Audi A4/b4 Engine TDI 1.9 (1Z and AHU) - Service Manual

Engine data
Engine code 1Z AHU

Manufactured 06.95 > 08.96 >
Capacity ltr 1.9 1.9
Power output kW at rpm 66/4000 66/4000
Torque Nm at rpm 202 202
1900 1900
Bore mm 79.5 79.5
Stroke mm 95.5 95.5
Compression ratio 19.5: 1 19.5: 1
CN not less than 45 45
Firing order 1-3-4-2 1-3-4-2
Catalytic converter yes yes
Exhaust gas recirculation yes yes
Charging yes yes
Charge air cooler yes yes
Engine code 1Z AHU

Valve timing
At 1 mm valve lift and 0 mm valve clearance
Inlet opens after TDC 16° 16°
Inlet closes after BDC 25° 25°
Exhaust opens before BDC 28° 28°
Exhaust closes before TDC 19° 19°
CUT
Removing and installing engine
Special tools and workshop

equipment required
Engine support bracket 10-222 A
Lifting tackle 2024 A
Special tool 3147
V.A.G 1202 A
V.A.G 1306
Special tool Matra V/175

Removing
Notes:
The engine is lifted out without the gearbox.
Catch drained-off coolant in a clean container for re-use or

disposal.
All cable ties which are opened or cut open when removing
the engine must be replaced in the same position when
installing the engine.
- Obtain radio code on vehicles with coded radio.
- With ignition switched off disconnect battery earth strap.
Warning!
Hot steam can escape when the cap on the expansion tank
is opened. Cover the cap with a cloth, and open it carefully.
- Open cap on coolant expansion tank.
Õ - Remove noise insulation (two sections) -arrows-.
- Place drip tray V.A.G 1306 below engine.

900058 Type Type description
4A
Õ - Turn drain screw -arrowon radiator anti-clockwise, if
necessary fit drain hose to connection.
Õ - To drain off remaining coolant, disconnect coolant hoses

-arrows-.
4A
Õ - Slacken bolts 2 ... 6.
- Slacken V-belt by loosening tensioning nut -1-.
- Remove V-belt.
900058 Type
4A
Õ - Unbolt vane pump for power steering and bracket (at rear)
-arrows-. Do not disconnect hydraulic connections.
- Secure vane pump to body with wire to avoid overtensioning

the hydraulic connections.
Õ - Disconnect positive wire to fan motor at series resistance

-arrow-.
- Installation position: behind front bumper, on left.
- Move wiring clear.

4A
Õ - Unbolt torque reaction support from engine and cross member
-arrows-.
Õ - Disconnect bottom air hose -3- from charge air cooler.
- Disconnect wiring-1-from alternator.
- Unbolt earth wire -2- from longitudinal member.

4A
Õ - Unbolt starter from engine/gearbox and secure as necessary.
Note:
Starter cables do not have to be disconnected.
Vehicles with automatic gearbox
Õ - Unscrew 3 torque converter nuts through starter opening using

Matra V/175 15 mm A/F socket attachment (turn crankshaft 1/3
turn each time).
Note:
When loosening torque converter bolts, counterhold crankshaft

by applying spanner to central bolt on vibration damper.
All models
- Unscrew engine/gearbox securing bolts accessible from below

4A
Õ - Remove engine cover panel -arrows-.
Õ - Remove air intake pipe -arrow- between lock carrier and air
cleaner housing.
4A
Õ - Unscrew earth connection to fan motor at earth point -arrow- at
front left of engine compartment.
- Unbolt radiator fan cowl from radiator and lift out.
Õ - Disconnect wires/unplug connectors as follows:
1 -Exhaust gas recirculation valve -N18
2 -Air mass meter -G70
4 -Charge pressure control solenoid valve -N75
5 -Intake manifold temperature sender -G72
- Disconnect vacuum hose from mechanical exhaust gas

recirculation valve-3-.
- Disconnect thin hose-6-from bottom of valve for exhaust gas

recirculation -N18.
- Move wiring and hoses clear.
- Disconnect air hose from air mass meter.
- Remove upper section of air cleaner housing with air mass

meter.
4A
Õ - Unbolt charge pressure control solenoid valve -2- from air duct
-1-. Do not disconnect hoses.
- Remove air duct-1-between charge air cooler and intake

manifold.
- Remove air intake hose between charge air cooler and

turbocharger.
Vehicles with air conditioner:
- Remove ribbed belt => Page 13-11.
- Remove lower section of air cleaner housing.
- Disconnect connector on A/C compressor.
Warning!
The air conditioner refrigerant circuit must not be opened.
- Remove A/C compressor and secure to body with wire.
All models
Õ - Unscrew bolts securing turbocharger to catalytic converter

-arrows-.
- Disconnect front exhaust pipe with catalytic converter from

turbocharger.
Note:
Secure the flange of the front exhaust pipe to the right

suspension turret with wire. It is then not necessary to remove
the front exhaust pipe.
4A
1 -Injection pump
2 -Injection pump
3 -Wiring for engine speed sender -G28
4 -Needle lift sender -G80
5 -Coolant temperature sender -G62
6 -Electronic thermo switch -F76
7 -Oil pressure switch -F1
8 -Oil temperature sender -G8
- Unplug connectors from glow plugs.
- Unplug connector from speedometer sender -G22 on left of

gearbox, and move wire clear.
900058 Type Type description Vehicles with manual gearbox:
4A
- Unplug connector for reversing light switch on gearbox, and
move wire clear.
All models
Õ - Disconnect diesel supply and return pipes -arrows- at injection

pump and move clear to one side.
Note:
Use clean plugs to block off the pipes.
Õ - Disconnect coolant hoses -arrows-.
- Remove hose with non-return valve from exhauster pump.
- Unscrew upper engine/gearbox securing bolts. Leave one bolt

in place (hand-tight).
4A
Õ - Unscrew top nuts -arrowon left and right engine mounts.
Õ - Position support bar 10-222 A on bolted flanges of wing panels

-arrows-.
Note:
Support bar must be positioned behind gas strut for bonnet, and
spindles must face forwards.
- Engage gearbox support 3147 in top right bolt hole in bell

housing on gearbox, as illustrated.
Notes:
The height of the gearbox can be adjusted via the wing nut on
the lifting hook.
Do not overtension, otherwise the pressure pipe for the clutch

slave cylinder could be damaged (on manual gearbox).
The illustration shows the engine removed.

Õ - Attach lifting tackle 2024 A to engine and hook onto workshop
crane V.A.G 1202 A.
Note:
To balance the centre of gravity of the engine, position the hook

attachments as shown in the illustration.
Warning
The hook attachments and locating pins on the lifting tackle
must be secured with locking pins (arrows in illustration).
- Remove the last securing bolt.
Note:
Check that all hoses and other connections between engine and
body have been detached.
- Lift engine over studs of engine mounts.
- Tighten spindle of support bar 10-222 A.
- Raise engine carefully and lift out.
- Secure torque converter in gearbox to prevent it falling out.

Attaching engine to engine stand
Special tools and workshop equipment required
Engine and gearbox support VW 540

Work sequence
Õ When working on the engine, secure it to the engine stand using

engine bracket VW 540.
Installing
Installation is carried out in the reverse order, when doing this

note the following:
Notes:
When performing repairs, renew seals, gaskets, self-locking

nuts and bolts which have a specified tightening angle.
Secure all hose connections with the correct hose clips (same
as original equipment)
=> Parts catalogue
- Check whether the two dowel sleeves for centring engine and
gearbox are in the cylinder block, install if necessary.
- Push intermediate plate onto dowel sleeves.
Vehicles with manual gearbox
- Clean input shaft splines and (in the case of used clutch plates)
the hub splines. Remove corrosion and apply only a very thin
coating of grease G 000 100 to the splines. Do not grease
guide sleeve.
- Check clutch release bearing for wear and renew if necessary.
- Check that clutch plate is properly centred in vehicles with

manual gearbox.
- A needle bearing must be fitted in the crankshaft on vehicles

with manual gearbox. Install needle bearing if necessary =>
Page 13-53.
- In vehicles with automatic gearbox, no needle bearing must be

fitted in the crankshaft. Remove needle bearing if necessary
=> Page 13-53.
- To secure the torque converter on the drive plate only use the
correct nuts as specified in the parts catalogue.
=> Parts catalogue
- Tighten torque converter nuts with special tool Matra V/175.
- Before installing engine, rotate torque converter and drive plate

so that one hole and one stud are level with the aperture for the
starter motor.
Checking position of torque converter
Õ If the torque converter has been installed correctly, distance-A

-between the joint surface on the torque converter bellhousing
and the bottom contact surface on the torque converter studs
should be approx 23 mm.
If the torque converter has not been installed properly, the

distance will be about 13 mm.
If the torque converter is incorrectly inserted in the gearbox,

the driver of the torque converter or the ATF pump will be
severely damaged when the gearbox is attached to the
engine.
- Check ATF level:
=> Automatic gearbox 01N; Repair group 37; Checking and

changing ATF; Checking ATF level and topping up ATF=>
All models
- Ensure that engine mounts are free of stress by shaking engine

to align it before tightening engine mounts.
- Allow stop for torque reaction support to rest on rubber buffer

for torque reaction support under its own weight, and tighten
bolts.
- Install ribbed belt =>Page 13-12.
- Fill up with coolant=> Page 19-7.

Notes:
Drained-off coolant 1Z
may only be used
CUT
again if the original
cylinder head or cylinder block are re-installed.
Coolant must not be used again if it is dirty.
- Stress-free alignment of exhaust system => Page 26-10.
- Electrical connections and routing:
=> Current flow diagrams, Electrical fault finding and Fitting

locations
- Connect EGR hoses and pipes => Diagram of vacuum hose

connections, Page 26-15.
- Connect hoses and pipes for charge pressure control system

=> Diagram of connections, Page 21-2.
- After connecting battery, enter anti-theft code for radio
=> Radio operating instructions
The electronic control units can be damaged if a rapid

charger is used to start the engine.
- Close windows fully using electric window switches.
- Then operate all electric window switches again for at least one
second in the "close" direction to activate the automatic one
-touch function.
- Set clock to correct time.
- Check oil level before starting engine.
- Interrogate fault memory:

=> Diesel direct injection and glow plug system (4-cyl. TDI);
Repair group 01; Interrogating and erasing fault memory=>
Note:
Faults will have been stored in the memory because connectors
have been unplugged. Therefore interrogate and erase fault
memory after installing engine.
Tightening torques
Notes:
The tightening torques listed on this page apply only to lightly

greased, oiled, phosphated, or black-finished nuts and bolts.
Additional lubricant such as engine or gearbox oil may be

used, but do not use graphite lubricant.
Do not use degreased parts.
Tolerance for tightening torques is ±15%.
Õ Engine/gearbox mountings (manual gearbox)
Item No. Bolt Nm

1, 3, 4 M12 x 67 65
2, 6 M12 x 90 65
5, 11 M12 x 110 65
7, 8 1), 9, 10 M10 x 45 45
1)M8 bolt fitted up to approx. 07.96: tightening torque 25 Nm
A: centering sleeves
Õ Engine/gearbox mountings (automatics)
Item No. Bolt Nm

1, 8, 9, 10 M10 x 45 45
2, 3, 4, 11 M12 x 67 65
5 M12 x 110 65
6 M12 x 90 65
7 M10 x 60 45
A: centering sleeves
Component Nm
Bolts/nuts M6 10
M8 20
M10 45
M12 65
Except for the following:
Engine mount to subframe 25
Engine support to engine mount 25
Torque reaction support M8 20
M10 40
Drive plate to
torque converter M10 x1 85
A/C compressor to compressor bracket 25
Power steering pump to bracket 25
Catalytic converter to turbocharger 25
Hose clamps 2
Dismantling and assembling engine
Ribbed belt drive for alternator, V-belt drive for coolant

pump and vane pump
Notes:
The following illustration shows the belt drive on vehicles

without air conditioner.
Mark the direction of rotation before removing the ribbed belt.

If the belt rotates in the wrong direction when it is refitted, this
can cause breakage. Ensure that the belt is properly seated in
the pulleys when installing.
1 - V-belt
For coolant pump
For vane pump
Check for wear
Removing and installing
=> Page 13-9
2 - 25 Nm
If necessary, brace pulley with
strap wrench (oil filter wrench) when
loosening and tightening.
3 - Bolt
Bolt with strength rating 8.8:
tighten to 25 Nm
tighten to 35 Nm
=> Parts catalogue
4 - Pulley
For vibration damper
V-belt version
5 - Ribbed belt
Check for wear
=> Page 13-11
6 - Cover cap
Prise off with screwdriver
7 - Tensioning roller
For ribbed belt
Removing and installing ribbed
belt => Page 13-11
8 - 65 Nm
9 - Pulley
For alternator
For ribbed belt
10 - 25 Nm
11 - Alternator
Removing:
- Disconnect battery earth strap
- Remove ribbed belt
- Loosen bolts on alternator (top and
bottom)
- Detach alternator and unscrew
wiring connections
To facilitate positioning of
alternator, knock back bush for
bottom retaining bolt on bracket
slightly
12 - Lever
For tensioning roller
Engage flats on end of lever in
tensioning element -Item 17-
13 - 25 Nm
14 - Seal
15 - 25 Nm
16 - 10 Nm
17 - Tensioning element
Removing:
=>Page 13-11.
Engage on flats on lever for
tensioning roller -Item 12-
18 - Bracket
For alternator
19 - 25 Nm
20 - Vibration damper
For ribbed belt
With pulley for V-belt
Can only be installed in one
position. Holes are off-set
21 - Coolant pump
Check that pump runs freely
=> Page 19-11
22 - Bolt
tighten to 25 Nm
tighten to 35 Nm
=> Parts catalogue
23 - Bracket
For vane pump
24 - Bolt/nut
tighten to 25 Nm
tighten to 35 Nm
Tighten nut to 25 Nm
=> Parts catalogue
25 - 25 Nm
26 - Rear bracket
For vane pump
27 - Vane pump
For power steering
Removing and installing:
=> Running gear, Front-wheel drive and

four-wheel drive; Repair Group 48;
Assembly overview: Vane pump;
Vehicles with 4-cylinder engine
28 - 25 Nm
29 - Frontbracket
For vane pump
30 - Retainer
31 - 25 Nm
32 - Bolt - 25 Nm
With tensioner nut
33 - Pulley
For vane pump
V-belt version
34 - 25 Nm
35 - 25 Nm
36 - Pulley
For coolant pump
V-belt version
Ribbed belt drive for alternator, V-belt drive for coolant
pump and vane pump
Notes:
The following illustration shows the belt drive on vehicles

without air conditioner.
Mark the direction of rotation before removing the ribbed belt.

If the belt rotates in the wrong direction when it is refitted, this
can cause breakage. Ensure that the belt is properly seated in
the pulleys when installing.
1 - V-belt
For coolant pump
For vane pump
Check for wear
=> Page 13-9
2 - 25 Nm
3 - Bolt
tighten to 25 Nm
tighten to 35 Nm
=> Parts catalogue
4 - Pulley
For vibration damper
V-belt version
5 - Ribbed belt
Check for wear
=> Page 13-11
6 - Cover cap
Prise off with screwdriver
For ribbed belt
Removing and installing ribbed
belt => Page 13-11
8 - 65 Nm
9 - Pulley
For alternator
For ribbed belt
10 - 25 Nm
11 - Alternator
Removing:
- Disconnect battery earth strap
- Loosen bolts on alternator (top and
bottom)
- Detach alternator and unscrew
wiring connections
To facilitate positioning of
alternator, knock back bush for
bottom retaining bolt on bracket
slightly
12 - Lever
For tensioning roller
Engage flats on end of lever in
tensioning element -Item 17-
13 - 25 Nm
14 - Seal
15 - 25 Nm
16 - 10 Nm
17 - Tensioning element
Removing:
=>Page 13-11.
Engage on flats on lever for
tensioning roller -Item 12-
18 - Bracket
For alternator
19 - 25 Nm
20 - Vibration damper
For ribbed belt
With pulley for V-belt
21 - Coolant pump
Check that pump runs freely
=> Page 19-11
22 - Bolt
tighten to 25 Nm
tighten to 35 Nm
=> Parts catalogue
23 - Bracket
For vane pump
24 - Bolt/nut
tighten to 25 Nm
tighten to 35 Nm
Tighten nut to 25 Nm
=> Parts catalogue
25 - 25 Nm
26 - Rear bracket
For vane pump
27 - Vane pump
For power steering
=> Running gear, Front-wheel drive and

four-wheel drive; Repair Group 48;
Assembly overview: Vane pump;
Vehicles with 4-cylinder engine=>
28 - 25 Nm
29 - Frontbracket
For vane pump
30 - Retainer
31 - 25 Nm
32 - Bolt - 25 Nm
With tensioner nut
33 - Pulley
For vane pump
V-belt version
34 - 25 Nm
35 - 25 Nm
36 - Pulley
For coolant pump
V-belt version
Removing and installing V-belt
- Slacken V-belt by turning tensioner nut -1-.
- Remove V-belt.
Installation is performed in the reverse order.
- Check that V-belt is properly seated.

- Routing of belt=>Page 13-13
- Tensioning V-belt=>Page 13-10.

Tensioning V-belt
- Adjust belt tension with tensioner nut -1-.
- Check tension of V-belt:
- Press in the belt firmly with the thumb at a point half-way

between the pulleys with the longest run of belt.
The amount of yield should be as follows:
V-belt for coolant pump and and vane pump Belt yield (max.)
New V-belt 2 mm
Used V-belt 5 mm
- TIghten securing bolts on vane pump.
Tightening torques
Component Nm
Vane pump to bracket 25
Vane pump to tensioning bar 25
Removing and installing ribbed belt
Removing
Note:
Mark the direction of rotation with chalk or felt pen before

removing the ribbed belt. If the belt rotates in the wrong direction
when it is refitted, it may break.
- Remove V-belt=>Page 13-9.
- Detach cover cap -Item 6-, Page 13-3, from tensioning roller.
Õ - To slacken ribbed belt tensioning roller, apply 17 mm socket

with extension to central nut.
- To slacken ribbed belt, turn tensioning element in direction of

arrow.
- Remove ribbed belt and release tensioning element.

Installing
- Fit ribbed belt over crankshaft pulley and tensioning element.
Õ - Turn ribbed belt tensioning element in direction of arrow.
- Fit ribbed belt over alternator pulley last. Release tensioning

element.
Note:
Ensure that the ribbed belt is properly seated in the pulleys when
installing.
- Install V-belt=>Page 13-9.

- Routing of belts=>Page 13-13
- Press on cover cap -Item 6-, Page 13-3, for tensioning roller.
- Start engine and check that belts run properly.

Routing of belts
Õ - Routing of ribbed belt on vehicles without air conditioner.
Õ - Routing of ribbed belt on vehicles with air conditioner.

Toothed belt drive
Note:
Mark the direction of rotation with chalk

or felt pen before removing the toothed
belt. If a used belt rotates in the wrong
direction when refitted, this can result in
breakage.
1 - Toothed belt guard - top

When installing, engage carefully
in bottom toothed belt guard
2 - Toothed belt
Mark direction of rotation with
chalk or felt pen before removing
Check for wear
Removing=>Page 13-20
Installing=>Page 13-26
3 - 20 Nm
Checking semi-automatic toothed
belt tensioning roller
=> Page 13-30
Position
=>Fig.1, Page 13-18
5 - 45 Nm
Counter-hold with 3036 to loosen
and tighten
6 - Camshaft sprocket
Release from camshaft taper by
tapping with a hammer (using a drift
through toothed belt guard opening)
7 - 25 Nm
8 - Idler roller
9 - 10 Nm
10 - Toothed belt guard - rear

11 - 10 Nm
12 - 25 Nm
13 - Woodruff key
Check proper seating
14 - Injection pump sprocket

Removing injection pump sprocket
=>Fig. 3, Page 13-19
Check that Woodruff key is fitted
correctly
15 - Intermediate shaft sprocket

Installation position
=>Fig. 2, Page 13-18
correctly
16 - Crankshaft sprocket
Contact surface between sprocket
and crankshaft must be free of oil.
position.
17 - 90 Nm + 1/4 turn (90 °) further
Renew
Do not use oil
Use counter-hold tool 3099 or
3415 to loosen and tighten
Bolting on counter-hold tool 3099
=> Page 13-39
18 - 45 Nm
Use counter-hold tool 3036 to
loosen and tighten
19 - 45 Nm
20 - 10 Nm
21 - Toothed belt guard - bottom

To remove, unbolt vibration
damper
22 - Spreader clip
4A 1Z
Õ Fig.1Position of semi-automatic CUT
tensioning roller
The retaining lug must fit in the opening in the rear toothed belt
guard.
Õ Fig.2Installation position of intermediate shaft sprocket
The wider rim -arrows- of the intermediate shaft sprocket is at

the front.
The side of the sprocket with the lettering is at the rear.

4A 1Z pump sprocket
Õ Fig.3Removing injection CUT
z Toothed belt removed => Page 13-20
- Unscrew nut for injection pump sprocket.
- Release arms of puller 3032 and apply puller.
- Align arms of puller with holes in injection pump sprocket and

secure.
- Apply tension to injection pump sprocket by tightening puller.
- Release injection pump sprocket from taper of injection pump

by lightly tapping spindle of puller (hold sprocket while doing
this so it does not fall out).
Removing and installing toothed belt

equipment required
Mandrel 2064
Setting bar 2065 A
Retainer 3036
Special tool Matra V/159

900058 Type Type description Removing
4A
Õ - Unbolt pulley with vibration damper.

Õ - Remove top and bottom sections of toothed belt guard -arrows-.
4A
Õ - Turn crankshaft to TDC No. 1 cylinder -arrow- (vehicles with
manual gearbox).

automatic gearbox).
Note:
Turning crankshaft to TDC No. 1 cylinder with engine

removed=> page 13-31.
- Remove cylinder head cover =>Page 15-8.

4A
Õ - Lock camshaft using setting bar 2065 A.
Õ - Centralize setting bar as follows:

With setting bar in position, turn camshaft so that one end of
setting bar contacts cylinder head. Using feeler gauge,
measure gap at other end of setting bar. Insert a feeler gauge
corresponding to half the measured gap between setting bar
and cylinder head. Now turn camshaft until setting bar contacts
feeler gauge. Place a 2nd feeler gauge, of the same thickness,
at the other end between setting bar and cylinder head.
Õ - Lock injection pump sprocket with pin 2064.
- Mark direction of rotation of toothed belt with chalk or felt pen.
- Loosen tensioning roller.
- Remove idler wheel.
- Take off toothed belt.

Installing (adjusting valve timing)
z Camshaft locked in position with setting bar.
z Injection pump locked in position with pin 2064.
Notes:
The position of the toothed belt must be set as described

below, even after repairs in which the belt is only taken off the
camshaft sprocket.
The crankshaft must not be at TDC at any cylinder when the

camshaft is turned. Otherwise there is a risk of damage to
valves and piston crowns.
Never use the setting bar to hold the camshaft when

loosening and tightening the bolt securing the camshaft
sprocket. Counter-hold with 3036.
Õ - Loosen camshaft sprocket securing bolt 1/2 turn. Release

camshaft sprocket from camshaft taper by tapping with a
hammer (using a drift through rear toothed belt guard opening).
- Check again whether TDC mark on flywheel and reference

mark are aligned.
- Fit toothed belt (check direction of rotation) on crankshaft

sprocket, intermediate shaft sprocket, injection pump sprocket
and tensioning roller.
- Fit camshaft sprocket together with toothed belt and locate with
securing bolt (camshaft sprocket can still turn).
- Install idler wheel.

Õ - Using a suitable wrench (e.g. Matra V/159), turn eccentric
mounting on tensioning roller clockwise until notch aligns with
raised portion (arrows).
Note:
If the eccentric mounting is turned too far to the right (by mistake)
, slacken completely before re-tensioning.
- Tighten lock nut on tensioning roller to 20 Nm.
- Check again whether TDC mark on flywheel and reference

mark are aligned.
- Tighten bolt securing camshaft sprocket to 45 Nm.
Note:
On no account use the setting bar to hold the camshaft when

loosening and tightening the bolt securing the camshaft sprocket.
Counter-hold with 3036.
- Remove setting bar.
- Remove pin 2064.
- Turn crankshaft two full revolutions in normal direction of

rotation and set again to TDC No. 1 cylinder.
Õ - Check tension of toothed belt.
- Markings -arrows- should be in line.
- Re-tension toothed belt if necessary.
- Check whether injection pump sprocket can be locked with pin

2064.
- Check position of camshaft with setting bar.

Note:
If the setting bar or pin do not fit in place, repeat adjustment

procedure.
- Remove setting bar.
- Remove pin 2064.
- Check injection pump commencement of delivery (dynamic)

=> Diesel direct injection and glow plug system (4-cylinder TDI);
=> Repair group 23; Servicing diesel direct injection system;=>
=> Dynamically checking and adjusting commencement of

injection
Tightening torques
Component Nm
Toothed belt sprocket to camshaft 45
Idler wheel to console 25
Semi-automatic tensioning roller to cylinder block
20
Bottom section of toothed belt guard to cylinder block
10
Vibration damper with 8.8 25
pulley to crankshaft 10.9 35
Checking semi-automatic toothed belt tensioning roller
Test requirements
z Toothed belt in position and tensioned.
Test sequence
Õ - Tension toothed belt with firm thumb pressure.

Notch and raised portion -arrows- must move apart.
- Release thumb pressure on toothed belt. The tensioning roller

should move back to its initial position.
- Markings -arrows- should be in line.
Turning crankshaft to TDC with engine removed
Adjustment bar 2068 A for top dead centre
Vehicles with manual gearbox
z Oil filter removed.
Õ - Fit TDC adjuster gauge 2068 A with screw as illustrated.
- Set adjuster gauge to 107 mm (the reference point is the left

notch of the vernier -arrow-).
- Turn crankshaft until TDC marking "0" on flywheel coincides

with end of adjuster gauge.
z Oil filter removed.

Õ - Fit TDC adjuster gauge 2068 A with screw as illustrated.
- Set adjuster gauge to 99 mm -arrow- (the reference point is the

left notch of the vernier -arrow-).
- Turn crankshaft until TDC marking "0" on drive plate coincides

with end of adjuster gauge.
Note:
TDC marking "0" is stamped into the cylinder block side of the
drive plate.
Removing and installing sealing
flanges and flywheel/drive plate
Note:
For repairs to the clutch:
=> 5-Speed manual gearbox 012/01W,

Front-wheel drive; Repair group 30;
Servicing clutch=>
1 - Oil seal
To remove, remove sealing flange
-Item 27-
Install with 10-203
Lightly oil sealing lip
2 - Intermediate shaft sprocket

=>Fig. 1, Page 13-38
Check position of Woodruff key
-Item 25-
3 - 45 Nm
Use counter-hold 3036 to loosen
and tighten
4 - 25 Nm
5 - Oil seal
Renewing => Page 13-39
Lightly oil sealing lip of oil seal
6 - 10 Nm
7 - Front sealing flange

Before fitting sump, apply a small
amount of sealant
"AMV 174 004 01"to sealing points
between sealing flange and cylinder
block
8 - Gasket
Renew
900058 Type Type description MY
4A
9 - Cylinder block
Removing and installing crankshaft
=> Page 13-48
Dismantling and assembling
pistons and conrods
=> Page 13-57
10 - Vacuum pump
For brake servo
11 - O ring
Renew
12 - Cover
13 - 10 Nm
14 - 20 Nm
15 - Bracket
For exhauster
16 - O ring
Renew
4A
17 - Oil seal
Renew
18 - 10 Nm
19 - Rear sealing flange

With oil seal
Only renew complete
Lightly oil sealing lip of oil seal
Before fitting sump, apply a small
amount of sealant
"AMV 174 004 01"to sealing points
block
20 - Gasket
Only install gasket if sealing flange
has no sealing lip on cylinder block
side
21 - Flywheel/drive plate
Removing and installing flywheel
=> Page 13-44
Removing and installing drive plate
=>Page 13-45
4A
22 - 60 Nm + 1/4turn (90 °) further
Renewing
23 - Intermediate plate
Must be located on dowel sleeves
Do not damage orbend when
assembling
24 - Intermediate shaft
Axial clearance max. 0.25 mm
25 - Woodruff key
correctly
26 - O ring
Renew
27 - Sealing flange for intermediate

shaft
28 - 25 Nm
4A 1Z of intermediate
Õ Fig.1Installation position CUT shaft sprocket
The wider rim -arrows- of the intermediate shaft sprocket is at

the front.
The side of the sprocket with the lettering is at the rear.

Renewing crankshaft oil seal - pulley
end -

equipment required
Oil seal extractor 2085
Oil seal fitting tool 3083
Counter-hold tool (retainer) 3099

Removing
z Engine in vehicle

4A
- Remove toothed belt => Page 13-20.
Õ - Remove crankshaft toothed belt sprocket. To do this counter

-hold sprocket with 3099.
Note:
Special tool 3415 can be used instead.
Õ - Screw cheese-head bolt from 3083 five or six turns into

crankshaft before applying oil seal extractor.
- Unscrew inner part of the oil seal extractor 2085 two turns
(approx. 3 mm) out of the outer part and lock with knurled
screw.
4A
Õ - Lubricate threaded head of oil seal extractor, place it in position
and, exerting firm pressure, screw it as far as possible into oil
seal.
- Loosen knurled screw and turn inner part against crankshaft

until the oil seal is pulled out.
- Clamp flats of oil seal extractor in vice. Remove oil seal with
pliers.
- Clean contact surface and sealing surface.

Installing
- Lightly oil sealing lip of oil seal.
Õ - Place guide sleeve from 3083 onto crankshaft journal.
- Slide oil seal over guide sleeve.

4A
Õ - Press oil seal in onto stop using press sleeve and bolt from
3083.
- Renew bolt for toothed belt sprocket.
- Install crankshaft sprocket and lock in position with retainer

3099.
Notes:
Contact surface between toothed belt sprocket and crankshaft

must be free of oil.
Do not grease bolt for toothed belt sprocket.
- Install toothed belt (adjust valve timing) => Page 13-26.
- Allow stop for torque reaction support to rest on rubber buffer

for torque reaction support under its own weight, and tighten
bolts.
Tightening torques
Component Nm
Toothed belt sprocket to crankshaft 90 + 90°1)2)
Torque reaction support M8 20
M10 40
1)Renew bolt
2)90° is a quarter turn

Removing and installing flywheel/ drive plate
Flywheel
Counter-hold tool 10-201
Work sequence
Õ - Reverse position of retainer 10-201 for loosening/tightening

bolts.
- Mark position of flywheel relative to engine.
- Renew bolts.
Tightening torque
Component Nm
Flywheel to crankshaft 60 + 90°1)
1)90°= 1/4turn
Drive plate
4A
Counter-hold tool VW 558
Hexagon bolt M8 x 45 and two M10 hexagon nuts
Depth gauge
Removing
Õ - Secure counter-hold tool VW 558 to the drive plate with a

hexagon bolt M8x45. Place two M10 hexagon nuts -1- between
counter-hold tool and drive plate.
- Mark position of drive plate relative to engine.
- Loosen securing bolts on drive plate.

Installing
4A
Õ - Locate drive plate with shim -2- and packing plate -1- .The lug
-arrow- must face towards torque converter.
- Insert at least 3 old securing bolts and tighten to 30 Nm.
Õ - Measure distance -a- at three points and calculate average

value.
- Specified distance: 26 ... 28 mm
If the specification is exceeded:
4A
Õ - Remove drive plate again and install without shim -2-. Tighten
bolts to 30 Nm again.
- Measure distance again.

If the specification is attained:
- Fit new bolts and tighten.
Tightening torque
Component Nm
Drive plate to crankshaft 60 + 90°1)
1)90°= 1/4turn
Removing and installing crankshaft
Note:
Secure engine to engine bracket VW

540 on assembly stand when
dismantling/assembling engine.
1 - Thrust washers
For bearing 3
Different versions for cylinder
block and bearing cap
Note fixing arrangement
2 - Bearing shell
Bearing shell with oil groove for
cylinder block
Do not interchange used bearing
shells (mark with waterproof pen)
3 - Crankshaft
Axial clearance new: 0.07...0.17
mm
Wear limit: 0.37 mm
Check radial clearance with
Plastigage
New: 0.03...0.08 mm
Wear limit: 0.17 mm
Do not rotate the crankshaft when
checking the radial clearance
Crankshaft dimensions
=> Page 13-56
4 - Bearing shell
Bearing shell without oil groove for
bearing cap
5 - Thrust washers
For bearing 3 bearing cap
Different versions for cylinder
block and bearing cap
Note fixing arrangement
6 - 65 Nm + 1/4turn (90 °) further
Renewing
When measuring radial clearance
of crankshaft, tighten to 65 Nm but
do not turn further
7 - Bearing cap
Bearing cap 1: Pulley end
Bearing cap 3 with recesses for
thrust washers
Bearing shell retaining lugs
(cylinder block/bearing cap) must be
on the same side
8 - 10 Nm + 1/4 turn (90 °) further

Renew
Always renew sender wheel if
bolts have been unscrewed
=>Fig.1, Page 13-52
9 - Needle bearing
Pulling out and driving in
=> Page 13-53
10 - Sender wheel
For engine speed sender (G28)
Always renew sender wheel if
securing bolts have been
unscrewed
=>Fig. 1, Page 13-52
11 - Fitted pin
Checking projection from
crankshaft=>Fig. 2, Page 13-52
4A 1Z
Õ Fig.1Removing and installing senderCUT
wheel
- Always renew sender wheel -2- if securing bolts -1- have been
unscrewed.
Notes:
If the securing bolts are tightened a second time, the seats for
the countersunk bolt heads in the sender wheel will be distorted
to such an extent that the bolt heads will come into direct
contact with the crankshaft -3- (-arrows-) and the sender wheel
will only fit loosely under the bolts.
The mounting holes are asymmetrically spaced, so it is only

possible to install the sender wheel in one position.
Tightening torque
Component Nm
Sender wheel to crankshaft 10 + 90° 1)2)
1)Renew bolts
2)90° is a quarter turn
Õ Fig. 2Checking dowel pin projection out of crankshaft
Dowel pin projection -3- out of crankshaft
a =2.5...3.0 mm
Removing and installing needle bearing in crankshaft
Drift VW 207 C
Special tool Kukko 21/1 (Item 1) and Kukko 22/1 (Item 4)

Notes:
A needle bearing must be fitted in the crankshaft on vehicles

with manual gearbox. Install needle bearing if necessary.
The needle bearing must not be fitted in the crankshaft on

vehicles with automatic gearbox. Remove needle bearing if
necessary.
Removing
4A
Õ - Pull out needle bearing using Kukko 21/1 and Kukko 22/1.
Installing
Õ - Knock in with drift VW 207 C or centring mandrel 3176.

- Lettering on needle bearing must be visible when installed.
4A Õ Installation depth for needle
1Z bearing
Distance a = 1.5 mm
Crankshaft dimensions
(in mm)
Honing dimension Main journal dia. Conrod journal

dia.
-0.022 -0.022
Basic dimension 54.00 47.80
-0.042 -0.042
-0.022 -0.022
1st undersize 53.75 47.55
-0.042 -0.042
-0.022 -0.022
2nd undersize 53.50 47.30
-0.042 -0.042
-0.022 -0.022
3rd undersize 53.25 47.05
-0.042 -0.042
Dismantling and assembling pistons
and conrods
Note:
Vehicles can be fitted with two different

types of conrods:
Conrods with fitted pin -item 8-: use

conrod bolts without centring location.
Conrods without fitted pin: use conrod

bolts with centring location(fitted bolts).
1 - 7 Nm
Version fitted>06.96
Apply sealant AMV 188 001 02
when installing
2 - Oil spray jet

For piston cooling
With pressure relief valve
(opens at 1.3 ... 1.6 bar)
3 - Pressure relief valve, 27 Nm
Version fitted 07.96>(phased in)
opens at:
1.3 ... 1.6 bar
Do not apply locking fluid
4 - Oil spray jet

For piston cooling
Version fitted 07.96>(phased in)
5 - Bearing shell
Note installation position
Ensure retaining lugs fit tightly in
recesses
Axial clearance
Wear limit: 0.37 mm
Plastigage:
Wear limit: 0.08 mm
Do not rotate crankshaft when
checking radial clearance
6 - Cylinder block
Checking cylinder bores
=>Fig. 4, Page 13-64
Piston and cylinder dimensions
=>Page 13-68
7 - Bearing shell
Ensure retaining lugs fit tightly in
recesses
Axial clearance
Wear limit: 0.37 mm
Plastigage:
Wear limit: 0.08 mm
Do not rotate crankshaft when
checking radial clearance
8 - Fitted pin
See note
=>Page 13-57
The fitted pin must seat securely in
the conrod, not in the bearing cap
9 - Conrod
See note
=>Page 13-57
Only renew as a set
Mark cylinder number -A-
Installation position:
Marking -B- faces towards pulley
end
10 - Circlip
11 - Piston pin
If difficult to move, heat piston to
approx. 60 °C
Remove and install with VW 222a
12 - Piston
With combustion chamber
Checking=>Fig. 3, Page 13-64
Mark installation position/cylinder
number=> Fig.5, Page 13-65
Renew piston if there are cracks in
piston skirt
Arrow on piston crown points to
pulley end
Install using piston ring clamp
Checking piston projection at TDC
=>Page 13-66
=>Page 13-68
13 - Piston ring
Offset gaps by 120 °
Remove and install with piston ring
pliers
"TOP" must face towards piston
crown
Checking ring gap
=>Fig. 1, Page 13-63
Checking ring-to-groove clearance
=>Fig. 2, Page 13-63
14 - Conrod bearing cap

Mark cylinder number -A-
Marking -B- faces towards pulley
end
15 - Conrod bolt, 30 Nm + 1/4 turn (90

°) further
See note
=>Page 13-57
Renew
Oil threads and contact surface
To measure radial clearance use
old bolts
4A 1Zring gap
Õ Fig. 1Checking piston
- Push ring squarely from above down to approx. 15 mm from

bottom end of cylinder.
Piston ring New Wear limit

Dimensions in mm
1st compression ring 0.20...0.40 1.0
2nd compression ring 0.20...0.40 1.0
Oil scraper ring 0.25...0.50 1.0
Õ Fig. 2Checking ring to groove clearance
- Clean groove before checking clearance.
Piston ring New Wear limit

Dimensions in mm
1st compression ring 0.06...0.09 0.25
2nd compression ring 0.05...0.08 0.25
Oil scraper ring 0.03...0.06 0.15
4A Õ Fig. 3Checking piston
- Measure pistons approx. 10 mm from lower edge of skirt, at 90°

to the piston pin axis.
- Deviation from nominal dimension
not more than 0.04 mm
4A 1Z bores
Õ Fig. 4Checking cylinder
Internal dial gauge 50...100 mm
- Take measurements at 3 positions in both lateral -A- and

longitudinal -B- directions.
- Deviation from nominal dimension
not more than 0.10 mm
4A 1Z position andCUT
Õ Fig.5Piston installation piston/cylinder
allocation
- Mark installation position and cylinder number on inside of

pistons (not on piston crown) with electric scriber or felt-tip pen.
- Pistons in cylinders 1 and 2: larger recess for inlet valve
-arrows- goes towards flywheel end
- Pistons in cylinders 3 and 4: larger recess for inlet valve
-arrows- goes towards pulley end
Note:
On new pistons, allocation to cylinders is shown by a coloured

marking on the piston crown.
Piston for cylinder 1 and 2:

marked 1/2
Piston for cylinder 3 and 4:

marked 3/4
Arrowon piston crown points to pulley end

Checking piston projection at TDC
Special tool VW 382/7
Special tool VW 385/17

4A Õ The piston projection at
1ZTDC must be measured
CUT when MICLEF
installing
new pistons or a short engine. Install the correct cylinder head
gasket for the piston projection - see table below.
Piston projection above top Gasket identification

surface of cylinder block (No. of holes)
0.91 mm ... 1.00 mm 1
1.01 mm ... 1.10 mm 2
1.11 mm ... 1.20 mm 3
4A Õ Cylinder head gasket1Z
identification
Part No. = arrow 1
Holes = arrow 2
Production code = arrow 3 (can be disregarded)
Notes:
If different values are measured at individual cylinders when

checking piston projection, select the gasket for the highest
value.
Installation position: marking "OBEN / TOP" or Part No. goes

towards cylinder head.
Honing Piston dia. Cylinder bore

dimension
Basic dimen. mm 79.47 79.51
1st oversize mm 79.72 79.76
2nd oversize mm 79.97 80.01
Removing and installing cylinder head
Notes:
Cylinder heads which have cracks between the valve seats

can continue to be used without reducing service life, provided
there are only small cracks not wider than 0.5 mm.
When fitting a new cylinder head or cylinder head gasket,

drain off all the old coolant and re-fill with new coolant.
The cylinder head on a diesel engine must not be reworked.
When installing an exchange cylinder head with fitted

camshaft, the contact surfaces between tappets and cams
must be oiled after installing the head.
The plastic protectors fitted to protect the open valves must

only be removed immediately before fitting the cylinder head.
Before applying sealant, check updated information:
=> Parts catalogue

1 - Cylinder head
Removing => Page 15-13
Check for distortion
=>Fig. 1, Page 15-6
Installing => Page 15-23
After replacing, fill with fresh
coolant
2 - 25 Nm
3 - Lifting eye
4 - Lower sealing cone
5 - Cylinder head cover gasket

Renew if damaged or leaking
Before fitting gasket apply
AMV 174 004 01at sealing points
=>Fig.3and Fig. 4, Page 15-7
Fit projections into drill holes on
cylinder head
6 - Cylinder head cover
=> Page 15-8
7 - Upper sealing washer

Renew if damaged
8 - Dished washer
9 - 10 Nm
10 - Cover cap
11 - Gasket
Renew if damaged or leaking
12 - Fillercap
13 - Breather hose
14 - Hose clip
After fitting hose clip on hose,
engage in retaining tab on cylinder
head cover
15 - Pressure regulating valve
For crankcase breather
16 - Gasket
Renew if damaged
17 - Cylinder head bolt

Renew
Note sequence when loosening
=> Page 15-22
Note sequence when tightening
=> Page 15-26
18 - Injector pipes
Tighten to 25 Nm
Remove with 3035
Always remove pipework complete
Do not alter shape
19 - 10 Nm
20 - Coolant flange
With coolant temperature sender
21 - O ring
Renew
22 - Coolant flange
23 - 10 Nm
24 - Connector
For needle lift sender -G80
25 - Return pipe
To injection pump
26 - Cylinder head gasket

Different thicknesses
Note marking
=>Fig. 2, Page 15-6
Renew => Removing cylinder
head, from Page 15-13onwards
Position: Marking "OBEN / TOP"
or Part No. towards cylinder head
After replacing, fill with fresh
coolant
4A 1Z head for distortion
Õ Fig. 1Checking cylinder CUT
- Use knife-edge straightedge and feeler gauge to measure at

several points.
- Max. permissible distortion: 0.1 mm
Note:
Reworking Diesel cylinder heads is not permissible.

4A 1Z
Õ Fig.2Cylinder head gasket CUT
identification
Part No. = arrow 1
Holes = arrow 2
Production code = arrow 3 (can be disregarded)
Notes:
Cylinder head gaskets of different thicknesses must be

installed according to the amount of piston projection=>Page
13-66. When only the gasket is being replaced, install a new
gasket with the same identification as the old one.
Installation position: marking "OBEN / TOP" or Part No. goes

towards cylinder head.
4A 1Zjoint between CUT
Õ Fig. 3Sealing sides of bearing cap and
cylinder head
- Apply a small quantity of sealant "AMV 174 004 01" to sides of

joints -arrows- on upper sealing surface of cylinder head.
Õ Fig. 4Sealing sides of joint
- Apply a small quantity of sealant "AMV 174 004 01" to sides of

joints -arrows- on upper sealing surface of cylinder head.
Removing and installing cylinder head cover
Removing
Õ - Slacken hose clamps -arrows- and disconnectcrankcase

breather hoses from pressure control valve.
Õ - Pull off caps -7-.
- Loosen nuts -6- on cylinder head cover.
- Take off dished washer -5- and upper sealing washer -4-.
- Remove cylinder head cover -3-.
- Remove gasket -2- and lower sealing cone -1-.

Installing

note the following:
If damaged, fit new cylinder head cover gasket, upper sealing
washer and sealing cone.
Õ - Apply a small quantity of sealant "AMV 174 004 01" to sides of

joints -arrows- on upper sealing surface on cylinder head.
Õ - Apply a small quantity of sealant "AMV 174 004 01" to sides of

joints -arrows- on upper sealing surface on cylinder head.
- Position cylinder head cover (with attached parts).

Tightening torque
Component Nm
Cylinder head cover to cylinder head 10
Removing and installing intake manifold
Removing
- Remove turbocharger =>Page 21-29.
Õ - Slacken hose clamp -1-.
- Unscrew bolts -arrows-.
Õ - Unscrew nuts -1- and remove heat shield.
- Unscrew bolts -arrows-.
- Remove intake manifold.

Installing
Installation is performed in the reverse order.
Tightening torques
Component Nm
Intake manifold to cylinder head 25
Heat shield to exhaust manifold 25
Mechanical exhaust gas recirculation valve to intake
manifold 25
Removing cylinder head

equipment required
Mandrel 2064
Setting bar 2065 A
Open ring spanner 3035
Counterhold tool 3036
Guide pin 3070
V.A.G 1306
Work sequence
z Engine in vehicle
Note:
All cable ties which are released or cut open when removing
must be fitted in the same position when installing.
- Obtain radio code on vehicles with coded radio.
- With ignition switched off disconnect battery earth strap.
Warning!

cleaner housing.

recirculation valve -3-.
- Disconnect thin hose -6- from bottom of exhaust gas

recirculation valve -N18.
- Detach air hose at air mass meter.

4A
- Remove upper section of air cleaner housing together with air
mass meter.
Õ - Unscrew charge pressure control solenoid valve -2- from air

pipe -1-. Leave hoses connected.
- Remove air pipe -1- between charge air cooler and intake
manifold.
- Remove air intake hose between charge air cooler and

turbocharger.

-arrows-.

turbocharger.
Note:
Tie up flange of front exhaust pipe on right suspension turret with

wire. It is then not necessary to remove front exhaust pipe.
Õ - Remove noise insulation (two sections -arrows-).
- Place a drip tray underneath.
Õ - Detach oil return pipe from cylinder block -arrow-.
- Draincooling system=> Page 19-4

Õ - Disconnect fuel return hose -1- between injectors and injection
pump.
- Disconnect connectors-2 ...5-.
- Disengage connector for engine speed sender from its retainer.
- Disconnect coolant hose at rear of cylinder head -arrow-.
- Remove injector pipes.

Note:
Always remove complete set of injector pipes together. Use

special spanner for injector pipes 3035.
- Unplug connectors from glow plugs.
Õ - Disconnect coolant hoses -arrows- on left side of cylinder head.

900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -7-
manual gearbox).

automatic gearbox).
Õ - Lock camshaft with setting bar 2065 A.
- Remove toothed belt guard (upper) => Page 13-14.
Õ - Unscrew 2 bolts -arrows- securing rear toothed belt guard on

both sides of cylinder head.
- Take toothed belt off camshaft sprocket.
- Remove toothed belt tensioning roller.

Note:


- Remove camshaft sprocket.

4A 1Z CUT MICLEF - 10 -
Õ - Keep to specified sequence when loosening cylinder head bolts.
- With a second mechanic, lift cylinder head up slightly and

swivel out to the rear.
4A 1Z
Installing cylinder head CUT MICLEF -1-
Notes:
Always renew cylinder head bolts when assembling.
When performing repairs, renew seals, gaskets, self-locking

nuts and bolts which have a specified tightening angle.
If repairing, carefully remove any remains of gasket material

from the cylinder head and cylinder block. Make sure that no
long scores or scratches are made on the surfaces.
Carefully remove any remaining emery and abrasive material.
No oil or coolant must be allowed to remain in the blind holes

for the cylinder head bolts in the cylinder block.
Remove new cylinder head gasket from packaging just before

installation.
Handle gasket extremely carefully. Damaging the silicone

layer or the indented area will lead to leaks.
After working on the valve gear, turn the engine carefully at

least 2 rotations to ensure that none of the valves make contact
when the starter is operated.

note the following:
Õ - Turn crankshaft and camshaft to TDC of cylinder No. 1 before
fitting cylinder head. It should be possible to insert setting bar
2065 A in camshaft ....
Õ - ... and TDC marking should be in line with reference edge.

Note:
Illustration shows vehicle with manual gearbox.

Õ - Check identification on cylinder head gasket:
- Part No. = arrow 1
- Holes = arrow 2
- Production code = arrow 3 (can be disregarded)
Notes:
If the cylinder head gasket or the cylinder head has been

replaced, select a new gasket according to the number of holes
on the old gasket.
If parts of the crankshaft drive have been replaced, the new

cylinder head gasket must be selected by measuring the piston
projection at TDC => 13-66.
Õ - To centre, screw guide pins 3070/9 from 3070 into the outer
holes in the cylinder block.
- Place cylinder head gasket in position.

- Check that centring sleeve in cylinder block is fitted correctly.
- Check installation position of cylinder head gasket: the word
"oben" (top) or the Part No. should face towards the cylinder
head.
- Place cylinder head in position.
- Screw in 8 cylinder head bolts and tighten by hand.
- Unscrew guide pins with removal tool from 3070 through bolt
holes in cylinder head and install remaining cylinder head bolts.
Õ - Tighten cylinder head bolts in four stages in sequence shown

as follows:
- Tighten using torque wrench:

- 1st stage: 40 Nm
- 2nd stage: 60 Nm
- TIghten with normal fixed wrench:

- 3rd stage:1/4 turn (90°) further
- 4th stage: 1/4 turn (90°) further
Note:
It is not necessary to tighten cylinder head bolts again later after

repairs have been performed.
Note:
Follow all instructions for removing and installing toothed belt
=>Page 13-20.
- Install cylinder head cover =>Page 15-9.

900058 Type Type description - Aligning
MY exhaust system
Engine
freeIDof stressGearbox
=> ID User Workshop Manual
4A Page 26-10. 1Z CUT MICLEF -5-
- Fill cooling system with fresh coolant => Page 19-7.
- After connecting battery, enter anti-theft code for radio
=> Radio operating instructions
- Close windows fully using electric window switches.
- Then operate all electric window switches again for at least one
second in the "close" direction to activate the automatic one
-touch function.
- Set clock to correct time.
Tightening torques
Component Nm
Oil return pipe to cylinder block 30
Injector pipes to injectors/
injection pump 25
Idler wheel to console 25
Toothed belt sprocket to camshaft 45
Hose clamps 2
4A 1ZChecking compression
CUT MICLEF
pressure -1-

equipment required
Special tool 3220
V.A.G 1763
V.A.G 1381/12
Requirements for test:

z Engine oil temperature not less than 30 °C
z Battery voltage not less than 12 V

Test sequence
- Unplug connector for fuel cut-off valve on injection pump.
- Disconnect connector to quantity adjuster on injection pump.
- Remove all glow plugs using socket spanner 3220.
Õ - Screw in adapter V.A.G 1381/12 in place of the glow plugs.
- Check compressions with compression tester

V.A.G 1381/V.A.G 1763.
Note:
Using the compression tester
=> Operating instructions
- Operate starter until tester shows no further pressure increase.
Compression pressure:
New Wear limit Permissible difference

between cylinders
bar bar
bar
25 ... 31 19 max. 5
- Install glow plugs with jointed spanner 3220

Tightening torque: 15 Nm.
- Interrogate and erase fault memory:

=> Repair group 01; Interrogating and erasing fault memory=>
Note:
Faults will have been stored in the memory because connectors

have been unplugged from the injection pump. Interrogate and
erase fault memory after checking compression.
Tightening torque
Component Nm
Glow plugs in cylinder head 15
4A Servicing valve gear 1Z CUT MICLEF -1-
Notes:
Cylinder heads which have cracks between the valve seats

can continue to be used without reducing service life, provided
there are only small cracks not more than 0.5 mm wide.
After installing the camshaft, wait for about 30 minutes before

starting the engine. The hydraulic tappets must be allowed to
settle, otherwise the valves will contact the pistons.

Renew all gaskets and seals.
=> Parts catalogue

1 - Cylinder head
See note
=> Page 15-32
Checking valve guides
=>Page 15-54
Reworking valve seats
=> Page 15-51
2 - Oil seal
To remove and install, remove
bearing cap and camshaft sprocket
Removing and installing toothed
belt =>Page 13-20and13-26
3 - Camshaft sprocket
Take off toothed belt before
removing and installing =>Page
13-20or 13-26
Drive off camshaft taper using
hammer and drift through toothed
belt guard openings
4 - 45 Nm
Counter-hold with 3036 to loosen
and tighten
5 - 20 Nm
6 - Bearing cap
=>Fig. 1, Page 15-38
Installation sequence
=> Page 15-40, removing and
installing camshaft
Before installing first bearing cap,
apply a thin coat of sealant "D 454
300 A2" to contact surfaces
ApplyAMV 174 004 01at sealing
points=>Fig.3and Fig.4, Page 15-7
7 - Camshaft
Checking axial clearance
=> 15-39
=> Page 15-40
Plastigage
Wear limit: 0.11 mm
Run-out: max. 0.01 mm
8 - Hydraulic bucket tappet

Checking => Page 15-46
=> Page 15-48
Do not interchange
Store with cam contact surface
downwards
Before installing check camshaft
axial clearance
=> Page 15-39
Oil contact surface
9 - Valve cotters
10 - Upper valve spring plate
11 - Outer valve spring

with cylinder head removed:
use 2037
with head installed: => Page 15-48
12 - Inner valve spring

with cylinder head removed:
use 2037
with head installed: => Page 15-48
13 - Valve stem seal

Renewing=> Page 15-48
14 - Valve guide
Renew cylinder head if wear limit
is exceeded
15 - Lower valve spring plate
Use puller 3047 A to remove and
install
16 - Valve
Do not rework; only lapping-in is
permitted
Valve dimensions
=>Fig. 2, Page 15-38
4A Õ Fig. 1Fitting position1Z CUT caps
of camshaft bearing MICLEF -7-
Note offset. Before installing camshaft fit bearing caps and

determine fitting position.
Õ Fig. 2Valve dimensions
Note:
Valves must not be reworked. Only lapping-in is permitted.
Dimension Inlet valve Exhaust valve

Dia. -a- mm 35.95 31.45
Dia. -b- mm 6.963 6.943
c mm 96.85 96.85
α <° 45 45
4A 1Z clearance CUT
Checking camshaft axial MICLEF -1-
Special tool VW 387
Dial gauge
Õ - Perform measurement with bucket tappets removed and front

and rear bearing caps fitted.
- Wear limit: 0.15 mm
4A 1Z camshaft CUT
Removing and installing MICLEF -1-
Mandrel 2064
Setting bar 2065 A

Removing
z Cylinder head installed
- Remove toothed belt guard (upper) => Page 13-14.


manual gearbox).

automatic gearbox).
Õ - Lock camshaft with setting bar 2065 A.

Note:
If the belt runs in the wrong direction when it is refitted, it can

break.
- Take toothed belt off camshaft sprocket.
Note:

- Remove camshaft sprocket.
- First remove bearing caps 1, 3 and 5. Loosen bearing caps 2

and 4 alternately and diagonally.
Installing

note the following:
Notes:
Renew camshaft oil seal.
When installing the camshaft No. 1 cylinder cams must point

upwards.
Õ When installing the bearing cap note offset. Before installing

camshaft, fit bearing caps and determine correct position.
- Oil camshaft running surfaces.
- Tighten bearing caps 2 and 4 alternately and

diagonally to 20 Nm.
- Install bearing caps 5, 1 and 3 and also tighten to 20 Nm.

Notes:
Follow all instructions for removing and installing toothed belt

=>Page 13-20onwards.


- Install cylinder head cover =>Page 15-9.
- Check injection pump commencement of delivery (dynamic)

4A => Diesel direct injection
1Z and glow plugCUT
system (4-cylinder
MICLEF
TDI); -5-
=> Dynamically checking and adjusting commencement of

injection
Tightening torque
Component Nm
Bearing caps to cylinder head 20
4A 1Z
Checking hydraulic bucket tappets CUT MICLEF -1-
Feeler gauge
Wood or plastic wedge
Notes:
Hydraulic tappets cannot be adjusted or repaired.
Irregular valve noises when starting engine are normal.
- Start engine and run until coolant temperature reaches approx.

80 °C.
- Increase engine speed to about 2500 rpm for 2 minutes

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

short journeys, a new oil retention valve must be fitted. The oil
retention valve is located in the oil filter bracket.
If the hydraulic tappets are still noisy, locate defective tappets as

follows:
- Rotate crankshaft until cams of cylinder to be checked are

pointing upwards.
- Determine play between cam and bucket tappet.

Õ - Press tappet down with a wooden or plastic wedge. If an 0.20
mm feeler gauge can be inserted between camshaft and tappet,
renew tappet.
- Renewing tappets, => Removing camshaft, Page 15-40.

Notes:


4A 1ZRenewing valve
CUTstem seals MICLEF -1-

equipment required
Valve lever VW 541/1A with thrust

piece VW 541/5
Fitting tool 2036
Puller 3047 A
Fitting tool 3129
Removing
z Cylinder head installed
- Remove camshaft => Page 15-40.

- Remove the bucket tappets and put them down with the
contact surface downwards. When doing this ensure that the
tappets are not interchanged.
- Set piston of respective cylinder to top dead centre (TDC).
Õ - Position fitting tool 2036 with shaft parallel to sealing edge of

cylinder head cover. Tighten bolts to secure fitting tool.
- Adjust shaft of fitting tool so that it is level with the studs for the
bearing caps.
- Remove valve springs with lever VW 541/1A.

Note:
The valves are supported by the piston crown.
Õ - Pull off valve stem seals with 3047 A.
Installing
Õ - To prevent damage to the new valve stem seals -B-, place
plastic sleeve -A- on valve stem.
- Lightly oil sealing lip of valve stem seal.
- Insert valve stem seal in the tool 3129 and push it down
carefully onto the valve guide.
- Remove plastic sleeve.
- Install camshaft => Page 15-44.

Notes:


4A 1Z
Reworking valve seats CUT MICLEF -1-
Note:
If a good seating pattern cannot be obtained by grinding the

valve seats (lapping), they must be refaced (reworked):
Depth gauge
Valve seat refacing tool
Notes:
When repairing engines with leaking valves, it is not sufficient

to reface the valve seats and renew the valves. The valve
guides must also be checked for wear. This is particularly
important on high mileage engines =>Page 15-54.
The valve seats should only be reworked just enough to

produce a perfect seating pattern.
Calculate the maximum permissible reworking dimension

before reworking.
If the maximum permissible reworking dimension is 0 mm or

less than 0 mm, measure again with a new valve. If it is still 0
mm or less than 0 mm, the cylinder head must be replaced.
Calculating max. permissible reworking dimension
- Insert valve and press it firmly against valve seat.
Note:
If the valve is to be renewed as part of a repair, use a new valve

for the calculation.
Õ - Measure distance -a- between end of valve stem and upper
edge of cylinder head.
- Calculate max. permissible reworking dimension from

measured distance -a- and minimum dimension.
Minimum dimension:
Inlet valve 35.8 mm
Exhaust valve 36.1 mm
Measured distance minus minimum dimension

= max. permissible reworking dimension.
Example:
Measured distance 36.5 mm

- Minimum dimension 35.8 mm
= max. perm. rework dimension 0.7 mm
Õ Reworking inlet valve seat
a = 35.7 mm ш
b = 1.6 mm
45 ° = Valve seat angle
Note:
The 30 ° lower valve seat chamfer is required for gas flow

characteristics in the inlet port.
4A 1Z seat
Õ Reworking exhaust valve CUT MICLEF -3-
a = 31.4 mm ш
b = 2.7 mm
45 ° = Valve seat angle
4A 1Z
Checking valve guides CUT MICLEF -1-
Special tool VW 387
Dial gauge
Õ - Insert valve into valve guide until end of valve stem is flush with
end of guide. Due to the slight difference in stem diameters,
ensure that only an inlet valve is used in the inlet guide and an
exhaust valve in the exhaust guide.
Wear limit
Notes:
If the wear limit is exceeded, repeat the measurement with

new valves. If the wear limit is again exceeded, renew the
cylinder head.
Amount of sideways play: not more than 1.3 mm If the valve is to be renewed as part of a repair, use a new
valve for the calculation.
4A 1Z parts of theCUT
Removing and installing MICLEF
lubrication system -1-
Notes:
If large quantities of metal shavings or particles are found in

the engine oil when repairing the engine, the oil passages must
be cleaned carefully, and the oil cooler renewed in order to
prevent further damage occurring later.
The oil level must not be above the max. mark - danger of
damage to catalytic converter.
=> Parts catalogue
Viscosity grades and oil specifications:
=> Maintenance
Oil system capacity:
=> Binder "Emissions test"

4A 1ZPart I CUT MICLEF -1-
1 - Oil drain plug, 30 Nm
2 - Gasket
Renew
3 - 18 Nm
Tighten in stages and in diagonal
sequence
4 - Gasket
Renew
Install dry
Apply a small amount of sealant
"AMV 174 004 01" only to sealing
points between sealing flange and
cylinder block (front and rear)
5 - 10 Nm
6 - Suction pipe
Clean strainer if soiled
7 - O ring
Renew
8 - Pressure relief valve, 27 Nm

opens at:
1.3 ... 1.6 bar
Do not apply locking fluid
Version fitted 07.96 >(phased in)
9 - Oil spray jet

For piston cooling
Version fitted 07.96 >(phased in)
=>-Item 2-, Page 13-57
10 - Gears
Checking backlash
=>Fig. 1, Page 17-8
Checking axial clearance
=>Fig. 2, Page 17-8
11 - Oil pump cover with pressure
relief valve
Opening pressure: 5.7...6.7 bar
12 - 10 Nm
13 - 25 Nm
14 - Sump
=> Page 17-9
Clean sealing surface before
installing
Before installing sump, apply a
small amount of sealant
"AMV 174 004 01" to sealing points
block
15 - Engine/gearbox support
Remove support in order to
remove sump => Page 17-9
When installing engine/gearbox
support with engine removed from
vehicle, ensure that support is
positioned flush with intermediate
plate at flywheel end (i.e. engine/
gearbox support should protrude 0.8
mm from cylinder block).
16 - 45 Nm
4A 1ZPart II CUT MICLEF -1-
1 - Oil filter
Observe change intervals
=> Maintenance manual
Loosen with strap wrench
Observe installation instructions on
oil filter
2 - 25 Nm
3 - Oil cooler
See note
=> Page 17-1
Coolant hose connection diagram
=>Page 19-2
4 - 25 Nm
5 - Oil filter bracket
6 - Gasket
Renew
7 - 0.9 bar oil pressure switch -F1
- 25 Nm
Grey
8 - Seal
If seal is leaking, cut open and
renew.
9 - Oil temperature sender -G8

-10 Nm
10 - Seal
If seal is leaking, cut open and
renew.
11 - O ring
Renew
Engage in projections on oil cooler
4A 1Z backlash CUT
Õ Fig. 1Checking oil pump MICLEF -3-
New: 0.05 mm
Wear limit: 0.20 mm
Õ Fig. 2Checking oil pump axial clearance
Wear limit: 0.15 mm

4A 1Z sump
Removing and installing CUT MICLEF -1-
Workshop crane V.A.G 1202 A
Drip tray
Sealant AMV174 004 01

Removing
Õ - Remove noise insulation (two sections, -arrows-).
- Drain engine oil.

Õ - Support subframe with workshop crane V.A.G 1202 A.
Õ - Unscrew retaining clamps -arrows- for starter cable from

subframe.
- Unscrew front subframe bolts -1- and -2-.

Note:
The subframe should be detached and lowered only at the front,

otherwise it will be necessary to check wheel alignment.
Õ - Lower subframe slowly using workshop crane V.A.G 1202 A.
Õ - Unscrew bolts -1 ... 8- from engine/gearbox support.
- Take off engine/gearbox support.
- Unbolt and remove sump: if necessary loosen it by striking

lightly with a rubber hammer.
Installing

note the following:
4A Notes: 1Z CUT MICLEF -4-
Renew seals and gaskets.
Õ When installing the engine and gearbox support -3- with the
engine removed from the vehicle, make sure that the support is
positioned flush with the intermediate plate -1- at the flywheel
end. In other words, the engine/gearbox support should
protrude by 0.8 mm (distance a) from cylinder block -2-.
- Clean sealing surfaces before installing sump.
- Lightly coat the sealing points for the sump between sealing
flange and cylinder block (at front and rear) using AMV 174 004
01.
- Tighten bolts securing sump to cylinder block in diagonal

sequence and in two stages, tightening to 18 Nm at second
stage.
- Installsubframe
=> Running gear, Front-wheel drive and four-wheel drive;
=> Repair group 40; Servicing front suspension;=>
=> Removing and installing subframe
- Fill up with engine oil and check oil level.
Tightening torques
4A Õ Attachments of engine/gearbox
1Z supportCUT MICLEF -5-
Item No. Bolt Nm

1 M10 x 28 45
2, 4, 5 1) M10 x 45 45
3, 7 M10 x 95 45
6 M10 x 50 45
8 M10 x 65 45
1)Vehicles up to approx. 07.96: M8 bolt; tightening torque 25 Nm
Component Nm
Sump to cylinder block1) 18
Oil drain plug 30
1)Special
bolts; use only correct type (same as original
equipment)
=> Parts catalogue

4A 1Z oil pump CUT
Removing and installing MICLEF -1-
Removing
- Remove sump => Page 17-9.
Õ - Loosen bolts -arrows-.
- Take off oil pump.

Installing

note the following:
- Installing sump => Page 17-12.
Tightening torque
Component Nm
Oil pump to cylinder block 25
4A 1ZTesting oil pressure
CUT and oil pressure
MICLEF -1-
switch

equipment required
V.A.G 1342
V.A.G 1527 B
V.A.G 1594 A
z Oil level ok.
z Oil pressure warning lamp -K3 must come on when ignition is

900058 Type Type description switched
MY on. Engine ID Gearbox ID User Workshop Manual
z In vehicles with auto-check system the "OK" display must
appear (call up symbol).
z Engine oil temperature approx. 80 °C
Testing warning lamp
The oil pressure warning lamp lights up when the ignition is

switched on ("terminal 15 on") with the engine not running (this
does not apply to vehicles with auto-check system).
Testing oil pressure switch
- Disconnect wire from oil pressure switch.
Õ - Unscrew oil pressure switch and screw in oil pressure tester V.

A.G 1342.
- Screw oil pressure switch -2- intoV.A.G 1342.
- Connect brown wire -1- of tester to earth (-).
- Connect voltage tester V.A.G 1527 B to oil pressure switch and

positive side of battery (+) using test leads from V.A.G 1594 A.
- Test lamp should not light up
- If test lamp lights up, renew oil pressure switch.
- Start engine
Note:
The switching point of the oil pressure switch can be reached

when the engine is cranked on the starter motor, so watch the
tester and the test lamp while starting the engine.
- Test lamp should light up at 0.75...1.05 bar.
If test lamp does not light up, renew oil pressure switch.
Testing oil pressure
- Disconnect wire from oil pressure switch.

Õ - Unscrew oil pressure switch and screw in oil pressure tester V.
A.G 1342.
- Screw oil pressure switch -2- intoV.A.G 1342.
- Start engine (engine oil temperature at least 80°C).

- Oil pressure at 2000 rpm: at least 2.0 bar
- Oil pressure at higher engine speeds: max. 7.0 bar
If the specifications are not obtained:
- Pressure relief valve or oil pump defective; renew oil pump =>
Page 17-14.
4A Engine oil 1Z CUT MICLEF -1-
A high-quality multigrade oil is put in at the factory: this can be

used all year round, except in extremely cold climates.
Viscosity grades and oil specifications
Viscosity grades and oil specifications:
=> Maintenance
4A Checking oil level 1Z CUT MICLEF -1-
z Engine oil temperature at least 60 °C
z Vehicle must be level (horizontal)
z After switching off the engine, wait a few minutes to allow the
oil to flow back into the sump.
Test sequence
- Pull out the dipstick, wipe off with a clean cloth and insert it
again as far as it will go.
- Pull out the dipstick again and read off the oil level.
Õ Markings on oil dipstick:
a -Do not top up oil.
b -Oil can be topped up. The oil level may rise as far as area -a-
after topping up.
c -Oil must be topped up. It is sufficient if the oil level is

somewhere in area -b- (grooved area on dipstick) after topping
up.
Note:
The oil level must not be above marking -a- on the dipstick.
4A 1Z parts of cooling
Removing and installing CUT system MICLEF -1-
Warning!
Notes:
When the engine is warm the cooling system is under

pressure. If necessary release pressure before commencing
repair work.
=> Parts catalogue
V.A.G 1921 pliers are recommended when installing spring

-type clips.
Renew all gaskets and seals.
The arrow markings on the coolant pipes and on the ends of

the hoses must be aligned with each other.
4A 1ZParts of cooling
CUTsystem MICLEF -1-
Diagram of coolant hose connections
1 - Radiator
=> Page 19-18
After replacing, fill system with
fresh coolant
2 - Return pipe
To expansion tank
3 - Expansion tank
4 - Fillercap
With pressure relief valve
Testing pressure relief valve
=>Page 19-23
5 - Oil cooler
=>Page 17-6, item 3
6 - Return pipe
From heat exchanger (for heater)
7 - Heating system heat exchanger

After replacing, fill system with
fresh coolant
8 - Supply pipe
To heat exchanger
9 - Coolant pump/coolant thermostat

Removing and installing coolant
pump =>Page 19-11
Check for ease of movement
Removing and installing coolant
thermostat =>Page 19-16
Checking =>Page 19-17
4A 1Z
Draining and filling cooling system CUT MICLEF -1-
Drip tray V.A.G 1306
Special tool T10007 (for coolant additive G 012 A8 D)

Draining
Note:
Catch drained-off coolant in a clean container for re-use or

disposal.
Warning!

Õ - Remove front section of noise insulation -lower arrows-.
- Place drip tray V.A.G 1306 below engine.
Õ - Turn drain screw -arrowon radiator anti-clockwise, if

necessary fit drain hose to connection.
Õ - To drain off remaining coolant, disconnect coolant hoses
-arrows-.
Filling
Notes:
The cooling system is filled all year round with a mixture of

water and coolant additive (combined anti-freeze and corrosion
protection agent).
Coolant additive G 011 A8 C (green) is used in vehicles up to

06.96.
Only coolant additive G 012 A8 D (red) is used in vehicles

from 07.96 onwards.
Caution
The two different coolant additives G
If the fluid in the expansion tank is brown, this means G 012

A8 D has been mixed with another type of coolant. In this case,
flush out the cooling system and put in fresh coolant. To flush
the system, fill it with clean water and run the engine for about
2 minutes. This should remove very nearly all of the old coolant.
G 011 A8 C and G 012 A8 D (and coolant additives marked

"meeting specification TL VW 774 C" or "meeting specification
TL VW 774 D") prevent frost and corrosion damage, stop
scaling and at the same time raise the boiling point of the
coolant. For these reasons the cooling system must be filled all
year round with the correct anti-freeze and anti-corrosion
additive.
Because of its high boiling point, the coolant improves engine

reliability under heavy loads, particularly in countries with
tropical climates.
Protection against frost must be assured down to about -25

°C (in countries with arctic climate downto about -35 °C).
The coolant concentration must not be reduced by adding

water even in warmer seasons and in warmer countries. The
anti-freeze ratio must be at least 40 %.
If greater frost protection is required in very cold climates, the

amount of G 012 A8 D can be increased, but only up to 60 %
(this gives frost protection to about -40 °C), as otherwise frost
900058 Type Type description protection
MY is reducedEngine
again and
ID cooling
Gearbox
effectiveness
ID User
is also Workshop Manual
4A reduced. 1Z CUT MICLEF -4-
Only use clean tap water for mixing coolant.
If radiator, heat exchanger, cylinder head or cylinder head

gasket is replaced, do not reuse old coolant.
Special tool T10007 must be used for testing the anti-freeze

concentration if the cooling system contains coolant additive
G012 A8 D.
Recommended mixture ratios:
Anti-freeze Anti-freeze G 012A8 D 1) Water 1)

protection down to concentration
-25 °C 40 % 2.60 ltr. 3.90 ltr.
-35 °C 50 % 3.25 ltr. 3.35 ltr.
1)Cooling
system capacity: 6.5 litres (may vary according to
equipment fitted on vehicle)
- Close drain screw on radiator.
Õ - Fill up with coolant to max. mark on expansion tank.
- Fit expansion tank cap.
- Start engine.
- Then run engine at idling speed until bottom hose on radiator

becomes hot.
- Check coolant level and top-up if necessary. When the engine

is at normal operating temperature, the coolant level must be
on the max. mark, when the engine is cold, between the min.
and max. marks.
Warning!
- Stop engine.
4A 1Z coolant pump
Removing
- Draincooling system=> Page 19-4.
- Slacken V-belt by turning tensioning nut -1-.
- Remove V-belt.
Õ - Unbolt vane pump for power steering complete with rear
bracket -arrows-. Do not disconnect hydraulic connections.
- Secure vane pump to body with wire to reduce load on

connections.
Õ - Disconnect coolant hoses from coolant pump and thermostat

housing -arrows-.
Õ - Detach bracket for engine cover panel below injection pump -2-.
- Unbolt bracket for vane pump-1 ... 3-.

Õ - Unbolt coolant pump housing from toothed belt guard -4-.
- Unbolt support for injection pump console -1 ... 3-.
- Remove coolant pump.
Õ - Unbolt bearing housing -1- from pump housing -4-.

Installing

note the following:
- Clean sealing surfaces on both sections of housing.
- Renew gasket and O-ring.
- Insert hammer-head bolt in drilling in coolant pump.
- Install V-belt =>Page 13-9.
Tightening torques
Component Nm
Bearing housing to pump housing 10
Pump housing to toothed belt guard 10
Vane pump bracket to cylinder block 25
Bracket for engine cover panel 25
Hose clamps 2
4A 1Z checking coolant
Removing and installing, CUT MICLEF
thermostat -1-
Removing
- Drain cooling system=> Page 19-4
- Slacken V-belt by turning tensioning nut -1-.

- Remove V-belt.
Õ - Unbolt vane pump for power steering complete with rear

bracket -arrows-. Do not disconnect hydraulic connections.
- Secure vane pump to body with wire to reduce load on

connections.
Õ - Unscrew bolts -4- and remove connection -3-, O-ring -2- and
coolant thermostat -1-.
Installing
- Clean and smooth down sealing surface for O-ring as required.
- Insert coolant thermostat.
- Install V-belt =>Page 13-9.
Tightening torques
Component Nm
Connection to pump housing 10
Hose clamps 2
Testing coolant thermostat
- Heat thermostat in water bath.
Starts to open Fully open Opening travel

approx. 87 °C approx. 102 °C1) min. 8 mm
1)cannot be tested
4A 1Z radiator
Removing
- Remove front bumper.
=> General body repairs; Repair group 63; Front bumper=>
- Drain coolant from drain plug on radiator=> Page 19-4
Õ - Disconnect both coolant hoses at bottom of radiator -arrows-.
- Unplug connector -1- from radiator fan thermoswitch -F54.
- Disconnect coolant hose at top left of radiator.

- Removing ATF pipes/hoses from radiator:
=> Automatic gearbox 01N; Repair group 37;=>
=> Dismantling and assembling gearbox; Removing and

installing ATF pipes
Warning!
Note:
To prevent damage to the condenser and refrigerant pipes/

hoses, ensure that the pipes and hoses are not stretched, kinked
or bent.
- Remove securing bolts for condenser.
- Pull condenser out of its bracket, pivot towards the side and
900058 Type Type description secure
MYwith wire. Engine ID Gearbox ID User Workshop Manual
All models
Õ - Remove securing screw -arrow A- and pull out headlight trim in

direction indicated by arrow.
Õ - Remove screw securing bracket -2- for headlight trim on
housing.
- Detach air cowls from radiator -1- and -3- (left and right).
Õ - Unscrew nuts -2- on bonded rubber mountings.
- Pull radiator forwards out of bracket for bonded rubber

mounting at the bottom ...
- ... and pull downwards out of top bracket -arrow- (if necessary,
unscrew bolt -1- on radiator support).
Installing

note the following:
Tightening torque
Component Nm
Radiator to front end M6 10
M8 20
Condenser to radiator 10
Hose clamps 2
4A 1Z for leaks CUT
Checking cooling system MICLEF -1-
V.A.G 1274 with V.A.G 1274/1
Test requirement:
z Engine at operating temperature.
Test sequence
Warning!
Hot steam can escape when opening cap on expansion tank:
Cover cap with a cloth and open carefully.
Õ - Attach tester V.A.G 1274 with adapter V.A.G 1274/1 to

expansion tank.
- Using hand pump on tester, build up a pressure of approx. 1.0

bar.
- If pressure is not maintained, trace leak and rectify fault.

Testing pressure relief valve in filler cap.
Õ - Fit tester V.A.G 1274 with adapter V.A.G 1274/1 onto filler cap.
- Operate hand pump.

- Pressure relief valve must open at 1.2 ... 1.5 bar.
4A Fuel supply system 1Z CUT MICLEF -1-
Safety precautions when working on the fuel supply system
When removing and installing the fuel gauge sender from a full
or partly full fuel tank, note the following points:
The fuel tank must not be more than2/3full.
If necessary, drain the tank according to instructions:

=> Page 20-6.
Before commencing work, switch on exhaust extraction

system and place an extraction hose close to the sender
opening in the fuel tank to extract escapingfumes.
If no exhaust extraction system is available, a radial fan (as
long as motor is not in air flow) with a displacement greater
than 15 m3/h can be used.
Avoid skin contact with fuel. Wear fuel-resistant gloves.
Drain the fuel tank before removal from the vehicle in order to
reduce weight.

=> Page 20-6.
4A 1Z working onCUT
Safety precautions when MICLEF
the fuel supply system -1-
When removing and installing the fuel gauge sender from a full
or partly full fuel tank, note the following points:
The fuel tank must not be more than2/3full.

=> Page 20-6.
Before commencing work, switch on exhaust extraction

system and place an extraction hose close to the sender
opening in the fuel tank to extract escapingfumes.
If no exhaust extraction system is available, a radial fan (as
long as motor is not in air flow) with a displacement greater
than 15 m3/h can be used.
Avoid skin contact with fuel. Wear fuel-resistant gloves.
Drain the fuel tank before removal from the vehicle in order to
reduce weight.

=> Page 20-6.
4A Rules for cleanliness1Z CUT MICLEF -1-
When working on the fuel supply/injection system, pay careful

attention to the following "basic rules":
Thoroughly clean all unions and the adjacent areas before

disconnecting.
Place parts that have been removed on a clean surface and

cover them over. Do not use fluffy cloths!
Carefully cover over or seal opened components if the repair

cannot be completed immediately.
Only install clean components:

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

Do not work with compressed air.
Do not move vehicle unless absolutely necessary.
Also ensure that no Diesel fuel runs onto the coolant hoses. If
necessary hoses must be cleaned immediately. Affected hoses
must be replaced.
4A 1ZOverview of components:
CUT MICLEF
fuel tank -1-
with attachments
Notes:
All hose connections must be secured

with hose clips (same as original parts).
=> Parts catalogue
Always renew gaskets and seals

when performing repairs.
1 - Securing strap
For fuel tank
2 - Fuel tank
=> Page 20-7
3 - Vent pipe
4 - Hose for filler pipe
5 - Filler pipe insert

With non-return flap
6 - Filler pipe
7 - Overflow hose
8 - Oval head screw
9 - Clamp
10 - Union nut, 60 Nm
Remove and install with spanner
3217
11 - Fuel gauge sender -G

Testing => Page 20-10
=> Page 20-13
Internal dia. of supply pipe: 8 mm
Internal dia. of return pipe: 6 mm
12 - Seal
13 - Clamping washer
14 - Heat shield
For fuel tank
Ensure proper seating on rubber
plugs
Engage on retaining pins on fuel
tank and secure with clamping
washer
15 - Collar nut - 20 Nm
4A Draining fuel tank 1Z CUT MICLEF -1-
Observe safety precautions=> Page 20-1.
Observe rules for cleanliness => Page 20-2.
Fuel extractor V.A.G 1433 A

Work sequence
- Remove filler cap from fuel tank filler neck.
- Drain tank as far as possible via fuel filler neck.

4A 1Z fuel tank
Engine/gearbox jack V.A.G 1383 A
Removing
- Drain fuel tank if necessary using fuel extractor V.A.G 1433 A

=> Page 20-6.
Note:
The fuel tank must be empty when it is removed from the vehicle
in order to reduce weight.
- Detach cover for fuel gauge sender unit under floor trim in
luggage compartment.
Õ - Disconnect return pipe -2- and supply pipe -3- from fuel gauge
sender.
- Release and unplug connector -1-.

Õ - Remove screw -arrowon filler neck.
- Clean area around tank filler neck.
- Remove rear right wheel housing liner.
- Detach overflow hose from bracket.
- Disconnect overflow hose from filler neck.
Õ - Release hose clamp on lower connecting hose between fuel

tank and fuel filler pipe -arrow-.
Note:
The lower connecting hose must remain on the hose connection

on the tank.
- Pull off filler pipe and remove from vehicle.
- Position engine/gearbox jack V.A.G 1383 A below vehicle to

support tank.
- Mark the correct positions of the securing straps.
- Loosen nuts on securing straps.
- Lower fuel tank (2nd mechanic required).
Installing

note the following:
Notes:
4A Secure all hose connections
1Z with theCUT
correct hose clips
MICLEF
(same -3-
=> Parts catalogue
Always renew sealing rings and gaskets when assembling.
- Transfer heat shield from old tank to new tank.
- Position fuel tank and securing straps on underside of vehicle

using engine/gearbox jack V.A.G 1383 A.
Tightening torque
Component Nm
Securing straps for fuel tank to body 20
4A Checking fuel gauge1Z
sender -G CUT MICLEF -1-
Hand-held multimeter V.A.G 1526 A
Adapter set V.A.G 1594 A

Note:
Testing signal from fuel gauge sender:
=> Electrical system; Repair group 90; Servicing dash panel

insert; Identification of contacts on multi-pin connectors in dash
panel insert=>
4A Work sequence 1Z CUT MICLEF -2-
- Detach cover for fuel gauge sender under floor trim in luggage
compartment.
Õ - Release connector -1- and unplug.
Õ - Measure resistance at contacts -2- and -3- on flange:
Sender unit Tank full Tank empty

Fuel gauge sender -G
58 Ω 550 Ω
According to the amount of fuel in the tank, the resistance should
be somewhere between the specified values for "tank full" and
"tank empty".
- If the resistance is 0 Ωor ∞ Ω, this means there is a short circuit

or an open circuit in the wiring in the tank.
Notes:
In order to test the maximum and minimum values for "tank

full" and "tank empty", remove the fuel gauge sender -G =>
Page 20-13and move the float all the way to its top or bottom
position.
When the sender is removed from the tank the float travel is
greater, so the resistance readings will differ slightly from those
given in the table.
4A 1Z fuel gauge CUT
Removing and installing sender MICLEF -1-
Union nut spanner 3217
Hose clamp pliers V.A.G 1275

Removing
- Detach cover for fuel gauge sender under floor trim in luggage
compartment.
Õ - Disconnect fuel return pipe -2- and supply pipe -3- from fuel
gauge sender.
- Release and unplug connector -1-.
Õ - Remove union nut with spanner 3217.
- Take out fuel gauge sender and seal from opening in fuel tank.
Installing

note the following:
Note:
Secure all hose connections with the correct hose clips (same as
original parts)
=> Parts catalogue
- Fit new seal for fuel gauge sender (dry) in opening in fuel tank.
Õ - Insert fuel gauge sender in fuel tank; note correct installation
position:
- Notch -2- on flange must be aligned with marking on fuel
tank -1-.
Õ - Tighten union nut with spanner 3217 (60 Nm).

Note:
Hold guide for hose in position when tightening union nut.
- Connect pipes and plug in the connector.
Note:
Ensure that fuel pipes are securely seated.

4A 1ZServicing fuelCUT
filter MICLEF -1-
Notes:
All hose connections must be secured

with hose clips (same as original parts).
=> Parts List
Always renew seals and gaskets.
Draining water from fuel filter;

renewing
=> Maintenance booklet
1 - Water drain plug

Loosen and allow approx. 100 cm3
fluid to drain
Loosen vent screw in order to
drain water
2 - Seal
Renew if damaged
3 - Fuel filter
Loosen with strap wrench
Lightly lubricate seals with diesel
before installing
Fill with clean fuel before installing
Tighten by hand
4 - Seal
Renew if damaged
5 - Supply pipe
From fuel tank
6 - Supply pipe
To injection pump
7 - O-Ring
Renew
8 - Return pipe
From injection pump
9 - Control valve
Installation position: arrow points
towards fuel tank
10 - Retainer plate
11 - 5 Nm
12 - Return pipe
To fuel tank
13 - Non-return valve
Installation position: arrow points
towards fuel tank
14 - Vent screw - 10 Nm
Loosen in order to drain water
15 - Seal
16 - Fuel filter flange

17 - Insert
18 - Heat shield
19 - 10 Nm
20 - Bracket
21 - 10 Nm
4A 1ZBleeding fuel CUT
system MICLEF -1-

equipment required
Hose clamps 3094
Adapter V.A.G 1318/10
Hand-operated vacuum pump V.A.G

1390
Bleeder container V.A.G 1390/1

4A Work sequence 1Z CUT MICLEF -2-
Õ - Screw adapter V.A.G 1318/10 into return connection on

injection pump.
- Connect hand vacuum pump V.A.G 1390 and bleeder

container V.A.G 1390/1 to adapter.
Note:
4A Õ At temperatures below1Z CUTvalve for fuelMICLEF
+ 15 °C the control pre -3-
-heating opens the passage from the fuel return hose to the filter.
If this is the case, clamp off the return hoses on both sides of the
control valve using hose clamps 3094.
- Operate hand vacuum pump until fuel flows free of bubbles.
Important:
Empty the bleeder container it becomes completely full. No
fuel must be allowed to enter the hand vacuum pump.
- Reconnect return pipe to injection pump (25 Nm).
Note:
Replace seals.
- Remove hose clamps 3094 from return hose.
- Start the engine and check fuel system for leaks (visual check).
4A 1Zfor leaks
Checking fuel system CUT MICLEF -1-
Hose clamps 3094
Cooling system tester V.A.G 1274 with adapterV.A.G 1274/2

A
Leaks in the fuel system may result in the following:
Foam build-up or air bubbles in the supply pipe
Loss of power, misfiring
Starting problems
Work sequence
Õ - Attach adapter 1274/2 to cooling system tester V.A.G 1274.
- Unscrew return pipe from injection pump and connect hose

from adapter V.A.G 1274/2 in its place.
Õ - Fit hose clamps 3094 at the following points:
- On supply hose downstream of fuel filter
- On return hose downstream of fuel filter
- On return hose from injection pump
- Use hand pump on tester to create a pressure of between 1.0

and 1.5 bar.
- If the pressure constantly drops, locate leak and eliminate fault.

Note:
By moving the hose clamps from the filter to the fuel tank
connections it is also possible to test the fuel hoses.
4A 1ZServicing accelerator
CUT linkageMICLEF -1-
1 - Bush
2 - Circlip
3 - Accelerator pedal
4 - Torsion spring
5 - 10 Nm
6 - Spring washer
7 - Cable cam
8 - Square nut
9 - Mounting
10 - Accelerator position sender -G79

Installing and adjusting
=> Page 20-35
11 - 10 Nm
4A 1ZTesting accelerator
CUT position MICLEF
sender -1-
-G79

equipment required
V.A.G 1526 A
V.A.G 1594 A
V.A.G 1598/18
VAS 5051 withVAS 5051/1andVAS

5051/2
or
V.A.G 1551 with V.A.G 1551/1
Accelerator position sender -G79 is located on the accelerator

pedal. Its function is to tell the control unit what position the
pedal is in.
- Remove cover from additional relay carrier I on left of plenum

chamber.
Õ - Connect up vehicle diagnostic, testing and information system
VAS 5051 with diagnostic cable VAS 5051/1 and diagnostic
adapterVAS 5051/2. Alternatively, connect fault reader V.A.G
1551 using diagnostic cable V.A.G 1551/1.
Note:
The following description refers only to the diagnostic procedure

using fault reader V.A.G 1551.
When using vehicle diagnostic, testing and information system

VAS 5051, follow the instructions in the operating manual for the
equipment.
- With the ignition switched off, connect black connector to black

diagnostic connection.
V.A.G - SELF DIAGNOSIS HELP Õ Indicated in display

1 - Rapid data transfer 1)
2 - Flash code output 1)
1)appears alternately
- Connect white connector to white diagnostic connection (blue

connector is not used).
- Switch on ignition.
- Switch on fault reader printer with the print key. The warning
lamp in key should light up.
- Press key 1 for "Rapid data transfer".
Rapid data transfer HELP Õ When this display appears:

Enter address word XX
- Press keys 0 and 1 for address word "Engine electronics" and
900058 Type Type description confirm
MY entry with Q key.
Engine ID Gearbox ID User Workshop Manual
028906021A 1.9l R4 EDC SG D .. ⇒Õ The display on fault reader V.A.G 1551 will show the control unit
Coding 00000 WSC 00000 identification, as in thisexample.
- Press ⇒ key twice to advance the programme sequence.
Rapid data transfer HELP Õ When this display appears:

Select function XX
- Press keys 0 and 8 for the function "Read measured value
block" and confirm entry with Q key.
Read measured value block Q Õ When this display appears:

Enter display group number XXX
- Press keys 0, 0 and 2 for "Display group number 002" and
confirm entry with Q key.
Read measured value block 2 ⇒ Õ Indicated on display:

0 rpm 0.0 % 0 1 0 18.4 5C
- Check display in display zone 2 (accelerator pedal position).
- Specification: 0.0 % (accelerator not depressed)
- Check display in display zone 3.

- Specification:
0 1 0 (accelerator not depressed)
0 0 0 (accelerator depressed)
- Press accelerator pedal down slowly.

0 rpm 100 % 0 0 0 18.4 5C - Specification: The value in display zone 2 should increase
steadily to 100 % (accelerator fully depressed).
On vehicles with an automatic gearbox the kickdown switch

pressure point must be distinctly felt before the full throttle stop
position is reached.
- If the specifications for the initial and/or final readouts are not
obtained, adjust accelerator position sender -G79 => Page
20-35.
If the display does not change or only changes irregularly:
- Switch off ignition.
- Unplug connector for accelerator position sender -G79 (located

900058 Type Type description in footwell
MY on accelerator
Engine
pedal).
ID Gearbox ID User Workshop Manual
Õ - Set hand-held multimeter V.A.G 1526 to resistance measuring

range and connect to the following contacts on connector for
accelerator position sender -G79 using test leads from V.A.G
1594 A:
Contacts Accelerator Specification

1+3 Not depressed 0.8 ... 1.4 kΩ
Depressed ∞Ω
5 + 6 1) Not depressed ∞Ω
Fully depressed 0.8 ... 1.2 kΩ
1)Only on vehicles with automatic gearbox.
- If the specifications are not obtained, renew accelerator

position sender -G79.
Testing voltage supply
Õ - Set hand-held multimeter V.A.G 1526 to voltage measuring

range (20 V direct current) and connect it to contacts 2 and 3
on connector.
- Specification: approx. 5 V
If the specification is obtained:
- Check the wiring.
Testing wiring
Õ - With the ignition switched off, connect test box V.A.G 1598/18
to connector -1- (the control unit -2- remains disconnected).
- Remove storage compartment (shelf) on driver's side.

=> General body repairs; Repair group 70; Dash panel;
Removing driver's side shelf=>
- Unplug connector for accelerator position sender -G79 (located

in footwell on accelerator pedal).
Õ - Test for open circuit and short to positive or earth in the

following wiring connections:
Connector Test box V.A.G 1598/18

Contact Socket
1 15
2 57
3 55
4 65
6 1, 24, 46
5 1) 62
1)Only on vehicles with automatic gearbox.
- Rectify any open/short circuit as necessary.

4A 1Z accelerator CUT
Installing and adjusting position senderMICLEF
-G79 -1-
Note:
To renew accelerator position sender -G79, first remove the

accelerator pedal.
Setting jig 3226
Work sequence
Õ - Turn accelerator position sender -10- anticlockwise as far as

possible in slots in bracket -9- and tighten bolts to secure in
position.
- Fit eye from cable cam -7- onto stud on accelerator pedal -3-
(pedal is already in position).
- The eye must be properly seated in the slot on the cable
cam.
- The cable cam must be able to turn freely on the shaft of the
accelerator position sender.
- Turn the cable cam anticlockwise slightly and pull the

accelerator pedal until it touches the stop on the bracket.
- Secure the cable cam in its new position on accelerator

position sender -10- by tightening the nut and counterholding
with an open-ended spanner (AF 17) on the flats of the cable
cam.
- Install the pre-assembled throttle mechanism in the vehicle and

adjust as follows:
- Remove the full-throttle stop.

Õ - Push together setting jig 3226 and screw it in the hole instead
of the full-throttle stop.
- The threaded section of the setting jig must be screwed in
as far as it will go.
- Pull apart the setting jig and lock it in position with the pin
-arrow-.
- Slacken bolts securing accelerator position sender and turn

sender so that accelerator pedal rests against setting jig without
exerting pressure.
- Tighten bolts to secure accelerator position sender in this

position.
- Remove setting jig and install full-throttle stop.

4A 1Z turbochargerCUT
Charge air system with MICLEF -1-
Notes:
=> Parts catalogue
Charge air system must be free of leaks.
When performing repairs, replace gaskets, seals, self-locking

nuts and stretch bolts which have to be tightened to a specified
angle.
4A 1ZDiagram of connections
CUT MICLEF
for charge -1-
pressure control system
1 - Control unit with intake manifold

pressure sender -G71
2 - Pressure unit
For charge pressure control
Testing =>Page 21-12
3 - Pressure connection on
turbocharger
Pressure supply for charge
pressure control
4 - Solenoid valve for charge

pressure control -N75
Position: front left of engine
compartment
Testing =>Page 21-14
5 - Charge air cooler

4A 1Z and charge pressure
Checking turbocharger CUT MICLEF
control system -1-
Safety notes
Note the following points if test equipment has to be used during

a road test:
Warning
Test equipment must always be secured on the rear seat and

operated from the rear seat by a second person.
If test equipment is operated from the front passenger seat,

the occupant could be injured by the passenger's airbag in an
accident.
z Fault memory has been interrogated
=> Repair group 01; Interrogating and erasing fault memory=>
z Final control diagnosis has been performed
=> Diesel direct injection and glow plug system (4-cylinder TDI;
=> Repair group 01; Final control diagnosis=>
z No leaks in intake or exhaust system
z No faults in engine or injection system, e.g compression

pressure, injectors or commencement of injection.
z Coolant temperature at least 80 °C

4A 1Z
Checking charge pressure CUT MICLEF -1-
To isolate the cause of the fault, first check the turbocharger

on its own (without charge pressure control), then check the
charge pressure with charge pressure control.
Turbocharger tester V.A.G 1397 A
VAS 5051 with VAS 5051/1and VAS 5051/2

or
V.A.G 1551 with V.A.G 1551/1
Test sequence
Õ - Connect measuring hose from turbocharger tester V.A.G 1397/

A to connecting pipe and secure with a hose clamp -arrow-.
- Route measuring hose under rear edge of bonnet and into

passenger compartment via right-hand window.
Testing charge pressure without charge pressure control:
Õ - Unplug connector -arrow- at charge pressure control solenoid
valve.
Õ - Switch on turbocharger tester and set measuring range

selector switch to position -I- (absolute pressure).
- Connect measuring hose to connection -I-.

Notes:
Hose connections must be completely airtight, otherwise

measurements will not be correct.
Ensure that measuring hose is not pinched at bonnet or side

window.
Pressing memory key M on turbocharger tester will store the

last measured value until memory key M is pressed again or
tester is switched off.
The decimal point in the display flashes to indicate that the

value is being stored.
If the battery voltage of the turbocharger tester drops below

the minimum level, an arrow will appear at the top left of the
display.
Observe safety notes => Page 21-3.
- Read measured value block, Display Group 011
=> Repair group 01; Reading measured value block=>

840 rpm 938 mbar 978 mbar 92 %
- Measure the charge pressure at full throttle.
- Accelerate from 1500 rpm at full throttle in third gear (or with
selector lever at position 2), and watch rev counter.
- Press PRINT key on V.A.G 1551 and the memory key -M- on V.
A.G 1397 A simultaneously at approx. 3000 rpm.
Specifications:
Õ Specification for V.A.G 1397/A:
1.550 ... 1.750 bar
Read measured value block 11 ⇒ Õ Specification for display zone 3 on V.A.G 1551:
3040 rpm 1846 mbar 1693 mbar 39 %
1550 ... 1750 mbar
Note:
The charge pressure should bemeasured with turbocharger

tester V.A.G 1397/A. Fault reader V.A.G 1551 is used to check
whether the charge pressure is being registered by the control
unit.
- If the measured charge pressure is OK., repeat charge

900058 Type Type description pressure
MY measurement
Engine
with ID
charge pressure
Gearboxcontrol
ID active
User Workshop Manual
4A =>Page 21-10. 1Z CUT MICLEF -4-
If the charge pressure is not attained:
Leak between turbocharger and intake manifold
Fault in linkage or pressureunit for charge pressure control;

Turbocharger defective (turbine jammed by foreign body)
If the charge pressure is exceeded:
Hose connections for charge pressure control loose, leaking,

or blocked
Charge pressure control solenoid valve blocked
Actuating mechanism (linkage or shaft) of bypass valve does

not move easily or is sticking (valve does not open).
Testing charge pressure with charge pressure control:
- Connect connector to charge pressure control solenoid valve

-N75.
- Erase fault memory.
Note:
A fault was stored in the fault memory when the connector for
charge pressure control solenoid valve -N75 was disconnected.
- Read measured value block, Display Group 011.

840 rpm 938 mbar 978 mbar 92 %
- Measure the charge pressure at full throttle.
- Accelerate from 1500 rpm at full throttle in third gear (or with
900058 Type Type description selector
MY lever at position
Engine
2), and
ID watch
Gearbox
rev counter.
ID User Workshop Manual
- Press PRINT key on V.A.G 1551 and the memory key -M- on V.
A.G 1397 A simultaneously at approx. 3000 rpm.
Specifications:
Õ Specification for V.A.G 1397/A:
1.800 ... 2.050 bar
Read measured value block 11 ⇒ Õ Specification for display zone 3 on V.A.G 1551:
3090 rpm 1866 mbar 1917 mbar 62 %
1800 ... 2050 mbar
If the charge pressure is not attained:
Electrical fault in charge pressure control solenoid valve
Charge pressure control solenoid valve -N75 is jammed in the

open position
If the charge pressure is exceeded:
Charge pressure control solenoid valve -N75 is jamming at

times in the closed position
Charge pressure has been increased as a result of tuning

4A 1Z
Testing linkage and pressure CUT
unit for MICLEF
charge pressure -1-
control valve
Test requirement:

Test sequence
cleaner housing.
Õ - Unplug connector -arrowon charge pressure control solenoid

valve.
Õ - Start the engine and increase to maximum rpm briefly by
operating throttle.
- Operating rod -2- for charge pressure control valve should
move.
If the operating rod does not move:
- Check charge pressure control valve lever -1- for ease of

movement. If lever has seized due to corrosion, install new
turbocharger.
If the operating rod does not move, even though the lever is free
to move:
- Renew pressure unit for charge pressure control valve -3-.
- Erase fault memory.
Note:
A fault was stored in the fault memory when the connector for
charge pressure control solenoid valve -N75 was disconnected.
4A 1ZTesting charge
CUT MICLEF
pressure control valve -1-
-N75

equipment required
V.A.G 1526 A
V.A.G 1594 A
V.A.G 1598/18
Testing internal resistance

- Pull connector off charge pressure control solenoid valve -N75.
Õ - Connect multimeter to valve (resistance measurement range)

- Specification: 25 ... 45 Ω
If the specification is not obtained:
- Renew charge pressure control solenoid valve -N75.
Õ - Connect multimeter (voltage test range) between contact 2 and

earth.
- Specification: approx. battery voltage
- Test wiring for open circuit and short to positive or earth:

locations
Testing control signal wiring

Õ - Remove lower section of right-hand A-pillar trim and also right
-hand sill panel trim around front door.
=> General body repairs; Repair group 70; Trims; Removing and
installing A-pillar trim and Removing and installing inner sill
panel trim=>
- Pull back floor covering at front of right-hand footwell. (If

necessary, cut open the perforated seam on the left with a knife.
)
Õ - Remove screws on cover for electronics box -arrows-.
- Carefully detach upper and lower sections of cover.

Õ - Pull out cross-piece (arrow -3-) together with attached
components.
- Remove screws (arrows -1- and -2-).
- Take out engine control unit.
- Disengage retainer clip and unplug control unit connector.

Note:
Always make sure that the ignition is switched off before

unplugging or fitting the connector for the diesel direct injection
system control unit.

Contact Socket
1 47
- If the wiring is OK, fit a new engine control unit:

=> Renewing control unit for engine electronics

Testing intake manifold pressure sender
The intake manifold pressure sender is located in the diesel

direct injection system control unit.

or
V.A.G 1551 with V.A.G 1551/1
Test sequence
Õ Indicated on display:
Read measured value block 10 ⇒ - Check displays in display zones 2 and 3.

0 mg/H 1027 mbar 1013 mbar 0.0 % - Specification: The pressures should be the same.
Tolerance: ± 30 mbar
- Disconnect pressure hose from engine control unit.

If the specification is still not obtained:
- Fit a new engine control unit:
=> Diesel direct injection and glow plug system (4-cylinder

MICLEF
TDI);
=> Renewing control unit for engine electronics

4A Rules for cleanliness1Z CUT MICLEF -1-
When working on theturbocharger, pay careful attention to the

following "5 rules":
Thoroughly clean all unions and the adjacent areas before

disconnecting.
Place parts that have been removed on a clean surface and

cover them over. Do not use fluffy cloths.
Carefully cover over or seal opened components if the repair

cannot be completed immediately.
Only install clean components:

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

Do not work with compressed air if this can be avoided.
Do not move vehicle unless absolutely necessary.
4A 1ZRemoving and
CUT MICLEF
installing turbocharger -1-
- overview
1 - Pressure unit
For charge pressure control
2 - Bracket
3 - 10 Nm
4 - 10 Nm
Lock nut for operating rod -Item 6-
Adjusting=>Page 21-27
5 - Securing clip
6 - Operating rod
For charge pressure control valve
Adjusting=>Page 21-27
7 - 10 Nm
Install with locking fluid D 000 600
A2
8 - Gasket
Renew
9 - 25 Nm
Renew
10 - 25 Nm
11 - Oil supply pipe

From cylinder head to
turbocharger
Tighten union nut to 25 Nm
12 - Banjo bolt, 25 Nm
13 - Seals
Renew
14 - Exhaust manifold
With connection for exhaust gas
recirculation
15 - Intake manifold
=> Page 15-11
16 - Cap
For charge pressure test
connection
Secure with hose clamp
17 - Gasket
Renew
18 - From charge air cooler
19 - 25 Nm
20 - 30 Nm
Renew
Coat threads and bolt head
seating surface with high
-temperature lubricant "G 052 112
A3"
21 - Gasket
Renew
22 - 25 Nm
Renew
23 - Heat shield
24 - 25 Nm
Renew
25 - Turbocharger
Checking => Page 21-3onwards
=> Page 21-29
Fill with engine oil at connection
for oil supply pipe
26 - From air cleaner

27 - To solenoid valve for charge
Diagram of connections
=>Page 21-2
28 - 40 Nm
29 - Seal
Renew
30 - Oil return pipe

To cylinder block
31 - Seal
Renew
32 - Banjo bolt, 30 Nm
33 - To charge air cooler
34 - From solenoid valve for charge

Diagram of connections
=>Page 21-2
4A 1Z pressure unit
Removing and installing CUT MICLEF
for charge pressure -1-
control valve
Removing
- Remove turbocharger => Page 21-29.
Õ - Unclip securing clip -4-.
- Unscrew bolts -2-.
- Take pressure unit -6- off.

Installing
- Apply locking fluid D 000 600 A2 to bolts -2- for pressure unit -6
-, install on turbocharger and tighten to 10 Nm.
- Loosen operating rod -3- lock nut -1-.
- Pivot charge pressure control valve lever -5- in towards

pressure unit onto stop and hold.
- Adjust rod length -3- so that the rod eye will fit easily on lever
pin -5-. (Lever lies against stop with no play).
Õ - From this position, screw in operating rod 8 full turns

(rod shortens).
- Tighten lock nut -1-.
- Fit operating rod on to lever and install securing clip -4-.
- Install turbocharger => Page 21-32.

4A 1Z turbocharger
Removing
Õ - Remove noise insulation (two sections, -arrows-).
- Place a drip tray underneath.
Õ - Detach oil return pipe from cylinder block -arrow-.


Warning!
- Remove A/C compressor and secure to body with wire.

All models
cleaner housing.



mass meter.
- Remove front air intake hose from turbocharger.

Õ - Remove air intake hose -5- between turbocharger and charge
air cooler.
- Unscrew oil supply pipe -3- at turbocharger.
- Unbolt bracket -2- for oil supply pipe from exhaust manifold.
- Disconnect hose -6- from pressure unit for charge pressure

control.
- Disconnect hose -4- from turbocharger.
- Unscrew nuts -1- securing turbocharger to catalytic converter.
- Unscrew bolts securing turbocharger to exhaust manifold and

remove turbocharger.
Installing

note the following:
Notes:
Apply high-temperature paste G 052 112 A3 to threads and

bolt head contact surfaces of turbocharger bolts.
Fill turbocharger with engine oil at connection for oil supply

pipe.
=> Parts catalogue
Always renew seals, gaskets and self-locking nuts.
Charge air system must be free of leaks.
To ensure adequate lubrication of turbocharger, let engine idle

for about one minute after installing turbocharger and do not
increase engine speed immediately.
- Check oil level => Page 17-19.
Tightening torques
4A Component 1Z CUT MICLEF
Nm -4-
Turbocharger to exhaust manifold 30
Turbocharger to catalytic converter 25
Oil return pipe to cylinder block 30
Oil supply pipe to turbocharger 25
Hose clamps 2
4A 1ZRemoving and CUT MICLEF
installing parts of -1-
charge air cooling system
Notes:
Secure all hose connections with the

correct hose clips (same as original
equipment)
=> Parts Catalogue
Charge air system must be free of

leaks.
1 - Air ducting
2 - 20 Nm
3 - Washer
4 - Front retaining bracket
5 - Rubber grommet
For front retaining bracket
6 - Charge air cooler (intercooler)
=> Page 21-37
7 - 20 Nm
8 - Cheese head bolt - 20 Nm

With shoulder
9 - Rubber grommet
For rear retaining bracket
10 - Rear retaining bracket
11 - Air intake hose

Between intake manifold and
charge air cooler (intercooler)
12 - Air intake hose

Between turbocharger and charge
air cooler (intercooler)
13 - Vacuum pipe
To engine control unit
In engine wiring harness
Must not be lengthened or
shortened
When renewing, use same length
and inside diameter
=> Parts List
14 - Self-tapping screw
4A 1Z charge air cooler
Removing and installing CUT (intercooler)
MICLEF -1-
Removing
- Remove front bumper.
=> General body repairs; Repair group 63; Front bumper=>
cleaner housing.



mass meter.
- Remove front air intake hose from turbocharger.
Õ - Remove air duct -1- between charge air cooler and intake
manifold.
- Remove air intake hose between turbocharger and charge air

cooler.
- Remove lower section of air cleaner housing.
Õ - Unscrew rear bolt -arrow-.

Õ - Remove front section of noise insulation -lower arrows-.
- Disengage air ducting from charge air cooler.
Õ - Pull charge air cooler out of rubber mountings at the front

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

Installing
Installation is carried out in the reverse order.
Tightening torques
Component Nm
Charge air cooler to retaining bracket
20
Hose clamps 2
4A 1Z parts of exhaust
Removing and installing CUT system MICLEF -1-
Notes:
After working on the exhaust system ensure that the system is

not under stress, and that it has sufficient clearance from the
bodywork. If necessary, loosen clamp and align silencers and
exhaust pipe so that sufficient clearance is maintained to the
bodywork at all points and the mountings are evenly loaded.
Do not bend the flexible connection (de-coupling element) in

the exhaust system more than 10 °, otherwise it may be
damaged.
Removing and installing floor cross member

=>Fig.3, Page26-5.
After installing exhaust system, knock back retaining tabs on

exhaust mountings approx. 90°=>Fig.1, Page 26-4and Fig.2,
Page 26-4.
1 - 25 Nm
Renew
2 - Clamp
3 - Seal
Can be damaged by knocks; do
not drop on the floor
4 - Clamp
5 - Rear silencer
Aligning exhaust system free of
stress => Page 26-10
6 - Front silencer
Aligning exhaust system free of
stress => Page 26-10
7 - 40 Nm
8 - Clamp
Align exhaust system so it is free
of stress before tightening clamp
=> Page 26-10.
bolted connection on the right
Position of bolts => Fig.4
Tighten bolted connections evenly.
9 - Catalytic converter
With flexible connection (de
-coupling element)
Do not bend flexible connection
more than10°- otherwise it can be
damaged
Protect from damage by knocks
and impact
=> Page 26-8
10 - Gasket
Renew
11 - 25 Nm
Renew
4A 1Z
Õ Fig.1Bending back retaining tabs onCUT
front exhaust MICLEF -4-
mountings
z Front and rear silencers
- After installing exhaust system, knock back retaining tabs

-arrows- approx. 90°.
- Maintain a clearance (distance -a-) between mounting ring and

retaining tab.
- Distance a = 2 mm
Õ Fig.2Bending back retaining tabs on rear exhaust

mountings
z Rear silencer
- After installing exhaust system, knock back retaining tabs

-arrows- approx. 90°.
4A 1Z
Õ Fig.3Removing and installing CUT member MICLEF
floor cross -5-
Tightening torque: 20 Nm
Õ Fig.4Installation position of clamp
- Fit clamp in horizontal position.

- Bolted connection faces right
4A 1Z exhaust manifold
Removing
- Remove turbocharger=>Page 21-29.
- Unbolt heat shield.
- Unbolt exhaust gas recirculation pipe.
Õ - Unscrew all nuts -arrows- on exhaust manifold.
- Remove washers and take off exhaust manifold.
Installing

note the following:
Note:
Fit new gaskets and self-locking nuts.
- Install turbocharger=>Pages 21-32.
Tightening torques
Component Nm
Exhaust manifold to cylinder head 25
Heat shield to exhaust manifold 25
Exhaust gas recirculation pipe to exhaust manifold
25
4A 1Z front exhaust
Removing and installing CUT MICLEF
pipe with catalytic -1-
converter
Removing
Note:
Do not bend the flexible connection (de-coupling element) in the

exhaust system more than 10 °, otherwise it may be damaged.

-arrows-.

turbocharger.
Õ - Remove noise insulation (2 sections) -arrows-.
- Slacken clamp on exhaust system.
- Slide the clamp towards the rear and remove the exhaust pipe.
Installing

note the following:
Note:
Fit new gaskets and self-locking nuts.
- Aligning exhaust system free of stress =>

Page 26-10.
MY torques
Tightening
Component Nm
Clamp for exhaust pipe 40
4A Stress-free alignment1Zof exhaust system
CUT MICLEF -1-
z The exhaust system must be aligned when cold.
- Slacken bolted connections on clamp -Item 8-, Page 26-3.
Õ - Push exhaust system towards front of vehicle -arrow- so that

rear mounting of rear silencer is pre-loaded by amount a = 7 ...
10 mm.
- Tighten bolted connections on clamp evenly to 40 Nm.

Aligning tailpipes
Õ - Align tailpipes so that distance -a- is the same on both sides.

4A 1Z
Checking exhaust system for leaks CUT MICLEF -1-
- Start engine and run at idling speed.
- Plug tailpipes (e.g. with rags or stoppers) until check is

completed.
- Listen for noise at the connection points (cylinder head/

manifold, manifold/turbocharger, turbocharger/catalytic
converter, etc.) to locate any leaks.
- Rectify any leaks that are found.

4A 1Z
Exhaust gas recirculation system CUT MICLEF -1-
Notes:
The exhaust gas recirculationsystem is activated by the diesel

direct injection system control unit -J248 via the exhaust gas
recirculation valve -N18 and themechanical exhaust gas
recirculation valve.
The tapered plunger in the mechanical exhaust gas

recirculation valve gives an opening of variable cross-section
for different amounts of valve travel.
All required valve positions can beachieved by means of

pulsed control.
=> Parts catalogue

4A 1ZRemoving and CUT MICLEF
installing parts of -1-
exhaust gas recirculation system
1 - Intake manifold
2 - Gasket
Renew
3 - Exhaust gas recirculation valve

4 - 25 Nm
5 - Gasket
Renew
6 - 25 Nm
7 - Exhaust gas recirculation pipe
When installing, just nip all bolts
(parts must be just free to move),
then tighten stress free
8 - 25 Nm
9 - Gasket
Renew
10 - Exhaust manifold
=> Page 26-6
4A 1ZDiagram of vacuum
CUT hose connections
MICLEF -1-
1 - Brake servo
2 - Vacuum connection
3 - Vacuum pump (exhauster)

For brake servo
4 - Mechanical exhaust gas

recirculation valve
5 - Exhaust gas recirculation valve

-N18
6 - Air cleaner
7 - Breather pipe
To air cleaner
4A Checking mechanical1Zexhaust gas recirculation
CUT MICLEF
valve -1-
V.A.G 1390
Test sequence
- Pull vacuum hose off mechanical exhaust gas recirculation

valve.
- Connect hand vacuum pump V.A.G 1390 to valve.
- Operate pump.
- The diaphragm rod should move towards the vacuum
connection.
Note:
Õ Watch the diaphragm rod through the opening -arrow-.
- Pull hose of hand vacuum pump off exhaust gas recirculation

valve.
- The valve must be clearly heard to close. The diaphragm
rod should move towards the intake manifold.
4A Testing exhaust gas 1Z
recirculation CUT MICLEF -1-
The function of the exhaust gas recirculation system is tested by

checking the mass of air inducted. If exhaust gas is being
recirculated, a smaller quantity of fresh air is registered by the air
mass meter. The more exhaust gas recirculated, the weaker the
signal from the air mass meter.
or
V.A.G 1551 with V.A.G 1551/1

Test requirement:
Test sequence
- Read measured value block, Display Group 001:

Read measured value block 1 ⇒
840 rpm 6.5 mg/H 1.480 V 87.3 5C
Õ Indicated on display:
- Check display in display zone 4 (coolant temperature).

- Specification: at least 80 °C
- Wait until the coolant has reached the specified temperature

before continuing with the test.
Read measured value block 3 " Õ Indicated on display:

840 rpm 272 mg/H 268 mg/H 54 %
- Briefly depress the accelerator pedal, then allow the engine to
continue running at idling speed.
- Observe displays in display zones 2 and 3.
Display zone Possible cause of fault

2 (spec.) 3 (actual)
230...370 230...370 Okay

mg/H mg/H
> 370 mg/ > 370 mg/ Engine too cold
H H Electrical equipment on
Temperature of intake manifold too
high
Injection pump too lean
230...370 < 230 mg/ Unmetered air
mg/H H Too much EGR
230...370 > 370 mg/ Too little EGR
mg/H H or none at all
Constant Fixed substitute value caused by open
425 mg/H circuit in wiring to air mass meter or
implausible air mass signal
Note:
If display zone 3 shows a constant value of 425 mg/H, check the

air mass meter:
900058 Type Type description => Diesel
MY direct injection
Engine
and glow
ID plugGearbox
system (4-cylinder
ID UserTDI); Workshop Manual
=> Repair group 23; Testing exhaust gas recirculation;=>
=> Testing air mass meter -G70
If the specifications are not obtained:
- Start final control diagnosis and activate exhaust gas

recirculation valve -N18:
=> Repair group 01; Final control diagnosis=>
Final control diagnosis ⇒ Õ Indicated on display:

Exhaust gas recirculation valve -N18
The valve shouldclick.
If the valve does not click:
- Test exhaust gas recirculation valve -N18 => Page 26-21.
If the valve clicks:
- Check vacuum hose connections => Page 26-15.
If vacuum hose connections are OK:
- Check mechanical exhaust gas recirculation valve

=> Page 26-16.
4A 1ZChecking exhaust
CUT gas recirculation
MICLEF -1-
valve -N18

equipment required
V.A.G 1526 A
V.A.G 1594 A
V.A.G 1598/18
Testing internal resistance
- Unplug connector from exhaust gas recirculation valve.

Õ - Connect multimeter to valve (resistance measurement range)

- Specification: 14 ... 20 Ω
Note:
The resistance will be at lower end of tolerance at room

temperature, and at upper end of tolerance at engine operating
temperature.
If the specification is not attained:
- Fit new exhaust gas recirculation valve -N18.
Õ - Connect multimeter (voltage measurement range) between

contact 1 and earth.
- Specification: approx. battery voltage
- Test wiring for open circuit and short to positive or earth.

locations
Testing control signal wiring

Õ - Remove lower section of right-hand A-pillar trim and also right
-hand sill panel trim around front door.
=> General body repairs; Repair group 70; Trims; Removing and
installing A-pillar trim and Removing and installing inner sill
panel trim=>
- Pull back floor covering at front of right-hand footwell. (If

necessary, cut open the perforated seam on the left with a knife.
)
Õ - Remove screws on cover for electronics box -arrows-.
- Carefully detach upper and lower sections of cover.

Õ - Pull out cross-piece (arrow -3-) together with attached
components.
- Remove screws (arrows -1- and -2-).
- Take out engine control unit.
- Disengage retainer clip and unplug control unit connector.

Note:
Always make sure that the ignition is switched off before

unplugging or fitting the connector for the diesel direct injection
system control unit.

Contact Socket
2 25
- If the wiring is OK, fit a new engine control unit:

=> Repair group 23; Servicing diesel direct injection system;

Renewing control unit for engine electronics=>

Audi A4/b4 Engine TDI 1.9 (1Z and AHU) - Service Manual

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Audi A4/b4 Engine TDI 1.9 (1Z and AHU) - Service Manual

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Engine data

Engine code 1Z AHU

Engine code 1Z AHU

Special tools and workshop

 Engine support bracket 10-222 A

 Lifting tackle 2024 A

 Special tool 3147

 Special tool Matra V/175

 The engine is lifted out without the gearbox.

 Catch drained-off coolant in a clean container for re-use or

- Obtain radio code on vehicles with coded radio.

- With ignition switched off disconnect battery earth strap.

- Open cap on coolant expansion tank.

Õ - Remove noise insulation (two sections) -arrows-.

- Place drip tray V.A.G 1306 below engine.

Õ - To drain off remaining coolant, disconnect coolant hoses

- Slacken V-belt by loosening tensioning nut -1-.

- Secure vane pump to body with wire to avoid overtensioning

Õ - Disconnect positive wire to fan motor at series resistance

- Move wiring clear.

Õ - Disconnect bottom air hose -3- from charge air cooler.

- Disconnect wiring-1-from alternator.

- Unbolt earth wire -2- from longitudinal member.

Starter cables do not have to be disconnected.

Vehicles with automatic gearbox

Õ - Unscrew 3 torque converter nuts through starter opening using

When loosening torque converter bolts, counterhold crankshaft

- Unscrew engine/gearbox securing bolts accessible from below

- Unbolt radiator fan cowl from radiator and lift out.

Õ - Disconnect wires/unplug connectors as follows:

1 -Exhaust gas recirculation valve -N18

2 -Air mass meter -G70

4 -Charge pressure control solenoid valve -N75

5 -Intake manifold temperature sender -G72

- Disconnect vacuum hose from mechanical exhaust gas

- Disconnect thin hose-6-from bottom of valve for exhaust gas

- Move wiring and hoses clear.

- Disconnect air hose from air mass meter.

- Remove upper section of air cleaner housing with air mass

- Remove air duct-1-between charge air cooler and intake

- Remove air intake hose between charge air cooler and

- Remove ribbed belt => Page 13-11.

- Remove lower section of air cleaner housing.

- Disconnect connector on A/C compressor.

- Remove A/C compressor and secure to body with wire.

Õ - Unscrew bolts securing turbocharger to catalytic converter

- Disconnect front exhaust pipe with catalytic converter from

Secure the flange of the front exhaust pipe to the right

3 -Wiring for engine speed sender -G28

4 -Needle lift sender -G80

5 -Coolant temperature sender -G62

6 -Electronic thermo switch -F76

7 -Oil pressure switch -F1

8 -Oil temperature sender -G8

- Unplug connectors from glow plugs.

- Unplug connector from speedometer sender -G22 on left of

Õ - Disconnect diesel supply and return pipes -arrows- at injection

Use clean plugs to block off the pipes.

Õ - Disconnect coolant hoses -arrows-.

- Remove hose with non-return valve from exhauster pump.

- Unscrew upper engine/gearbox securing bolts. Leave one bolt

Õ - Position support bar 10-222 A on bolted flanges of wing panels

Engine support bracket 10-222 A

Lifting tackle 2024 A

Special tool 3147

Special tool Matra V/175

The engine is lifted out without the gearbox.

Catch drained-off coolant in a clean container for re-use or

Do not overtension, otherwise the pressure pipe for the clutch

The illustration shows the engine removed.

Engine and gearbox support VW 540

When performing repairs, renew seals, gaskets, self-locking

Coolant must not be used again if it is dirty.

The tightening torques listed on this page apply only to lightly

Additional lubricant such as engine or gearbox oil may be

Do not use degreased parts.

Tolerance for tightening torques is ±15%.

The following illustration shows the belt drive on vehicles

Mark the direction of rotation before removing the ribbed belt.

The following illustration shows the belt drive on vehicles

Mark the direction of rotation before removing the ribbed belt.