Audi 100 200 Manual

V.A.G Service.
Workshop Manual
Audi 100 1983 », Audi 200 1984 »
Engine SB
Code letters
| 5 Cylinder F. 1. engine
Bookl et (4 valve), mechanics
Edition 05,89
VA G
Service Department. Technical Information
V.A.G Service.
Repair Group Index to Workshop Manual
Audi 100 1983 », Audi 200 1984 »
Engine
Code letters 3B
5 Cylinder F.|. engine (4 valve), mechanics
Booklet зол.
Please note: the technical supplements given here start at page 86
Repair Group Workshop Bulletins
00 Technical data
13 Crankshaft grou
15 Cylinder head, Valve gear
17 Lubrication
19 Cooling
20 Fuel supply system
21 Exhaust gas turbocharging
26 Exhaust system
Technical Information should always be available to all foremen and mechanics, because compliance
with the instructions given is essential to ensure vehicle roadworthiness and safety. In addition, the
normal safety precautions to be observed when working on motor vehicles are aiso applicable.
The Workshop Manual is only intended for use within the
V.A.G Organisation, and passing on the third parties 1s not permitted. Printed in Germany
© 1989 VOLKSWAGEN AG 000.5164.59,20
Index
00 Technical data
— Г
- List of engin
13 Crankshaft group
- Insta:1ing toothed belt
- Tensioning alzernator vee bel:
- Tensioning central aydrauitc vee belt
Dismantiing and assembling cylincer biock, crankshaft and f
- Checking crankshaft radial clearanc
- Crangshaft dimensions
Inserting pin for ignition timi int
bismantling and assembling pistons and conrods
- Checking corrod radial clearance
15 Cylinder head. valve gear
- Removing and Installing cvlinder he
- (hecking compression pressure —.
- vervicing vaive gear -
reworking Valve seats
Checking hydraulic t So
RENEWING camshaft oll sea]
Removing and installing camshaf
Checking and renewing valve guides
Renewing valve stem seals (cylinder fitted)
renewing va.ve stem seais (cylinder )
17 Lubrication
zemoyi {
- Removing cil
~ Checking oil pres
Sstire and oil pr
- Checking all press
Ei
ure sender
19 Cooling
Removing and installing parts of the cooling system
« Checking cooling system for leaks
- Draining and filling with coolant
- Checking thermo switch and coolant xhaust tur
20 Fuel supply system
Removing and installi rts of
- Rules for cleanliness when workd the fuel s
Connecting r control V.A.G 1548/3A With a
Fitti 5 fuel filter
Removing and installing fuel
Removing and instaliing fuel
Dismantiing and assembling fuel
Checking fue
Checking delivery rate of electric fuel
Checking electric fuel ron-return valy
Renewing non-return valve
Checking fuel relay and control circu
Repairing activated charcoal Tilter tank venting system
Repairing throttle Link
Adjusting tne 1
с ing and adjusting throttle
21 Exhaust gas turbocharging
Femovin ne de
Е di
- RKemevin
- К
- cking overr
20 Exhaust system
Rermovina and alling parts ©
- Joint between main and rear silencer
- Aligning e t system stress fr
"N
- Checking ex” for |
LIST OF ENGINES
Engíne code
TECHNICAL DATA
Ar dd A TA AAA ——
ENGINE CODE AND SERIAL NUMBER
——
—# Engine code and serial number are stamped on the right hand
side at the rear of the cylinder head.
Engine characteristics
Marñufactured
Ko, of cylinders
Capacity
Qutput
Torque
Bore
Stroke
Compression ratio
152/5709
clearahée DEE. SEES nen DE
Inlet closes after BDC Végge
RON ER EE
| (unleaded)
tem: #2) -Motronic
Fuel injection sys
Catalytic converter 2 x
Lambda contro! X |
Turbocharger X
Vehicle is specially Low pollutant
tuned for: exhaust
00-7
10 11
12 13 14
15
16 17 18
19 20
13-494
10 11
12 13 14
15
16
17 18
1920
13-4 9 4
DISMANTLING AND ASSEMBLIRG ENGINE
dd dd dd dd da dd AAA AAA что AT E A DD AA TA E
MALO MALL MALO OLLAS ULE LL LALO 30 МЕ MO FEN PU BE Fe Fm fy my my mmm mm mm O O a ны бе ==
Note:
a Always renew al seals, gaskets and
01) seals on shafts
See manual gearbox assembly for
repairs to clutch
e Removing and installing sump
- Figs. 3 and 4
e Checking compression - Repair
Group 15
I~ 10 Nm
2- Tootned belt cuard, upper
3- Tootneid belt
& Inetallino ~ page 1
# Turn coolant pump $
tension - sage 13-9
3-7
o ¡eft to
4- 43 №
5- Ves-Belt deflection Timiter (right)
6- Spacer bushes
e Long spacer bush {top}
e Short spacer bush [bottom]
7- 67 Nm
8- Camshaft sprocket
position when Fitting toothed
belt - page 13-8
Top WET АД СОВЕТ”
еее
e REMOVING - Fig. 2
UE CE, when instaliing, tighten to
Vee-belt deflection limiter (left)
Coolant pump
e Turn to left to tension tootned
belt - page 13-9
0 ring
13-2
DISMANTLING AND ASSEMBLING ENGINE
o A TAPA AAA Ad lo dp dp AA AA AA TE NT E A ee
A ALA E E a A A A DATO ap ah Ap A A AE A A A A о =
57 Hm
Eylinder head
¢ Removing and refitting -
repair group 15
(viinder head gasket
4 Ensure correct installation
position. The marking "OBEN"
or the part number must face
the cylinder head.
Fit over locating pin in
cylinder block,
=
Heat shield
Crankcase breather pipe
Ignition cable cover
Cylinder head cover
4 Remove throttle valve housing
before removing cylinder head
Je Tighten Securing solts to 22 Nm.
© De Use hex key V.A.G 1659. for remo-
vel and installation. ©
“Vehicles equipped with:C65 cruise
— Fig. 1 Removing and installing vibration damper
- Tightening torque 350 Am,
- Use special tools 2079 and 2084,
- Coat threads and contact surface of bolt head with anti-
corrosion compound AMY 188 006 02.
Caution
The tightening torque applies when using the special
too! 207% and this tool must be flush with the torque
| wrench during this operation.
— Fig. 2 Removing idler nuliey using 3034
a Fig, 3 Removing and installing ai! sump
Caution
The subframe will suddenly drop approx. 100mm.
| Caution : $
“| Renew the
~ There are two cutouts on the flywheel side of the sump
en REDET hexagon socket head bolls,
~~ When installing the sump tighten all bolts by hand and
then tighten Mb
13-6
INSTALLING TOOTHED BELT
Cylinder head cover in situ
—- Mark on camshaft sprocket must align with arrow on cylinder
head cover,
a Cy)inder head cover off
- Mark on camshaft sprocket must align with upper edge of
cylinder head.
-= - Fit toothed belt on crankshaft toothed Selt sprocket and
secure vibration damper to crankshaft - Fig, В, раде 13-5.
Caution
When securing vibration damper, the toothed belt must
not become trapped between the oil pump and toothed
belt sprocket.
ES Wit | | :
A ds - AÑ | - Hitch housing.
WIth engine Gui;
a - Align notch on vibration damper with adjustment park on où
pump housing.
- Install lower toothed belt guard,
(Additional adjustment mark provided.)
- Fit toothed belt over idler pulley and coolant pump onto
camshaft sprocret.
| y e - Tension toothed belt by turning loosened coolant pump
anti-clockwise {upwards}.
—æ + [t should just be possibie to turn the toothed beit 90°
with thumb and forefinger between camshaft sprocket and
coolant pump.
- Tighten gogiant pump to 20 Nm.
~ Turn crankshaft two full turns and check adjustment,
~ Check basic setiing of distributor - Repair Group 28
TENSTONING ALTERNATOR V-BELT
- Remove screws securing radiator cowl at top.
~~ Slacken off at Teast one turn securing belts (A) and (В)
for tensioner arm, and boit {CC} for alternator.
Note:
the alternator must move easily after the mounting bolts have
been $lackened.
- Tension V-belt by turning tensioner nut {D) with a torque
wrench and tighten tensioner nut locking belt (B) to 35 Nm
New Y-belt mw B Nm
Used V-belt м & №
# Check tension by defiecting belt with thumb,
New Y-belt - approx. Z mm
Used V-belt = approx, 5 mm
- Tighten alternator securing bolt -C- to 35 Nm, and tensioner
arm -A- to 20 Nm.
13-11
TENSIONING V-GELT FOR CENTRAL HYDRAULIC Pump
Note:
The torgue wrench Y.A.G 1410 in conjunction with socket
Y.A.G 1410/2, 22 mm is particularly suitable for this ad-
justment.
- Slacken bolts (1),
13-12
17
16 15
16
ISMANTLING AND ASSEMBLING CYLINDER
BLOCK, CRANKSHAFT AND FLYWHEE
orm or rm vn hl hen ord vn bn Hae hele Hae HH Hn BH RH BH Meh HH A BAL Ama jap AL Rp Lm mu muy my
l-lif E HH J +f J+ P+ AN Me TNA PA PRE TL TNT NA
Notes:
e Rerew all gaskets, 'D' rings, and oi
seals on shafts.
э Do not ratate crankshaft when checking
radial ciearance,
I- Suction pipe gasket
Zw Locking plate
# Replace
3- 10 Nm
4- Suction pipe
e First secure to oil pump
5- Bearing cap
# No. 1 cap at pulley end
¢ Retaining lugs on bearing shells
must align
# Watch bore offset
6- 65 Nm
7- 100 Am
8 Renzw bolls
e Fit bolts using locking
compound -D6-
13-15
8- Needle bearing
ge Puiling our - see Fig, 1
page 13-17
# Knocking in - see Fig, 2
page 13-17
e After fitting the bearing the
lettered side must be visible.
$- Flywhee]!
e Remove and refit using locking
spanner 10-201,
s Fit ignition timing pin subse-
quentiy ~ see page 13-23 onward,
10- 011 seal
* Press out using special tool
2086 - see Fig. 3 page 13-18
« Lightly coat sealing lip and
outer edge before fitting.
s Uffer up using 2003/24,
e Press home using 2003/1 - Fig. 4
page 13-18
11- Sealing flange, rear
12- Rear sealing flange gasket
a Replace
13-14
>
rt
AH
TA
x
O 19 18 17 16 15 16 3-95]
3 21 3 20 1918 17 16 15 16
13m
14-
15-
16~
17
18
19-
20-
Crankshaft
® Measure axial clearance - Fig, 7
р. 13-20
New: 0.07 ... 0.23 mm
wear limit: 0.30 mm
# Measure radial clearance with
Plastigage - page 13-21,
New: 0.018 ,.. 0,058 mm
Wear limit: 0.16 mm.
¢ Crankshaft dimensions -
page 13-22
Thrust washer
# For cap
» Watch method of securing
Bearing shell 4
e Complete with thrust washers
a for cap without oil groove
# For cylinder block with oil
groove
Thrust washer
e For cylinder block (without re-
taining lug)
Bearing shells 1, 2, 3, 5 and 6
e for cap without oil groove
e for cylinder block with oil groove
® Do not interchange worn bearing
shells
# Retaining lug must engage recess
in crankcase/bearing cap
Gil pump gasket
13-15
Oil pump
e Watch crankshaft drive dog when
installing pump.
Vii seal
e Remove using 2086 - Fig, 5
page 13-19
+ Lightly coat sealing Tip and
outer edge with oil before
fitting.
e Offer up using 2080 A - Fig, 6
page 13-19
¢ Press home using thrust sieeve
{part of 2080 A} - Fig. 6
page 13-19.
22 Nm
13-16
— Fig, 1 Withdrawing needle bearing
- Remove using bearing extractor and holding tool (А),
e.g. Kukko 21/2 = 146,5 ... 18.5 mm and Kukko ZZ-1.
— Fig, 2 Knocking-in needle bearing
After instaliation the lettered side must be clearly visible,
- Knock bearing home until flush using YW 432,
13-17
—u Fig. 3 Removing crankshatt oil seal, flywheel end
- Lightly coat sealing lip and outer edge of seal with oil
ИНН РАНЫ „вето EL sta 1 dd 19 e
~ Press home oil seal using special tool 2003/1.
13-18
i
Measure axial clearance at no
Fi. 5 Removing crankshaft oil seal, pulley end
La]
L
ig. © Pressing-in crankshaft oil seal until flush, pulley end
Lse vibration damper mounting bolt.
tightly coat sealing lip and outer edge of seal with oil
before pressing in.
Caution
Press seal fully home if crankshaft shows signs of
scoring.
Offer up using locating sleeve from 2080 A,
Press in using thrust sleeve from 2080 A,
13-19
Fig. 7 Crankshaft - measuring axfal ciearance
. 4 bearing (thrust bearing),
0.07 ... 0.23 mm
CHECKING RADIAL CLEARANCE OF CRANKSHAFT
sam ou ee ET EEE ENS EEE CCS EE EE EERE вн
== eb der mem reel rem robe AH DE HH J Pje py Jue ul maja mi ue LL RYO мн EER WE I EE EE ER TR ver mw ve hy mm am
NOTES
Radial clearance can be checked with Plastigage, even with
engine in situ.
Measuring range of Plastigage strip:
Colour Type
0.025 .,, 0.076 Ш Green PE]
0.050 ... 0.1250 m Red PR-1
0.100 ... 0.250 mm Blue PR-1
- Take bearing cap off.
- Clean bearing shell and crankshaft Journal,
- Place Plastigage strip on journal or bearing shell in an
axial directien,
- Insta:1 can ard shell and tighten to 65 Nm
Caution
Do not rotate crankshaft.
- Take hearing cap off again.
- Compare width of strip with measuring scale.
New: 0. En .. 0.05% mm
0.
Wear limit:
13-21
Hip LJ que Llp LE RE WU PN mM rem mp my fem my pe pk de
EEE EL ES SESE SERS
(mm) o:
HTA Tirension Main bearing Crank pin
| С Journal & 2
"0,022 ~0, 042
58.00 47,80
-0,042 -0 042
"0.062 ~-0.022
57.75 47-55
«0.042 -0.042
-0.022 -0.022
i 2nd undensize... 57.54 47.30
e «0.042 0.042
-0.022 -0,022
3rd undersize 57.25 37.05
„0,042 “0.042
13-22
= Inserting pin for ignition timing point
Do not bend pin when fitting a new flywheel.
Caution o о |
Install pin for ignition timing point when fitting a new
flywheel otherwise the electronic ignition system will |
not receive control pulses and the engine cannot start. |
Drive ignition timing point pin into flvwhée] 56 that 1t 15
flush.
Measure distance between pin and firing point sender (G 4)
and distance between flywheel and engine speed sender (G 28)
> E ~~ Rotate flywheel until pin is below firing point sender
CO 7 \© 1 aperture,
||
ОПС TI
I — ——————"" A A se
patates E ever aan
————— —— ————
pr — AA
13-23
firing point sender.
- Insert feeler gauge between flywheel starter ring gear teeth
and engine speed sender.
Specified gap: 6.50 - 1,25 mm
13-24
a Inserting pins for ignition angle
De not bend pins when fitting a new flywheel.
Height of pins: 36 ~ 0.5 mm (Dim. "a"
rm mh mh LA dd AAA A A A AA A LA ват оной ин тов отв = ел точны ств ен == == КВ ЧН A —А
т ЗБ To Cin Mm БОЕ НО dp Rb Ch UE EL EE О ыы кн тв кеш e A =т —
же rr mm кл отит TC A A тб кто
= отт ет чт PE Pe TT TT mr A
1- Pisten rings
y Offset gaps to 120°
s "TCP" points towards pistón Crown
- Fig, |
& Removing and installing with piston
ring pliers ~ Fig. 2
¢ Checking clearance in groove =
Fig. 3
e Checking ring gap - Fig. 4
2- Piston
¢ Checking - Fig. 6
e Mark installation position and
cylinder number - Fig. 7
e Install using piston ring clamp
- Fig. 8
e Arrow on piston crown points to
pulley end
s Piston dimenstons - page 13-31
3- Conrad
a Always renew as à set
e Mark cylinder number (A) |
a Installation position: Markings (В)
point towards pulley end
2— e 5 Ta]
13-26
8-
10
Conrod bearing cap
10-
il-
e Mark cylinder number (A)
e Installation position: Markings (RB)
point towards pulley end
30 Nm + 1/4 turn (90°)
¢ Oil contact surface
¢ For measuring radial clearance,
tighter to 30 Nm but no further.
Circlip
e Lever out - Fig. 5
Piston pin
e 1f difficult to remove, heat
piston to approx. 60° C
e ise special tooi 10-508 for re»
moving and installing
Conrod bolt
9- Cylinder block
e Checking cylinder borss - Fig. 9
¢ Piston and cylinder dimensions
- page 13-31
Bearing shell
9 Note installation position
# Do not interchange used bearing
sheiis
e Ensure that retaining lugs locate
in recesses in bearing caps and
conrad.
8 Measuring axial clearance -
Fig, 10
Wear limit: 0.4 mm
a Checking radial clearance with
Plastigage - page 13-35
New: 3.010 - 0.052 mm
Wear limit: 0,12 mm
Note:
00 not rotate crankshaft when checking
radial clearance,
¢ for cooling piston
12- LU Nm
13-28
<<
— Fig, 1 Pistons rings, insta:lation position
e “TOP” must face towards piston crown,
e Chamfer on plain ring must face towards piston crown.
eg Step on stepped ring must face towards piston pin,
a Fig, 2 Removing and installing piston rings
Sle
1
3
+
X
— Fig, 4 Checking piston ring gap
Push ring squarely into lower end of cylinder until it is
about 1% mm from bottom edge.
New: 0.15 ... 0.35 mm
Wear limit: 1.6 mm
13-30
Piston dimensions
Honing dimension Piston día, Lyi. Dore
Basic dimension 50,95 81.01
1st oversize 81.23 81,26
znd oversize 81.48 81.51
13-31
mi Fig, 6 Checking piston
Measure piston about 12 mm from bottom of skirt at 90° to
piston pin axis.
Meximum deviation from nominal dimension: 6.04 mm.
13-32
- Fig, 7 Marking piston installation position
Arrow on piston crown points towards the puliey end. Mark with
cylinder number.
— Fig, 8 Removing and installing piston
e Use piston ring clamp to install.
ocatíons in both directions, i. e. (А)
En.
FE:
E
+
rè
+
[in]
wi
fai
=
+
{Tr
Ex
—
=
TAC]
Use internal dial gauge 50 - 100 mm.
(Piston and cylinder dimensions - page 13-31).
Rotez fu = Ti
bleck is mounted on
correct measurements would then be possible,
. Fig, 10 Measuring conrod axial clearance
Wear limit: 0.4 mm
13-38
CHECKING CONROU RADIAL CLEARANCE
Fm i em aa dh ly dm iy bm yr yr vk TT TT MER FEU LA — hrb hdr vam ПКО A dy di AA de de wim
o a I OO LA A A e e A mmm mm FE + т тЫ ны mm nal aw ae 25 or OT
Note;
It is possible to check radial clearance with Plastigage, even
with engine in situ.
wa Measuring range of Plastigage strip:
colour Type
0.025 - 0.076 mm Green PO-1
0,050 - 6,150 mm Red PR-1
0.100 - 0.230 mm Blue PE-1
1
Remove big end bearing cap,
„ Clean shell and crank pin.
~ Place Plastigage strip corresponding to width of crank pin
on crank pin in axial direction or in bearing shell,
To measure radial clearance, install big end cap and tighten
to 30 Nm but no further,
Caution
Do not rotate crankshaft.
- Take big end cap off again.
— - Compare width of strip with measuring scale.
0.010 - 0.082 mm
0.12 mm
New!
wear limit:
REMOVING AND INSTALLING CYLINDER HEAD
a Le mea LER md Err rm mm Rye Md Aa AA a a wT AT TR ET Tm rem
fm eller gr ler AT AT — ACT Y 4 fps SEES
Notes:
Removing and installing injectors -
see Repair Group 24
installing toothed belt - see Repair
Group 13.
The cylinder head can be removed
with the engine in situ.
Always renew all seals and gaskets
when performing assembiy work.
When installing a replacement cylinder
head, oil the contact surfaces Detween
the bucket tappets and cam surfaces.
Caution
When new tappets have been installed,
the engine must not be started for
about 3C minutes {valves will strike
pistons).
$ Checking compression » page 15-6
22 Nr
Z Ni
=
ra
25 Nm
6. Cytinder head
cking cylinder head for distor-
РН]
1x Lylimder head gasket .
ERT ar gatas Ti -
9 0bserve correct. mounting position,
> | RP ER
e CO
Tre marking part
gan Number must face the cylinder head.
Exs;Fit gasket over locating pins in
= cylinder block.
9. Heat shield
10~ Crankcase breather pipe
11- Tanition cable cover
12- Cylinder head cover
e Remove throttle valve housing
before removing cylinder head
cover.
*
13- Induction manifold
в Tighten securing bolts to 22 Nm,
e Use hexagonal key Y.A,G. 1669 for
removal and insta:tation of in-
ducätion manifold.
e Yenicies equipped with CCS cruise
control.
Remove CCS vacuum unit before
rempving the induction manifold -
page 13-10,
14- Coolant manifoid
» Tighteen securing bolts to 10 Nm,
REMOVING AND INSTALLI
rd dr or rer Air To mv rm т mmm mu me mur mim mA LL Ly ES EH JL ALL CR A WL WH Se WH rel rehab me
rk emp ma em dy mL WLU EU LU Rm uh rn gu fu fede] wy wy Gd Sh JA Е Fe ae
NG CYLINDER READ
Mr SEARS QUE EE ebro E. o
E. № | Note: Mila Rea Io
- Fit cylinder head gasket on to centering pins. The word
"OBEN" or the Pari No. must face the Cylinder head
(watch pattern Wea a
dy Bit. cylinder head bolts and tighten
Max. permissible distortion: 0.1 mm
æ - Tighten cylinder head bolts in three stages.
sequence - see diagram,
Tightening torque: Engine cold
= 4
Stage I №
stage il = 60 Nm |
Stage [11 = 1/2 turn (186%)
further, with normal spanner, without stopping.
(2 x 90° is also permissible),
Notes:
e Slackening cylinder head bolts: reverse sequence,
a It is not necessary to retighten the cylinder head bolts
during the Inspection Service or after repairs.
tage
Note:
Tn
©
*
e
cs
Pe ^»
Compression pres -
New
$ - 13 7
Overall permissible difference between cylinders: 3 bar,
101
! 0° ; x +
i г. La
a +f " .. I,
> le а no
ERA NT
x Ea
` 3 =. % 1
В ARH
TE X À a ar; *
. “JF 7
= AZ
e E | WE A
ч 1 Ni wr
20 à HE, RE у
+ i
В aia Li
a >
a+
о .
Е
10
11
[15-758 |
SERVICING VALVE GEAR
— ed ph pled ph pid ph ple ip is E ds dd dla A dy pied bk phe ik
TA AA Ark pie ply Le dir di del dpi ple ply ir pik ih pi bik
Note:
Cylinder heads which have cracks between
the valve seat inserts and the spark
plug threads can be used further without
reducing service life, provided the
cracks do not exceed a maximum of
0,5 mm in width or when no more than
the first spark plug thread is cracked.
1- Bearing са
s Installation position - Fig. 1
and Fig. 2
0 instailation sequence = see
installing camshafts® = раде
15-20
2- 15 Nm
3- Vil seal
e Renew
e 11 sealing lip end outer edge of
oil sea;
a Removing and installing -
page 15-17
5- Quter valve spring
e Remove and install with 2037 or
fitting tool 2036, valve lever
VW 541/1 and adapter VW 541/5
10
1
15-758
inner valve spring
e Remove and install with 2037 or
fitting tool 2036, vaive lever
Vid 541/1
- ie Remove and install wich 3047 A
85 valve stem seal |
e:Renewing:- page 15-25. :
“ce With cylinder head removed -
Ly
shred through a cyiinder head
hole.
bol
15-8
il- Yalves
e Uniy grind in, do not rework
a Valve dimensions ~ Fig. 4
8 Sodium~filled exhaust valves,
see note on page 15-12
12- Camshafts
e Checking axiay clearance - Fig. 3
s Removing and installing -
Page 15-19
a Check radial clearance with
Plastigage
Wear limit: 0.2 mm
e Max. runout 0.04 mm with bearing
cap in front of chain and last
bearing cap fitted.
13~ Bucket tappets
# With hydraulic valve clearance
compensation
e When removing, mark cylinder
number
e Cnecking - page 15-15
e unen removing, piace tanpet with
cam contact surface facing down-
wards
s Before installation, check axial
clearance of camshafts = Fig, 3
a 0il contact surface
14- Valve cotters
Ф Removing - page 15-26
15- Upper valve spring seat
- Fig, 1 Installation positicn of camshaft bearing cap
The recesses (corners) on the bearing caps must point towards
> > A A а the intake side of the eylinder head {arrow).
E ty
pagtil
EEE FE TT Eire
er TU, =
Г
Dee
=
CE Free — efi e Cr E PET — Ca
Watch offset. Before installing camshaft, fit bearing cap and
=, determine installation position. uu ree pde td de me
15-10
~= Fig, 3 {necking camshaft axial play
© Wear Limit: 0.2 mm
Take reading with bucket tappets removed, chain removed and
first and last bearing caps fitted.
15-11
— Fig. 4 Valve dimensions
inlet valve Exhaust valve
à = dia, 32,00 mm 28.00 mm
a = dia, 6,97 mm 6.94 mm
os 95,50 mm 98.20 mm
o =
Cautièn |
er à
ng this operation they must
| | Throw a maximum of 10 valves
р red in this nto a ket of water and step back
quickly to avoid any danger from the ensuing chemical reaction
15-12
REWORKING VALVE SEATS
| Note:
- Only rework the valve seats enough to produce a perfect contact
surface. Before reworking commences, calculate the maximum
permissible reworking dimension. If this dimensions is exceeded,
correct functioning of the hydraulic tappet can no longer be
guaranteed and the cylinder head must bs renewed,
Calculating maximum permissible reworking dimensionih)
- Insert valve and press it tightly against the valve seat
te
—a . Measure the distance between the end of the valve stem
centre and upper edge of cylinder head.
Е dir
NV
7
G
i
+
ts
f= + т " = + = + + + я
= Measured dimension minus mimimum dimension gives the maximum
A permissible reworking dimension,
Minimum dimension
inlet valve = 36.0 mm
Exhaust valve = 36,3 mm
15-13
- a Reworking inlet valve seat
7
/ à = 31.2 mm 2 |
Les a Ь* = max. dermissible reworking dimension
30>< 1 A c = 1.5... 1,8 mm |
\ ad (1 necessary, rework valve seat with 75° reseating too!)
\ i Z = Lower edge of cy'inder head
30% Upper correction angie
45%= Valve seat angle
EEE E ia
ne -
|
Co 7% ВЕ Upper correction angle
LY | р Os i РЕЙ: ee рн | = A e AAA а dr ra ome lr bean ho ore
b— Do ben E A
| | Pa
„
| 7 >
| 547
|
CHECKING HYDRAULIC BUCKET TAPPETS
ve
;
№
°
me Eds LA di ds Ap ва Зы НК стай стат pik phy ый бет М сит сток слои STR FE FE EE Ed Mer кок к = = =
Ton ld tim mre Fd anh ra a WRN WF WE EER OBL JU) LN LY RL SH
oles:
Place removed tapoet with the contact surface (cam side)
facing downwards, on a clean surface,
Renew tappetls complete {cannot be adjusted or repaired).
irregular valve noises when starting engine are quite normal,
Start engine and run it until radiator fan has switched on
once.
increase engine speed to approx. 2500 rpm for 2 minutes.
If the tappets are still noisy, locate defective tappet as
follows:
Remove cylinder head cover.
Rotate crankshaft clockwise until cam of tappet to be checked
18 pointing upwards,
15-15
“ress tappet down with a wooden or plastic wedge. If free
travel in excess of 0.1 mm is felt before the valve opens.
renew tappet.
Caution
when new tappets have been installed, the engine must
not be started for about 30 minutes {valves will strike
pistons),
15-16
RENEWING CAMSHAFT OIL SEAL
o rr rr er ate pt
лин == pe mm my pn mh mh mw me i me de mk wm mk ms eet da ld ted ао нал on
- Remove upper toothed belt guard.
- Rotate crankshaft until No. 1 cylinder is at TDC.
- Release tension on toothed bell and remove.
~ Remove camshaft sprocket.
- Screw camshaft sprocket securing bolt with washer into
camshaft as far as it will go.
- Unscrew inner part of 011 seal extractor 2065 two turns
(approx. 3 mm) out of the outer part and lock in position
With knurled screw,
~ Lubricate threaded head of oil seal extractor, place it in
position and screw it into 011 seal as far as possible while
exerting pressure,
- Loosen knurled screw and turn inner part of extractor against
camshaft until oil seal 18 extracted.
- Clamp extractor in vice on flats and remove oil seal with
pliers.
Insta!ling:
REMOVING ARD INSTALLING CAMSHAFTS
Tht = ply or br dry A CO AA CT TE TT TR FE TT am швы < кет A O A A Ad AA fk i
Aa AL EZ HA nn kn
Removing:
- Remove upper toothed belt guard,
- Remova intake manifold,
- Remove cylinder head cover.
- Rotate engine until No. 1 cylinder is at TDC,
- Release tension of toothed belt at coolant pump and remove,
+
Remove camshaft sprocket,
Exhaust camshaft:
~m ~ Remove bearing cap in front of chain, as well as cans 2 and 4,
y - slacken bearing caps 1, 5 and 5 alternately in diagonal
(5. sequence,
EY e
Inlet camshaft:
- Remove bearing cap in front of chain, as well as caps 7
and 9,
sequence,
- Slacken bearing caps 6, 6 and 10 alternate!y in diagonal
15-19
> | 7 N instailing:
EN «a - Fit camshafts with chaîn so that markings on chain sprockets
2 TE A Fi lign (arrows).
| We ати aiig \ 1
a e AA
AA
[
Caution
dhen Installing the bearing caps, ensure that the recesses
i(corners}'of the caps face towards the intake sice of the
=
iñg caps.
— Tightening tordué: 15 Nm
15.70
Exhaust camshaft.
- Tighten bearing caps 1, 3 and 5 alternately and in diagonal
sequence.
Tightening torque: 15 Nm,
- Fit remaining bearing caps.
Tightening torque: 15 im.
- Fit camshaft seals ~ page 15-18
- Fit camshaft sprocket and tighten,
Tightening torque: 67 Am,
- Install toothed belt,
{Adjusting valve timing = Repair Group 13).
Caution
when new tappets have been installed, the engine must not
be started for about 30 minutes {valves will strike pistons).
CHECKING AND RENEWING VALVE GUIDES
ih gH RA MAL наш vp my hoi bo Ade Ad Ry TIT Tm щи TEA er opm oer phe abl a we am om
pre aa SES SSSR ap CSS LR re rt HER
Checking valve guides
Wher servicing engines with leaking vaives, it is net sufficient
to rework or renew the valve seats and valves. It is alse
Theart.néw valve into guide until end of valve stem is flush
4
with end of guide. Due to the difference in stem diameters,
ensure that orly an inlet valve is used in the iniet quide
“2 and an exhaust valve in the exhaust guide.
- Determine rock.
Wear limit:
Inlet valve guide
Exhaust valve guide
11 Bf
Же |
Lo CD
=
15-22
Renewing valve guides
Cylinder heads in which the valve seats can по longer be re-
worked, or cylinder heads which heve already been machined
te The minimum dimension, should no longer be repaired.
—æ - Press worn valve guides out from the combustion chamber side
using 3121. By way of support, use sieeve 30-23 during this
operation,
15-23
—t- Coal new guides with oil and press in using 3121 from camshaft
J side with head cold until shoulder makes contact,
3121 ——— 1 Ne. ee Ii Note:
E НЕЙ о Se Lise Support 3173 for pressing inlet valve guides in,
Caution
When the shoulder on guide makes contact, the pressure
must not exceed 1.0 tonnes otherwise shoulder may break off.
=r—iReam-guides outh with hand reamer 3120, using plenty of
cutting fin tesi
- Rework valve seats.
Note;
when reworking valve seats, watch minimum dimension -
page 15-13,
15-24
VW 5411
Pe.
RENEWING VALVE
тт =
(with cylinder head in situ)
STEM {IL SEALS
da A dd A — «о
Th AR a ya y q Ai y op Ay
- Remove camshaft and bucket tappets.
- Remove spark plugs.
- Set piston of appropriate cylinder to "BEC".
- Screw compressed air hose VW 653;
apply a continuous pressure of
3 into plug thread and
minimum 6 bar
Inlet side:
a. instal] fitting appliance 2036 and adjust te height of studs.
- Remove valve springs with valve lever YW 541/1 and adapter
YW 541/5,
- Remove. Valve Stein seals with 3047 A.
- Install valve stem seals.
Fit plastic sleeve ~&~ onto valve stem. Oil valve stem seal
-B-, place it in fitting too! 3129 and push 1% down care-
fully onto the valve guide,
Caution
To prevent damaging the valve stem seal, always use the
plastic sieeve.
18-26
RENEWING VALVE STEM OIL SEALS
{Cylinder head removed) |
- Remove camshaft and bucket tappets.
- Remove spark plugs.
Note:
Loosen tight valve cotters by lightly tapping the assembly
fever VW 5431/1 with a nammer,
N AN —~a = Install fitting appliance 2036 and adjust to height of studs.
POL - Remove valve springs using valve lever YW 541/1 and adapter
Na, XA Yw 54175.
#4 > a с
2036- NE
) EN «= r
15-27
3 + - Remove valve stem seals using 3047 A.
115-762 |
—= - Install valve stem seals.
Fit plastic sleeve ~A- over valve stem. Coat valve stem
seal -B- with oil, place in fitting tool 3129 and care-
fuliy slide over valve guide.
3129
Caution
Always use the plastic sleeve when fitting valve stem
seals to prevent damage.
{ETE
15-28
789
10 11 1 12 13 14 15
|
16
1171819201 21
REMOVING AND INSTALLING LUBRICATION
dry rrr mE ET ET Tr méme me Ar rr e a 4 A A He
E A — == +
aap a ma mm ww A A A A A A A
—— in mm mr OA Pa Ar de AAA Aa ma
Note:
ATi parts shown in the illustration
can be removed and installed with engine
fitted,
1- 10 Nm
2- Upper toothed belt guard
3- Toothed belt
à Fitting/tensioning - Repair
Group 13
4 43 Nm
5- Vee-belt deflection limiter (right)
6- Spacer bushes
¢ Long spacer bush top
a Short spacer bush bottom
7» 57 Nm
&- Camshaft sprocket
6 Note observe position when
fitting toothed belt - Repair
Group 13
9- Rear toothed belt quard
17-1
1G= 350 Nm
¢ Tightening torque applies only
when using special tools 2079
and 2084 - Repair Group 13,
» Coat threads and seating surface
of boît head with sealing com-
pound AMV 188 DE 02.
» Loosening and tightening - Repair
Group 13.
11- Vibration damper
e Removing and installing - Repair
Group 13.
12- Lower toothed belt quard.
13- Idler pulley
e Remoyai - page 17-11
18- 011 seal
# Removai - page 17-12
# Fitting = раде 17-12
15- 20 №
16- 011 temperature sender (G8) and oil
pressure relief valve (45 Im)
e Ovening pressure:
6.0... 6.5 bar
17- 011 pump housing
18- 011 pump gears
8 The] mark faces towards the
cover plate
19- 011 pump
€ Renew oniy as a complete unit
¢ Observe crankshaft drive dog when
fitting pump.
20- Cover plate
21- 091 pump gasket
» Renew
00 1 12
17-3
17 during repairs the engine oil is
found to be contaminated (swarf or
metal particles caused by partial sei-
zure of e.g, the big end or crankshaft
bearings), the oil galleries must be
cleaned carefully to prevent further
damage,
sua a Tighten oil sprayjet for piston cooling
ste 10 Am,
1- Cap
# Renew seal if damaged
2- 011 check valve £ Nm
¢ Remove and fit using commercial
multi-point socket driver (8 mm)
e Apply 06 locking fluid before
fitting
3- Adapter 50 Mm
4- Gasket
a Renew
e Do not use adhesive
5- 10 Nm
6- Lock plate
® Renew
/- M 6 - ID Nm
МВ - 20 М
uo E Ро о N
[17-288 |
Bm Dipstick
9- 011 pressure switch {white}, 25 Nm
a 1.6 bar
¢ Checking - page 17-13
10- 011 pressure switch, 25 Nm
e Checking - page 17-15
11- Intake pipe
e Secure to oi! pump first
12- 10 Nm
13- Baffle plate
14- Sump
¢ Removing and installing:
Remove front subframe securing
polis - page 17-9
# Clean sealing surface before
installing
fa
15- Seal
e Renew
16- 30 Am
Note:
4 Always renew gaskets
e Gil capacity: 4,0 1
4.5 1
without oil filter
change
with all filter
16-
change
Flow line (oil cooler)
Return line foil cooler)
Adapter SC Mm
10 №
041 thermostat seal
6 Kenew
Oil couler thermostat
Dil filter housing gasket
s Renew
Oil return Tire gasket (turbo-
charger)
® Renew
Flow line gasket {turbocharger}
e Kenew
567859
li-
Flow Tine (turbocharger)
12- Q-ring seal
21
22
e Renew
Cil cooler
Self-tapping screw
e For securing air duct
Ar duct
Banjo bolt 70 Nm
Gil filter 20 Nm
® Release using strap wrench, tighe
ten by hand
e Observe installation instructions
printed on oil filter.
di! filter housing
Flow line gasket (turbocharger)
on oil filter housing
® Kenew
Gasket
¢ Renew
22 hm
— REMOVING OIL FUMP
- Release both bolts -i~-, nut ~Z2- and bolt ~3~ to slacken and
remove Yee-beit for alternator, air condifioning com presser
and central hydraulics pump.
- Remove pump from hydraulic unit and move to one side {without
disconnecting hoses).
- Slacken vibration damper centre bolt - see Repair Group 13.
- Remove toothed belt guard,
«x Hemoving oil sump
Caution
The subframe will suddenly drop by approx. 100 mm,
- Remove both front subframe bolts.
Note:
| These two subframe bolts must be renewed.
- During refitting the two subframe bolts should be tightened
to 65 Nm plus a quarter turn.
- Remove 01) dipstick.
a - Remove 0731] suction jine,
17-10
— - Release toothed belt and remove. To do this, loosen coolant
pump and turn in direction ef arrow (clockwise),
important
Crankshaft must not be ratated further,
» Remove vibration damper with toothed belt pulley.
— - Remove idler pulley with 3034,
8 It is only necessary to remove the idler pulley when
renewing the oil pump and ıf the 1dler pulley bearings
are damaged, Only the securing bolt has to be removed to
take out the oil pump.
- Remove oil pump.
—# = Press in crankshaft, oil seal pulley end, so that i£ is
flush.
- Use vibration damper mounting bolt for pressing oil sea!
in,
- Before installing, tightly ofl sealing {ip and outer edge
of oil seal.
Caution
If the crankshaft shows signs of scoring, press on
seal as far as it will go.
- Offer up sealing ring with sleeve from 2080 А.
- Press-in seal using thrust sleeve {part of 2080 A},
17-12
658664)
ko Ly
Maa na A
+
OC
”
q АН Jem
VAG 1527
ен EE EEE ee
=D:
CHECKING OIL PRESSURE SWITCH AND OIL PRESSURE
(Audiovisual oil pressure indication)
Test conditions:
e 0il level О.К,
» 01 pressure indicator {K3) must glow when ignition is
switched on,
On vehicles with auto check system the indication must be
0.K. {Call up symbols).
e Minimum engine oil temperature: 80 deg. C. {radiator fan
must have cut in once}.
011 pressure switch 1,8 bar
Remove cables from oil pressure switch and oil pressure
sender,
Unscrew oil] pressure sender and screw into oil
pressure sender test unit Y.A.G 1342.
Screw Y.A.G 1342 into the crankcase in place of the oil
pressure sender,
|
Connect wire -2- (brown) to earth [-).
Connect wire -1- (blue) to 1,8 bar oil pressure switch
{white insulation).
нелевнн)Й PN тн © Leen TTT TTL Ln ny Tn
15 not the case the of pressure wien is be renewed,
- Increase engine so
At 2000 rpm and an of temperature of 80 deg. C tha oi}
pressure: must. heat: least. ie Behan ag
Нева хе engine-speedi further” He on af Temen bee AUTO AÑ
Pressure relief valve working pressure:
“
De C * . 8. 0 bar. mi BEN, a.
This pressure should nôt- bé pkédeded except by a minimal
amount. RINE IE (Et
Note;
e If the oil pressure is excessive (pressure relief valve
sticking or incorrectly fitted) the hydraulic tappets will be
subjected to excessive pressure. As a result the engine will
cut out soon after starting and turn over noticeably fast
during subsequent starting because of lack of compression.
e If the wires are incorrectly connected to be oil pressure
sender the auto check system will cause the engine oil
pressure warning symbol to illuminate (oil can).
i7-14
Ipcorrectowiv ingegfaths 01 T:pres cir vender 4
CHECKING QIL PRESSURE SENDER (G 10)
Test conditions:
e Oil level OK.
e Oil pressure warning lamp {K 3) must glow when ignition is
switched on.
On vehicles with auto check system the indication must be
О.К. (Call up symbols),
¢ Minimum engine oi! temperature: 80 дес. С. {radiator fan
must have cut in once}.
# Tachometer in electronic instrument panel assembly 0.K.
Notes:
e Check auto check system or oi] pressure sender (G10) if the
cit pressure indicator tight {K3) does not illuminate.
¢ For oil pressure sender {G10} mounting position see page
i7-5 item 10.
« Disconnect wire from 017 pressure sender contact G.
- Connect test unit Y.A.G, 1526 between oil pressure sender
contact G and engine earth using the auxiliary cable from
V.A.G, 1594,
- Switch V.A.G 1526 to the 200 ohm range;
Specified reading: 5 ... 10 ehrs,
- Start engine and run at idiing speed.
Specified reading: 70 ... 120 ohms.
- Increase engine speed to 3000 rpm,
Specified reading: ¿70 ,., 200 ohms.
a - Connect VA. € 1526 test unit “between oil pressure. sender
contact WK and engine earth using - the e auxiliary cable
from V.A.G 1584, i mi À LE CE
- Switch off engi
i
Specified readi :
“cause 166 auto
Thess System to display | the engine oil pressure warning symbol
17-16
REMOVING AND INSTALLING COOLING SYSTEM
we mk Lm mm TA re em re pb ph ih mi A За ны LA Al Ld MA EE A mh A Sd Sw ew bw va bw
= Em mm Er mm fr he re AAA A a a yo AA i i au mm mm mm by A A a
— == — an
Draining and refilling coolant -
page 15-6
Checking cooling system for leaks =
Fig. 1.
Thermostat - Fig, 3
1- Auxilliary radiator
èm Cooiant hose
{Between auxiliary radiator and main
radiator)
Im Thermo switch 25 Nm for electric fan
Switch Switching temperature
an Off
=D
supply
ist stage 92 .. 97%] 84 approx
er A LA
HN
à = 2nd stage 99 ..105“! 91 approx
4. Seal
e Kenew
5- 10 №
6- Radiater cowi
7- Radiator fan
19-1
a For Fi1Ting and checking tank
1 Se page 19-8-
hoses and withdraw radiator
vertically.
тен
19—— Umi
10D PEL
7
19-331
Lociant flow to turbocharger
12- U-ring seal
# Renew
Gasket
¢ Renew
Coclant manifold
Ta heat exchanger
From heat exchanger
Turbocharger ecolant mump
4 Checking, page 19-10
10 Nm
Coolant thermostat seal
+ Renew
Coolant thermostat
e Fig, 3
a Opens at 87° approx.
s Fully open at 102° approx.
e Opening stroke Amm min.
V-belt deflection limiter {left}
22 hm
22 Nm
1
24~ Coolant pump
a5 Coolant pump seal
because of
temperatures,
— Fig, 1 Checking cooling system for leaks
This test should only be carried out when engine is at
operating temperature.
Fit test unit to expansion tank.
Pressurise cooling system to 1.0 bar approx. using the test
unit hand pump. If pressure drops locate leak and repair.
— Fig. 2 Checking cap pressure relief valve
Fit cap to test unit,
Pressurise cap using the test unit hand pump.
The pressure relief valve must open at 1.2... 1.5 bar.
19-5
— Fig. 3 Thermostat, installation position
Starts opening: 87° approx,
Fully stroke: 102° approx.
Working stroke: 8 mn min.
DRAINING AND FILLING COOLING SYSTE
же
За
Uraining:
19-6
— - Drain coolant by detaching coolant hose io heater et rear
of engine block. Cateh coolant for re-use,
— - Detach coolant hese at lower coolant pipe.
19-7
Filling cooling system:
Note:
The cooling system is filled ail the year round with a mixture
of water and GI1 antifreeze,
G11 and coolant additives marked as being "in accordance
with TL YW 774 A” prevent freezing, corrosion damage and scale
formation and raise the coolant boiling point. For these
reasons the > cooling system « should de Filled all the year round
Ferny Fran Set. Heater! controls to hot
L.
aii
=
=
ry
er
>
с
Cx
ск
ey
a
oy
oF
=.
=
ra
a
ot.
ry
=
a
it,
2
Ta
a
=
ir
mba
La
—.
eE
Вы
=
=.
Di
+
iQ
—
mt
Е
level mark.
19-6
- Replace expansion tank cap.
- Allow engine te run until the eletríc radiator fan
cuts in.
- Check coolant level again and top up if necessary.
—a When the engine is at operating temperature the coclant level
should be somewhat above the minimum level mark. When the
engine 1$ cold the level should at least reach the point of the
marker.
CHECKING TURBOCHARGER THERMO SWITCH AND COCLANT PUMP
- Allow engine to run until the electric radiator fan
cuts in,
- Switch off engine.
- After 5 min. anprox. the electric coolant pump and
radiator fan must switch on,
- If electric coolant pump and radiator fan are not
o Disconnect wires from thermoswitch and
© gachiother. ОР cn
REMOVING AND INSTALLING FUEL SYSTEM
Phnom TL TU A A A WA LAL MAL SL JL SN SW MAL Ve MA MAL WA AML dk A A A A A — о
=== = нк == == wr Em Ed ip or] rm Bd br] — —
Ie Er т == = == —
Always observe the safety rules
when working on the fuel system,
Note:
e Always renew seals, gaskets and hose
clips when working on the fuel system,
All hoses are secured either with
screw or spring-type hose clips.
Always observe rules of cleanliness
- page 20-4.
Connecting remote control - page 20-58.
Checking fuel pump relay - page 20-15,
When removing or installing fuel gauge
sender unit ensure that the
wires are not damaged.
20-1
Fuel suppiy line
Fuel return line
Fuel gauge sender
Tank filler neck
Overflow hose
Tank filler pipe
Tank filler pipe insert
- Tank filler pipe hose
12. Tank breather/vent valve
13- Support hose
20-2
Us > A EM =
©
1
12
13 —
14- Banjo bolt 20 Am
15- Ventilation hose
16- Ventilation pipe to activated
charcoal filter
17- Seals
18- Retainer ring
19- Sea:
a Renew
20- Gravity valve
21- Fuel pump
# Removal and installation -
page 20-8
a Dismantling and assembling ~
page 20-11
eg Checking - page 20-12
22- Fuel tank
20-3
RULES FOR CLEANLINESS WHEN WORKING ON
THE FUEL SYSTEM
Important
When working on the fuel system the
following five rules should be
observed:
1- Throughly clean ail unions etc.
and the adjacent areas before
disconnecting.
ud Plate parts removed from the
fuel system on a clean surface
and cover against contamina-
tion.
13. Components that have been
opened or cismantied must be
carefully covered or sealed if
the repair cannot be carried
out immediately..
4- Only install clean components.
e Do not remove replacement
parts from their packaging
until ready for installation.
e Do not use parts that have
been stored without their
packaging (e.g. in tool-
“boxes etc.).
| | 8 When the fuel system is open:
“e Do not use compressed air.
6 Do not move the vehicle
untess absolutely necessary,
20-4
— Fig. 1 Connecting remote contra! Y,A.G 1348/38
using adapter cable Y.A.Gk 1348/3-7
- Remove fuel sump relay from relay plate
“location 10},
- Connect remote contro? Y.A.G. 1348/3A to
contact
battery terminal using adapter cable V.A.G
1348/3-2,
— Fig, 2 Fuel filter mounting position
Arrow Indicates direction of fuel flow to
ReMOVING AND INSTALLIKG FUEL GAUGE SENDER
Removal:
a - Remove fuel gauge sender unit cover (below
trim}.
- Pull off connector for fuel gauge and fuel
52 of relay Tecation 10 and the positive
engine,
E
<
E
ET
boot floor
pump,
ie The fuel, tank. shoal dibe not more than 2/3 full,
20-6
20-607
+ Release the retainer using special tool 3087 and
withdraw the fuel gauge sender from the fuel tank.
Note:
When removing and installing the fuel gauge sender unit
ensure that the connecting cables are not damaged.
disconnect supply and return Lines from the inside of the
sender housing,
- Disconnect fuel pump electrical connections.
- Unclip gravity valve.
20-7
REMOVING AND INSTALLING FUEL PUMP
Removal:
«a - Remove fuel gauge sender unit cover {below boot floor
The fuel tank should be more than 2/3 full.
20-8
— — Release the retainer using special tool 3087
and withdraw the fuel gauge sender from the fuel
tank.
Note:
When removing and installing the fuel gauge sender unit
ensure that the connecting cables are not damaged.
- Disconnect supply and return lines from the inside of the
sender housing,
- Disconnect fuel pump electrical connections.
20-607]
~~ Rotate pump housing approx. 15mm counter-clockwise using
special tool 3214,
- Withdraw pump upwards,
20-708
Installing fuel pump
= Fit fuel: pump in its fuel reservoir so that the Y mark
SA Co faces mark -A-.
- Rotate fuel pump clockwise until the V mark «C-
faces mark Ba,
DISMANTLING AND ASSEMBLING FUEL PUMP
S de A ha МЫ кл = rE TE TOE FEE OW O EA BL dk UE dh AA pik LE AA LA y di dp de rm de pk AE E
HT bk Hn о a a er mm vm mm mms mu Rb Lt bm aa as Tass aan abl AO a LTS IL TT OTT
Always replace seals and gaskets. The
strainer is fitted to the fuel reservoir
by a bayonet connection.
1- Silencer 15 Nm
———
CHEW
=
A
E- fuel reservoir unper section
o
1
Ent
; Nm
i= Electrical connections
e M6 positive (+)
e MS earth (-)
8- Non-return valve
e Checking, page 20-16
Sm Fuel pump
# Checking - page 20-12
1G- Strainer
20-681 20-11
o mmm = CEE Di ; ori ВЕ “REE RG FULL PUME
i Ut E Test conditions:
e Fuse ОК ZN. 13 on relay bosrc with fuse holder)
— Remove fuel gauge sender and fuel pump caver (below boot
floor trim).
ai 1 0. Disconnect fuel pump and fuel gauge connector,
20-12
96 - BiG
a - Check voltage across connector contacts 1 (green/yeliow)
and 4 (brown using a voltmeter, Keep remote control switch
pressed during the check,
The reading shouls be approximately equal to the battery
voltage.
- If the specified voltage is not available repair open circuit
using the current flow diagram,
- If the specified voltage 1s available re-connect connector,
- Press remote control switch, If the fuel pump is not heard
running remove fuel pump - page 20-8.
- Check connection between connector and fuel pump for con-
tinuity using an ehmmeter.
Specified resistance: Ü ohms.
- If specified reading is net obtained replace connecting cabie,
- If specified reading is obtained replace fuel pump.
20-13
© CHECKING, FUEL PUMP DELIVERY RATE
Test conditions:
e Fuel filter CK
e Battery fully charged {12V min.)
1348/32
Withdraw tie]
lat
- Connect remote control Y.A.G 1348/34 to contact 52 of relay
location 10 and to the positive battery terminal using adap-
ter cable V.A.G 1348/3-2,
20-14
a - Unscrew supply pipe union [upper fuel line) - see arrow.
el - Connect a hose to tke fuel supply pipe and run other end of
nose into a graduated measuring vesssl,
A Chi 20-15
== Check pump delivery rate by pressing the switch of remote
controt Y .A.t 1348; 34 for 15 sec,
The specified minimum delivery rate can be read from the
1: ditagram,
arena Ear
a
Check fuel pump voltage with engine switched off and pump
running (TES voltage should be approx. 2V less than the
CHECKING FUEL PUMP NON-RETURN VALVE
Note:
For this test fuel pressure regulator, fuel pump and
injectors must be working properly and there must be no leaks -
in the fuel system,
Important
The pressure gauge lever must remain closed during the
test.
20-16
— - Disconnect fuel return line from pressure regulator.
„“ - Disconnect connecting Tine between fuel ring main and pressure
regulator from the fuel ring main.
PT
20-17
~~ Unscrew connecting line from pressure regulator.
20-18
a - Connect connecting Tine to fuel ring main after rotating
through 180 degrees.
Ренн — - Connect fuel return Tine to pressure regulator,
2
0,5 bar.
¡f pressure drop exceeds this value check pressure gauge
and fuel supply line connections for leaks; if there are
ho leaks replace non-return valve,
2020
- Installing the pressure reguiator is & reversal of removal.
— Note that the connecting line should be fitted to the
pressure regulator in alignment with the pressure regulator
bracket.
Replacing non-return valve
- Remove fuel pump - page 20-8
—æ# ~ Unscrew non-return valve and replace complete with seal.
Tightening torque: 20 Nm
Caution
Do not clamp the electric fuel pump in a vice!
20-41
os AConnect:dTado: test: amp: VAL 1527-between earth and the
Tn “hand ‘contact: of “fuse 18: oo
i
Operate starter motor briefiy
(If the diode test Tamp Sum’ nates as soon as the ignition is
switched on connect diode test lamp to the right-hand contact
of fuse 24),
- Connect diode test lamp Y.A.G 1527 between earth and the
ieft-hand contact of fuse 28.
- Operate starter motor briefly, (If the diode test lamp
jiluminates as soon as the ignition is switched on connect
diode test lamp to the right-hand contact of fuse 28),
- The diode test Tamp must illuminate during all three checks and
the relay must operate audibly (If relay cannot be heard
operating place fingertip on relay housing to check
operation},
20-28
| HEE = == == ¡FER =r) ET) Е — E
a. Er A
20-734
a - If the diode test lamp does not illuminate the fuel pump relay
(117) should be withdrawn from relay location 10 on the
relay plate,
- Check connecting cable between fuse 13 and contact 52 of
relay location 10 for continuity using an ohmmeter.
- Check connecting cable between fuse 24 and contact 59 of
relay location 10 for continuity using an ohmmeter,
- Check connecting cable between fuse Z8 and contact 53 of
relay Tocation 10 for continuity using an ohmmeter.
- If necessary repair any open circuit.
- If the relay does not operate check the fuel pump relay
contro? circuit,
- If the control circuit is OK replace fuel pump relay,
Checking fuel pump relay contro circuit
7
- Withdraw fuel pump relay (417) from relay location 10 on the
relay board,
~ Switch on ignition.
» Connect voltmeter first to contacts 46 and 50 and then to
contacts 48 and 50 of the relay socket.
- The voltmeter should read approx. 12Y.
+ - Connect ‘di
= When the ignition is switched on the diode test Temp should
Da me vVisialy brighter as St nas the starter
jrow cdinly and’ Beco |
e MOLOF 1 operated. Ta
- If tre diode test 7 does not become brighter check the
wiring as follows: И
Contiect test box E...
harness using adapte sab] é 1598/5 - See repair group 01.
{Control unit connactor plug disconnected;.
37 19 55 38 20 1
iA
eT EER ED AG
NAAA DON |
ARENAL ABE 33 2
a - Check connecting cable between contact 47 of relay location
10 and test box socket 3 for continuity and if necessary
repair open circuit between contact 47 of relay socket and
contact 3 of control unit connector plug.
- If there is no open circuit replace control unit.
- Refit fuses 13, Zé and 28.
20-24
REPAIRING ACTIVATED CHARCOAL FILTER TANK VENTING SYST
= AA e yt bm bd ed Td Bm ed hm hk ed Bd om Bt bm hd Ak dd e A A dp da em fp fb bp poy E 8H
DT E E A A E E == oO Y E A A TN Y A
i- Fuel gauge sender unit
2 Activated charcoal! filter
3- 10 Mm
â- Induction marifoid {rear face)
5- Support hose
6- Breather/vent valve
7- Activated charcoal fiiter solenoid valve
a Checking - Repair Group 24
a Checking control circuit, Repair Greup 24
8- Pressure check valve
(connected to crankcase breather pipe)
9- Connection for venting line
20-25
REPAIRING THROTTLE LINKAGE
25 Nr
Ba: Throttie cabie abutment
Induction manifold
7- Throttle cable
s Adjusting - page 20-28
8- Square mounting
Ga Securing clip
10~ Accelerator pedal stop
20-26
10 №
бар
Closing damper
g Adjusting - page 20-31
Throttle valve housing
10 Km
Gasket
e Калем
Bearing bush
Securing clio
Accelerator pedal
20-25
20-731
N
7
20-73)
Note:
The throttle cable 1s fixed to the accelerator veda! and the
cam disc. The longitudinal adjustment of the throttle cable
sleeve 1s not fixed by the circlip,
- Fuliy depress accelerator pedal.
E - Pull back throttles cable sleeve until the CCS cruise control
Tever comes to rest against the full load stop.
~~ Fix longitudinal adjustment using the clip.
Checking: See next page
20-29
Ehecking: 1 1 В
== - Accelerator pedai in cling position. с o
e The cruise control lever must rest against the full Toad
stop.
20-30
CHECKING AND ADJUSTING THROTTLE DAMPER
— - (pen throttle valve,
- Clamp a 5.5 mm twist drill centrally between stop and
; oF
throttle valve lever (see arrow),
t= 1 E |
eu
в)
DES
FT
№
pe >
ta
Te
ASE
=“ - The throttle damper should just start 1ifting off the throttle
valve roller. If this is not the case slacken locking nut
À and rotate throttle damper until it no longer touches the
rolier,
- Re-tighten Tocking nut -A-.
REMOVING AND INSTALLING TURBOCHARGER
E dd hh Mb i hh 00 dd Ad A AAA A dh AA Ah Ah dl A ke dy dy dy de dy rm ет rm ph rr rh Tw ES
FIT fie ie wo "a ml ml lo mamo om Mm amo lu de mk mm mk he mm = а
COMPONENTS
Note;
Always renew seals and gaskats,
1- 25 Nm
2- Corrugated pipe
e The end of the corrugated pipe
with a protruding pipe must de
towards the by-pass pips.
3- Banjo belt 25 Am
4- Coolant flow 25 Nm
5- Adapter 27 Nm
6- Eypass pipe
8- Turbocherger
e Checking - page 21-18
э Removing and instailina - page 21-5
9- Adapter 35 Nm
Coolant return line 30 Nm
10 Nr
011 return line
22 Nm
wastegate
se Checking - page 21-16
“Repair Group 24
REMOVING AND INSTALLING CHARGE AIR COOLER
CRANKCASE VENTILATION COMPONENTS
A y AA A A A
ma ee DS Aie Ll EEL E AL O ELI FYE EE E PAOLA A A POE. BE PW EN EL
1+ Collar screw 10 Nm
2- Charge air cooler
3- O-ring sea!
8 Renew
d- Securing clip (2-piece)
3- Boost pipe
b- Pressure check valve
7- To induction maifold
g- To activated charcoal filter
solenoid valve
9~ ZZ Nm
10- Induction pipe
11- 22 Nm
| 21-063 21.3
12- Crankcase ventilation pipe
(rivetted to heat shield)
13- Pressure regulating valve
14- Flame trap
21-4
Aa
2
REMOVING AND INSTALLING TURBOCHARGER
Note;
Always renew seats and se f-locking ruts,
~ Disconnect battery.
Removing air cleaner
wm ~ Pull off connector from hot wire air volume meter.
- Release hote clip.
~ Pull off hose from hot wire air volume meter.
a - Slacken air cleaner upper section securing screw.
Tu
pa
i
CT
= - Release spring clips securing air cleaner upper section to
Tower section.
- Remove air cleaner upper section from engine compartment,
q
- - Remove connecting hose between charge air cooler and induction
pipe.
— Kemoving wastegate
~ Disconnect control line from wastegate.
Mote:
Keep banjo boit clean and safe.
- Urbolt corrugated sine from exhaust pipe.
- Unbolt waste gate from exhaust manifold.
21-7
a - Remove hose between hot wire air volume meter and turbo-
charger from crankcase ventilation pipe and turbocharger by
slackening the two hose clips (arrows).
\' E
E
ENT
\
-= - Unbelt exhaust pipe from turbocharger.
Note:
The fairly inaccessible nue measures 15 mm across flats.
—# - Release hose clip securing the coolant flow pipe to the
turbocharger -L-,
e - Disconnect ceoiant flow pipe -C- from turbocharger.
- Disconnect oii flow pipe -0- from turbocharger.
= os7| В
21-10
—#< (nbolt turbocharger oil return line from crankcase.
Note:
The coolant return line should be plugeoed immediately after
uncarnecting,
- Disconnect coolant return line from turbocharger.
21-11
_— - Remove heat shield mounted on right-hand side member below
turbocharger,
21-12
REMOVING AND INSTALLING CHARGE AIR COOLER
- Remove and install front bumper - Repair Group 63.
- Remove and install radiator grille - Repair Group 50.
— - [Detach hose between charge air cooler and induction pipe from
intercooler,
„ея - Unscrew side air duct from front panel.
4
NN
Con
AEDS
21-13
~~ Unscrew side air duct from Bottom air duct.
21-14
[21 068 Fa
e - Unbalt auxiliary radiator.
e. Remove boost pipe from charge air cooler by releasing hose clip
and 2-piece securing clamp.
„ча = Unbo7t boost pipe complete with mounting bushes from cross-
member and withdraw downward awey from charge aír cocler,
21-16
Lg a
Rg TT EEE
==
LI
COUT ri
—
VAG 1397
a - Unbolt charge air cooler from front panel.
- Push side air duct to the left,
a — Push charge air cooler to the left out of its rubber mounting.
- Remove charge air cooler forwards cut of engine compartment.
To instal? charge air cooler reverse removal sequence,
21-17
CHECKING TURBOCHARGER AND WASTEGATE
4 - Connect turbocharger test instrument V.A.G 1397 between
vacuum hose and Motronic control unit.
Note:
EEE Before checking the boost pressure the vehicle should be taken
a
vehicie is being driven, For safety reasons a second verson
see .Sh0u1d.De. present: to take the readings from the turdocharger
“eus best. instrumentar.
— - (Open turbocharger test instrument valve.
- Fully depress accelerator in fourth gear when the road speed
is approx. 60 kph.
21-18
VAG 1397
w Observe tachometer,
a - Close test instrument valve when engine speed reaches
3000 rpm.
Specified readings:
E
Bar Altitude (Mm)
0,78 - 0.65 Sea level
0,84 - 0,91 500
0.30 - 0,95 1200
0.94 - 0.98 1800
0,97 - 1.03 280%
26-697
- If these readings are obtained remove cause of fault in the
Motronic fuel injection and ignition system or interrogate
fau:t memory.
« Repair Group 28.
- IF the above readings are not obtained check boost pressure
limiting solenoid valve control circuit {final control
diagnosis.
- Repair Group 28 or replace vaive and check.
- If the above readings are not obtained check bypass valve -
page Zl-21.
21-19
¡EL ELO E LI TF Me specified reading is not obtained temporarily replace
1 PE, Ci ci, wastegate and check,
o | - 1f after & repeated boost pressure check the appropriate
— reading is: still not obtained the turbocharger should be
— replaced.
al-20
CHECKING OVERRUN BYPASS VALVE USING VACUUM PUMP Y, A.G 1390
The overrun bypass valve 15 fitted in front of the turbocharger,
It opens in the overrun phase thus relieving the existing boost
pressure from in front of the throttle valve to prevent load
shocks when accelerating again.
If the power output is down or shock Toads occur during load
changes the overrun bypass valve should be checked.
- FIL vacuum pump V.A.G 1390 to overrun bypass valve.
= Operate vacuum pump.
a The bypass valve must open (arrow).
- Operate vacuum pump venting valve after 30 seconds approx.
e The bypass valve should close (arrow).
- IT the overrun bypass vaive does not open or close or if the
valve is leaking, renew valve.
Secure bypass vaive connections using hose clips.
21-21
REMOVING AND INSTALLING EXHAUST SYSTEM
= к I EEE AA | rb df em dd dk Al mE Em TE FE TT ET ow rr hr ovr dry mri A Ae A ply Bed ber
nn ESSEN a mm mw mm mr rw rrr hen her rer dvr irl Spl pel eh dh pied тей at ber dei
mr rrr Tm mr = re pr yb i A
Arle Srv A те тЫ a dE
Note:
Always replace gaskets and self-locking
nuts.
1+ 25 Nm
2- 25 NN
3- Exhaust manifold gasket
e Install with beading facing
manifold.
6. 25 Nm
/- Corrugated pipe
e The end of the corrugated pipe
with a protruding pipe must be
towards the by-pass pipe.
8- CO take off pipe 20 Nm
9. Lambda probe 50 Nm
s Checking - Repair Group 24
e Grease thread using G5. Gb must
not come into contact with the
slat area in the probe body.
10- 25 Nm
26-1
11- 30 №
12- 60 tm
13- 22 Nm
Separating point between main ang rear
silencers - Fig, 1 page 26-3
être
eed]
26-674
Separating point between main and rear silencers
A separating point is provided to facilitate the replacement of
mair and rear silencers.
Dimension a = 176.5 om
Dimension 9 = 142,5 mm
Alicning exhaust system free of stresses
Before tightening the exhaust system bolts ensure sufficient
clearance exsists between body and exhaust system,
Particular attention should be paid to the following points:
e Clearance between exhaust system and transmission in the
crossmember area
e Clearance between exhaust system and rear axle crossmember
,— 6 Pre-stress (a = 10 mm approx.) at the rear silencer rear
| mounting.
wr
КР
F
LE
REMOVING AND INSTALLING EXHAUST MANIFOLD
—— [721-0471]
“Discomect connector plug from hot wire air volume sensor
“À +
= =nSlacken hose clip.
“PUTT off nose from hot wire air flow sensor -А-.
Release air cleaner upper section securing screw.
21-048
—#- \nciip air cieaner top section from bottom section,
~ Remove gir cleaner top section from engine compartment,
a = Remove air cleaner bottom section.
26-5
Removing waste gate
~~ Unscrew control line from waste gate.
Note:
Keep banjo boit clean and safe.
- Unbolt corrugated pipe from exhaust pipe.
- Unbolt waste gate from exhaust manifold.
26-6
…- Remove hose between hot wire air volume sensor and turbo»
charger from crankcase ventilation pipe and turbocharger by
releasing the two hose clips (arrows),
W
1
LM
— - Hemove hose between turbocharger and electrical boost pressure
Timiting valve ~B- from turbocharger.
-= - Release hose clip securing coolant flow pipe «£- to turbe-
charger.
x = Unscrew coolant flow pipe -C~ from turbocharger,
« Disconnect oil flow Tine «Ue from turbocharger.
—# - Remove hose between turbocharger and charge air cooler from
turdocharger.
25-10
wat Remove heat shield mounted on right-hand side member below
turbocharger.
=. Unboit turbocharger from exhaust manifold and remove.
-.Jo.instalh.exhaust manifold reverse-removel procedure.
The gasket between .exhayst.manifold and cylinder head
shovid be fitted in suchzal way that the gasket beading
26-12
CHECKING EXHAUST SYSTEM FOR LEAKS
Leaks located in the exhaust system upstream of the
Lamdda probe can cause
8 starting problems
+ engine fo cut out
e uneven idiing
9 uneven acceleration
s poor progression
Before fault finding is carried out on the fuel system,
Repair Group Z4, or ignition system, Repair Group 26,
The exhaust system should be checked for leaks as
fellows:
* Engine should be cold or hand-warm.
e Engine should be switched off.
- Insert compressed air jet into exhaust system tailpipe
and seal with a rag.
- Seal the second tailpipe also with a rag.
- Sel compressed air system operating pressure to 6 bar
approx.
- Open aîr jet.
- Check cylinder head joints,
26+ 14
V.A.G Service.
Workshop Bulletin to Workshop Manual
Audi 100 1983 >, Audi 200 1984 >
Code letters 1
5-cylinder fuel injection engine, (4-valve),
Booklet mechanics | Edition 05.89
Mark Repair Group Index Column 13 with Bulletin No. 2
Models affected: dll vehicles
a | Bulletin | Booklet
Subject page from page
Flywheel mounting bolts - | 1 13-13
Different tightening method |
before installing.
L40/444/-
Printed in Germany | 000.5164,32.70 Bulletin Edition: 01.91
V.A.G Service.
Workshop Bulletin to Workshop Manual
Audi 100 1983 >, Audi 200 1984 >
“Engine
Code letters a
5-Cyl, . engine (4-valve), mechanics
Booklet Edition 0, 89
Mark Repair Group Index Column 2] with Builetin No. 3
Models affected: A1! vehicles
Bulletin | Booklet
Subject page | from page
CHECKING TURBOCHARGER AND WASTEGATE 1 |21-18
Due to the introduction of turbocharger tester
V.A.G 159//A boost pressure is no longer
measured as relative pressure but as absolute
pressure. The checking procedure has changed
as follows:
De eb Ene g
Ч40/4447-
Printed in Germany 000.5164 .33.20 Bulletin Edition: 03.91
CHECKING TURBOCHARGER AND WASTEGATE
a Engine oil temperature 30% C min.
® № leaking vacuum connections.
- Hemove Motronic control unit cover on -A-
pillar in front passenger footwell.
- Remove vacuum hose from Motronic control
unit,
= = Connect turbocharger tester V.A.G 1397/4
between disconnected vacuum hose and Mo-
tronic control unit.
- Connect plug connector on vacuum hose to
connection I on turbocharger tester.
- Set selector switch to position IT {absolute
pressure range).
- Switch on turbocharger tester.
E,
Notes:
e When memory button M on turbocharger tester
is pressed the last reading is stored until
memory button M is pressed again or the
tester 1s switched off.
a A flashing decimal point in the display
indicates that a reading has been stored.
e Before testing, “the vehicle. should be | taken
sun а: fast run over a distance of at least
- When the rosd speed 15 approx. bO km/h accel-
grate in fourth gear and observe the rev.
counter,
me — al - At 3,000 rpm press memory button M on turbo-
charger tester.
- Specified readings:
Altitude (m) har
Sea level to 1,200 m 1.825
1,300 m 1.785
1,600 m 1.755
+ 2,300 m | 1,755
2,600 m 1.745
- If the specified reading 15 obtained but
there is reduced performance below 2,500 rpm,
check for wrong fuel (e.g. less than 95
RON): and check overrun by-pass valve - Repair
Group 21.
- If the specified reading is not obtained
interrogate fault memory and carry out final
control element diagnosis - see Workshop
Manual, Motronic fuel injection and ignition
system. Temporarily replace wastegate and
repeat check.
- If the specified reading is still not obtained
replace turbocharger.
Service.
Technical Bulletin to Workshop Manual
Audi100 1983 >, Audi 200 1984 >
5- cylinder fuel injection engine | В
Booklet ~ (4-valve), mechanics ~~ Edition 05.89
Enter in Repair Group list | | | Е ВЕ
Repair Group 17 | o | | Bulletin No. 4
Affected: — Al] vehicles —
Subject
~ REMOVING AND INSTALLING OIL SUMP -
EL EE EE Ey Ve ито и о И С А НМ FP
РА РА РА РР РАНЫ РУНЫ Баня bbe dildo: uds bbb ni lé, béni mim be
Contents | 5 | | —. - 1. page frompage — 5
Removing and installing oil sump Е ВЕ | 1 17-10
cite lelerer x
Cera ERT cian HH era rea
— 440/444/-
Printed in Germany ВЕ 000, 5164, 34,20 | | ВЕ Bulletin Edition: 02. 92
AMENDMENT
REMOVING AND TNSTALLTNG OTL SUMP
When installing the cil sump, tighten the M8
screws to 20 Nm first, and then tighten the
M6 screws to 10 Ni.