engine amf.pdf

Service 5

Service Department. Technical Information Printed in Czech RepublicS00.5325.00.20

Workshop ManualFABIA 2000 1.4/55 TDI Engine, MechanicsEdition 07.03Engine code AMF

Service5

The Workshop Manual is intended only for use within the Organisation koda.It is not permitted to pass it on to other persons.

KODA AUTO a. s.

Printed in Czech RepublicS00.5325.00.20

FABIA 2000 1.4/55 TDI Engine, Mechanics

List of SupplementsEdition 07.03S00.5325.00.20

List of Supplements to Workshop ManualFABIA 2000 1.4/55 TDI Engine, MechanicsEdition 07.03

Supple-ment Edition Subject Article Number

07.03 Basic Edition S00.5325.00.20


List of Supplements Edition 07.03S00.5325.00.20


Table of ContentsEdition 07.03S00.5325.00.20

I

Table of Contents

00 Technical DataTechnical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Engine number ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Engine characteristics .. ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Removing and Installing EngineRemoving and Installing Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing engine ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Securing the engine to the assembly stand ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Installing the engine ..... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Tightening torques ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Assembly bracket ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 CrankgearRemoving and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing V-ribbed belt ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Routing of the V-ribbed belt ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing, tightening the timing belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Timing belt - Summary of components ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing, tightening the timing belt ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Cylinder block - Summary of components ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Replacing gasket ring for crankshaft - on the belt pulley side ........ . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing the front sealing flange ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft, Piston and Conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing crankshaft . ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Disassembling and assembling piston and conrod ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Checking piston projection in TDC ... ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing balancing shaft and retaining frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- removing and installing balancing shaft ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 Cylinder Head, Valve GearRemoving and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing cylinder head ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Testing the compression ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Summary of components ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing camshaft ... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing gasket ring for camshaft ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seats, valves guides, valve stem seals- Grinding in valve seats ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Inspect valve guides .... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Replacing valve stem seals ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

00-1 page 100-1 page 100-1 page 1

10-1 page 110-1 page 110-1 page 510-1 page 710-1 page 910-1 page 9

13-1 page 113-1 page 113-1 page 2

13-2 page 113-2 page 113-2 page 2

13-3 page 113-3 page 1

13-4 page 113-4 page 213-4 page 3

13-5 page 113-5 page 113-5 page 313-5 page 5

13-6 page 113-6 page 2

15-1 page 115-1 page 315-1 page 6

15-2 page 115-2 page 1

15-3 page 115-3 page 115-3 page 3



Table of Contents Edition 07.03S00.5325.00.20II

17 LubricationRemoving and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Lubrication system - Summary of components ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Disassembling and assembling oil filter holder ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing oil pan ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 CoolingParts of cooling system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Parts of the cooling system fitted to body .. ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Parts of cooling system engine side ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Connection diagram for coolant hoses ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Draining and filling up coolant . ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Checking the coolant system for tightness ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing radiator, coolant pump and coolant thermostat . . . . . . . . . . . . . . .- Removing and installing radiator ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing coolant pump ..... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing coolant regulator . ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 Fuel SupplyRemoving and installing parts of the fuel supply - Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Fuel tank with component parts - Summary of components ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Repairing the fuel filter ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Safety precautions when working on the fuel supply system ......... . . . . . . . . . . . . . . . . . . . . . . . . . .- Rules of cleanliness ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing the fuel delivery unit ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- removing and installing fuel gauge ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Check the fuel delivery unit .... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing parts of the fuel supply - Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing the fuel tank ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing fuel cooler ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Inspecting a tandem pump ..... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing the tandem pump ......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Summary of components ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 TurbochargingCharge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Safety measures ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Rules of cleanliness ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing exhaust turbocharger with component parts ....... . . . . . . . . . . . . . . . . .- Removing and installing parts of the charge air cooling ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing charge-air cooler . ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Charge-air system with exhaust turbocharger - Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing turbocharger ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Checking charge pressure control ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 Exhaust System

17-1 page 117-1 page 117-1 page 3

17-2 page 117-2 page 1

17-3 page 1



20-1 page 120-1 page 120-1 page 320-1 page 420-1 page 420-1 page 520-1 page 620-1 page 6

20-2 page 120-2 page 120-2 page 220-2 page 220-2 page 4

20-3 page 120-3 page 1


21-2 page 121-2 page 121-2 page 2


Table of ContentsEdition 07.03S00.5325.00.20

III

Removing and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Align exhaust system free of stress ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Replacing front or rear silencer ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing parts of the exhaust gas recirculation system ... ...... . . . . . . . . . . . . .- Testing mechanical exhaust gas recirculation valve ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26-1 page 126-1 page 226-1 page 2

26-2 page 126-2 page 126-2 page 2


Table of Contents Edition 07.03S00.5325.00.20IV


Technical DataEdition 07.03S00.5325.00.20

00-1 page 1

00

00-1 Technical Data

Engine numberThe engine number (engine code and serial number) is located at the front at the joint separating engine/gear-box.

In addition, a sticker with the engine identification char-acters and serial number is affixed to the timing belt guard.

The engine identification characters are also indicated on the vehicle data sticker.

Engine characteristics

00 Technical Data

Engine identification characters AMFManufactured 06.03 Exhaust limits conforming to EU-3Displacement l 1,4Power output kW at rpm 55/4000Torque Nm at rpm 195/2200Bore mm 79,5Stroke mm 95,5Compression 19,5 : 1CN minimum 49Firing order 1-2-3Catalytic converter yesExhaust gas recirculation yesTurbocharging yesCharge air cooler yes


Technical Data Edition 07.03S00.5325.00.2000-1 page 2

00


Removing and Installing EngineEdition 07.03S00.5325.00.20

10-1 page 1

10

10-1 Removing and Installing Engine

Special tools, test and measuring equipment and auxiliary items required

Workshop crane (e.g. -V.A.G 1202 A -) Catch pan (e.g. - V.A.G 1306-) Torque wrench Engine/gearbox jack (e.g. -V.A.G 1383 A-) Engine mount -T10012- Bushing -T30010- Socket insert -MP 9-200/7- Engine mount -MP 1-202- Assembly stand -MP 9-101- Lifting device -MP 9-201- Pliers for spring strap clips Snap hook Grease -G 000 100- Hot bolt paste -G 052 112 A3- Wire Adhesive tape

Removing engine

The engine is removed towards the front together with the gearbox.

Jacking up points for raising the vehicle Inspection and Maintenance.

Pay attention to the correct assignment of the connec-tors, if necessary mark.

If the battery is disconnected and reconnected, carry out certain additional operations Electrical System; Rep. Gr. 27.

Procedure

Disconnect the battery-earth strap with the ignition off. Remove the sound dampening system -arrows-

Body work; Rep. Gr. 50. Remove drive shaft to the right Running gear;

Rep. Gr. 40. Unscrew the drive shaft to the left of the gearbox

flange. Raise drive shaft on the left and secure. Remove front exhaust pipe with catalyst Chapter

26-1.

10 Removing and Installing Engine

Note

S10-0114


Removing and Installing Engine Edition 07.03S00.5325.00.2010-1 page 2

10

Remove front bumper Body work; Rep. Gr. 63. Release screw -3-. Remove charge-air pipe at bottom -1- with connecting

hose -2- -arrows-. Remove charge-air routing from charge-air cooler

Chapter 21-1.

Unbolt the pendulum support -arrows-. Drain coolant Chapter 19-1. Remove engine cover. Remove air filter with intake hose 1.4/55 TDI En-

gine, Fuel Injection; Rep. Gr. 23. Remove battery and battery tray Electrical System;

Rep. Gr. 27. Unscrew the generator cables from the battery cover

and remove the wiring loom from the holder. Remove the coolant hoses from the radiator.

For vehicles with air conditioning

Release the retaining clips of the AC system lines. Remove AC compressor Heating, Air conditioning;

Rep. Gr. 87, the lines remain connected. Tie up AC compressor to lock carrier.

For all vehicles

Removing lock carrier Body Work; Rep. Gr. 50 and lay aside.

Caution!

Refrigerant circuit of the air conditioning sys-tem must not be opened. Therefore, when re-moving the lock carrier the hoses must be fitted onto the air conditioning. They must neither be folded nor exposed to stress.

To avoid damaging the condenser, wiring and air conditioning hoses make sure the lines and hoses are not excessively expanded, buckled or bent.

S10-0128



10-1 page 3

10

Disconnect the coolant hose -1- from the pipe. Disconnect the fuel-intake hose -3- and the fuel-return

hose -2- from the pipes.

Remove charge-air pipe at the top -1- with connecting hose -2- -arrows-.

Pull off the coolant hose from the expansion bottle at the bottom.

Pull out vacuum hoses from the valve block Chapter 21-1 .

Remove the coolant feed hose -3- from the supports -4-.

Remove the coolant return hose -2- from the heat ex-changer connection fittings -1-.

1

2

3

S10-0148

1

2

6

43

S10-0150

5



10

Unplug connector -1- from the engine control unit. Disconnect the plug connections -2- and -3- and re-

move from bracket. Unclip cable clip -4- -arrows-. Remove shift cables of shift mechanism from bracket

at gearbox and place down to the side Manual Gearbox 02R; Rep. Gr. 34.

Disconnect lines for brake fluid from clutch slave cyl-inder Manual Gearbox 02R; Rep. Gr. 30.

Unplug connector from reversing light switch -F4-. Unscrew the earth line from the body. Disconnect connector and cables from the starter.

Disconnect the plug connections -2- and -3- under the starter and remove from bracket.

Suspend lifting device -MP 9-201- as follows and carefully raise engine with gearbox with workshop crane -V.A.G 1202 A-.

12 3

S10-0117

4

3

1

2

S10-0151

Warning!

Use securing pins on the hooks and rig pins to prevent release.



10-1 page 5

10

Unscrew bolts for engine mounting -arrows-.

If the engine/gearbox unit drops when the screws are re-leased raise it up again.

Unscrew bolts for gearbox mount -arrows-.The note on unscrewing the engine mounting also ap-plies for the gearbox mount.

Carefully raise the engine with gearbox and pull out towards the front.

Carefully guide the engine and gearbox during withdraw-al. Ensure adequate clearance to other neighbouring components.

Securing the engine to the assembly standTo perform the assembly work the engine must be se-cured to the assembly stand -MP 9-101-.

When measuring the cylinder bore ( Chapter 13-4) the engine must not be fixed to the assembly stand.

Modify engine mount -T10012-

Make additional hole -a- according to the given dimen-sions at the height of the already existing holes, if these do not yet exist.

max

min

S10-0149

Note

S10-0120

Note

Note



10

Procedure

Screw centering pin -1- and centering pin -2- accord-ing to the illustration onto the engine mount -arrows-.

Fix engine mount -T10012- with fixing nut -3- and fix-ing bolt at cylinder block.

Unscrew the bottom fixing screws for the engine/gear-box.

Raise the engine and gearbox with the engine/gear-box jack.

Dismantle the lifting device -MP 9-201-.

Position engine/gearbox with engine/gearbox jack onto a work bench.

Lower the engine/gearbox unit in such a way that the gearbox is positioned on the support.

Remove cover plate -A- for flywheel behind the right flange shaft -arrows-.

Unplug the connector from the speedometer sender -G22-.

Remove engine/gearbox connecting screws. Press gearbox from engine.

T 10012 V.A.G 1383/AN10-0148

A

V34 - 3005



10-1 page 7

10

Suspend lifting device -MP 9-201- and lift engine out of engine/gearbox jack using the workshop crane.

On the belt pulley side: 4. Hole of the perforated bar in po-sition 1

On the flywheel side: 2. Hole of the perforated bar in po-sition 8

The rig positions on the supporting bracket marked 14 point towards the belt pulley.

The holes in the perforated bars are counted from the hook.

Unscrew Engine mount - T10012-. Attach engine to the assembly stand -MP 9-101 - with

the engine / gearbox mount -MP 1-202 - and sleeves -T30010-. (The figure shows the 1.9l/47kW SDI en-gine; the fixing system is identical).

Engine can be fixed at the engine mount -MP 1-202 - without sleeves -T30010-.

Installing the engine

Always replace the seals and gaskets during assem-bly work.

Always replace self-locking nuts. Coat stud bolts of exhaust manifold with hot bolt paste

-G 052 112 A3- before installing. Tightening torques 10-1 page 9. Assembly bracket 10-1 page 9.

ProcedureInstallation is performed in the reverse order. Pay atten-tion to the following points:

Check whether the dowel sleeves for centering the engine/gearbox are present in the cylinder block; in-sert if necessary.

Check whether the intermediate plate has been insert-ed on the sealing flange and rests on the dowel sleeves -arrows-.

Warning!

Use -arrows- securing pins on the hooks and rig pins to prevent release.

Note

T30010

MP 1-202

S10-0123

Note

Note

A10-0129



10

If necessary check the centering of the clutch driver disc.

Inspect clutch release bearing for wear, replace if nec-essary.

Grease the drive shaft serration with grease -G 000 100-.

Assemble together the engine with gearbox Manual gearbox 02R; Rep. Gr. 34.

When installing the unit, ensure adequate clearance to other components.

Align unit free of stress and attach firmly.When tightening the bolts for engine and gearbox mounts, engine and gearbox support brackets must be resting fully against mount.

Tightening torques 10-1 page 9. Connect lines for brake fluid to clutch slave cylinder

Manual Gearbox 02R; Rep. Gr. 30. Install and adjust the shift cables of the shift mecha-

nism Gearbox 02R; Rep. Gr. 34. Install the right drive shaft and screw the left drive

shaft onto the gearbox Chassis; Rep. Gr. 40. Install the front exhaust pipe with catalytic converter

and the exhaust system so that they are not under tension. Chapter 26-1.

Install the lock carrier with component parts Body Work; Rep. Gr. 50.

Electrical connections and proper routing Current Flow Diagrams, Electrical Fault Finding and Fitting Lo-cations.

Install coolant hoses Chapter 19-1.

Only then re-use drained coolant if none of the following components has been replaced: Engine block, cylinder head, radiator, heat exchanger.

Top up coolant Chapter 19-1. Check oil level before starting the engine. Perform test drive, interrogate fault memory 1.4/55

TDI Engine, Fuel Injection; Rep. Gr. 23.

Note



10-1 page 9

10

Tightening torques

Assembly bracket

Engine assembly bracket

1 - 30 Nm + 90 (1/4 turn) - replace2 - 40 Nm + 90 (1/4 turn)3 - 45 Nm

Gearbox assembly bracket

1 - 50 Nm + 90 (1/4 turn) - replace2 - 40 Nm + 90 (1/4 turn) - replace

Hinged bracket

Position the screws -1- in the elongated holes of the pen-dulum support in such a way that there is maximum dis-tance between the gearbox and the assembly carrier.

1 - 30 Nm + 90 (1/4 turn) - replace2 - 40 Nm + 90 (1/4 turn) - replace

Component NmScrews/nuts M6 9

M8 23M10 40M12 60

In variation of this:Front exhaust pipe to turbo-charger

25 Nm

2

11

1

1 S10-0125

1

2S10-0126

Note



10


Removing and installing V-ribbed beltEdition 07.03S00.5325.00.20

13-1 page 1

13

13-1 Removing and installing V-ribbed belt

Removing and installing V-ribbed belt


Locking pin -T10060-

Mark the rotation direction before removing the V-ribbed belt. Reversing the rotation direction of an al-ready used belt may destroy it.

Pay attention to the correct position of the V-ribbed belt in the belt pulley when installing it.

Removing the V-ribbed belt

Remove engine cover. Remove charge-air pipe at the top -1- with connecting

hose -2-. Mark the rotation direction of the V-ribbed belt. Loosen the V-ribbed belt by turning the tensioning pul-

ley in the -direction of the arrow-.

13 Crankgear

Note

A13-0083


Removing and installing V-ribbed belt Edition 07.03S00.5325.00.2013-1 page 2

13

Lock tensioning pulley with rig pin -T10060-. Remove the V-ribbed belt.

Installing the V-ribbed belt

Installation is carried out in the reverse order.

Inspect V-ribbed belt Inspection and Maintenance. Before fitting the ribbed V-belt make sure that all as-

semblies (generator, AC compressor) are securely mounted.

Pay attention to the correct position and rotation direc-tion of the V-ribbed belt in the belt pulley when install-ing it.

Finally position the V-ribbed belt on the generator.After finishing the work always:

Start engine and check belt run.

Routing of the V-ribbed belt

Belt run without AC compressor

Belt run with AC compressor

Note


Removing and installing, tightening the timing beltEdition 07.03S00.5325.00.20

13-2 page 1

13

13-2 Removing and installing, tightening the timing belt

Timing belt - Summary of components1 - Timing belt guard - top part2 - Timing beltT before removing mark run-

ning directionT check for wearT do not kinkT removing and installing, ten-

sioning 13-2 page 23 - 20 Nm + torque a further 1/8

turn (45 )4 - Tensioning pulley5 - 100 Nm6 - 20 Nm + torque a further 1/8

turn (45 )7 - Camshaft sprocket8 - HubT with rotorT to release and tighten use

the counterholder -T10051 -T to remove use the extractor

-T10052-T removing and installing

Chapter 15-39 - 10 Nm

10 - Timing belt guard rear11 - Sealing sleeve

T replace if damaged12 - Guide pulley13 - Coolant pump

T removing and installing Chapter 19-2

14 - Timing belt gear - crankshaftT contact surface between crankshaft timing belt sprocket and crankshaft must be clean and free of greaseT Fitting position: flats on timing belt sprocket and on crankshaft must be aligned

15 - 120 Nm + torque a further 1/4 turn (90)T replaceT to release and tighten use counterholder -MP 1-310- or -T30004-T neither oil nor grease new screw

16 - 15 Nm17 - 20 Nm18 - Timing belt guard - bottom part19 - Belt pulley with vibration damper

T Assembly only possible in one position - holes offset20 - 10 Nm + torque a further 1/4 turn (90)21 - Timing belt guard - middle part


Removing and installing, tightening the timing belt Edition 07.03S00.5325.00.2013-2 page 2

13

Removing and installing, tightening the timing belt


Rig pin -MP 1-301- or -3359- Two-hole nut turner -T10020- Locking device -T10050- Torque wrench Supporting device -MP 9-200- with feet -MP 9-200/3-

Removing

Adjusting work on the timing belt must only be performed on a cold engine, as the position of the pointer at the ten-sioning element is temperature dependent.

Remove engine cover. Remove charge-air pipe at the top -1- with connecting

hose -2-. Remove the connecting pipe between the charge air

cooler and the intake Chapt. 21-1. Install supporting device -MP 9-200- according to the

illustration and support engine in fitting position.

Remove engine mount -1- and engine console -2-. Remove the V-ribbed belt Chapter 13-1. Remove locating bolts -T10060- from tensioning ele-

ment. Remove timing belt guard - top part.

Note



13-2 page 3

13

Remove the noise insulation.

Release screw -3-. Remove charge-air pipe at bottom -1- with connecting

hose -2- -arrows-. Remove belt pulley item 19 in 13-2 page 1. Remove middle part of timing belt guard item 21 in 13-2 page 1.

Remove bottom part of toothed belt guard item 18 in 13-2 page 1.

Position crankshaft on TDC cylinder 1.

Turn crankshaft until the marking on the timing belt sprocket and the marking on the timing belt guard stand are opposite each other -arrows A- at the rear.

Lock hub with locking pin -MP 1-301- or -3359-. Insert locking pin through the free left slot into the hole at the cylinder head.

Secure crankshaft timing belt sprocket with locking device-T10050-. Insert locking device from the front of the timing belt sprocket into the teeth.

To facilitate this step, it is recommended to colour the TDC marking at the crankshaft timing belt sprocket and on the locking device-T10050- with white paint -arrows B-.

The marking on the crankshaft timing belt sprocket and the marking on the locking device must be posi-tioned opposite -arrows B-. Pin of locking device must engage in the hole of the sealing flange -arrow C-.

Locking device - T10050- must not be used as a coun-terholder when releasing or tightening the bolts for the toothed belt gear - crankshaft.

Mark the rotation direction of the timing belt.

S10-0114

Note

Note



13

Loosen the fixing nut on the tensioning roller. Slacken bolts of camshaft sprocket -1- sufficiently so

that the camshaft sprocket can be turned in the area of the slots.

Remove guide pulley item 12 in 13-2 page 1.

Turn two-hole nut turner -T10020- up to the stop and first of all remove the timing belt from the coolant pump and then from the other timing gears.

Install timing belt and tension

Adjusting work on the timing belt must only be performed on a cold engine, as the position of the pointer at the ten-sioning element is temperature dependent.

Turn camshaft sprocket in the slots anti-clockwise in -direction of arrow- as far as the stop.

Fit timing belt onto crankshaft timing belt sprocket, tensioning pulley, camshaft sprocket and onto the coolant pump.

Note



13-2 page 5

13

Pay attention to correct fitting of the tensioning pulley in the rear timing belt guard -arrow-.

Install guide pulley item 12 in 13-2 page 1. Carefully turn tensioning pulley with two-hole nut turn-

er -T10020- in anti-clockwise direction until the pointer is positioned in the middle of the recess in the base plate.

Hold tensioning pulley in this position and tighten fix-ing nut of the tensioning pulley as follows:

20 Nm + torque a further 45 (1/8 turn) Tighten bolts of camshaft sprocket to 20 Nm + torque

a further 1/8 turn (45). Remove locking pin -MP 1-301- and locking device

-T10050-. Turn crankshaft two turns further in the direction of ro-

tation of the engine and again position on TDC for cyl-inder 1.

Pin for locking device must engage in the sealing flange. (Locking device should be inserted just ahead of TDC on toothed belt sprocket.)

If the crankshaft is positioned after TDC of piston for cylinder 1 and the pin of the locking device does not engage in the sealing flange, rotate the crankshaft back no more than 1/4 revolution and again set the crankshaft to the TDC of the piston for cylinder 1 by turning in direction of rotation of engine.

It is not permittedto carry out the correction by turning in the opposite direction of rotation of the engine in or-der to insert the locking device.

Check after inserting the locking device -T10050-, if the hub can be interlocked with the rig pin -MP 1-301- or -3359-.

If the hub cannot be arrested:

Remove pin for locking device from the hole at the sealing flange and rotate the crankshaft until the hub can be arrested with the rig pin.

Slacken bolts of camshaft sprocket -1-.

Note

A13-0053

Note



13

Rotate crankshaft in opposite direction of rotation of engine long enough until the pin for the locking device in the sealing flange is positioned close to the hole -ar-row-.

Now turn crankshaft in direction of rotation of engine until the pin for the locking device clicks during this motion into the sealing flange.

Tighten bolts of camshaft sprocket to 20 Nm + torque a further 1/8 turn (45).

Remove locking pin -MP 1-301- and locking device -T10050-.

Turn crankshaft two turns further in direction of rota-tion of engine until the crankshaft is again in TDC for cylinder 1.

Pin for locking device must engage in the sealing flange. (Locking device should be inserted just ahead of TDC on toothed belt sprocket.)

If the crankshaft is positioned after TDC of piston for cylinder 1 and the pin of the locking device does not engage in the sealing flange, rotate the crankshaft back no more than 1/4 revolution and again set the crankshaft to the TDC of the piston for cylinder 1 by turning in direction of rotation of engine.

It is not permitted to carry out the correction by turning in the opposite direction of rotation of the engine in or-der to insert the locking device.

Further installation occurs in a similar way in reverse order to removal.

Tightening torques for engine mounts and pendulum sup-port Chapter 10-1.Tightening torque of the engine mount on the vehicle body: 45 Nm.

Note


Disassembling and assembling engineEdition 07.03S00.5325.00.20

13-3 page 1

13

13-3 Disassembling and assembling engine

Cylinder block - Summary of components1 - 45 Nm2 - Engine mount3 - Cylinder blockT removing and installing the

sealing flange and flywheel Chapter 13-4

T disassembling and assem-bling pistons and conrod Chapter 13-5

4 - Connection fitting, 40 NmT for oil return line from turbo-

chargerT replace

5 - Distance sleeve6 - Rubber bearing7 - BracketT for plug connections from

hall sender -G40- for cam-shaft position and for engine speed sender -G28-

8 - 10 Nm9 - GasketT replace

10 - Oil filter holderT disassembling and assem-

bling Chapter 17-111 - 15 Nm + torque a further 1/4

turn (90)T replaceT first of all set up the bolt at

the top left and the bottom right and then tighten all four bolts cross-wise

12 - O-ringT replace

13 - 20 Nm14 - Engine speed sender -G28-15 - Connection fittings

T for coolant regulator16 - 15 Nm17 - Coolant regulator

T removing and installing Chapter 19-218 - 45 Nm

T Tightening sequence: from inside to outside19 - Compact holder

T for generator, AC compressor and tensioning pulley for ribbed V-beltT note the fitting bush between the compact holder and the cylinder block

20 - Tensioning pulleyT for the V-ribbed belt

21 - 25 Nm


Disassembling and assembling engine Edition 07.03S00.5325.00.2013-3 page 2

13

22 - Oil panT clean sealing surface before installingT fit with silicone sealant -D 176 404 A2- Chapter 17-2T The gearbox must be removed in order to remove the oil pan Manual Gearbox 02R; Rep. Gr. 34

23 - 15 NmT The gearbox must be removed in order to remove the rear bolts to the gearbox Manual Gearbox 02R;

Rep. Gr. 3424 - Cover

T with sealing tapeT clean strainer if dirty

25 - Retaining frameT before assembly, check whether the dowel sleeve is present in the cylinder block and the O-ring is seated in

the retaining frameT removing and installing Chapter 13-6

26 - 40 Nm27 - Protective cap

T for drive shaft


Removing and installing sealing flange and flywheelEdition 07.03S00.5325.00.20

13-4 page 1

13

13-4 Removing and installing sealing flange and fly-wheel

Repairs to clutch Manual Gearbox 02R; Rep. Gr. 30.

Secure the engine with engine mount - MP 1-202- and distance sleeves - T30010- on the assembly stand be-fore performing assembly work.

1 - Gasket ringT do not additionally lubricate

or grease sealing lips of the gasket ring

T before installing remove oil residues on crankshaft jour-nal with a clean cloth

T replace the gasket ring for the crankshaft - on the belt pulley side 13-4 page 2

2 - Front sealing flangeT must be positioned on dowel

sleevesT removing and installing

13-4 page 3T install with silicone sealant

-D 176 404 A- 13-4 page 4

3 - Cylinder blockT removing and installing

crankshaft Chapter 13-5T disassembling and assem-

bling pistons and conrod Chapter 13-5

4 - FlywheelT for removing and installing

secure Fig. 1 in 13-4 page 2 the flywheel using -MP 1-504-

5 - 60 Nm + torque a further 1/4 turn (90)T replace

6 - Intermediate plateT must be positioned on dowel sleevesT do not damage/bend during assembly workT hang on the sealing flange Fig. 2 in 13-4 page 2

7 - 15 Nm8 - Sealing flange with sealing ringT must be replaced completelyT do not additionally lubricate or grease sealing lips of the gasket ringT before installing remove oil residues on crankshaft journal with a clean clothT use supporting sleeve supplied for installingT supporting sleeve must not be removed until after pushing sealing flange onto the crankshaft journal

Note


Removing and installing sealing flange and flywheel Edition 07.03S00.5325.00.2013-4 page 2

13

Fig. 1: Lock the flywheel

Position the flywheel lock -MP 1-504- on the ring gear and turn until it rests against the distance sleeve -T30010-.

Fig. 2: Installing intermediate plate

Insert intermediate plate on sealing flange and push onto the dowel sleeves -arrows-.

Replacing gasket ring for crankshaft - on the belt pulley side


Gasket ring extractor -MP1-226- Counterholder -T 30004- Assembly device -T10053 - Torque wrench

Removing

Remove the timing belt Chapter 13-2. Remove crankshaft timing belt sprocket. To this end

lock the timing belt gear with counterholder -T 30004-. To guide the gasket ring extractor, screw central bolt

by hand fully into the crankshaft. Unscrew inner part of the gasket ring extractor

-MP1-226- two turns (approx. 3 mm) out of the outer part and lock with knurled screw.

MP 1-504S13-0191

T30010T30010

MP 1-202

A10-0129



13-4 page 3

13

Oil the thread head of the gasket ring extractor, posi-tion and forcely screw into the gasket ring as far as possible.

Release knurled screw and turn the inner side against the crankshaft until the gasket ring is pulled out.

Installing

Sealing lip of the gasket ring must not be oiled or greased additionally.

Remove oil residue on the crankshaft stub with a clean cloth.

Install guide bushing -T10053/1- on the crankshaft stub.

Slide gasket ring over the guide bushing onto the crankshaft stub.

Press in gasket ring -T10053- with the pressure plate up to the stop of the central screw.

Replace central screw for toothed belt gear - crankshaft.

Tighten new central screw for toothed belt gear - crankshaft to 120 Nm and turn a further 90 (1/4 turn).

Installing the timing belt, tightening Chapter 13-2.

Removing and installing the front seal-ing flange


Counterholder -MP1-226- Assembly device -T10053 - Torque wrench Hand-held power drill with plastic brush insert Silicone sealant - D 176 404 A2- Flat scraper

Note

Note



13

Removing

Remove the timing belt Chapter 13-2. Remove crankshaft timing belt sprocket. To this end

lock the timing belt gear with counterholder -T30004-. Removing oil pan Chapter 17-2. Unscrew front sealing flange. Remove sealing flange, if necessary release by apply-

ing slight blows with a rubber-headed hammer. Use a flat scraper to remove sealant residues on the

cylinder block. Cover the gasket ring with a clean cloth.

Use a rotating plastic brush to remove sealant resi-dues on the sealing flange (wear protective goggles).

Clean the sealing surfaces. They must be free of oil and grease.

Installing

Pay attention to the 'use by date' on sealant. The sealing flange must be installed within 5 minutes

after applying the silicone sealant.

Cut off nozzle tube of the silicone sealant at the front marking ( of nozzle approx. 3 mm).

Apply silicone sealant to the clean sealing surface of the sealing flange, as shown in the illustration.

Thickness of sealant bead -arrows-: 2...3 mm

The sealant bead must not be thicker, otherwise ex-cess sealant may get into the oil pan, clogg the strain-er in the retaining frame cover and can get onto the sealing surface of the sealing ring for the crankshaft.

Before applying the sealant bead cover over the gas-ket ring with a clean cloth.

Fit sealing flange immediately and lightly tighten all bolts.

Note

Note



13-4 page 5

13

When installing the sealing flange with the gasket ring fit-ted use guide sleeve -T10053/1-.

Tighten the fixing screws of the sealing flange cross-wise. Tightening torque: 15 Nm

Remove excess sealant. Installing oil pan Chapter 17-2.

After installing, allow the sealant to dry for about 30 min-utes. Only then may engine oil be filled in.

Installing the toothed belt and setting the timing Chapter 13-2.

Note

T10053/1 S13-0194

Note



13


Crankshaft, Piston and ConrodEdition 07.03S00.5325.00.20

13-5 page 1

13

13-5 Crankshaft, Piston and Conrod

Removing and installing crankshaft

Before removing the crankshaft, ensure a suitable place is available for placing it down so that the sensor rotor ( item 5) does not rest against anything or get damaged.

Before assembly moisten all bearing and work surfac-es with oil.

1 - Bearing shells 1, 2 and 4T for bearing cap without lubri-

cating grooveT for cylinder block with lubri-

cating grooveT do not mix up used bearing

shells (mark)2 - 65 Nm + torque a further 1/4

turn (90 )T replace

3 - Bearing capsT Bearing cap 1: on the belt

pulley sideT retaining lugs of the bearing

shells of the cylinder block/bearing cap must be on top of one another

4 - Bearing shell 3T for bearing cap without lubri-

cating grooveT for cylinder block with lubri-

cating groove5 - RotorT for engine speed sender

-G28 -T replace if damagedT removing and installing

Fig. 2 in 13-5 page 26 - 10 Nm + torque a further 1/4

turn (90 )T replace

7 - Fit pinT Checking projection from crankshaft Fig. 1 in 13-5 page 2

8 - Crankshaft Crankshaft bearing journal: 54.00 mm Conrod bearing journal 47.80 mmT Axial play when new: 0.07...0.17 mm

Wear limit: 0.37 mm9 - Thrust washerT for cylinder block, bearing 3

Note

3

12

4


Crankshaft, Piston and Conrod Edition 07.03S00.5325.00.2013-5 page 2

13

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


Depth gauge

Test sequence

Use depth gauge to inspect projection -a- of dowel pin when rotor -1- is removed.

1 - Rotor2 - Fixing screw3 - Projection of the fit pin -3- from crankshaft a =

2.5...3.0 mm

Fig. 2: Removing and installing sensor rotor

Always replace the sensor rotor -2- each time the bolts -1- are slackened.

Tightening torque: 10 Nm + 90 (1/4 turn)

After being attached a second time, the attachment point of the recess head screws in the sensor rotor is sufficient-ly misshapen that the bolt heads rest against crankshaft -3- -arrows- and the sensor rotor is positioned loosely be-low the screws.

1 2

A13-0150

3

Note



13-5 page 3

13

Disassembling and assembling piston and conrod1 - Piston ringsT Offset joint 120 T use piston ring pliers for re-

moving and installingT Marking TOP faces upT inspect gap clearance

Fig. 3 in 13-5 page 4T inspect end clearance

Fig. 4 in 13-5 page 42 - PistonT with combustion chamberT mark installation position and

matching cylinderT Installation position and as-

signment of piston/cylinder Fig. 6 in 13-5 page 5

T arrow on piston crown faces towards the belt pulley side

T use piston ring tensioning strap for installing

T if cracks present on piston stem - replace piston

T inspect piston projection at TDC 13-5 page 5

Pistons: 79.47 mm3 - Piston pinT if stiff, heat piston to 60CT removing and installing with

Drift -222A-4 - Circlip5 - ConrodT replace as a set onlyT mark matching cylinder -ar-

rows A-T Fitting position: Markings -arrows B- point towards the belt pulley side

6 - Bearing shellT Check fitting positionT Pay attention to version:

top bearing shell (towards the piston) must be in long wearing materialDistinguishing feature:Black streak on working surface close to separation cut

T do not mix up used bearing shellsT insert bearing shells in the middleT check for firm seatingT Axial clearance:

Wear limit: 0.37 mm7 - Cylinder blockT inspect cylinder bore Fig. 5 in 13-5 page 5 Cylinder: 79.51 mm

8 - Conrod capT Check fitting position

9 - Oil injection nozzleT for cooling pistons

10 - Pressure relief valve, 25 Nm



13

T opens at an overpressure of 0.25 to 0.32 MPa (2.5 to 3.2 bar)T replace without sealant

11 - Conrod bolt, 30 Nm + torque a further 1/4 turn (90)T replaceT oil thread and head contact surface

Fig. 3: Inspecting piston ring gap clearance


Feeler gauge Insert ring at right angles from above down into lower

cylinder opening, about 15 mm away from edge of cyl-inder.

Fig. 4: Inspect piston ring end clearance


Feeler gaugeClean ring groove before inspecting.

Piston ring dimensions in mm

new Wear limit

1. Compression ring 0,25...0,40 1,02. Compression ring 0,20...0,40 1,0Oil scraper ring 0,25...0,50 1,0

V13 - 0687

Piston ring dimensions in mm

new Wear limit

1. Compression ring 0,06...0,09 0,252. Compression ring 0,05...0,08 0,25Oil scraper ring 0,03...0,06 0,15



13-5 page 5

13

Fig. 5: Inspecting cylinder bore


Internal precision measuring instrument 50...100 mmPiston dimenston item 2 in 13-5 page 3.Cylinder dimenston item 7 in 13-5 page 3.Test sequence

Measure at 3 points crosswise in a transverse direc-tion -A- and lengthwise -B-.

Variations compared to nominal dimension max. 0.10 mm

Do not measure the cylinder bore if the cylinder block is fixed to the assembly stand with the engine mount -MP 1-202-, as this may result in incorrect measure-ments.

Fig. 6: Piston fitting position and assignment of the piston/cylinder


e.g. electric stylusProcedure

Mark installation position and assignment on inside of piston (not on piston crown), with e.g. an electric sty-lus.

Piston in cylinder -1- and -2-:

Large piston relief for inlet valve to flywheel side -arrows-

Piston in cylinder -3-:

Large piston relief for inlet valve to belt pulley side -arrow-

For new pistons the cylinder assignment is colour-coded on the piston crown.

Pistons in cylinders 1 and 2: Identification 1/2 Piston in cylinder 3: Identification 3

Checking piston projection in TDC


Measuring tool for piston projection -MP 1-107-

Note

Note



13

ProcedureWhen installing new pistons or a short engine, inspect the piston projection at TDC. Depending on the piston projec-tion fit the relevant cylinder head seal in accordance with the table below:

Turn the engine in a clockwise direction in order to meas-ure the piston projection in TDC.

Identify cylinder head gasket Spare parts No. = -arrow 1- Control code = -arrow 2- (ignore) Bores = -arrow 3-

If different values are measured during the piston projec-tion measurement, the greatest dimension applies for the seal assignment.

Note

Piston projection over cylinder block - top side

Marking of bore

0.91 mm 1.00 mm 11.01 mm 1.10 mm 21.11 mm 1.20 mm 3

Note


Removing and installing balancing shaft and retaining frameEdition 07.03S00.5325.00.20

13-6 page 1

13

13-6 Removing and installing balancing shaft and re-taining frame

Before assembly moisten all bearing and work surfaces with oil.

1 - ChainT pay attention to correct in-

stallation position 13-6 page 2

T before removing mark run-ning direction

2 - 100 Nm + torque a further 1/4 turn (90 )T replaceT tightening may occur in suc-

cessive stages3 - Balancing weightT can be installed only in one

position4 - SprocketT for balancing shaftT can be installed only in one

position5 - Fitting sleeve6 - 20 Nm + torque a further 1/4

turn (90 )T replace

7 - SprocketT for oil pumpT can be installed only in one

position8 - CoverT Clean strainer if dirty

9 - 5 Nm10 - O-ring

T replaceT check tightnessT lightly oil for assembly

11 - 20 Nm12 - Oil pump

T with pressure relief valve 1.15 MPa (11.5 bar)T Before installing, check whether both dowel sleeves are present

13 - Balancing shaftT removing and installing 13-6 page 2

14 - Retaining frameT before assembly, check whether the dowel sleeve is present in the cylinder block and the O-ring is seated in

the retaining frameT removing and installing 13-6 page 2

15 - O-ringT replaceT check for correct fitting in the retaining frame

Note


Removing and installing balancing shaft and retaining frame Edition 07.03S00.5325.00.2013-6 page 2

13

16 - Cylinder block17 - Chain sprocket for guide pulley18 - 20 Nm19 - Chain tensioner with tensioning rail

T to remove lock with -T10060-T removing and installing 13-6 page 2

20 - 8 Nm + torque a further 1/4 turn (90 )T replace

removing and installing balancing shaft


Locating bolts -T10060- Torque wrench

Removing

Remove the timing belt Chapter 13-2. Removing oil pan Chapter 17-2. Remove the sealing flange on the belt pulley side

Chapter 13-3. Unscrew fixing screws for cover. Remove cover from retaining frame. Lock chain tensioner with locating bolts -T10060- -ar-

row-. Unscrew chain sprocket for guide pulley -1- from re-

taining frame. Unscrew fixing screws -2- from the chain tensioner

and remove chain tensioner. Remove chain from chain sprockets and place on a

clean surface. Lock balancing shaft with open-end wrench -1-.

The open-end wrench must be positioned in the centre for the safety weight of the balancing shaft and at right angles to the balancing shaft.

Loosen fixing bolt -2- for balancing weight.

Only loosen fixing bolt -2- for balancing weight, do not un-screw.

Unscrew retaining frame -3- from cylinder block and remove retaining frame with balancing shaft.

Lay aside retaining frame on a clean surface. Unscrew fixing bolt from the balancing weight.

Note

Note



13-6 page 3

13

Remove balancing weight and chain sprocket from the balancing shaft.

Turn balancing shaft in such a way that it can be taken out of its bearing.

Installing

Oil work surfaces of the bearing. Insert balancing shaft in the bearing. Slide chain sprocket and balancing weight onto the

balancing shaft.

Assembly of chain sprocket and balancing weight is only possible in one position.

Tighten fixing bolt for balancing weight and chain sprocket by hand.

Screw retaining frame onto cylinder block clearance free and by hand.

When installing the retaining frame ensure, that the dowel sleeve is seated in the cylinder block and the O-ring in the retaining frame.

Align retaining frame in such a way, that it is aligned on the belt pulley side with the cylinder block outer side.

Screw retaining frame with balancing shaft onto cylin-der block.

Tightening torque: 20 Nm.

Check if the retaining frame is aligned on the belt pul-ley side with the cylinder block outer side.

Lock balancing shaft with open-end wrench -1- ac-cording to the illustration.

The open-end wrench must be positioned in the centre for the safety weight of the balancing shaft and at right angles to the balancing shaft.

Tighten fixing bolt -2- for balancing weight.

Tightening torque: 100 Nm + torque a further 1/4 turn (90)

Fixing bolt is an antifatigue bolt and must always be re-placed.

Install chain tensioner.

Tightening torque: 8 Nm + torque a further 1/4 turn (90)

Note

Note

Note

Note



13

Fixing bolts for chain tensioner are antifatigue bolts and must always be replaced.

Clean chain with a non-fluffy cloth. Check, if the marking -arrow- at the chain sprocket of

the crankshaft is located at the top.

Fit chain onto chain sprocket of crankshaft, onto chain sprocket of oil pump and onto chain sprocket of bal-ancing shaft. While doing so the markings of the col-our marked chain links -arrows- at chain sprocket of crankshaft and at chain sprocket of balancing shaft must be opposite each other, as shown.

Colour marked chain links are additionally marked with a notch.

Insert chain sprocket for guide pulley into the chain and screw chain sprocket for guide pulley onto retain-ing frame.

Tightening torque: 20 Nm.

Remove locating bolts -T10060- from chain tensioner. Check if the markings of the colour marked chain links

-arrows- at chain sprocket of crankshaft and at chain sprocket of balancing shaft are opposite each other.

Colour marked chain links are additionally marked with a notch.

Install the sealing flange on the belt pulley side Chapter 13-3.

Install cover for balancing shaft.Tightening torque: 5 Nm.

Oil O-ring for oil pump and inner shank of cover before installing the cover.

Pay attention to correct fitting of the sealing tape in the cover.

When installing the cover ensure that it locks into the retaining frame.

Installing oil pan Chapter 17-2.

Note

Note

Note

Note



13-6 page 5

13

Install the timing belt Chapter 13-2.



13


Removing and installing cylinder headEdition 07.03S00.5325.00.20

15-1 page 1

15

15-1 Removing and installing cylinder head

Removing and installing toothed belt Chapter 13-2Testing compression pressure 15-1 page 6.

When installing an exchange cylinder head with the camshaft installed, it is necessary to oil the contact surfaces between bucket tappets and the cam track.

Do not remove the plastic covers supplied as a protec-tion for the open valves until just before fitting on the cylinder head.

If the cylinder head is replaced, also the entire coolant must be replaced.

It is not permissible to rework the cylinder head of die-sel engines.

1 - Timing belt guard - top part2 - Timing beltT removing and installing, ten-

sioning Chapter 13-23 - 10 Nm4 - 20 Nm + torque a further 1/8

turn (45 )5 - 100 Nm6 - Camshaft sprocket7 - HubT with rotorT to release and tighten use

the counterholder -T10051 -T to remove the extractor

-T10052- useT removing and installing

Chapter 15-38 - Timing belt guard rear9 - Sealing sleeveT replace if damaged

10 - Camshaft position sensor -G40-T for removing the sealing

grommet item 9 from the timing belt cover remove from behind

11 - Cylinder head boltT replaceT pay attention to sequence for

loosening and tightening 15-1 page 3

15 Cylinder Head, Valve Gear

Note


Removing and installing cylinder head Edition 07.03S00.5325.00.2015-1 page 2

15

T if bearing caps of the camshaft are removed, insert special bases into the cylinder block before installing the cylinder head bolts Chap. 15-2

12 - Bolts, 10 NmT for the engine cover

13 - Cylinder head coverT before fitting on, thoroughly clean sealing surface with a clean cloth

14 - to charge air pipe at the rear15 - 10 Nm

T tighten all bolts first of all by handT Tighten crosswise from the inside outwards

16 - Pressure control valve17 - Oil filler inlet18 - Cap19 - Sealing sleeve

T replace if damaged20 - Bracket

T with fuel line 21 - Gasket for cylinder head cover

T replace if damaged22 - 20 Nm23 - Lifting eye24 - The unit injector

T removing and installing 1.4/55 TDI Engine, Fuel Injection; Rep. Gr. 23 25 - Central plug connection

T for pump-nozzle unit26 - To the brake servo unit27 - Tandem pump

T for fuel and vacuum supplyT removing and installing Chapter 20-2T inspect Chapter 20-2

28 - Intake hoseT from the fuel filter Chapter 20-1T white markingT check for firm seatingT secure with spring strap clamps

29 - Return-flow hoseT to fuel filter Chap. 20-1T blue markingT check for firm seatingT secure with spring strap clamps

30 - GasketT replace

31 - Bracket32 - Hexagon taper nut33 - Cylinder head

T removing and installing 15-1 page 3T after replacing fill entire system with fresh coolantT Inspecting the cylinder head for distortion Fig. 1 in 15-1 page 3

34 - Cylinder head gasketT replaceT Pay attention to the marking Fig. 2 in 15-1 page 3

35 - Glow plugT 15 Nm



15-1 page 3

15

36 - Tensioning pulley37 - 20 Nm + torque a further 1/8 turn (45 )

Fig. 1: Inspecting the cylinder head for distortion


Feeler gauge Knife-edge straightedgeMax. permissible distortion: 0.1 mm

It is not permissible to rework the cylinder heads of diesel engines.

Fig. 2: Identify cylinder head gasket

Spare parts No. = -arrow 1- Control code = -arrow 2- (ignore) Bores = -arrow 3-

Cylinder head seals of different thicknesses are fitted de-pending on the piston projection from the cylinder block. If only the gasket is replaced, then it must be replaced with a gasket with the same marking.

Removing and installing cylinder head


Supporting device - MP 9-200- Bracket -T10014- Catch pan (e.g. -V.A.G 1306-) Torque wrench Hand vacuum pump, e.g. -V.A.G 1390 - Ventilation reservoir e.g. -V.A.G 1390/1-

Removing

Remove intake hose between air filter and intake manifold 1.4/55 TDI Engine, Fuel Injection; Rep. Gr. 23.

Remove battery and battery tray Electrical System; Rep. Gr. 27.

Removing charge air pipe at the rear with connecting hose Chap. 21-1.

Unplug connector with glow plugs.

V15 - 0673

Note

Note



15

Remove front exhaust pipe with catalytic converter from exhaust manifold.

Remove charge air connection hose between turbo-charger and charge air pipe at bottom Chapter 21-1.

Pull out vacuum hoses from the turbocharger Chapter 21-1 .

Remove oil feed and oil return line for the exhaust tur-bocharger Chapter 21-1.

Drain coolant Chapter 19-1. Unscrew inlet connection from intake manifold and

place to the side with the hoses connected 1.4/55 TDI Engine, Fuel Injection; Rep. Gr. 23.

Slacken bolts of cylinder head cover. Use hand vacuum pump and bleeding bottle to extract

the fuel at the return-flow hose of the tandem pump Chap. 20-2.

Remove fuel hoses -1- and -4-. Remove coolant hose -5-. Remove central plug connection -2- for pump-nozzle

unit. Disconnect plug -3- from the fuel temperature sender

-G81-. Unbolt oil feed line at the brackets for oil filter, turbo-

charger and from the mounts. Disconnect coolant hose -1- from T-piece and the

coolant hoses -2- and -3- from the connection fittings. Disconnect plug -4- from the coolant temperature

sender -G62-.

Remove the coolant hose -3- from the supports -4-. Pull off vacuum hose -6- from tandem pump -5-.

1

2

3

5

4

S15-0165

1

2 43

S15-0166

1

2

6

43

S10-0150

5



15-1 page 5

15

Screw bracket -T10014- into the threaded holes in the area of the coolant pump in the cylinder block. Tight-ening torque: 20 Nm.

Follow the specified order for loosening cylinder head bolts.

Installing

Always replace the cylinder head bolts. When conducting repairs sealant residues should

carefully be removed from the cylinder block and cyl-inder head using a chemical cleaner.

Remove the new cylinder head seal from its wrapping immediately before fitting.

Treat the new seal with the utmost care. Damage to the silicone layer and in the area of the bead results in leakages.

Before fitting the cylinder head position the crankshaft on the TDC marking.

Turn crankshaft against the running direction of the engine until all pistons are almost evenly at TDC.

Fit on cylinder head gasket. Fit on cylinder head and screw on all 8 cylinder head

bolts by hand. Tighten cylinder head in four stages in the following

order:1. Pre-tighten with torque wrench:

Stage I = 40 Nm stage II = 60 Nm

2. Tighten further with a rigid wrench:

Stage III = 1/4 turn (90) Stage IV = 1/4 turn (90)

Tightening up the cylinder head bolts after doing repair work is not necessary.

Note

Note



15

After securing the cylinder head turn the camshaft in such a way that the cams for cylinder 1 point upwards evenly. Before fitting on the timing belt set the crank-shaft in the direction of rotation of the engine to the TDC Chapter 13-2.

After installing the cylinder head, fill tandem pump and cylinder head with fuel using a hand vacuum pump and ventilation reservoir Chapter. 20-2.

Further installation occurs in reverse order to removal. Perform test drive, interrogate fault memory 1.4/55

TDI Engine, Fuel Injection; Rep. Gr. 23.

Testing the compression

Test condition

Engine oil temperature at least 30 CSpecial tools, test and measuring equipment and auxiliary items required

Flexible-head wrench for glow plugs Torque wrench Adapter (e.g. -V.A.G 1381/12-) Compression tester e. g. (-V.A.G 1763-)

Test sequence

Separate central plug connection for unit injector. Remove all glow plugs using a flexible-head wrench. Screw in adapter -V.A.G 1381/12- instead of the glow

plugs. Check compression pressure with compression tester

-V.A.G 1763 -.

Use of tester Operating Instructions. Operate starter until the tester no longer indicates a

pressure rise.

Compression readings:

Screw in glow plugs with flexible-head wrench.Tightening torque: 15 Nm

Interrogate fault memory 1.4/55 TDI Engine, Fuel Injection System; Rep. Gr. 23.

barZyl

Zylinder

PRINT

! C

V.A.G 1783

Note

New engine Wear limit Pressure differ-ence between individual cyl-inders

2.5...3.1MPa (25...31 bar)

1.9 MPa (19 bar)

max. 0.5 MPa (5 bar)



15-1 page 7

15

Faults are stored as a result of separating the central plug connection for the unit injector. For this reason interro-gate fault memory or erase 1.4/55 TDI Engine, Fuel In-jection; Rep. Gr. 01.

Note



15


Repairing Valve GearEdition 07.03S00.5325.00.20

15-2 page 1

15

15-2 Repairing Valve Gear

Summary of components

Cylinder heads with cracks between the valve seats may continue to be used without any reduction in the life time provided the cracks are slight and max. 0.5 mm wide.

1 - 20 Nm + torque a further 1/4 turn (90 )T replaceT Pay attention to tightening

and release sequence Chapter 15-3

2 - Valve-lever shaftT do not interchange

3 - Cylinder head boltT replaceT Pay attention to tightening

and release sequence Chapter 15-1

T before installing, insert washers item 4 into the cylinder head

4 - WasherT for cylinder head screwsT before installing the bearing

cap, insert into the cylinder head

5 - Bucket tappetsT do not interchangeT with hydraulic valve clear-

ance compensationT lay aside with contact sur-

face facing downT before installing check axial

play of the camshaft Fig. 1 in 15-2 page 2

T oil contact surfacesT before removing, take off

camshaft bearing shell6 - Collets7 - Valve spring retainer8 - Valve spring outsideT removing and installing: Cylinder head removed: with - MP 1-206-, -MP 1-211-, -MP 1-213- Cylinder head installed Chap. 15-4

9 - Valve spring insideT removing and installing: Cylinder head removed: with - MP 1-206-, -MP 1-211-, -MP 1-213- Cylinder head installed Chap. 15-4

10 - Valve stem sealT replacing Chapter 15-4

11 - Valve guide

Note


Repairing Valve Gear Edition 07.03S00.5325.00.2015-2 page 2

15

T inspect Chapter 15-412 - The unit injector

T removing and installing 1.4/55 TDI Engine, Fuel Injection; Rep. Gr. 23 13 - Cylinder head

T pay attention to note 15-2 page 1T reworking valve seats Chapter 15-4

14 - Gasket ringT Neither oil nor grease sealing lip of sealing ringT before installing, remove oil residues on the camshaft studs with a clean clothT before fitting cover slot on the camshaft cone with adhesive tape (e.g. Scotch tape).T removing and installing Chapter 15-3

15 - ValvesT Valve dimensions Fig. 3 in 15-2 page 3

16 - Bearing shellT do not mix up used bearing shells (mark)T ensure the retaining lugs are correctly located in the bearing caps and in the cylinder head

17 - CamshaftT inspecting axial play Fig. 1 in 15-2 page 2T removing and installing Chapter 15-3T Slack: max. 0.01 mmT Identification, timing Fig. 4 in 15-2 page 3

18 - Bearing capsT Fitting sequence Chap. 15-3T Bearing cap 4 is identified like bearing cap 5.T for installing seal the separator surfaces of bearing caps 1 and 4 with sealant -AMV 174 004 01- Fig. 2 in 15-2 page 3

19 - 8 Nm + torque a further 1/4 turn (90 )T replace

Fig. 1: Inspecting axial play of camshaft


Universal dial gauge holder -MP 3-447- Dial gaugePerform measurement with removed bucket tappets and installed bearing caps.

Wear limit: max. 0.15 mm

MP 3-447

S15-0168


Repairing Valve GearEdition 07.03S00.5325.00.20

15-2 page 3

15

Fig. 2: Seal contact surface of bearing caps 1 and 4 with sealant -AMV 174 004 01-

Apply a thin layer of sealant -AMV 17400401- evenly to the sealing surfaces -1-.

Make sure no sealant penetrates into the slots -ar-rows-.

Bearing cap 4 is identified like bearing cap 5.

Fig. 3: Valve dimensions

Valves must not be reworked. Only grinding in is permis-sible.

Fig. 4: Camshaft identification, timing

Base circle of cam: a = 52.8 mm Camshaft identified with digits and characters

stamped in on the end face of the cam for outlet valve on 3rd cylinder.

N15-0270

1

Note

Note

Dimension Inlet valve Exhaust valve a mm 35,95 31,45 b mm 6,980 6,956c mm 89,95 89,95 45 45

3. Cylinder -arrow- 858 C


Repairing Valve Gear Edition 07.03S00.5325.00.2015-2 page 4

15


CamshaftEdition 07.03S00.5325.00.20

15-3 page 1

15

15-3 Camshaft

Removing and installing camshaft


Counterholder - T10051- Extractor -T10052- Torque wrench Sealant -AMV 174 004 01-

Removing

Remove the timing belt Chapter 13-2. Unscrew fixing screws -1- for camshaft sprocket. Take camshaft sprocket off the hub. Loosen fixing screw -1- of the hub.

Use counterholder -T10051- for this purpose.

Turn bolt attaching the hub out about 2 turns. Position extractor -T10052- align them with the hub

bores. Screw fixing screws -1- into the hub. Put the hub under tension by uniformly tightening the

central bolt -2- until the hub is released from the cam-shaft cone.

Hold the extractor firmly using an open-end wrench.

Remove hub from cone of camshaft. Remove cylinder head cover. Remove valve-lever shaft.

First release crosswise the two outer and then both inner fixing screws.

Remove tandem pump Chap. 20-2. First remove bearing caps 2 and 3. Release bearing

caps 1 and 4 alternately and crosswise.

Note

Note


Camshaft Edition 07.03S00.5325.00.2015-3 page 2

15

Bearing cap 4 is identified like bearing cap 5.

Installing

When fitting the camshaft the cams of cylinder 1 must point upwards.

Do not mix up used bearing shells (mark). When installing the camshaft, ensure it is correctly lo-

cated in the retaining lugs of the bearing shells in the bearing caps and in the cylinder head.

Before installing the bearing caps make sure the washers for the cylinder head screws have been in-serted in the cylinder head.

Oil the contact surfaces of the bearing shells. Tighten bearing caps 2 and 3 alternately crosswise

and tighten to 8 Nm + torque a further 1/4 turn (90 ) (replace screws).

Install bearing caps 1 and 4 and also tighten to 8 Nm + torque a further 1/4 turn (90 ) (replace screws).

Bearing cap 4 is identified like bearing cap 5. Seal the separator surface of bearing caps 1 and 4

with sealant -AMV 174 004 01- Chap. 15-2 Bearing cap 4 must be aligned with the outer edge of

the cylinder head, as this may otherwise cause leaks on the tandem pump

Install camshaft seal 15-3 page 3. Install valve-lever shafts and tighten evenly and cross-

wise, clearance free to bearing, first the two inside and then the outside fixing screws, once again tighten.

Tightening torque: 20 Nm + torque a further 1/4 turn (90 ) (replace)

Position hub onto camshaft. Tighten fixing screw -1- of the hub.

Tightening torque: 100 Nm

Use counterholder -T10051- for this purpose.

Note

Note

Note


CamshaftEdition 07.03S00.5325.00.20

15-3 page 3

15

Push camshaft sprocket onto hub.

The gear segment -arrow- of the camshaft timing gear must be at the top.

Align camshaft so that the longitudinal holes are in the centre position.

Fit the bolts -1- attaching the camshaft sprocket on by hand so that no play exists.

Lock hub with rig pin -3359-. Installing the timing belt, tightening Chapter 13-2. Install tandem pump Chap. 20-2.

After installing new bucket tappets, the engine must not be started for about 30 minutes. The hydraulic clearance compensation elements must settle (otherwise valves would strike the pistons).

Removing and installing gasket ring for camshaft


Insertion tool -MP 1-214- Gasket ring extractor -T30003- Torque wrench Screw -M12x65-

Removing

Remove the timing belt Chapter 13-2. Remove camshaft sprocket and hub 15-3 page 1. Unscrew inner part of the gasket ring extractor

-T 30003- two turns (approx. 3 mm) out of the outer part and lock with knurled screw.

Oil the thread head of the gasket ring extractor, posi-tion and forcely screw into the gasket ring as far as possible.

Slacken knurled screw and turn inner part of gasket ring extractor against the camshaft until the gasket ring is pulled out.

Installing

Sealing lip of the gasket ring must not be oiled or greased additionally.

Remove oil residue on the camshaft stud with a clean cloth.

Note

Note

Note


Camshaft Edition 07.03S00.5325.00.2015-3 page 4

15

Cover slot on the camshaft cone with commercially available adhesive tape (e.g. with sellotape).

Carefully fit seal onto the camshaft. Push on the sealing ring with the pressure plate of the

insertion tool -MP 1-214- and with screw -M12x65- up to the stop.

Installing the timing belt, tightening Chapter 13-2.


Valve seats, valves guides, valve stem sealsEdition 07.03S00.5325.00.20

15-4 page 1

15

15-4 Valve seats, valves guides, valve stem seals

Grinding in valve seats


Depth gauge

Do not re-mill valve seats. Only grinding in of valves is permissible.

inspecting valve guides 15-4 page 2. If the wear limit is exceeded, repeat measurement with new valves. If the wear limit is again exceeded, replace cyl-inder head.

Calculating max. permissible reworking dimension 15-4 page 1. If the wear limit is exceeded, repeat measurement with new valves. If the wear limit is again exceeded, replace cylinder head.

Calculating max. permissible reworking dimen-sion

Insert valve and press firmly into the valve seat.

If the valve is replaced when carrying out repair work, use a new valve for the measurement.

Measure distance -a- between the end of the valve stem and the upper face of the cylinder head.

Calculate max. permissible reworking dimension from the distance -a- measured and from the minimum di-mension.

Minimum dimension:

Inlet valve 43.4 mm Outlet valve 43.2 mmMeasured distance less minimum dimension = max. per-missible reworking dimension.

Example:

Note

Note

a

N15-0253

-Measured distance minimum dimension

44,143,4

mm mm

= Max. permissible rework-ing dimension

0,7 mm


Valve seats, valves guides, valve stem seals Edition 07.03S00.5325.00.2015-4 page 2

15

If the max. permissible reworking dimension is 0 mm, re-peat measurement with a new valve. If the max. permis-sible reworking dimension is again 0 mm, replace cylinder head.

Inspect valve guides


Universal dial gauge holder -MP 3-447- Dial gauge

Test sequence

Insert a new valve into the guide. The end of valve stem must be flush with guide.

Because of the different stem diameters only use inlet valve in inlet guide or outlet valve in outlet guide.

Valve rock: max. 1.3 mm

If the wear limit is exceeded, repeat measurement with new valves. If the wear limit is again exceeded, replace cylinder head.

If the valve is replaced when carrying out repair work, use a new valve for the measurement.

Replacing valve stem seals


Assembly device -MP 1-213 - Extractor -MP 1-206- Insertion tool -MP 1-212- Valve lever -MP 1-211-

Removing(Cylinder head fitted)

Removing camshaft Chap. 15-3. Remove bucket tappets and lay aside with the contact

surface facing down. Make sure that you do not mix up the tappets.

Position piston of the relevant cylinder in dead centre. Insert the assembly device -MP 1-213- and adjust

bearing to the stay bolt height. Remove valve springs with valve lever -MP 1-211-.

Note

Note

MP 1-211

MP 1-213

S15-0171


Valve seats, valves guides, valve stem sealsEdition 07.03S00.5325.00.20

15-4 page 3

15

The valves rest on the piston crown. Release collets that are tight by striking with light

blows of a hammer on the valve lever.

Pull off valve stem seals with -MP 1-206-.

Installing

Insert the supplied plastic bushings -A- on the relevant valve stem. This will prevent any damage to the new valve stem seals -B-.

Insert the new valve stem seal in the insertion tool -MP 1-212-.

Oil the sealing lip of the valve stem seal and carefully slide into the valve guide.

After carrying out work on the valve gear, carefully crank engine at least 2 revolutions to ensure that no valve touches the piston when the engine is started.

After installing the camshaft, the engine must not be started for about 30 minutes. The hydraulic clearance compensation elements must settle (otherwise valves would strike the pistons).

Note

Note


Valve seats, valves guides, valve stem seals Edition 07.03S00.5325.00.2015-4 page 4

15


Removing and installing parts of the lubrication systemEdition 07.03S00.5325.00.20

17-1 page 1

17

17-1 Removing and installing parts of the lubrication system

If considerable quantities of metal swarf or abrasion is found in the engine oil when carrying out engine re-pairs, carefully clean the oil galleries in order to avoid consequential damage and additionally replace the oil cooler.

Testing oil pressure and oil pressure switch Chapter 17-3.

The oil level must never exceed the max marking - risk of damage to catalytic converter!

Check oil specifications, capacity and oil level Inspection and Maintenance; Chap. 02-3

Lubrication system - Summary of components1 - 15 Nm2 - Sealing flangeT with gasketT must be positioned on dowel

sleevesT removing and installing

Chapter 13-4T fit with silicone sealant

-D 176 404 A2- Chapter 13-4

T Neither oil nor grease sealing lip of sealing ring

T before installing remove oil residues on crankshaft jour-nal with a clean cloth

T replace sealing ring for crankshaft at belt pulley side Chapter 13-4

3 - Cylinder block4 - GasketT replace

5 - Oil filter holderT disassembling and assem-

bling 17-1 page 36 - 15 Nm + torque a further 1/4

turn (90 )T replaceT first of all set up the bolt at

the top left and the bottom right and then tighten all four bolts cross-wise

7 - Dipstick

17 Lubrication

Note


Removing and installing parts of the lubrication system Edition 07.03S00.5325.00.2017-1 page 2

17

T oil level must not exceed max. marking8 - Filler funnelT Remove for extracting oil

9 - 5 Nm10 - Guide tube11 - 10 Nm12 - O-ring

T replaceT check tightnessT lightly oil for assembly

13 - CoverT with sealing tapeT Clean strainer if dirty

14 - 20 Nm15 - Oil pump

T with pressure relief valve 11.5 MPa (1.15 bar)T Before installing, check whether both dowel sleeves are present

16 - Fitting sleeve17 - 25 Nm

T replace without sealant18 - Retaining frame

T before installing, check whether the dowel sleeve is present in the cylinder block and the O-ring is seated in the retaining frame

T removing and installing Chapter 13-619 - Oil injection nozzle

T for cooling pistonsT check fitting position: Turn oil injection nozzle anti-clockwise up to the stop in the cylinder block and tighten

in this position20 - O-ring

T replace21 - Oil pan

T clean the sealing surfaces before installingT fit with silicone sealant -D 176 404 A2- Chapter 17-2T The gearbox must be removed in order to remove the oil pan Manual Gearbox 02R; Rep. Gr. 34

22 - BracketT for connection pipe of charge air cooler

23 - 15 NmT The gearbox must be removed in order to remove the rear bolts to the gearbox Manual Gearbox 02R;

Rep. Gr. 3424 -

engine amf.pdf

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