester
Draining
WARNING!
Hot steam may escape when the expansion reser-
voir is opened. Cover the cap with a cloth and
open carefully.
– Open the cap of the expansion reservoir.

– Remove noise insulation -arrows-. S10-0114

19-1 page 4 S00.5313.03.20
– Place a catch pan under the engine.
– Turn the drain plug -arrow- on the radiator to the left
and draw backwards, if necessary fit auxiliary hose
onto connection.
A10-0118
– Also detach the front coolant hose at bottom of oil

cooler -arrow- and allow remaining coolant to drain
off.
Note
Observe the disposal instructions for coolant.
Filling up
Select the appropriate coolant additive from the original
spare parts catalogue Škoda or from the list of allowed
coolant additives ⇒ Inspection and Maintenance;
Rep. Gr. 02.
Recommended mixture ratios: S10-0116
Antifreeze pro- Antifreeze con- Drinking

tection down to centration1)2) water2)
-25 °C 40 % (2.7 litres) 60 % (4.1 litres)
-35 °C 50 % (3.4 litres) 50 % (3.4 litres)
1) The antifreeze concentration must not exceed 60 %; the antifreeze
protection and cooling efficiency are reduced as the concentration
increases.
2) The coolant amount may differ according to the version of the vehi-
cle.
– Fit coolant hose onto oil cooler.

– Insert and tighten the coolant drain plug.
– Fill up coolant up to „max“ marking on the expansion
reservoir.
– Close expansion bottle.
– Run engine until fan starts.
2
G1
WARNING!
open carefully.
S19-0077

S00.5313.03.20
– Check the level of coolant and top up if necessary.

When engine is at operating temperature the coolant
level must be at the „max“ marking, when engine is
cold between the „min“ and „max“ markings.
Checking the coolant system for tight-

ness
♦ Coolant system tester, e.g. -V.A.G 1274-
♦ Adapter (e.g. -V.A.G 1274/8-)
♦ Adapter (e.g. -V.A.G 1274/9 -)
Test condition
• Engine must be warm
Test sequence
WARNING!
open carefully.
– Open the cap of the expansion reservoir.

– Position coolant system tester (e. g. -V.A.G 1274-)
with adapter (e. g. - V.A.G 1274/8-) on the expansion
reservoir.
V.A.G 1274
– Using the hand pump of the tester generate an over-
pressure of approx. 1 bar (0.1 MPa).
– If the pressure drops determine positions of the leak
and repair.
Testing the pressure relief valve in the cap V.A.G 1274/8

– Screw cap onto tester with adapter (e.g. -V.A.G 1274/
9 -).
G12
– Using the hand pump of the tester generate an over- S19-0082

pressure of approx. 1.5 bar (0.15 MPa).
– The pressure relief valve must open for an overpres-
sure of 1.2...1.5 bar (0.12…0.15 MPa).

19-1 page 6 S00.5313.03.20

Radiator, Coolant Pump,
Coolant Regulator
1
Removing and installing radiator
Special tools, test and measuring equipment and 2
♦ Torque wrench 3
Removing
– Drain coolant ⇒ Chapter 19-1.
– Remove connector -1- from thermo-switch for the S19-0078
coolant radiator -F18- and disconnect plug connection
-2- on the holder of the air duct scoop.
To do so press the latch clips.
There are 2 plug connections on vehicles fitted with air
conditioning.
– Separate the coolant hose from the radiator at the top

and bottom of the connection fittings.
To do so pull the retaining clip -3- up to the stop and
remove the quick coupling towards the rear.
Vehicles without air conditioning

1
– Unbolt cable clip -1- from the starter -arrow-.
Lay cable with clip towards the rear. S19-0079
– Remove front bumper ⇒ Body Work; Rep. Gr. 63.

– Unscrew bolts for radiator bearing -arrows-.
– Pull radiator with fan backwards and remove down-

wards.
Vehicles with air conditioning
WARNING!
Do not open the refrigerant circuit of the air condi-
tioning system.
S19-0080
Edition 11.03 Removing and Installing Radiator, Coolant Pump, Coolant 19-2 page 1
S00.5313.03.20 Regulator
– Unscrew bolts for radiator bearing -arrows-.

– Remove the lock carrier with component parts

⇒ Body Work; Rep. Gr. 50.
Attach the condenser with the radiator to the engine or
support.
Note
♦ Do not suspend the condenser to the wires.
♦ Do not fold the condenser wires.
S19-0083
– Release the bolts securing the condenser -arrows-

and remove radiator with fan.
Installing
Installation is carried out in the reverse order. Pay atten-
tion to the following:

– Re-adjust headlights on vehicles fitted with air condi-
tioning.
Removing and installing coolant pump S19-0081

♦ Torque wrench 5 through 50 Nm
Removing
Note
♦ Always replace seals and gasket rings.
♦ Cover the toothed belt with a cloth before removing
the coolant pump in oder to protect it from the coolant.

S10-0114
Removing and Installing Radiator, Coolant Pump, Coolant Edition 11.03

19-2 page 2 Regulator S00.5313.03.20
– Unscrew the fixing screws -1- of the coolant pump -2-
and carefully remove the coolant pump.
Installing
Installation is performed in the reverse order. Pay atten- 1 2 3
N19-0234
– Clean sealing surface for O-ring.
– Moisten new O-ring -3- with coolant and insert onto
coolant pump.
– Position the coolant pump -2- in the cylinder block and
tighten the fixing screws -1-.
Tightening torque: 15 Nm 1 2 3
Note
Plugs of coolant pump point down.

Removing and installing coolant regula- N19-0234
tor
♦ Torque wrench 5 through 50 Nm
Removing
Note
Always replace seals and gasket rings.
– Removing engine cover ⇒ Chapter 10-1.

Edition 11.03 Removing and Installing Radiator, Coolant Pump, Coolant 19-2 page 3
S00.5313.03.20 Regulator
– Remove coolant hose from connection fittings -2-.

– Unscrew bolts -1- attaching connection and remove
connections -2- together with coolant thermostat -4-.
– Turn coolant thermostat -4- 1/4 turn (90°) to the left and
remove from connection fittings -2-.
4
Installing
Installation is carried out in the reverse order. Pay atten-
3
tion to the following:
2
1
N19-0232
– Clean sealing surface for O-ring.
– Moisten new O-ring -3- with coolant and insert on con-
nection fitting -2-.
– Fit coolant regulator -4- in the connection fitting -2-
and turn 1/4 turn (90°) to the right.
Note 4
The coolant regulator clamps must be virtually vertical.
3
– Insert the connection fitting -2- with coolant regulator
-4- in the cylinder block.
– Tighten fixing screws -1-. 2
1
N19-0232
Removing and Installing Radiator, Coolant Pump, Coolant Edition 11.03

19-2 page 4 Regulator S00.5313.03.20
20 – Fuel Supply
20-1 Removing and installing parts of the fuel supply - Part 1
Fuel tank with component parts - Summary of components
Note
♦ Fuel lines are secured by plug connectors.
♦ Fuel hoses in the engine and fuel filter must only be secured with spring strap clamps. The use of clamp-type or
screw-type clips is not allowed.
♦ Observe safety measures ⇒ 20-1 page 2.
♦ Observe rules for cleanliness ⇒ 20-1 page 3.
Repairing the accelerator control ⇒ Chapter 20-3
1 - Cap
2 - 1.5 Nm
3 - Fuel tank lid unit
T with rubber bowl
4 - Gravity valve
T to remove, unclip valve at top
and lift out of filler neck.
T inspect valve for blockage:
♦ valve vertical: Valve open
♦ valve tilted 45°: Valve closed
5 - Earth connection
6 - 10 Nm
7 - Vent lines
T clipped in place on fuel tank
8 - 25 Nm
9 - Fuel tank
T when removing support, for
example with the engine/
gearbox jack
-V.A.G 1383 A -
⇒ Chapter 20-2
10 - Tensioning strap
11 - Fuel cooler
⇒ Chapter 20-2
12 - 20 Nm
13 - Fuel pump/sender unit for fuel
gauge display
T for vehicles ³ 04.00: Sender
for fuel gauge
T for vehicles 05.00 ³ Fuel pump with sender unit for fuel gauge display
T removing and installing ⇒ 20-1 page 5
T removing and installing fuel gauge sensor ⇒ 20-1 page 6
14 - Gasket ring
T moisten with fuel before installing
Edition 11.03 Removing and installing parts of the fuel supply - Part 1 20-1 page 1
S00.5313.03.20
15 - Union nut
T use wrench -MP 1-227- for removing and installing
16 - Feed line
T to fuel filter ⇒ 20-1 page 4
T on connection with identification -V- (flange)
T black
T to remove from connecting flange press release button
17 - Return-flow line
T from fuel cooler ⇒ Chapter 20-2
T on connection with identification -R- (flange)
T blue
T to remove from connecting flange press release button
18 - Vent valve
T to remove, unclip valve at side and take out of filler neck.
T before installing, unscrew cap
T check ⇒ Fig. 2 in 20-1 page 2
19 - O-ring
T replace
Fig. 1: Fitting position of the flange of the fuel de-

livery unit/fuel gauge sender unit
Marking on the flange must be aligned with marking on
the fuel tank -arrows-.
(Black) feed line -1- to connection marked -V-.
R V
(Blue) return-flow line -2- to connection marked -R-. 2
Note
After installing the fuel delivery unit/fuel gauge sender 1
unit check whether the feed and return-flow line is se-
cured to the fuel tank with retaining clips.
S20-0098
Fig. 2: Inspect vent valve

Lever in off position: Valve closed
Lever pushed in direction of arrow: Valve open
Note
Before installing the vent valve, unscrew cap of fuel tank.
Safety precautions when working on the

fuel supply system
Pay attention to the following points when removing and
installing the fuel delivery unit/ fuel gauge sender on a
fuel tank that is filled or partially filled: V20-1040
Removing and installing parts of the fuel supply - Part 1 Edition 11.03
20-1 page 2 S00.5313.03.20
♦ The extraction hose of an exhaust extraction system
which is switched on, must be positioned close to the
assembly opening of the fuel tank in order to extract
the released fuel gases, even before the work is com-
menced. If no exhaust extraction system is available,
a radial fan (motor not in air flow of fan) with a delivery
volume of more than 15 m3/h must be used.
♦ Avoid skin contact with fuel! Wear fuel-resistant
gloves!
Rules of cleanliness
Carefully observe the following 6 rules for cleanliness
when working on the fuel supply or injection system.
♦ Thoroughly clean the connection points and their sur-
roundings before releasing.
♦ Place removed parts on a clean surface and cover. Do
not use fuzzy cloths!
♦ Carefully cover or close opened components if the re-
pair is not completed immediately.
♦ Only install clean parts. Remove spare parts from
their wrapping immediately before fitting. Do not use
any parts which have been stored unwrapped (e.g. in
tool boxes).
♦ When the system is open: Avoid using compressed
air. Avoid moving the vehicle.
♦ Also make sure no diesel fuel runs onto the coolant
hoses. If this is the case clean the hoses immediately.
Replace immediately any hoses which have suffered
damage.
S00.5313.03.20
Repairing the fuel filter

The fuel flow direction is indicated with arrows on the hoses, on the glow valve and the fuel filter.
T from the tandem pump
T blue marking
2 - Intake hose
T to the tandem pump
T white marking
3 - Retaining clip
4 - Preheating valve
T Fitting position: Arrow points
to fuel tank
T if the filter is replaced remove
retaining clip and preheating
valve with the fuel lines con-
nected
T Temperature less than +
15°C: access to filter open
T Temperature above + 31°C:
access to filter closed
T to fuel cooler ⇒ Chapter 20-
2
T blue marking
6 - Fuel hose
7 - Fuel temperature sender
-G81-
8 - Intake hose
T from fuel tank
T white marking
9 - Fuel filter
T fill up with diesel fuel before
fitting
T do not interchange connections
T removing and installing ⇒ Fig. 3 in 20-1 page 5
10 - Gasket
11 - Drain plug
T to ventilate remove the retaining clip of the preheating valve and remove preheating valve with the fuel lines
connected
T release and drain approx. 0.1 litre fluid (catch)
12 - 25 Nm
13 - Bracket
14 - Plastic insert
T with holder ⇒ item 13 a spare part
20-1 page 4 S00.5313.03.20
Fig. 3: Removing and installing fuel filter
– Remove the preheating valve with the fuel hoses fitted

(pull out retaining clip).
– Remove fuel feed line.
– Push the retaining lugs -arrows- of the plastic insert
outwards.
– Remove fuel filter from the top.
Note
Fuel filter can be removed in one position only.
Removing and installing the fuel delivery S20-0097

unit/fuel gauge sender unit
Observe safety measures ⇒ 20-1 page 2.
Observe rules for cleanliness ⇒ 20-1 page 3.
2
♦ Wrench for union nut -MP 1-227-
5 2
Removing 4 1
– Press off cover -1- (below rear seat).
The rubber grommet -2- may remain fitted.
– Remove feed line (black) -5- and return-flow line

3
(blue) -4- from the flange of the sender unit. To do so
press the release buttons. S20-0092
– Unlock connector -3- and pull off from flange of fuel
delivery unit/sender unit.
– Unscrew union nut with wrench -MP 1-227 -.
MP 1-227
– Pull out the fuel delivery unit/fuel gauge sender unit
and the gasket ring of the opening of the fuel tank.
Note
If the fuel delivery unit is still filled with fuel, empty it be-
fore replacing.
Installing
Installation occurs in reverse order. Pay attention to the
following:
S20-0099
Note
♦ When inserting the fuel delivery unit/fuel gauge send-
er unit make sure the sender is not bent.
♦ Moisten the gasket ring of the flange with fuel before
fitting.
♦ Make sure the fuel hoses fit tightly.
S00.5313.03.20
check fitting position:

♦ Marking on the flange must be aligned with marking
on the fuel tank -arrows-.
♦ (Black) feed line -1- to connection marked -V-.
♦ (Blue) return-flow line -2- to connection marked -R-.
– Interrogate fault memory and erase ⇒ 1.9/74 TDI En- R V

gine, Fuel Injection; Rep. Gr. 01. 2
Removing and installing the fuel gauge

sender from the fuel delivery unit 1
Removing
S20-0098
– Removing the feeder pump/fuel gauge sender unit
⇒ 20-1 page 5.
– Unlatch and disconnect the line contact studs -3- and
-4-.
– Raise catches -1- and -2- with a screwdriver and re-
move the fuel gauge sender towards the bottom -ar-
row-.
Installing
– Insert the fuel gauge sender in the sender unit guides
and press upwards until they latch into position.
– Installing the feeder pump/fuel gauge sender unit
⇒ 20-1 page 5.
Testing fuel pump

♦ Multimeter, e.g. -V.A.G 1715-
♦ Remote control, e.g. -V.A.G 1348/3A-
♦ Adapter cable set, e.g. -V.A.G 1594 A- or
-V.A.G 1594 C -
♦ Wrench for union nut -MP 1-227-
♦ Pressure gauge appliance, e.g. -V.A.G 1318-
♦ Adapter, e.g. -V.A.G 1318/1-
♦ Adapter, e.g. -V.A.G 1318/11-
♦ Adapter, e.g. -V.A.G 1318/17-
♦ Adapter, e.g. -V.A.G 1318/23-
♦ Measuring vessel
Test conditions
• Battery voltage at least 11.5 volts
• Fuses o.k.
Inspecting proper operation and power supply

– Removing fuel delivery unit guard.
20-1 page 6 S00.5313.03.20
– Switch on ignition. The fuel pump must be heard to
start running.
– Switch off ignition. 1 6
11
12
17
18
23 31
24 32
2 7 13 19 25 33
If the fuel pump does not run: 3 8 14 20 26 34
4 9 15 21 27 35
– Remove cover from the fuse holder. 5 10 16 22 28 36
39 29 37
49 59
– Remove fuse No. 61 from the fuse holder. 40 50 60
30 38
– Connect remote control -V.A.G 1348/3A- with the

41 51 61
42 52 62
adapter cable combination from the adapter cable set 43 53 63
in fuse holder 61 and to positive terminal of battery (+). 44 54 64
45
– Activate remote control. 46
55
56
65
66
47 57 67
If the fuel pump starts running: 48 58 68
S01-0094
– Test fuel pump relay ⇒ Current Flow Diagrams, Elec-
trical Fault Finding and Fitting Locations.
If the fuel pump does not run:
– Disconnect the 4-pin plug from the fuel pump flange. V

– Connect the multimeter for voltage measurement to
contacts 1 and 4.
– Activate remote control.
Specified value: approx. battery voltage.
V
If the specified voltage value is not reached:
– Establish and remove an open circuit in the wiring ac- R
cording to the current flow diagram ⇒ Current Flow

Diagrams, Electrical Fault Finding and Fitting Loca-
tions A20-0099
If the specified voltage value is reached:
– Unscrew union nut with wrench -MP 1-227-.

– Remove fuel pump and check whether the electric wir-
ing between the flange and fuel pump is connected.
If no open circuit was detected:
– Replace fuel pump.
Inspecting fuel flow rate
Test conditions
• Supply voltage OK
• Battery voltage at least 11.5 V.
• Fuel temperature 15...30 °C.
• Fuel tank at least 1/4 full.
Test sequence
– Unscrew cap from fuel filler neck.
– Remove cover of fuel delivery unit/fuel gauge sender
under rear seat.
– Unplug 4-pin plug from fuel delivery unit.
S00.5313.03.20
– Connect remote control -V.A.G 1348/3A- with con-

nection lines from measuring tool set to contact -1- of
the fuel pump and to battery +.
– Use connection lines from the measuring tool set to
connect the contacts -4- to the plug and to the fuel
pump.
1
1
4
V
4
R
V.A.G 1348/3A
M20-0076
– Pull off the fuel feed line -arrow- and gather residual
fuel in a cloth.
WARNING!
The fuel feed line is pressurized! Place a clean
cleaning cloth around the connection point before
detaching hose connections. Reduce pressure by
carefully releasing the connection point.
S20-0136
20-1 page 8 S00.5313.03.20
– Connect pressure gauge -V.A.G 1318- with the adapt-
ers -V.A.G 1318/23 - and -V.A.G 1318/17 - to the fuel V.A.G 1318
feed line. V.A.G 1318/11
– Connect hose -V.A.G 1318/1- to adapter V.A.G 1318/23
-V.A.G 1318/11- of the pressure gauge and hold in the
measuring vessel.
– Open shut-off cock of the pressure gauge appliance.
The lever points in the direction of flow -A-.
– Activate remote control -V.A.G 1348/3A-. Slowly
close the shut-off cock until the manometer displays
0.35 bar overpressure (3.5 MPa). Now do not change
the position of the shut-off cock. A
– Drain the measuring vessel.
– Activate remote control for 30 seconds. B
Minimum specified volume: 660 ml/30 s
If the minimum flow rate is not reached:
– Check the fuel lines for possible diameter restrictions

(kinks) or blocking.
– Remove the fuel delivery unit and check whether the V.A.G 1318/1
pump strainer is not clogged up. V.A.G 1318/17
N20-0132
If no fault was detected until now:
– Replace fuel pump.
S00.5313.03.20
20-1 page 10 S00.5313.03.20
20-2 Removing and installing

parts of the fuel supply -
Part 2
Removing and installing the fuel tank

Observe the safety precautions ⇒ Chap. 20-1.
Observe the rules for cleanliness ⇒ Chap. 20-1.

2
♦ Torque wrench 5 through 50 Nm (e.g. -V.A.G 1331-)
♦ Engine/gearbox jack (e.g. -V.A.G 1383 A-) 5 2
♦ Fuel extraction device (e.g. - V.A.G 1433 A-) 4 1
Removing
to the coding; determine if necessary. 3
– Disconnect the earth strap from the battery with the ig-
nition off. S20-0092
– Press off cover -1- (below rear seat).
The rubber grommet -2- may remain fitted.
– Unlock connector -3- and pull off from flange of fuel

delivery unit/sender unit.
– Drain fuel tank using the fuel extraction device. Screw
cap remains off.
– Removing rear axle ⇒ Running Gear; Rep. Gr. 42.
– Removing front and rear silencer ⇒ Chap. 26-1.
– Remove left heat shield next to the fuel tank.
– Remove rear right wheelhouse liner.
– Unscrew bolts on tank filler neck -arrows-.
S20-0093
– Disconnect feed line (black) -1- and return-flow line

(blue) -2- from the fuel tank (press release buttons).
– Position the engine/gearbox jack under the fuel tank
for support.
1 2
S20-0094
S00.5313.01.20
– Release the securing bolts -arrows- of the fuel tank.

– Draw the filler neck from the rubber bowl of the tank lid
unit and lower fuel tank.
Installing
following:
S20-0095
– Connect the fuel lines to the flange of the feeder

pump/of the fuel gauge sender unit:
♦ (Black) feed line -1- to connection marked -V-.
♦ (Blue) return-flow line -2- to connection marked -R-.

gine, Fuel Injection; Rep. Gr. 01. R V
2
Removing and installing fuel cooler
Special tools, test and measuring equipment and 1
S20-0098
Removing
Observe the rules for cleanliness ⇒ Chap. 20-1.
Note
Fuel cooler is located at the return-flow line to the fuel
tank. It is attached to the underfloor of the vehicle body.
– Removing cover -A-.

– Separate fuel line at fuel cooler.
– Unscrew fixing nuts -arrows-. A
Installing
Carry out the installation in the same way in reverse or-
der. Pay attention to the following:
♦ Tighten nuts of the fuel cooler to 15 Nm.
Inspecting tandem pump

N20-0294
♦ Vehicle system tester -V.A.G 1552-
♦ Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C-
20-2 page 2 S00.5313.01.20
♦ Pressure gauge (e.g. -VAS 5187 -)
Test conditions
• The coolant temperature must be at least 85 °C.
• The pump/nozzle units must be O.K.
• Fuel filter and fuel line must not be blocked.
• The non-return valve in the fuel-intake hose must be
O.K.
• Fuel gauge sender must be O.K.
Procedure
N20-0288
– Unscrew screw plug -arrow-.
– Connect Pressure gauge (e.g. -VAS 5187-) as shown.
VAS 5187
– Connect vehicle system tester -V.A.G 1552- and se-
lect engine electronics „address word“ 01. The engine
must be running in idle ⇒ 1.9/74 TDI Engine, Fuel In-
jection; Rep. Gr. 01.
N20-0292
Readout on display: Vehicle system test HELP

Select function XX
– Select function 0 and 8 for „Read measured value
block“ and confirm the entry with the key Q .
Reading measured value block
Readout on display: Enter display group number XXX
– Select display group number 0 0 2 and confirm
entry with Q .
Reading measured value block 2 ->
Readout in display (1…4 = display blocks):
1 2 3 4
– Read off idle speed value in display block 1.
– The engine speed must increase to more than 1500
rpm.
– Observe pressure displayed on pressure gauge.
S00.5313.01.20
Specified value: at least 3.5 bar (0.35 MPa)

If the specified value is not reached:
– Replace tandem pump ⇒ 20-2 page 4.
Note
After removing the pressure gauge tighten screw plug to
25 Nm. Always replace the gasket ring.
Removing and installing the tandem

pump
V.A.G 1390
♦ Hand vacuum pump (e.g. -V.A.G 1390 -)
♦ Water drain reservoir (e.g. - V.A.G 1390/1-) V.A.G 1390/1
1
Removing
2
– Separate feed hose -1- (marked in white) and return-
flow hose -2- (marked in blue) from the fuel filter.
S20-0109
– Connect hand vacuum pump e.g. -V.A.G 1390- with
Water drain reservoir e.g. -V.A.G 1390/1- to return-
flow hose.
– Operate the hand vacuum pump, until there is no 1
more fuel from the return-flow hose. 2
Ensure that no fuel is drawn into the hand vacuum
pump.
– Disconnect vacuum hose -1- for brake servo unit from

tandem pump -4-.
– Remove feed hose -2- (marked in white) at the tan-
dem pump -4-.
– Unscrew securing bolts -arrows-. 4
– Remove tandem pump -4- from cylinder head. 3
– Pull tandem pump -4- upwards, separate return-flow N15-0254
hose -3- (marked in blue) and remove tandem pump
-4-.
Installing 1
2
Installation is performed in the reverse order. Pay atten-
Note
♦ Ensure the tandem pump coupling is correctly insert-
ed into the camshaft.
♦ Always replace the tandem pump seals.
– Connect return-flow hose -3- (marked in blue) to the 4

return-flow coupling of the tandem pump. 3
N15-0254
20-2 page 4 S00.5313.01.20
– Install tandem pump and tighten the bolts attaching it
to the top to 20 Nm.
– Tighten the bolts attaching it to the bottom to 10 Nm.
– Connect the feed hose -2- (marked in white) to the
feed connection and the vacuum hose -1- of the brake
servo unit to the tandem pump -4-.
– Connect feed hose -1- (marked in white) to fuel filter.
– Connect hand vacuum pump (e.g. -V.A.G 1390-) to- V.A.G 1390
gether with water drain reservoir (e.g. -V.A.G 1390/1-)
to return-flow hose -2- (marked in blue) of fuel filter.
– Operate the hand vacuum pump, until fuel flows from
the return-flow hose.
Ensure that no fuel is drawn into the hand vacuum V.A.G 1390/1
pump.
1
– Connect return-flow hose -2- (marked in blue) to fuel
filter. 2
S20-0109
S00.5313.01.20
20-2 page 6 S00.5313.01.20
20-3 Repairing the accelerator control

1 - Bracket
⇒ Running Gear;
1 2
Rep. Gr. 46
2 - Connector
T black, 6 pins
3 - Sender for accelerator pedal
position -G79-
T not adjustable
T the accelerator pedal sender 3
transmits the driver's instruc-
tions to the engine control
unit
T to remove the sender re-
move the bottom part of the
dash panel insert on the driv- 4
er's side
T inspecting ⇒ 1.9/74 TDI En-
gine, Fuel Injection;
Rep. Gr. 23
4 - 10 Nm
S20-0110
Edition 08.00 Repairing the accelerator control 20-3 page 1

S00.5313.00.20
Repairing the accelerator control Edition 08.00

20-3 page 2 S00.5313.00.20
21 – Turbocharging
21-1 Charge-air system with exhaust turbocharger - Part 1
Removing and installing exhaust turbocharger with component parts

Observe the rules for cleanliness ⇒ Chapter 21-2.
Note
♦ The hose connections are secured with clamps.
♦ The charge-air system must be tight.
1 - Exhaust manifold 1 2 3
T with exhaust turbocharger
T must be replaced completely
2 - Intake manifold 26
3 - From charge air cooler
25 4
4 - Gasket
T replace 8
5 - 25 Nm
24
6 - Gasket
T Check fitting position 7
5
7 - Washer
8
8 - 25 Nm
T replace 6
T Coat stud bolts with
G 052 112 A3
9 - From air filter
23
10 - To charge air cooler
11 - Pressure box 22 7
T For charge pressure control 8
T Components of the exhaust 21
9
gas turbocharger cannot be
replaced individually 20 10
12 - Shield 7 12
11
13 - Support 8
19
T Exhaust turbocharger - cylin-
der block 13
14 - 40 Nm 14
15 - 25 Nm
16 - Gasket ring
15
T replace
18 17 16 S21-0020
18 - 17 Nm
19 - Oil return line
T To cylinder block
T Tighten to 35 Nm
20 - Gasket ring for oil return line
T replace
Edition 11.03 Charge-air system with exhaust turbocharger - Part 1 21-1 page 1
S00.5313.03.20
21 - Exhaust turbocharger
T Can only be replaced complete with exhaust manifold
T Inspecting charge pressure control ⇒ Chapter 21-2
T charge pressure regulating valve and pressure box for charge pressure regulating valve are component parts
of the exhaust turbocharger and cannot be replaced individually.
T before connecting the oil feed line fill the exhaust turbocharger on the connection fitting with engine oil.
T After installing the turbocharger, run engine at idling speed for about 1 minute to ensure that oil is supplied to
the turbocharger.
22 - Gasket
T replace
23 - Front exhaust pipe with catalytic converter
25 - Oil feed line
T Tighten to 22 Nm
26 - 10 Nm
Charge-air system with exhaust turbocharger - Part 1 Edition 11.03

21-1 page 2 S00.5313.03.20
Removing and installing parts of the charge air cooling
Note
♦ The hose connections are secured with clamps.
♦ The charge-air system must be tight.
♦ Remove oil and grease from the charge pressure hoses and charge pressure pipes and from their connections
before installing.
1 - Air deflector
2 - Charge air cooler
⇒ 21-1 page 3
3 - 8 Nm
4 - O-ring
5 - Intake manifold pressure
sender -G71- with intake man-
ifold temperature sender
-G72-
6 - Bracket
7 - 5 Nm
8 - Connecting hose
9 - Top charge-air pipe
10 - To induction pipe
11 - From air filter
12 - From valve cover
T Crankcase ventilation
13 - Rear charge-air pipe
14 - Exhaust turbocharger
15 - Bottom charge air pipe
16 - Bracket
T screwed onto the V-ribbed
belt holder ⇒ Chapter 13-1
Removing and installing charge-air cool-

er
♦ Torque wrench
S00.5313.03.20
Removing
– Removing right headlights ⇒ Electrical System;
Rep. Gr. 94.
– Remove plug -1- from the intake manifold pressure
sender -G71- with intake manifold temperature sender
-G72- (-2-).
– Remove the connecting hose -3- from the supports.
– Remove front bumper ⇒ Body Work; Rep. Gr. 63.
– Remove the front right wheelhouse liner ⇒ Body
Work; Rep. Gr. 66.
– Unclip front charge-air routing.
– Remove the connecting hose -1- from the charge-air

cooler -3-.
– Release screws -2- and remove charge-air cooler -3-.
Installing
Installation is carried out in the reverse order.

21-1 page 4 S00.5313.03.20
Connection diagram for vacuum hoses for vehicles ³ 10.01
1 - Vacuum unit
T For intake manifold flap
2 - Changeover valve for intake
manifold flap -N239-
1 2 3 4 5 6
4 - Non-return valve
T white connection points to
charge pressure control so-
lenoid valve / vacuum reser-
voir / switchover valve
6 - To air filter
7 - Exhaust gas recirculation so-
lenoid valve -N18-
8 - Brake servo unit
9 - Distributor part 7
T With non-return valve for 8
brake servo unit 15
10 - Tandem pump 12
11 - Mechanical exhaust gas recir-
culation valve
12 - Solenoid valve for charge
pressure control -N75- 14 11
T Inspecting charge pressure 9
control ⇒ Chapter 21-2 13
13 - Vacuum reservoir
14 - Vacuum unit 10
T For charge pressure control
T Components of the exhaust
replaced individually S21-0023
15 - Connecting piece
S00.5313.03.20
Connection diagram for vacuum hoses for vehicles 11.01 ³

1 - Valve block
T Component parts of the
valve block are:
1 2
♦ Changeover valve for intake 3
manifold flap -N239-
♦ Exhaust gas recirculation so-
lenoid valve -N18-
♦ Solenoid valve for charge
pressure control -N75-
2 - Connecting strip 4
T Pay attention to the coding
when connecting the vacu-
um hoses
3 - Connecting piece 5
4 - Vacuum unit
11
T For charge pressure control
T Components of the exhaust
replaced individually
5 - Vacuum reservoir
6 - To air filter
7 - Vacuum unit
T For intake manifold flap 6
culation valve
9 - Tandem pump
T With non-return valve for 10
brake servo unit 9 8 7
11 - Brake servo unit
S21-0043

21-1 page 6 S00.5313.03.20
21-2 Charge-air system with

exhaust turbocharger -
Part 2
Rules of cleanliness
Carefully observe the following »5 rules« for cleanliness
when working on the exhaust turbocharger:
♦ Thoroughly clean the connection points and their sur-
roundings before releasing.
♦ Place removed parts on a clean surface and cover. Do
not use fuzzy cloths!
♦ Carefully cover or close opened components if the re-
pair is not completed immediately.
♦ Only install clean parts.
Remove spare parts from their wrapping immediately

before fitting.
Do not use any parts which have been stored un-
wrapped (e.g. in tool boxes).
♦ When the system is open:
Avoid using compressed air.

Avoid moving the vehicle.
Remove exhaust turbocharger

♦ Torque wrench
Removing
– Remove drive shaft to the right ⇒ Running gear;
Rep. Gr. 40. S10-0114
– Unscrew the propeller-shaft guard from the cylinder
block.
– Remove screws -3- and disconnect connecting hose
-2- on the charge-air cooler -right arrow-.
S00.5313.02.20
– Remove connecting hoses -1- and -2-.

– Unscrew the oil return line -5- from the cylinder block.
– Unscrew bolts -3- and -4- from support and remove
support.
1 2
– Remove the vacuum hose -7- from the vacuum unit
for charge pressure control. 4
– Remove front exhaust pipe with catalyst -6-
⇒ Chapter 26-1. 3
7 5
6 S21-0022

ment -arrow B-.
– Removing charge air pipe at top rear ⇒ Chapter 21-1.

– Remove connection pipes for inlet connection - ex-
haust manifold for exhaust gas recirculation
⇒ Chapter 26-2.
– Unscrew the oil feed line for the exhaust turbocharger
⇒ Chapter 21-1.
– Removing and installing exhaust manifold from the
cylinder head ⇒ Chapter 21-1.
– Remove exhaust turbocharger downwards.
Installing
following:
Note
♦ Tightening torques ⇒ Chapter 21-1
♦ Before connecting the oil feed line, fill the exhaust tur-
bocharger on the connection fitting with engine oil.
♦ After installing the exhaust turbocharger, run engine
at idling speed for about 1 minute to ensure that oil is
supplied to the exhaust turbocharger.
Checking charge pressure control

♦ Hand vacuum pump (e.g. -V.A.G 1390-)
♦ Hand multimeter (e.g. -V.A.G 1715 -)
♦ Vehicle system tester -V.A.G 1552-
♦ Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C-

21-2 page 2 S00.5313.02.20
♦ Adapter cable set (e.g. -V.A.G 1594 A- or
-V.A.G 1594 C -)
♦ Test box -V.A.G 1598/31-
Test conditions
• No fault stored in fault memory ⇒ 1.9/74 TDI Engine -
Fuel Injection; Rep. Gr. 01
• No leaks on the intake and exhaust side
• No fault on the engine/fuel injection system
• Engine oil temperature at least 80 °C
Test sequence
If test and measuring devices are required during test
drives observe the following:
♦ Always secure the test and measuring devices on the
rear seat and have a second person operate them
there.
♦ If the test and measuring equipment is operated from
the front passenger seat, this can result in injuries to
the persons sitting on that seat in the event of an ac-
cident which involves the front passenger airbag be-
ing deployed.
– The charge pressure is measured with vehicle system

tester -V.A.G 1552- when the engine is idling and dur-
ing a road test.
– Connect vehicle system tester -V.A.G 1552- and se-
lect address word 01„Engine electronics“. (the engine
must be idling at the time) ⇒ 1.9/74 TDI Engine - Fuel
Injection; Rep. Gr. 01.
– Select function 0 4 „Initiate basic setting“ and dis-
play group 0 1 1 .
Basic setting 11 ->
Readout on display:
1400 rpm OFF 200 mbar 99 %
Note
After selecting display group number 011, the idling
speed is increased by the engine control unit in display
block 1 to 1380…1420 rpm.
The display in display field 2 must switch between „off“
and „on“ every 10 seconds.
The following readouts must fluctuate in display fields 3
and 4:
Display field 2: off.
♦ Specified value display field 3: Atmospheric pressure
in mbar
♦ Specified value display field 4: 98…100 %
Display field 2: on.

♦ Specified value display field 3: Atmospheric pressure
in mbar +80…250 mbar
♦ Specified value display field 4: 0…2 %
S00.5313.02.20
Continue the test as follows:
→ Press.
– Read function 0 8 „Read measured value block“

and select display group 0 1 1 .
– Accelerate vehicle in 3rd gear at full throttle from
about 1500 rpm.
Reading measured value block 11 ->
– At about 3000 rpm read off value indicated in display 3090 rpm 1866 mbar 1917 mbar 62 %
block.
Specified value display field 3: 1850…2250 mbar
– Conduct actuator diagnosis for charge pressure con-

trol solenoid valve ⇒ 1.9 litre/74 kW TDI Engine - Fuel
Injection; Rep. Gr. 01.
Charge pressure control solenoid valve must operate for
this test. While doing so the linkage of the charge pres-
sure control vacuum unit at the bottom of the turbocharg-
er must move back and forward. This linkage must move
at least 3…4 times as long as a vacuum is present in the
vacuum system.
If the linkage moves and the nominal charge pressure is
not reached:
– Replace exhaust turbocharger ⇒ 21-2 page 1.

If the linkage does not move because the charge pres-
sure control solenoid valve is not operating:
– Inspecting charge pressure control solenoid valve

-N75- ⇒ 21-2 page 4.
– Inspect vacuum hoses ⇒ Chapter 21-1 .
If the linkage does not move although the charge pres-
sure control solenoid valve is operating:
– Connect hand vacuum pump to charge pressure con-

trol valve and inspect linkage for unobstructed move-
ment.
If the linkage only moves with difficulty or does not move
at all:
– Replace exhaust turbocharger ⇒ 21-2 page 1.

V.A.G 1390
Inspecting charge pressure control solenoid
valve -N75-
Note
On vehicles 11.01 ³ the charge pressure control sole-
noid valve -N75- is a component element of the valve
block.
– Switch off ignition.

– Remove plug from charge pressure control solenoid
valve -N75- or from the valve block.
N21-0078

21-2 page 4 S00.5313.02.20
– Measure the resistance between the contacts of the
charge pressure control solenoid valve -N75-
⇒ Current Flow Diagrams, Electrical Fault Finding
and Fitting Locations.
Specified value: 14…20 Ω
– Replace the charge pressure control solenoid valve

-N75- or valve block ⇒ Chapter 21-1.
If the specified value is reached:
– Check wiring between the charge pressure control so-

lenoid valve -N75- and the engine control unit
⇒ Current Flow Diagrams, Electrical Fault Finding
and Fitting Locations.
If the lines are not found to be faulty:
– Replace diesel direct injection system control unit

- J248- ⇒ 1.9/74 TDI Engine - Fuel Injection;
Rep. Gr. 23.
S00.5313.02.20

21-2 page 6 S00.5313.02.20
26 – Exhaust System
26-1 Removing and installing parts of the exhaust system
Note
♦ The exhaust turbocharger is a component part of the exhaust manifold and therefore must not be replaced individ-
ually; removing and installing ⇒ Chap. 21-2.
♦ Always replace gaskets and self-locking nuts.
1 - Gasket
T replace
2 - Front exhaust pipe with cata-
lytic converter
3 - 25 Nm
T replace
T before installing, coat stud
bolts with hot bolt paste G
052 112 A3
4 - Spring loop
T Press off from cross member
⇒ item 5 when removing
middle silencer with catalytic
converter
5 - Cross member
6 - 25 Nm
7 - Double clamp
T Align exhaust system free of
stress before tightening
⇒ 26-1 page 2
T Fitting position: bolts at bot-
tom and horizontal
T Tighten bolted connections
evenly
8 - 40 Nm
T replace
9 - Hanger
10 - Separation point
T For repairs ⇒ 26-1 page 2
11 - Middle and rear silencer 07.03
³
T replace individually when
carrying out repairs ⇒ 26-1 page 2
T Align exhaust system free of stress ⇒ 26-1 page 2
12 - Middle and rear silencer ³ 06.03
T replace individually when carrying out repairs ⇒ 26-1 page 2
T Align exhaust system free of stress ⇒ 26-1 page 2
Edition 11.03 Removing and installing parts of the exhaust system 26-1 page 1
S00.5313.03.20
Aligning exhaust system free of stress

♦ Torque wrench
Procedure
• The exhaust system is aligned when cold.
– Slacken bolted connections of double clamp between
catalytic converter and front silencer and replace nuts.
– Position double clamp at the distance -a- = 5 mm in
front of the marking on the pipe of the catalytic con- a
verter and tighten front bolted connection slightly S26-0064
(bolts at bottom and horizontal).
– Push front silencer -1- sufficiently far forward into the
double clamp until the dimension -b- of 3…7 mm is
achieved between hanger/body and hanger/front si- 1
lencer.
-Arrow- points in direction of travel.
– Tighten bolted connections on the double clamp in

this position.
Note
After tightening the double clamp, inspect dimension -b- b
and adjust if necessary.
S26-0065
Replacing front or rear silencer

♦ Torque wrench
♦ Body saw (e.g. -V.A.G 1523 -)
A separation point is provided for repair purposes for re-

placing the front or rear silencer.
– Separate exhaust pipe at right angles at the separa-

tion point -arrow 1- with body saw. 4
– When installing double clamp -4- position on the outer
markings -arrows 2 and 3-.
– Align exhaust system free of stress ⇒ 26-1 page 2.
– Align rear silencer horizontally.
– Tighten bolted connections of the double clamp even- 3
ly to 40 Nm. 2
Installation position of double clamp: Bolts positioned
vertically at front of exhaust pipe.
1
Checking the exhaust system for leaks S26-0063
– Start engine and run in idle.
Removing and installing parts of the exhaust system Edition 11.03

26-1 page 2 S00.5313.03.20
– Block tail pipe for the duration of the leak check (e.g.
with cloth or plug).
– Check the connection points for leaks by listening:
Cylinderhead/exhaust manifold, exhaust manifold/ex-
haust pipe with catalytic converter, etc.
– Eliminate any leak found.
Edition 11.03 Removing and installing parts of the exhaust system 26-1 page 3
S00.5313.03.20
Removing and installing parts of the exhaust system Edition 11.03

26-1 page 4 S00.5313.03.20
26-2 Exhaust gas recirculation

system
Note
♦ The exhaust gas recirculation system is operated by
the diesel direct injection system control unit -J248 -
via the EGR valve -N18- to the mechanical exhaust
gas recirculation valve.
♦ Inspecting exhaust gas recirculation and exhaust gas
recirculation valve -N18-: ⇒ 1.9/74 TDI Engine, Fuel
Injection; Rep. Gr. 23
♦ The mechanical exhaust gas recirculation valve with
conically shaped valve tappet makes it possible to
achieve different opening cross-sections at different
valve strokes.
♦ Any desired valve position is possible as a result of the
pulsed operation.
♦ Connection diagram for vacuum hoses ⇒ Chap. 21-1.
Removing and installing parts of the exhaust gas recirculation system

1 - Intake manifold
2 - O-ring
T replace 1 2 3 4 5
3 - Induction pipe
T with mechanical exhaust gas
recirculation valve and con-
trol flap
culation valve
T Component part of the induc-
tion pipe
T Must be replaced together 6
with the induction pipe
T check ⇒ 26-2 page 2
5 - 10 Nm 7
6 - from charge-air cooler 11
7 - Gasket
T replace 8
8 - 25 Nm 10
9 - Exhaust manifold
10 - 25 Nm
T replace
7
T Coat stud bolts with
G 052 112 A3
11 - Connecting tube 9
S26-0073
Edition 11.03 Exhaust gas recirculation system 26-2 page 1

S00.5313.03.20
Test mechanical exhaust gas recircula-

tion valve
♦ Hand vacuum pump (e.g. -V.A.G 1390 -)
Test sequence
– Removing engine cover ⇒ Chapter 10-1.
– Disconnect the vacuum hose at the mechanical ex-
haust gas recirculation valve.
– Connect hand vacuum pump to valve.

V.A.G 1390
– Operate pump and observe.
The diaphragm must move in the direction of the vac-
uum connection.
– Detach hose of hand vacuum pump from mechanical

exhaust gas recirculation valve.
The diaphragm must move back to its original position
against the direction of the arrow.
S13-0161
Exhaust gas recirculation system Edition 11.03

26-2 page 2 S00.5313.03.20

Engine ATD

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Engine ATD

Uploaded by

Copyright:

Available Formats

Service 5

Service Department. Technical Information Printed in Czech Republic

List of Supplements to Workshop Manual

Edition 11.03 List of Supplements

List of Supplements Edition 11.03

10 – Removing and Installing Engine

15 – Cylinder Head, Valve Gear

Edition 11.03 Table of Contents I

Removing and Installing Oil Pan ................................................................... 17-2 page 1

Table of Contents Edition 11.03

Exhaust gas recirculation system .................................................................. 26-2 page 1

Edition 11.03 Table of Contents III

Table of Contents Edition 11.03

00-1 Technical data

Identification characters ATD

Edition 08.00 Technical data 00-1 page 1

Technical data Edition 08.00

10 – Removing and Installing Engine

10-1 Removing and Installing

Edition 05.02 Removing and Installing Engine 10-1 page 1

– Disconnect the battery-earth strap with the ignition off.

– Screw out screw -3-.

– Unbolt the pendulum support -arrows-.

Removing and Installing Engine Edition 05.02

– Also detach the front coolant hose at bottom of oil

– Remove engine cover:

– Remove air filter with intake hose ⇒ 1.9/74 TDI En-

For vehicles with air conditioning

– Before removing the lock carrier:

Edition 05.02 Removing and Installing Engine 10-1 page 3

For all vehicles

– Remove charge-air pipe at the top -1- with connecting

– Remove the vacuum hose -1- from the intake manifold

Removing and Installing Engine Edition 05.02

– Unplug connector -1- from the engine control unit.

– Remove Bowden cable support -arrows-.

Edition 05.02 Removing and Installing Engine 10-1 page 5

– Remove slave cylinder -B-, lay aside and secure with

– Disconnect the plug connections -2- and -3- under the

Removing and Installing Engine Edition 05.02

– Unscrew the engine mounting from the engine sup-

– Unscrew the gearbox mount from the gearbox support

– Carefully lower the engine with gearbox and pull out

Securing the engine to the assembly S10-0120

Edition 05.02 Removing and Installing Engine 10-1 page 7

– With a lifting device bring the engine/gearbox unit to

T 10012 V.A.G 1383/A

– Remove cover plate -A- for flywheel behind the right

Removing and Installing Engine Edition 05.02

Installing the engine

– Check whether the dowel sleeves for centering the

Edition 05.02 Removing and Installing Engine 10-1 page 9

– Align the engine/gearbox unit free of stress and attach

– Install the slave cylinder of the hydraulic clutch

For vehicles with air conditioning

– Disconnect the refrigerant lines.

For all vehicles

– Top up coolant ⇒ Chapter 19-1.

Removing and Installing Engine Edition 05.02

1 - 30 Nm + 90° (1/4 turn) - replace

Edition 05.02 Removing and Installing Engine 10-1 page 11

Removing and Installing Engine Edition 05.02

13-1 Removing and installing V-ribbed belt