Engine - Repair - 1997-2000 EV Repair Manual

10-1
Engine, removing and

installing
Special tools and equipment
VAG 1921 Spring-clip Pliers
VAG 1306 Drip tray
3277A Installation tool
3408 Engine support
VAG 1383 A Engine/transmission jack
G 000 100 Grease (for vehicles with manual

transmission)
VAG 1331 Torque wrench (5 to 50 Nm)
Cable tie
- Remove engine/transmission assembly from

below.
CAUTION!
Obtain radio code before disconnecting

battery ground strap.
- Disconnect battery ground cable.
Ignition must be switched OFF
- Always replace cable ties in original position.

10-2
- Drain coolant Page 19-14 .
- Remove radiator and radiator cooling fan

Page 19-22 .
- Remove ribbed belt Page 13-22 .
- Detach hose from combi-valve at Air Cleaner upper section -arrow-.

- Remove intake manifold complete with intake manifold lower section
and Throttle Valve Control Module Page 15-9 .
- Disconnect power steering lines from right engine support.
- Remove power steering pump with bracket and secure to body with
wire (hoses remain connected).
Repair Manual, Suspension, Wheels, Brakes, Steering m.y. 1992-1996,
Repair Group 40 Repair Manual, Suspension, Wheels, Steering from
m.y. 1997, Repair Group 40
- Remove front exhaust pipe Page 26-2 .
- Disconnect wiring from transmission, generator and starter and move
out of the way.
- Disconnect all engine coolant, vacuum and breather hoses.
10-3
Vehicles with manual transmission:
- Pry off line/hose from slave cylinder on

transmission.
- Remove transverse support bolts -A- and -B-.

- Remove transverse support.
- Remove gearshift mechanism from transmission.
Vehicles with automatic transmission:
- Remove transmission shift cable.

Repair Manual, 4 Spd. Automatic Transmission 01P, Repair Group 37
Vehicles with A/C:
- Observe additional information and removal instructions Page 10-

14 .
10-4
All vehicles:
- Remove axle shafts.
Repair Manual, Suspension, Wheels, Brakes,

Steering m.y. 1992-1996, Repair Group 40
Repair Manual, Suspension, Wheels, Steering

from m.y. 1997, Repair Group 40
- Remove support bracket -1- from cylinder block and pull flange shaft -
3- out of transmission shaft -4-.
- Remove flange shaft -3- with flange shaft bearing -2-.
- Place 3408 engine support on VAG 1383 A engine/transmission jack.
- Place 3408 engine support on cylinder block and tighten nuts -1-.
40 Nm (30 ft lb)
- Remove pendulum support.
10-5
- Remove right assembly mount bolt -1-.
- Remove left assembly mount bolts -arrows-.

- Carefully lower assembly.
CAUTION!
Carefully guide assembly out of vehicle while lowering. Do not allow

assembly to contact or damage body.
10-6
Engine, mounting on engine stand
- Mount engine to VW 313 engine stand support

clamp using 3269 engine bracket.
VAG 1202 A Workshop crane
2024 A Lifting tackle
3269 Engine bracket
VW 313 Support clamp
Vehicles with manual transmission
- Attach 2024 A as follows:

- Lift off of VAG 1383 A engine/transmission jack with workshop crane.
Vibration damper end: 3rd hole in hook at position 1.
Flywheel end: 4th hole in hook at position 8.
10-7
CAUTION!
Hooks and locating pins must be secured

with locking pins.
Note:
Positions marked 1 to 4 on bar must face

toward vibration damper.
Holes in hooks are counted up from the hook.
If engine must be separated from transmission,

first separate torque converter from drive plate
(3 bolts). Secure torque converter so it cannot
fall out.
- Remove 3408 engine bracket from cylinder

block.
- Install 3269 engine bracket on cylinder block

and tighten bolts.
40 Nm (30 ft lb)
- Install engine in VW 313 support clamp using

VAG 1202 A workshop crane.
10-8
Engine, installing
Install engine in reverse sequence, note the

following:
- Check clutch release bearing in slave cylinder

for wear. If necessary replace slave cylinder with
release bearing.
- Clean splines of input shaft and lightly grease

with G 000 100.
All vehicles
- Check if engine/transmission locating dowels

are installed in cylinder block. Install if
necessary.
- Install mounting hardware approx. 5 to 6 turns

by hand.
- When installing right side engine mount, make sure hydro mount lugs
engage in engine bracket slot -arrow-.
- Align mounts stress-free by rocking Page 10-13 , tightening torques.
- Install pendulum support.
10-9
Vehicles with A/C
- Install A/C compressor.
Repair Manual, Heating & Air Conditioning

m.y. 1992-1996, Repair Group 87

- Connect line/hose on slave cylinder and secure

with clip.
- Install gearshift mechanism on transmission,

adjust if necessary.
Vehicles with automatic transmission
- Install transmission shift cable on transmission,

adjust if necessary.
Repair Manual, 4 Spd. Automatic

Transmission 01P, Repair Group 37
All vehicles
- Install axle shafts.


- Install power steering pump with bracket.

10-10

- Install front exhaust pipe Page 26-3 , item

8.
- Install intake manifold complete with lower

section and Throttle Valve Control Module (note
position of dowel sleeves in cylinder head when
installing) Page 15-9 .
- Install ribbed belt Page 13-22 .
- Install radiator and radiator fan Page 19-

22 .
- Fill system with coolant Page 19-14 .
- Adjust accelerator cable Page 20-25 .
- Re-connect wiring and route as necessary.
Electrical Wiring Diagrams, Troubleshooting &

Component Locations
- Check Diagnostic Trouble Code (DTC)

memory.
Repair Manual, 2.8 Liter VR6 2V Fuel Injection
& Ignition, Engine Code(s): AES,Repair Group
01
- Check idle speed and ignition timing.

& Ignition, Engine Code(s): AES,Repair Group
24
- Check headlight adjustment; adjust if

necessary.
Repair Manual, Maintenance

10-11
Tightening torques, chart
Bolted Tightening torque

connections
Engine to M8 25 Nm
transmission
(18 ft lb)
M10 60 Nm
(44 ft lb)
M12 80 Nm
(59 ft lb)
Flywheel cover M7 10 Nm
plate
(7 ft lb)
Pendulum support to 80 Nm
transmission
(59 ft lb) +1/4 turn
(90 ) further
Pendulum support to sub- 200 Nm
frame
(148 ft lb)
Starter to engine and 45 Nm
transmission
(33 ft lb)
Front exhaust pipe to exh. 40 Nm
manifold
(30 ft lb)
Front exhaust pipe to 25 Nm
catalyst
(18 ft lb)
10-12
Bolted connections Tightening

torque
Transverse support to 30 Nm
transmission and left mount
(22 ft lb)
Axle shaft to wheel hub 150 Nm
(111 ft lb)
+ 1/4 turn (90 )

further
Axle shafts to flanged shafts 80 Nm
(59 ft lb)
10-13
Assembly mounts, torque values
Tightening torques with bolts oiled
Right side assembly mount
A = 55 Nm (41 ft lb)
B = 60 Nm (44 ft lb)
C = 10 Nm (7 ft lb)
Left side assembly mount
A = 55 Nm (41 ft lb)
B = 50 Nm (37 ft lb) + 1/4 turn (90 ) further
C = 60 Nm (44 ft lb)
D = 30 Nm (18 ft lb)
10-14
Vehicles with A/C, additional

information and removal instructions
CAUTION!
Do not open A/C refrigerant circuit!
Note:
Only open A/C refrigerant circuit in workshops

which have trained personnel, necessary tools,
and equipment.
To remove and install engine without opening

refrigerant circuit:
- Remove refrigerant line retaining clamp(s).
- Remove generator.
Repair Manual, Electrical Equipment through

July 1998, Repair Group 27
Repair Manual, Electrical Equipment from

August 1998, Repair Group 27
- Remove A/C compressor.

- Secure A/C compressor to vehicle body to

relieve any strain or stress to refrigerant lines
and hoses.
13-1
Engine, disassembling and

assembling
Note:
Use engine stand and bracket 3269 or
equivalent.
From engine number: AES-003279 a single
chain with modified tensioning plate is installed
instead of double chain. For this reason chain
tensioner has been changed.
CAUTION!
When there is internal engine damage and if

you find metal chips or metal powder in engine
oil, thoroughly clean all engine oil passages,
replace all oil spray jets, oil check-valve and oil
cooler.
I Page 13-2
II Page 13-9
III Page 13-15

13-2
Part I
1 - Camshaft sprocket
For upper chain (item 18 )
Removing and installing Page 15-30
2 - Sensor wheel
For Camshaft Position sensor -G40-
Contact surfaces of timing chain and
sensor wheel must be dry when installing.
3 - 100 Nm (74 ft lb)
Oil bolt head contact surface when
installing.
To remove and install: counter-hold with 24
mm open wrench on camshaft Page 15-
30
4 - Pivot pin
25 Nm (18 ft lb)
For tensioning plate (item 16 )
5 - Seal
Replace
13-3
6 - Chain tensioner
30 Nm (22 ft lb)
Up to engine number AES 003278 with oil
hole for double chain.
Bleed before installing Fig. 3
Beginning with engine number AES-
003279 only single chains for camshaft
drive are installed. Therefore the tensioner
does not have an oil bore and can no
longer be bled Fig. 2 .
CAUTION!
Only turn engine with chain tensioner installed!
7 - Tensioning plate
For camshaft chain (item 18 )
Up to engine number AES 003278 for
double chain
As of engine number AES 003279 for
single chain
8 - Sprocket
For single chain (item 24 )
Installing Page 13-25
13-4
9 - Upper chain
- Mark direction of rotation before
removing Fig. 1 .
Up to engine number AES 003278 for
double chain
As of engine number AES 003279 for
single chain
10 - 100 Nm (74 ft lb)
11 - Sprocket
12 - 10 Nm (7 ft lb)
13-5
13 - Chain tensioner with tensioning plate

For lower chain (item 24 )
Before installing: release locking spline in
chain tensioner with a small screwdriver
and press tensioning plate against
tensioner.
CAUTION!
14 - Crankshaft sprocket
Part of crankshaft
Ground down tooth aligned with main
bearing joint: = TDC for Cyl No. 1 Page
13-25
15 - Lower chain
Mark direction of rotation before removing
Fig. 1 .
13-6
16 - Guide rail
For lower chain (item 24 )
Remove together with lower chain
page . Page 13-25
17 - Locating pin w/out collar
25 Nm (18 ft lb)
For guide rail (item 25 )
18 - Locating pin with collar
25 Nm (18 ft lb)
For guide rail (item 30 )
19 - 20 Nm (15 ft lb)
- Insert using D6 locking fluid .
20 - 20 Nm (15 ft lb)
21 - Guide rail
22 - 10 Nm (7 ft lb)
- Insert using D6 locking fluid.
23 - Thrust washer
24 - Intermediate shaft
13-7
Fig. 1 Marking single and double chains

- Mark single and double chains before removing (with mark pointing in
direction of rotation).
CAUTION!
Do NOT mark timing chains using a punch or any other mechanical

device that could cause damage.
Note:
As of engine number AES 003279 only single-link chains are used. As
a result, chain tensioner has no oil hole and does not have to be bled
Fig. 2 .
Only use single link chain with tensioning bar.
Fig. 2 Chain tensioner for camshaft chain

Install chain tensioner -A- with oil hole (arrow) only with double link
chain.
Install chain tensioner -B- only with single link chain.
13-8
Fig. 3 Chain tensioner for double chain, bleeding
Wire (diameter: 0.8 mm)

- Push piece of wire (diameter: 0.8 mm) through pressure piston hole
(arrow) up to ball valve and press piston and housing together onto
stop.
Note:
If piston moves out again, repeat bleeding procedure.

13-9
Part II
1 - Intake manifold
Removing and installing cylinder head
cover Page 15-9
- Torque to lower intake manifold on
cylinder head, then to two rear supports,
(items 7 and 3 )
Disassembly and assembly
Repair Manual, 2.8 Liter VR6 2V Fuel Injection &
Ignition, Engine Code(s): AES, Repair Group 24
2 - 25 Nm (18 ft lb)
3 - Right rear support
Between intake manifold and cylinder head
4 - Throttle Valve Control Module -J338-
Heated by coolant
Removing and installing:
13-10
5 - Connection
6 - Exhaust Gas Recirculation (EGR) valve
For EGR system Page 26-9 , item - 6 -
13-11
7 - Left rear support

8 - Cap
9 - Gasket
- Replace if damaged.
10 - Vacuum hose
To EGR valve/intake manifold junction
piece Page 26-8
11 - Oil fill pipe
12 - 10 Nm (7 ft lb)
13 - O-ring
14 - Cylinder head cover
- Replace if damaged or leaking.
15 - O-ring
- Always replace.
- Coat with oil before assembly.
- Insert in camshaft sprocket cover (item
16 ).
13-12
16 - Camshaft sprocket cover

Can be removed/installed with cylinder
head installed.
- Coat sealing surfaces with AMV 188 001
02.
If only camshaft sprocket cover has been
removed, prepare cylinder head gasket for
assembly Page 15-8 , Fig. 2 .
17 - Bracket
For -G98- 2-pin EGR Temp. sensor
harness connector Page 26-8
18 - Seal
- Always replace,
19 - Chain tensioner
30 Nm (22 ft lb)
For upper chain
- Bleed before installing Page 13-8
Beginning with engine number AES-
003279 only single chains for camshaft
drive are installed. Therefore the tensioner
does not have an oil bore and can no
longer be bled.
Only turn engine if chain tensioner is

installed!
13-13
20 - Ground connection
21 - Bracket
22 - Ignition coil -N152-*
Checking:
23 - Bracket
For fuel injector connectors (item 32 )
24 - Thermostat housing
Disassembly and assembly Page 19-12
25 - O-ring
- Always replace
26 - Cylinder head gasket
- Always replace.
- If replaced; completely replace engine
coolant.
27 - Cylinder head
- If replaced; completely replace engine
coolant.
13-14
28 - Cylinder head bolt

- Always replace.
- Follow sequence when loosening and
tightening Page 15-17 .
29 - Lower intake manifold gasket
- Always replace.
Note installed position.
30 - Ribbed belt tensioner
Removing and installing ribbed belts
Page 13-22
31 - Positive Crankcase Ventilation valve
Arrow on crankcase breather valve points
to intake hose.
32 - Harness connector
For injectors -N30-, -N31-, -N32-, -N33-, -
N83-, -N84-
Mounted to bracket (item 23 ).
33 - Retainer
For Secondary Air Injection pump motor
Page 26-14
13-15
Part III
1 - 10 Nm (7 ft lb)
2 - Oil pump drive cover
3 - O-ring
- Always replace.
- Oil before assembling.
4 - Oil pump drive
5 - Cylinder block
Removing and installing sealing flange and
flywheel/drive plate Page 13-34
Removing and installing crankshaft
Page 13-53
Disassembling and assembling pistons and
connecting rods Page 13-44
7 - Thrust washer
8 - 10 Nm (7 ft lb)
- Install with D6 locking fluid.
13-16
9 - Knock sensor (KS) 2 -G66-

Checking:
10 - 20 Nm (15 ft lb)
Tightening torque influences knock sensor
function
11 - O-ring
12 - Engine Speed (RPM) sensor -G28-
Checking:
13 - Gasket
- Coat sump flange/cylinder block flange
with D2 before installing gasket.
14 - Coolant line
To thermostat housing Page 13-13 ,
item 24
13-17
15 - O-ring
- Replace
16 - Oil pump
Disassembling and assembling Page
17-10
- Coat oil pressure line on block and oil
pump housing with AMV 188 001 02.
17 - 25 Nm (18 ft lb)
18 - 10 Nm (7 ft lb)
- Replace
- Install with D6 locking fluid.
13-18
19 - Seal
- Always replace
20 - Oil drain plug
30 Nm (22 ft lb)
Replace if leaking. See Parts Catalog for
correct application. In some cases, seal
and drain plug are combined; do not
interchange with separate seal and drain
plug.
21 - 15 Nm (11 ft lb)
- Remove and install using 3249 socket.
- With flywheel installed, turn flywheel until
recess aligns with bolts.
22 - Oil pan
- Clean sealing surfaces before installing.
23 - Oil cooler cover
25 Nm (18 ft lb)
24 - Oil cooler
- Coat contact area outside seal with AMV
188 100 02
- Make sure clearance with any adjacent
components.
See note Page 13-1
13-19
25 - Oil filter housing

17-8
26 - Gasket
- Replace
- Note installed position.
- Oil before installing.
27 - Vibration damper
Ribbed belt, removing and installing
Page 13-22
28 - 120 Nm (89 ft lb) plus additional1/ turn
4
- Replace
- Counter-hold using 3406 to loosen and
tighten Fig. 1 .
29 - Coolant pump
- Check shaft for ease of movement.
30 - 20 Nm (15 ft lb)
31 - Pulley
For coolant pump
13-20
32 - 25 Nm (18 ft lb)
Loosening and tightening: counterhold
using a punch fed through the holes.
33 - 55 Nm (41 ft lb)
34 - Guide tube
For dipstick
Bolted to intake manifold
35 - Right engine bracket
36 - Dipstick
CAUTION!
Oil must NOT be above MAX mark on dipstick!
37 - Oil check valve

5 Nm (44 in. lb)
- Note installed position
- Clean if contaminated.
- See note Page 13-1
13-21
Fig. 1 Holding vibration damper using 3406 counter-hold tool to

loosen or tighten mounting bolt
- Replace mounting bolt.
CAUTION!
Do not allow crankshaft to turn while tightening mounting bolt!

13-22
Ribbed belt, removing and installing
M8 x 80 hex bolt
Note:
When installing belt, be sure it is correctly seated

in pulley.
Removing
- Remove sound tray.
Repair Manual, Body Exterior, Repair Group

50
- Screw M8 x 80 bolt into tensioner hole -A- until ribbed belt is no longer
under tension.
CAUTION!
Only thread in bolt until belt can be removed, otherwise tensioner

housing can be damaged!
- Remove ribbed belt.

13-23
Installing
Note:
Before installing ribbed belt, generator, A/C

compressor, and power steering pump sub-
assemblies must be tight.
- Install ribbed belt.

- Remove M8 bolt from tensioner.
- Start engine and check belt.
Note:
Vehicles with A/C have a double ribbed belt.

13-24
Valve timing, checking
3268 Camshaft bar
Test sequence
- Remove sound dampening tray.

50
- Set crankshaft to TDC cyl. 1 mark -arrow- by turning crankshaft in

direction of engine rotation using vibration damper bolt.
- Remove cylinder head cover Page 15-9 .
3268 Camshaft bar must fit into both shaft grooves.
Note:
This position is only possible every 2nd TDC position.
13-25
Valve timing, adjusting
With timing chains removed
3406 Counter-hold tool
3268 Camshaft setting bar
Work sequence (with engine removed)
- Install lower chain and chain tensioner with

tensioning plate.
- Set/check position of crankshaft to intermediate shaft.

Ground down tooth on crankshaft sprocket -B- must align with the
main bearing joint (= TDC for cyl. 1).
- Install pin (without collar) for guide rail -2- and tighten.
25 Nm (18 ft lb)
13-26
- Install guide rail -2- with lower chain -1- and both sprockets -3- and -4-.
- Note direction of rotation for lower chain Page 13-7 , Fig. 1 .
Mark on lower chain sprocket -4- must align with notch -C- or -D-
on thrust washer.
- Release locking spline in chain tensioner with small screwdriver -A-.
- Press chain tensioner against tensioner plate, then tighten chain
tensioner.
10 Nm (7 ft lb)
- Lock vibration damper using 3406 counter-hold tool.

13-27
- Tighten intermediate shaft sprockets 3 and 4.

100 Nm (74 ft lb)
- Check position of crankshaft relative to intermediate shaft.
Ground down tooth on crankshaft sprocket -B- must align with
main bearing joint (= TDC for cyl. 1).
- Install upper chain and chain tensioner with tensioning plate.
- Position camshafts using 3268 camshaft ruler.

- Install tensioning plate pivot pins and tighten.
25 Nm (18 ft lb)
- Install tensioning plate for chain tensioner (upper chain).
- Install locating pin with collar for guide rail and tighten.
25 Nm (18 ft lb)
13-28
With cylinder head removed
Cylinder head, installing Page 15-17
- Place guide rail on locating pin, insert short

mounting bolt using D6 locking fluid and tighten
both bolts.
20 Nm (15 ft lb)
- Place upper chain on intermediate shaft.

Note direction of engine rotation for upper chain.
- Install camshaft sprocket and upper chain to camshaft for cylinders 2, 4
and 6 (short camshaft) and hand tighten.
- Install camshaft sprocket (with sensor wheel for Camshaft Position
sensor) and upper chain on camshaft for cylinders 1, 3 and 5 and
tighten by hand.
Note:
Contact surfaces of timing chain and sensor wheel must be dry when
installing.
Oil bolt head contact surfaces when installing.
- Remove 3268 camshaft bar.
- Tighten camshaft sprocket mounting bolts.
100 Nm (74 ft lb)
13-29
Note:
Only counter-hold using a 24 mm open end wrench on camshaft -arrow-.

3268 camshaft bar must not be installed when tightening or loosening
sprockets.
- Coat sealing flange surface with AMV 188 001 02 and install.
- Tighten mounting bolt.
10 Nm (7 ft lb)
- Replace sealing flange oil seal Page 13-34 .
- Prepare cylinder head gasket for assembly Page 15-8 , Fig. 2 .
- Coat camshaft sprocket cover sealing flange with AMV 188 001 02.
- Oil O-ring and insert in camshaft sprocket cover Page 13-11 , item
15 .
- Install cylinder head cover, insert bolts and lightly tighten.
- Tighten M8 mounting bolt.
25 Nm (18 ft lb)
- Tighten M6 mounting bolts
10 Nm (7 ft lb)
13-30
- Install chain tensioner and tighten.
30 Nm (22 ft lb)
Note:
If chain tensioner has been pulled apart, bleed

before installing Page 13-8 , Fig. 3 .
Beginning with engine number AES-003279

only single chains for camshaft drive are
installed. Therefore, chain tensioner does not
have oil bore and is no longer bled.

Otherwise lower or upper chain will jump
sprockets.
- Turn crankshaft two full turns in direction of

engine rotation and check valve timing Page
13-24 .
Engine installed, cylinder head removed
- Set crankshaft to TDC (cyl. 1) mark -arrow- by turning crankshaft in

direction of engine rotation using vibration damper bolt.
13-31
If TDC cyl. 1 setting is correct, a notch is visible on intermediate shaft

sprockets -arrow-.
If notch is not visible:
- Turn crankshaft one full turn in direction of engine rotation.
Note:
If crankshaft must be turned with cylinder head removed, use a 2nd

technician to guide upper chain to prevent it from jamming.
- Position camshafts using 3268 camshaft tool

- Prepare cylinder head gasket for assembly Page 15-8 , Fig. 2 .
- Install cylinder head Page 15-17 .
- Place guide rail on locating pin.
- Insert short mounting bolt using D6 locking fluid and tighten.
20 Nm (15 ft lb)
- Install camshaft sprocket and upper chain to camshaft for cylinders 2, 4
and 6 (short camshaft), hand-tighten.
13-32
- Install camshaft sprocket (with trigger wheel for

Camshaft Position sensor) and upper chain on
camshaft for cylinders 1, 3 and 5, hand-tighten.
Note:
Contact surfaces of timing chain and sensor

wheel must be dry when installing.
Oil bolt head contact surfaces when

installing.
- Remove 3268 camshaft tool.
- Tighten camshaft sprocket mounting bolts.
100 Nm (74 ft lb)
Note:
Only counter-hold using a 24 mm open end

wrench on camshaft -arrow-. 3268 camshaft tool
must not be installed when tightening or
loosening sprockets.
- Coat sealing flange sealing surface with AMV 188 001 02.
- Oil O-ring and insert in camshaft sprocket cover Page 13-11 (item
15 ).
- Install camshaft cover.
- install all bolts and lightly tighten.
- Tighten M8 bolt.
25 Nm (18 ft lb)
13-33
- Tighten M6 bolts.
10 Nm (7 ft lb)
- Install upper chain, chain tensioner and

tighten.
30 Nm (22 ft lb)
Note:
If chain tensioner has been pulled apart, bleed

before installing Page 13-8 , Fig. 3 .
Beginning with engine number AES-003279

only single chains for camshaft drive were
installed. Therefore, chain tensioner does not
have and oil bore and is no longer bled.
CAUTION!
Only turn engine with chain tensioner

installed! Otherwise chain (single or double)
will jump track!
-
Turn crankshaft two full turns in direction of
engine rotation and check valve timing Page
13-24 .
15-1
Cylinder head, removing and

installing
Compression pressure, checking Page 15-19
Note:
When installing an exchange cylinder head
(with camshaft), contact surfaces between
hydraulic lifter and cam must be oiled after
installation.
Plastic protectors (to protect open valves)
should be removed only just before installing
the cylinder head.
If cylinder head is replaced, replace all engine
coolant
1 - Intake manifold
- Tighten to lower intake manifold, then to
two rear supports (items 7 and 3 ).
Disassembly and assembly
2 - 25 Nm (18 ft. lb)
15-2
3 - Right rear support

cover
Heated by coolant.
5 - Connection
6 - Exhaust Gas Recirculation (EGR) valve
Page 26-8
7 - Left rear support
8 - Cap
9 - Gasket
15-3
10 - Vacuum line
To EGR valve/intake manifold junction
piece Page 26-8
11 - Oil fill tube
12 - 10 Nm (7 ft. lb)
13 - O-ring
- Replace.
14 - Cylinder head cover
- Replace if damaged or leaking.
15 - O-Ring
- Replace
Can be removed and installed with cylinder
head installed.
- Coat sealing surfaces with AMV 188 001
02.
- If only camshaft sprocket cover has been
removed, prepare cylinder head gasket
for assembly Fig. 2
15-4
17 - Spacer ring
18 - O-Ring
- Replace.
- Lubricate before installing
19 - Camshaft Position (CMP) sensor-G40-
Checking:
20 - Bracket
For -G98- EGR Temperature sensor, 2-pin
connector Page 26-8
CAUTION!
Only turn engine when chain tensioner is

installed.
15-5
21 - O-Ring
- Replace
22 - Chain tensioner
30 Nm (22 ft. lb)
For upper chain
- Bleed before installing Page 13-8 ,
Fig. 3
Up to engine number AES-003278 with oil
drilling for double link chain.
23 - Ground connection
24 - Bracket
25 - Ignition coil -N152-*
Checking:
26 - Bracket
For fuel injector connectors (item 35 )
15-6
28 - O-ring
- Replace
29 - Cylinder head gasket
- Replace.
- If replaced, replace all engine coolant.
30 - Cylinder head
- Check for distortion Fig. 1 .
- If replaced, replace all engine coolant.
- Note sequence when loosening and
31 - Cylinder head bolt
- Replace.
- Note sequence when loosening and
32 - Lower intake manifold gasket
- Replace
15-7
33 - Ribbed belt tensioner

Ribbed belts, removing and installing
Page 13-22
34 - Positive Crankcase Ventilation valve
Arrow on valve points toward intake hose:
35 - Connector
For injectors -N30-, -N31-, -N32-, -N33-, -
N83-, -N84-
Mounted to bracket (item 26 )
36 - Retainer
For Secondary Air Injection pump motor
Page 26-14
15-8
Fig. 1 Cyl. head, checking for distortion
Feeler gauge set
Max. permissible distortion: 0.1 mm
Fig. 2 Cyl. head gasket, preparing for assembly
AMV 188 001 02 sealant

- Remove old sealant from 3 mm holes in cylinder head gasket -arrows-.
- Fill 3 mm holes in cylinder head gasket using sealant AMV 188 001 02.
Note:
When cylinder head is installed, holes are only half visible.

15-9
Cylinder head cover, removing and

installing
3277A installation tool
VAG 1331 Torque wrench 5 to 50 Nm (4 to 37

ft. lb)
VAG 1921 spring clip pliers
Removing
CAUTION!

- Switch OFF ignition.
- Disconnect battery ground strap.
- Replace all cable ties removed to remove

engine, and place them in their original position.

50
- Remove radiator grille.

66
15-10
- Remove lock carrier bolts -1- on left and right side.

- Pivot lock carrier forward (with radiator) -arrow-.
- Disconnect heater element connector (on intake hose) .
- Remove intake hose between upper air cleaner and Throttle Valve
Control Module -J338- together with Positive Crankcase Ventilation
valve.
Repair Manual, 2.8 Liter VR6 2V Fuel Injection & Ignition, Engine Code
(s): AES, Repair Group 24
- Disconnect connectors from EGR valve -1-, Throttle Valve Control

module -2-, and Intake Air Temperature Sensor (ATS) -G72- -3-.
15-11
- If equipped, disconnect 2-pin connector from EGR Temperature sensor

-arrow-.
- Disconnect white 3-pin connector from Knock sensor 1 -arrow-.

- Release wiring from clips behind intake manifold and on EGR valve.
- Remove spark plug connectors using 3277A release tool and unclip
ignition cables from ignition cable guides.
- Detach accelerator cable (do not remove locating clip) from support
bracket and Throttle Valve Control Module .
15-12
- Mark coolant hoses -1- and -2- from Throttle Valve Control Module.
- Pull off hoses using VAG 1921 hose clamp pliers (after first releasing
pressure from cooling system).
- Seal coolant hoses.
- Remove breather hose from EVAP canister purge regulator valve -3-.
- Disconnect vacuum hose to brake servo from intake manifold.
WARNING!
Fire Hazard. Do NOT smoke or have anything in area that can ignite
fuel.
- Using VAG 1921 hose clamp pliers, remove fuel return line -1- (blue or
blue markings) and fuel supply line -2- (black or black markings).
WARNING!
Fuel supply lines are under pressure! Before disconnecting line

connections wrap a cloth around connection, then release pressure
by carefully pulling hose connection.
15-13
- Disconnect vacuum hose -3- from Secondary Air

Injection valve from junction piece.
- Disconnect line from exhaust manifold at EGR

valve connection.
- Disconnect fuel injector connectors and remove

connector from retaining bracket.
- Remove left rear support between intake manifold and cyl. head -
arrow-.
- Remove right rear support between intake manifold and cyl. head -
arrow-.
15-14
- Disconnect Secondary Air Injection system valve -1- and Secondary Air
Injection system pump motor -2-.
- Remove Secondary Air Injection pump motor Page 26-14 .
- Remove Secondary Air Injection combi-valve Page 26-19 .
- Remove combi-valve connection at cylinder head Page 26-14 .
- Remove dipstick guide tube.
- Remove intake manifold bolts.
- Remove intake manifold assembly/Throttle Valve Control Module.
When installing, note position of dowel sleeves in cyl head.
Note:
Seal dipstick guide tube opening in cylinder block and intake ports in
cylinder head using a clean cloth.
- Remove cylinder head cover.

15-15
Cylinder head, installing
- Install components in reverse sequence.
Note:
Replace cylinder head cover if damaged or

leaking.
Replace gasket between lower intake manifold

and cylinder head cover.
First tighten intake manifold (including lower

intake manifold) to cylinder head, then tighten
both rear supports.
Fuel lines must be tight.
- Replace engine coolant Page 19-14 .
- Adjust throttle cable Page 26-19 .
- Check Diagnostic Trouble Code (DTC)

memory.

& Ignition, Engine Code(s): AES, Repair Group
01
15-16
Tightening torques
Bolted joints Tightening

torque
Cylinder head cover to cylinder 10 Nm
head
(7 ft. lb)
Lower intake manifold to cylinder 25 Nm
head
(18 ft. lb)
Right and left rear supports to 25 Nm
intake manifold and cylinder
head (18 ft. lb)
Line to EGR valve connection 30 Nm
(22 ft. lb)

15-17
Cylinder head, installing
VAG 1332 Torque wrench 40 to 200 Nm (30 to

148 ft. lb)
3268 Crankshaft setting bar
Work sequence
- Set crankshaft to TDC cyl. 1 mark -arrow- by turning crankshaft with

vibration damper bolt in direction of engine rotation.
- Position camshafts using 3268 camshaft bar.
Note:
This position is only possible every 2nd TDC position.

15-18
- Install cylinder head gasket.

Note position of locating pins (in block holes 12, 20).
- Install cylinder head.
- Insert cylinder head bolts and tighten by hand.
- Tighten cylinder head using four stage sequence as follows:
- Tighten initially using torque wrench
Stage I 40 Nm (30 ft. lb)
Stage II 60 Nm (44 ft. lb)
- Turn further using ordinary wrench
Stage III additional 1/4 turn
Stage IV additional1/4 turn
Note:
Loosening cylinder head: reverse sequence.
Torquing cylinder head after repairs is not necessary.
15-19
Cylinder compression, checking
VAG 1763 Compression tester
3122 B Spark plug wrench
3277 Installation tool
Test conditions
Engine oil temperature 30 C (86 F)

minimum.
Work sequence

66
- Remove left and right screws.

- Pivot lock carrier forward (with radiator) -arrow-.
-
Disconnect heater element connector and remove intake hose between
upper Air Cleaner and Throttle Valve Control Module -J338- together
with Positive Crankcase Ventilation valve.
- Remove spark plug connectors using 3277 A tool. Unclip ignition
cables.
15-20
- Remove spark plugs with 3122 B spark plug

wrench.
- Disconnect 5-pin connector from ignition coil -arrow-.

- Hold throttle valve open.
- Check compression using VAG 1763 compression tester.
Note:
See manufacturer's instructions on how to use compression tester.
- Operate starter until tester shows no further pressure increase.
Compression checking specifications
New: 10 to 13 bar (145 to 189 psi)

Wear limit: 7.5 bar (109 psi)
Permissible difference between cylinders: 3 bar (44 psi)
17-1
Lubrication system
components
If you find metal shavings or large quantities of
metal particles (possibly caused by partial
seizure of crankshaft and connecting rod
bearings) in the engine oil while performing
engine repairs:
- Thoroughly clean all oil passages, replace all oil

spray jets, oil non-return valve and oil cooler.
Oil pressure and oil pressure switch, checking

Page 17-12 .
Oil Capacities up to MY 2000
Fluid Capacity Chart, from my 2001
Oil system capacity
Without oil filter: 5.5 ltrs. (5.8 quarts)
With oil filter: 6.0 ltrs. (6.3 quarts)
CAUTION!
Do NOT allow engine oil above MAX. mark.

This can lead to catalyst damage!
17-2
Engine oil specifications
The following terms must appear on the oil

container singly or in combination with other
designations: VW 502 00 or VW500 00 or
VW501 01, ACEA A2 or ACEA A3, or API-SJ or
API-SL.
Engine oils are graded according to viscosity. The proper grade to be

used depends on existing climatic or seasonal conditions.
The original engine oil has a viscosity grade of SAE 5W-40. Use this
oil over all temperature ranges for normal driving. If engine oil
viscosity grade SAE 5W-40 is not available, use SAE 5W-30.
17-3
Lubrication system components,

removing and installing
1 - 10 Nm (7 ft lb)
2 - Oil pump drive cover
3 - O-ring
Always replace.
Oil before installing.
4 - Oil pump drive
6 - Thrust washer
7 - 10 Nm (7 ft lb)
Install with locking fluid D6.
8 - Oil pump
Coat oil pump housing and oil pressure
pipe at cylinder block with AMV 188 001
02.
9 - 25 Nm (18 ft lb)
17-4
10 - 10 Nm (7 ft lb)
Replace.
Install with D6 locking fluid.
11 - Oil drain plug
30 Nm (22 ft lb)
Replace if leaking. See Parts Catalog for
correct application. In some cases, seal
and drain plug are combined; do not
interchange with separate seal and drain
plug.
12 - Seal
Always replace.
13 - Oil spray jet
For crankshaft bearings 2 to 7
For piston cooling
Removing and installing Fig. 1
Opening pressure: 2.0 bar (29 psi)
See note Page 17-2
14 - 15 Nm (11 ft lb)
Remove and install using 3249 socket.
With flywheel installed: turn flywheel so
recesses align with bolts.
15 - Gasket
Always replace.
Before installing gasket, coat sump
flange/cylinder block flange with D2.
17-5
16 - Oil pan
- Clean sealing surfaces before installing.
17 - Oil cooler
- Coat contact area to flange, outside the
seal, with AMV 188 100 02.
Make sure clearance to adjacent
components.
See note Page 17-1
18 - Oil cooler cover
25 Nm (18 ft lb)
19 - Gasket
- Replace.
20 - Oil filter housing
17-8
21 - Dipstick
Oil level must not be above max. mark.
17-6
22 - Guide tube
For dipstick
Bolted to intake manifold
23 - Oil non-return valve
5 Nm (44 in. lb)
Clean if necessary, see note Page 17-1
17-7
Fig. 1 Oil spray jet, removing and installing
4 mm diameter punch
6 mm diameter punch
Note:
Oil spray jets are installed in main bearings 2 through 7.
Requirement
Crankshaft must be removed.
Removing
- Remove using 4 mm diameter punch.
Installing
- Install by hand using 6 mm diameter punch -arrow-.

17-8
Oil filter housing, disassembling and

assembling
1 - Gasket
- Replace.
2 - O.3 Bar Oil Pressure Switch-F22-
20 Nm (15 ft lb)
Brown body
Blue/black wiring
Checking Page 17-12
If seal is leaking; nip replace.
3 - Oil filter bracket
4 - Stop plate
For oil cooler
Mounted to oil filter bracket
5 - Oil filter element
Note replacement intervals.
With by-pass valve: opening pressure: 2.0

bar (29 psi)
- Clip into lower oil filter section before
installing.
17-9
6 - O-ring
7 - Oil filter, lower section
30 Nm (22 ft lb)
- Drain before removing.
8 - Oil drain screw
10 Nm (7 ft lb)
9 - 25 Nm (18 ft lb)
10 - Oil pressure switch (1.4 bar, 20 psi) -F1-
20 Nm (15 ft lb)
Black body
Yellow wiring
Checking Page 17-12
- If sealing ring is leaking; nip open and
replace.
11 - Engine Oil Temperature sensor -G8-
10 Nm (7 ft lb)
Green/black wiring
17-10
Oil pump, disassembling and assembling
1 - Drive shaft
For oil pump drive
2 - Oil pump housing
3 - 25 Nm (18 ft lb)
4 - Gears
Backlash, checking Fig. 1
Axial clearance, checking Fig. 1
5 - Oil pump cover (with pressure relief valve)
Opening press: 5.3 to 5.7 bar
- Clean strainer if dirty.
6 - 10 Nm (7 ft lb)
Always replace.
- Install with locking fluid D6.
7 - Oil pressure pipe
- Coat cyl. block and oil pump housing.
with AMV 188 001 02.
8 - 10 Nm (7 ft lb)
9 - O-ring
17-11
Fig. 1 Oil pump backlash, checking
Feeler gauge
Wear limit: 0.20 mm (0.008 in.)
Fig. 2 Oil pump axial clearance, checking
Feeler gauge
Wear limit: 0.10 mm (0.004 in.)

17-12
Oil pressure and oil pressure switches,

checking
Note:
Functional check and servicing optical and

acoustic oil pressure warning:
Electrical Wiring Diagrams, Troubleshooting &

Component Locations
VAG 1342 Oil pressure tester
VAG 1527B LED tester
VW 1594 Adaptor kit
Wiring diagram
Test sequence

50
- Remove 0.3 bar (4 psi) oil pressure switch (brown body).
- Install oil pressure switch in tester.
- Install tester in oil filter bracket in place of oil pressure switch.
17-13
- Connect tester wire -3- (brown) to ground

- Connect VAG 1527B LED tester to battery positive (+) and 0.3 bar oil
pressure switch -A- using jumper wires from VW 1594 adaptor kit.
LED must light up.
- Start engine and slowly increase engine speed.
At 0.15 to 0.45 bar, LED must go out
If LED does not go out:
- Replace 0.3 bar oil pressure switch.

- Connect LED tester to 1.4 bar oil pressure switch -F- -B- (black).
At 1.2 to 1.6 bar, LED must light up.
If LED does not light up:
- Replace 1.4 bar oil pressure switch -F1-.

- Increase engine speed.
At 2000 rpm and an oil temperature of 80 C (176 F) oil pressure
must be 2.0 bar minimum.
At higher rpm, oil pressure must not exceed 7.0 bar.
- Replace oil pump if necessary Page 17-10 .
19-1
Cooling system components,

Note:
When engine is warm, cooling system is under

pressure. Release any pressure before starting
repair work.
A new coolant additive, G12, is being used in

production from 07.96. G12 is identified by its
red color. Never mix G12 with any other coolant
additive! You can see contamination of G12
with other color coolants by its color (brown,
purple, etc.). This mixture causes a foamy
deposit in the expansion tank and radiator.
G12 coolant additive may be used in older

vehicles when original coolant is drained and
the cooling system is flushed.
Contaminated coolant must be drained

immediately and the cooling system flushed.
Hoses are secured with spring-type clips. When

performing repairs only use spring-type clips.
VAG 1921 pliers are recommended for

installing spring-type clips.
When installing coolant hoses, always route

them stress-free, so they don't come into
contact with other components (observe
markings on coolant connection and hose).
Check cooling system for leaks using cooling

system tester VAG 1274 and adapter VAG
1274/3.
Cooling system components (body side) Page

19-3
Cooling system components (engine side)

Page 19-6
19-2
Coolant hose connections, diagram Page 19-

10
Coolant system, draining and filling Page 19-

14
Coolant mixing ratios Page 19-14
Coolant system, flushing Page 19-18

19-3
Cooling system components (body side)
1 - 10 Nm (7 ft lb)
2 - Lock carrier
3 - Securing rubbers
4 - Coolant Fan Control Thermal switch -F18-
35 Nm (26 ft lb)
Switching temperatures:
Stage 1:
ON: 84 to 89 C (183 to 192 F)
OFF: 76 to 83 C (169 to 181 F)
Stage 2
ON: 90 to 95 C (194 to 203 F)
OFF: 82 to 89 C (180 to 192 F)
5 - 3-pin harness connector
Black
For Coolant Fan Control Thermal switch -
F18-
6 - Left Coolant fan -V7-
7 - Right Coolant fan -V35-
19-4

Black
For Right Coolant fan -V35-
Black
For Left Coolant fan -V7-
10 - Fan ring
11 - Cable guide
12 - Lower coolant hose
Coolant hose connections, diagram
Page 19-10
13 - Vacuum line
To brake servo vacuum line
14 - Junction piece
15 - Vacuum unit
Arrow on vacuum valve points to After-run
Coolant pump.
|Checking Page 19-30
16 - Coolant hose

Page 19-10
19-5
17 - Coolant hose
Page 19-10
18 - After-run Coolant pump -V51-
Checking Page 19-27
19 - Retainer
For After-run Coolant pump
Black
For After-run Coolant pump
21 - Air intake duct
22 - Engine Coolant radiator
- If replaced, replace coolant mixture.
23 - Upper coolant hose
Page 19-10
24 - Coolant overflow hose
Page 19-10
19-6
Cooling system components (engine side)
1 - O-ring
- Replace
2 - 25 Nm (18 ft lb)
- To loosen and tighten pulley, counter-
hold using a punch inserted through
holes.
3 - Pulley
For coolant pump
4 - 20 Nm (15 ft lb)
5 - Coolant pump
- Check shaft for ease of movement.
6 - Coolant pipe
7 - Connection
On cylinder head
8 - Hose from heat exchanger
Page 19-10
19-7
9 - Throttle Valve Control Module

Heated by coolant
10 - To heat exchanger
Page 19-10
11 - Junction piece
12 - Cover
13 - Cap
- Check cooling system using VAG 1274
tester and VAG 1274/4 adapter.
- Test pressure: 1.2 to 1.5 bar
14 - Angle piece
15 - 10 Nm (7 ft lb)
Black
17 - Coolant overflow hose
Page 19-10
18 - Expansion tank
19-8
19 - Coolant hose
Page 19-10
20 - ATF cooler
Repair Manual, 4 Spd. Automatic Transmission
01P, Repair Group 37
21 - Lower coolant hose
From bottom of radiator
Page 19-10
22 - Upper coolant hose
To top of radiator
Page 19-10
19-12
24 - Oil cooler
Removing and installing Page 17-5 (item
17 )
19-9
25 - To cylinder block
Page 19-10
26 - Drain screw
10 Nm (7 ft lb)
Coolant, draining and filling Page 19-14
19-10
1 - Expansion tank
2 - Control valve
Option
3 - ATF cooler
Only installed in vehicles with Auto Trans.
4 - Vacuum valve
5 - Radiator
b = Bottom
a = Top
6 - After-run Coolant pump -V51-
7 - Coolant pipe
8 - Cylinder block
9 - Oil cooler
10 - Drain screw
10 Nm (7 ft lb)
11 - Coolant pump
12 - Cylinder head
19-11
14 - Throttle Body/Throttle Valve Control
Module -J338-
15 - Heat exchanger
For heating system
16 - Solenoid valve
Optional
17 - Auxiliary heat exchanger
Optional
19-12
Engine coolant thermostat housing,

disassembling and assembling
Note:
Connecting coolant hoses to thermostat housing

Page 19-6
2 - 10 Nm (7 ft lb)
3 - Coolant thermostat
Installed position: breather slot/valve
uppermost
Checking:
- Heat-up thermostat in water
Opening starts approx. 80 C (176 F)
Ends approx. 105 C (221 F)
Opening lift 7 mm minimum
4 - Connection
5 - 10 Nm (7 ft lb)
6 - O-ring
- Replace
7 - Connection
19-13
8 - A/C Cut-out Thermal switch -F163- / Third

Speed Coolant Fan Control Thermal
switch -F165-
Brown, 4-pin
For vehicles with A/C
Repair Manual, Heating & Air Conditioning m.y.
1992-1996, Repair Group 87 Repair Manual,
Heating & Air Conditioning from m.y. 1997, Repair
Group 87
Vehicles w/o A/C are plugged
9 - Engine Coolant Temperature (ECT) sensor
-G62-
Blue, 2-pin
For Motronic system
Checking:
10 - After-run Coolant Thermal switch -F95- /
Engine Coolant Temperature sensor -G2-
Yellow, 4-pin
Checking Page 19-27
11 - Retaining clip
- Make sure proper seating.
19-14
Cooling system, draining and filling
Note:
A new coolant additive, G12, is used in

additive. You can see contamination of G12
with other color coolants by discoloration
(brown, purple, etc.). This mixture causes a
foamy deposit in the expansion tank and
radiator.

vehicles when the original coolant is drained
and the system is flushed.

immediately and the system flushed.
VAG 1306 Drip tray
Draining
- Remove coolant expansion tank cap.


50
- Remove coolant line drain screw -arrow-.

19-15
Filling
Note:
The cooling system is filled year-round with a

mixture of water, anti-freeze and corrosion
protection agent G11 or G12. G11 or G12 and
coolant additives marked as being "in
accordance with TL VW 774 C" prevent frost
and corrosion damage, formation of chalk and
in addition raise coolant boiling point. For these
reasons the cooling system must be filled year-
round with an anti-freeze and corrosion
protection agent. Because of the higher boiling
point, coolant helps to run the engine efficiently
at high loads, particularly in tropical climates.
If you replace the radiator, heat exchanger,

cylinder head or cylinder head gasket,
completely replace engine coolant.
19-16
Recommended mixture ratios:
Equipment: Protection to: Anti-freeze quantity: G11 or G12: H2O

1) 2)
One heat exchanger -25 C (-13 40% 3.6 ltr. (3.8 qt) 5.4 ltr. (5.7
F) qt)
50% 4.5 ltr. (4.8 qt)
-35 C (-31 4.5 ltr. (4.8
F) qt)
Two heat exchangers -25 C (-13 40% 4.3 ltr. (4.5 qt) 6.5 ltr. (6.9
F) qt)
50% 5.4 ltr. (5.7 qt)
-35 C (-31 5.4 ltr. (5.7
F) qt)
Two heat exchangers and additional water -25 C (-13 40% 4.6 ltr. (4.9 qt) 6.8 ltr. (7.2
heater F) qt)
50% 5.7 ltr. (6.0 qt)
-35 C (-31 5.7 ltr. (6.0
F) qt)
1)Anti-freeze must not exceed 60%. Frost protection and cooling efficiency will decrease if the percentage of anti-freeze is too
high.
2)Coolant quantities shown are for vehicles with manual transmission. For vehicles with an automatic transmission, increase
both coolant additive and water by 0.1 ltr. (0.1 qt).
19-17
- Press down on top radiator hose.
- Fill expansion tank with coolant up to max. mark.

- Start engine and run at approx. 2500 rpm while filling with coolant up to
overflow hole on expansion tank.
- Install expansion tank cap.
- Run engine until radiator fan starts running.
- Run engine for an additional 10 minutes at approx. 2500 rpm.
- Check coolant level and top off if necessary.
With engine at normal operating temperature; coolant level must
be on max. mark.
With engine cold, coolant level must be between the min. and max.
marks.
19-18
Cooling system, flushing
Note:
A new coolant additive, G12, is used in

additive. You can see contamination of G12
with other colored coolants by discoloration
(brown, purple, etc.). This mixture causes a
foamy deposit in the expansion tank and
radiator.

vehicles when original coolant is drained and
cooling system is flushed.

immediately and cooling system flushed.
Engine must be at operating temperature and

heater turned on.
VAG 1306 Drip tray
Draining
- Remove coolant expansion tank cap.

50
- Remove coolant line drain screw -arrow-.

19-19
Flushing procedure
- Apply compressed air to expansion tank and

blow out remaining coolant.
- Close cooling system, fill with distilled water.
- Run engine for a minimum of 2 minutes.
- Drain water and apply compressed air as

before.
19-20
Filling after flushing, recommended mixture ratios
Equipment: Protection to: Anti-freeze quantity: G 11 or G 12: H2O

1) 2)
One heat exchanger -25 C (-13 40% 3.6 ltr. (3.8 qt) 5.4 ltr. (5.7
F) qt)
50% 4.5 ltr. (4.8 qt)
-35 C (-31 4.5 ltr. (4.8
F) qt)
Two heat exchangers -25 C (-13 40% 4.3 ltr. (4.5 qt) 6.5 ltr. (6.9
F) qt)
50% 5.4 ltr. (5.7 qt)
-35 C (-31 5.4 ltr. (5.7
F) qt)
Two heat exchangers and additional water -25 C (-13 40% 4.6 ltr. (4.9 qt) 6.8 ltr. (7.2
heater F) qt)
50% 5.7 ltr. (6.0 qt)
-35 C (-31 5.7 ltr. (6.0
F) qt)
1)Anti-freeze must not exceed 60%. Frost protection and cooling efficiency will decrease if percentage of anti-freeze is too
high.
2)Coolant quantities shown are for vehicles with manual transmission. For vehicles with an automatic transmission, start with
quantities shown and top off as needed.
19-21
- Press down on top radiator hose.
- Fill expansion tank with coolant up to max. mark.

- Start engine and run at approx. 2500 rpm while filling with coolant up to
overflow hole on expansion tank.
- Install expansion tank cap.
- Run engine until radiator fan starts running.
- Run engine for an additional 10 minutes at approx. 2500 rpm.
- Check coolant level and top off if necessary.
With engine at normal operating temperature; coolant level must
be at max. mark.
With engine cold, coolant level must be between the min. and max.
marks.
19-22
Radiator and radiator fan, removing and

installing
VAG 1921 Pliers for spring type clips
VAG 1306 Drip tray
Removing
- Remove sound tray:

50
Vehicles with A/C
- Remove ribbed belt Page 13-22 .
- Remove power steering pump with bracket and

secure to body with wire. Leave hoses
connected.


- Remove A/C compressor:


CAUTION!
Do not open A/C refrigerant circuit !

19-23
Note:
- Observe additional information. Page 19-24
All vehicles

66
- Remove lock carrier bolts -1- on left and right.

- Pivot lock carrier with radiator in forward direction -arrow-.
- Disconnect power steering line -1- from radiator -arrows- and lay to one
side.
- Pull connectors off thermal switch and radiator fan.
- Drain coolant Page 19-14 .
- Disconnect coolant hoses from radiator.
- Lift out radiator assembly (complete with fan cowl and fan) in upward
direction.
19-24
Installing
Installation is in reverse sequence. When

installing, note the following:
- Fill system with engine coolant Page 19-

14 .
- Route wiring and connect electrical

connectors.
Repair Manual, Electrical Equipment through

July 1998, Repair Group 97
Repair Manual, Electrical Equipment from

August 1998, Repair Group 97
- Check headlight adjustment, adjust if

necessary:
Repair Manual, Maintenance
Vehicles with A/C, additional information
CAUTION!
Do not open A/C refrigerant circuit.
CAUTION!
To prevent damage to condenser and
refrigerant lines and hoses, be sure lines and
hoses are not stretched, kinked or bent.
Secure these parts with wire.
- Remove retaining clamp(s) from refrigerant

lines.
- Remove condenser from radiator and pull

forward as far as possible.
- Remove radiator in an upward direction.

19-25
Coolant pump, removing and installing
VAG 1331 Torque wrench 5 to 50 Nm (0 to 50 ft

lb)
Punch
VAG 1306 Drip tray
Removing
- Remove ribbed belt Page 13-22
- Drain coolant Page 19-14
- Remove coolant pump bolts through holes in

pulley and remove coolant pump.
Installing
Installation is in reverse sequence. When

installing, note the following:
- Replace coolant pump O-ring.

- Install ribbed belt Page 13-22
- Fill with coolant Page 19-14

19-26
Tightening torques
Bolted connections: Tightening

torque:
Coolant pump to cylinder 20 Nm
block
(15 ft lb)
Coolant pump pulley 25 Nm
(18 ft lb)
Drain plug in coolant line 10 Nm
(7 ft lb)
19-27
After-run coolant thermal switch and

after-run coolant pump, checking
VW 1594 Adaptor kit
Fluke 83 or VAG 1526 multimeter
Wiring diagram
Checking conditions
Fuse 19 OK
Test sequence

50
- Disconnect 4-pin connector -arrow- from Engine Coolant Temperature

sensor -G2- -yellow- and After-run Coolant Thermal switch -F95-.
19-28
- Bridge connector terminals -1- (grey) and -4- (brown/green) using

jumper wires from VW 1594 adaptor kit.
After-run Coolant pump must run.
If pump does not run:
- Disconnect 2-pin connector from After-run Coolant pump -V51- -1- and
connect LED tester to disconnected harness connector using jumper
wires from VW 1594 kit.
LED must light up.
If LED lights up (voltage supply OK.):
- Replace After-run coolant pump.
- Locate and eliminate open circuit using wiring diagram.

19-29
After-run Coolant Thermal switch, resistance

checking
- Connect VAG 1526 multimeter between terminals 1 and 4 of Thermal

switch using jumper cables from VW 1594 adaptor kit.
Specifications:
Below approx. 103 C (217 F) = (open)
Above approx.: 104 C (219 F) = 0 (closed)
If specifications are not obtained:
- Replace After-run Coolant Thermal switch -F95- / Engine Coolant

Temperature sensor -G2-.
19-30
Vacuum valve, checking
VAG 1921 Pliers for spring type clips
VAG 1306 Drip tray
US 8012 Hand vacuum pump
- Remove insulation tray:

50
- Drain coolant Page 19-14
- Disconnect vacuum hose from vacuum valve.
- Remove vacuum valve.
- Connect US 8012 hand pump to vacuum valve -arrow-.

- Operate hand vacuum pump.
Vacuum valve must close
If vacuum valve does not close:
- Replace vacuum valve.
Note:
Note installed position (arrow on vacuum valve points to After-run coolant

pump).
20-1
Fuel supply system

components
Note:
Hose connections are secured with either

screw, spring or clamp-type clips.
Always replace clamp-type clips or screw or

spring-type clips with spring type clips.
Fuel hoses in engine compartment must only

be secured with spring-type clips. Do not use
clamp or screw-type clips.
VAG 1921 pliers are recommended for

installing spring-type clips.
Observe safety precautions Page 20-8
Observe rules of cleanliness Page 20-9
Accelerator mechanism, servicing Page 20-23
Evaporative emissions system components,

servicing Page 20-27
20-2
Fuel supply system components,

Note:
After repairs to fuel supply unit or fuel gauge sender

unit are completed, be sure supply and return
hoses do not make contact with fuel tank which
could cause pump noise transfer.
1 - Collar nut
- Remove and install using tool 3217.
2 - Fuel return line
Blue
- Secure with spring-type clips.
Return line must be securely seated.
- Secure from fuel pressure regulator
bracket
3 - 4-pin connector
Black
For Fuel Level sensor -G- and Fuel Pump -
G6-
20-3
4 - Flange
- Note installed position on fuel tank
Page 20-6 , Fig. 1 .
Underside marked with a "V" (for supply)
and an "R" (for return) hoses.
5 - Supply hose
6 - Return hose
7 - Sealing ring
- Coat with fuel when installing.
8 - Fuel Level sensor -G-
9 - Fuel delivery unit
Fuel pump, checking Page 20-15
10 - Strainer
- Clean if contaminated.
11 - Fuel tank
- When removing; support using
engine/transmission jack VAG 1383 A.
20-4
12 - Mounting straps
- Note different lengths.
13 - 25 Nm (18 ft lb)
14 - Bracket
For mounting straps
15 - Splash shield
16 - Retaining ring
17 - Gasket
- If damaged; replace together with cap as
an assembly
18 - Cap
19 - 10 Nm (7 ft lb)
20 - Check valve
For fuel tank ventilation
Checking Page 20-7 , Fig. 3
21 - Breather tube
To junction piece between EVAP canister
and EVAP canister purge regulator valve
20-5
22 - Breather tube
To EVAP canister
23 - Supply line
Black
Mount using spring clips
Must be securely seated
To fuel supply line (on lower intake
manifold)
24 - Fuel filter
Installed position: -arrow- points in direction
of flow
25 - Bracket
For fuel filter
26 - Breather tube
Fill vent
27 - O-ring
28 - Gravity/vent valve
Cannot be removed.
Replace as an assembly together with filler
neck.
Checking Page 20-6 , Fig. 2
20-6
Fig. 1 Fuel delivery unit/flange, installed position
Mark on flange must align with mark on fuel tank.
Fig. 2 Gravity/vent valve, checking

Lever in rest position: No Flow
Lever pushed in direction of arrow: Flow
20-7
Fig. 3 Check valve, checking
From direction of gravity/vent valve:
Check valve is open in both directions of flow: arrow -1-.
From direction of EVAP canister/EVAP canister purge regulator valve 1

junction piece:
Check valve is open in only one flow direction: arrow -2-.

20-8
Safety precautions
WARNING!
Fire hazard! Do not smoke or have anything

in the area that can ignite fuel.
When removing and installing fuel gauge sending

unit or fuel pump (fuel delivery unit) from a filled
or partly filled fuel tank; observe the following:
Before starting work, provide air extraction

close to opening for fuel delivery unit in the fuel
tank to draw off escaping fumes. If no extraction
system is available, use a fan (but DO NOT
place fan in path of fumes).
Wear fuel-resistant disposable protective gloves

whenever handling fuel.
WARNING!
Fuel system is under pressure! Before

opening system, place a rag around
connection and release pressure by slowly
loosening connection.
20-9
Rules for cleanliness
CAUTION!
When working on fuel system, carefully

observe following "Rules for cleanliness".
Thoroughly clean fuel system line and hose

connections as well as surrounding area before
disconnecting fuel connections.
Place removed components on a clean surface

and cover them with plastic sheeting or paper.
Don't use fluffy rags or materials that could
leave lint.
If repair cannot be done immediately, carefully

cover up any opened components.
Only install clean components.
Only unpack replacement parts at time of

installation.
Do not use parts that have been stored loose or

without their protective package (e.g. in tool
boxes, etc.).
When fuel system is open:
Do not work with compressed air if it can be

avoided.
Do not move vehicle if it can be avoided.

20-10
Fuel delivery unit, removing and

installing
3217 Collar wrench
Removing
- Observe safety precautions Page 20-8 .
- Switch off ignition.
CAUTION!
Obtain Anti-theft radio code before

disconnecting battery ground strap.
- Remove driver's seat.
Repair Manual, Body Interior, Repair Group

72
- Lift carpeting above parking brake lever.

- Remove cover plate.
20-11
- Disconnect 4-pin connector from flange.
WARNING!
Fuel system is under pressure! Before opening system, place a rag

around connection and release pressure by slowly loosening
connection.
- Disconnect supply and return lines from flange.
- Remove collar nut using tool 3217.

- Remove flange and seal from opening in fuel tank.
- Release delivery unit by turning left and then out of bayonet
connection.
- Remove delivery unit.
WARNING!
If delivery unit contains any fuel, empty it before replacing.

20-12
Installing
Note:
Reinstall fuel delivery unit in reverse sequence.
Note:
When installing fuel delivery unit, be sure fuel

level sender is not bent.
Coat flange seal with fuel when installing.
Fuel lines must be correctly located and

properly tightened
Note installed position of fuel delivery unit flange: marking on flange

must align with marking on fuel tank.
Do not interchange supply and return lines (return line is -blue-).
When fuel delivery unit is correctly installed, fuel level sender float
points in direction of travel A: = 25 to 35 .
20-13
Fuel tank, removing and installing
3217 Collar wrench
VAG 1383A Engine/transmission jack
Removing
Observe safety precautions Page 20-8 .
- Switch OFF ignition.
CAUTION!

- Drain fuel tank and clean area around filler

neck.
- Remove retaining ring and splash shield from

filler neck and remove bolt.
- Disconnect fuel tank mount straps.
- Support fuel tank with VAG 1383A

engine/transmission jack.
20-14
WARNING!

- Lower jack just enough to allow supply lines,

return lines and connector to be pulled from
flange
Note:
For vehicles with auxiliary heating, also

disconnect additional fuel lines mounted between
supply and return lines.
- Lower fuel tank
Installing
Install fuel tank in reverse sequence and note the

following:
- Route breather hoses kink free.
Fuel hoses must be correctly located and

tight.
Do not interchange supply and return lines
(return hose is -blue-).
20-15
Fuel pumps, checking
Fluke 83 Multimeter
VAG 1348/3A Remote control with VAG

1348/3-2 Adaptor cable
VAG 1466 Fuel analyzer
VW 1594 Adaptor kit
3217 Collar nut wrench
VAG 1318 Pressure tester
VAG 1318/1 Hose
1318/10 Adaptor
1318/11 Adaptor
Measuring container
Wiring diagram
20-16
Checking conditions
Battery voltage: 11.5 Volts minimum
Fuse 18 OK
- Remove sealing plug -1- on fuel pressure regulator bracket.

- Connect VAG 1318 pressure gauge to test connection using VAG
1318/10 adapter and hose VAG 1318/1.
Pressure gauge lever must be closed (-arrow- at right angle to
direction of flow)
WARNING!
Fuel system is under pressure! Before opening system, place a rag

around connection and release pressure by slowly loosening
connection.
- Start engine and let idle.

- Check fuel pressure.
Specification: approx. 2.5 bar
If fuel pressure does not build-up:

- Remove cover in front of fuse/relay panel.
- Remove fuel pump (FP) relay -J17- from fuse relay panel position 12.
20-17
Note:
If tools are required to pull relays or control

modules from relay panel, first disconnect
battery ground.
Obtain radio Anti-theft code before

disconnecting battery ground strap.
- Connect remote control VAG 1348/3A between

terminal 4 and battery positive (+) using adapter
cable VAG 1348/3-2.
- Operate remote control.
If fuel pressure builds-up:
- Check activation of fuel pump relay.
If fuel pressure is not built-up.

72
- Lift carpeting above parking brake lever.

- Remove access plate.
- Disconnect 4-pin connector from fuel tank flange.

20-18
- Connect VAG 1527B LED tester to connector outer terminals using

jumper wires from VW 1594 adaptor kit.
- Operate remote control.
LED tester must light up.
- Locate and eliminate open circuit using wiring diagram.
If LED lights up (voltage supply OK):
- Unscrew collar nut using 3217 tool.

- Check for good wire connection between flange and fuel pump.
If no open circuit can be found:
- Replace malfunctioning fuel pump Page 20-10 .

20-19
Delivery rate, checking
Voltage supply OK
VAG 1348/3A Remote control connected
- Remove filler cap from fuel tank filler neck.
WARNING!

- Disconnect fuel supply line -1- from fuel pipe.

- Connect the VAG 1318 pressure gauge to fuel supply line -1- using
1318/10 adapter.
- Push VAG 1318/1 hose on adapter VAG 1318/11 on pressure gauge
and hold hose in measuring container.
- Open pressure gauge tap.
Lever must point in direction of flow -A-.
- Operate VAG 1348/3A remote control and slowly close lever until
pressure gauge shows 3 bar. Once you reached pressure, do not move
lever any further.
- Empty measuring container.
20-20
- Measure battery voltage using Fluke 83

multimeter.
- Operate remote control for 30 seconds.
- Compare quantity of fuel delivered with specification.
*) Minimum delivery in cc's per 30 seconds
**)Voltage at fuel pump (running) with engine not running (approx. 2 volts
less than battery voltage)
Example:
For this example, 12.2 volts was measured at battery. If voltage at pump
is approx. 2 volts less than battery voltage,it equals a minimum delivery of
550 cc's in 30 seconds.
If minimum delivery rate is not obtained:
- Check fuel lines for possible restrictions, kinks or blockages.
- Disconnect supply line -1- from fuel filter inlet.

- Connect VAG 1318 pressure gauge to hose using 1318/10 adaptor.
- Repeat delivery rate check.
If minimum delivery rate was not reached:

- Replace fuel filter.
20-21
If minimum delivery rate was still not reached:
- Remove fuel delivery unit and inspect strainer

for clogging Page 20-10 .
If you did not find malfunctions to this point, fuel

pump is inoperative.
- Replace fuel delivery unit Page 20-10 .
If you measured minimum delivery but you still

suspect an intermittent fuel supply system
malfunction:
- Reconnect all disconnected fuel lines.

72
- Lift carpet above parking brake lever.
- Remove cover plate.
- Connect Fluke 83 multimeter to red/yellow wire with Fluke current

measuring adaptor.
- Start engine and let idle.
- Measure fuel pump amperage draw.
Specification: 8 amps maximum
Note:
If fuel system malfunction is intermittent, you can also perform check

during a test drive with a 2nd technician to read data.
20-22
If amperage draw is too high, fuel pump is

malfunctioning.
- Replace fuel delivery unit Page 20-10 .
Fuel pump check valve, checking
VAG 1348/3A Remote control connected
VAG 1318 Pressure gauge connected to fuel

supply line
Note:
This setup checks entire fuel supply line from fuel

delivery unit to VAG 1318 pressure gauge.
- Close pressure gauge tap position -B- (lever at right angle to direction
of flow).
- Operate remote control at short intervals until a pressure of approx. 3
bar has built-up.
- If pressure builds up too high, lower excess pressure by carefully
opening tap.
WARNING!
Danger of fuel spray when opening pressure tap. Hold open end of
pressure gauge over a suitable container to catch over spray.
- Observe pressure drop.
After 10 minutes pressure must not drop below 2.2 bar.
- Check line connections for leaks and/or replace fuel delivery unit if
necessary Page 20-10 .
20-23
Accelerator mechanism, servicing

2 - Tab
3 - Support bracket
For accelerator cable
4 - 25 Nm (18 ft lb)
5 - Accelerator cable
Adjusting Page 20-25
Removing:
- Disconnect accelerator cable at
accelerator pedal bracket. Support
bracket and Throttle Valve Control
Module. Break off spreader clips (in
vehicle interior) and pass accelerator
cable through to engine compartment.
Do not re-use damaged accelerator cable,
ALWAYS replace.
6 - Rubber bushing
7 - Accelerator pedal
20-24
8 - Bushing
9 - Accelerator pedal bracket
10 - Circlip
20-25
Throttle cable, adjusting
- Adjust throttle cable by moving support bracket retainer -arrow- until

Wide Open Throttle position is obtained at throttle body lever.
Vehicles with automatic transmission
Fluke 83 Multimeter
VW 1594 Adaptor kit
11 mm Spacer
Work sequence
- Clamp spacer -1- (a = 11 mm) between accelerator pedal -2- and stop -
3-, hold accelerator pedal in this position.
20-26
- Fully open throttle body by pulling on outer cable and secure in this
position with retainer -arrow-.
- Release accelerator pedal.
- Disconnect 2-pin connector from Kick Down switch -F8- in engine
compartment on bulkhead.
- Connect multimeter to kick-down switch with jumper wires from VW

1594 adaptor kit.
- Measure switch resistance.
Specification: (open)
- Slowly move accelerator pedal in direction of Wide Open Throttle
(WOT).
Shortly after kick-down pressure point, resistance must drop to 0 .
At this point, pedal must be just off the stop.

28-1
Motronic Ignition system,

servicing
Notes:
Only components specifically relating to the

ignition system are contained in this Repair
Group. For fuel injection and ignition system
shared components:
Repair Manual , Fuel Injection & Ignition,

Repair Group 24
The fuel injection and ignition system Control

Module (ECM) is equipped with an On Board
Diagnostic (OBD) system
Components marked with an asterisk (*) are

automatically checked via the On Board
Diagnostic system
Check DTC memory before starting repairs and

troubleshooting page 01-12 .
During some checks it is possible that the

check itself can trigger the Control Module to
recognize and store a malfunction. Therefore
after completing all checks and repairs; DTC
memory must be checked and if necessary,
erased page 01-12 .
Safety precautions page 24-24
Technical data, spark plugs page 28-7

28-2
Ignition system, component overview
Note:
For Motronic Engine Control Module (ECM)-J220- * with

connector page 24-7
1 - Camshaft Position (CMP) Sensor-G40-*

Checking page 28-8
Note spacer ring (item 4 )
To remove, unclip ignition coil cable duct (item 3 )
2 - 10 Nm (7 ft lb)
3 - Cable duct
For ignition coil -N152- (item 7 )
4 - Spacer ring
For ignition coil -N152-
6 - Suppressor
0.6 to 1.4 k
28-3
7 - Ignition coil -N152-

With ignition cable identification, do not interchange
Checking page 28-20
Removing and installing
Repair Manual , 2.8 Liter VR6 2V Engine Mechanical,

Engine Code(s): AES, Repair Group 15

For knock sensor 1: white
For knock sensor 2: black
Sensor and connector terminals are gold-plated
10 - 20 Nm (15 ft lb)
Tightening torque influences knock sensor function
11 - Knock sensor (KS) 2 -G66-*
Installation location: cyl. block exhaust side
Knock sensor wiring, checking page 28-29
28-4
12 - Sensor wheel
For camshaft position (CMP) sensor -G40-
Contact surface of timing chain and sensor wheel
must be dry when installing
If sensor wheel has been removed, check timing
after installation:
Repair Manual , 2.8 Liter VR6 2V Engine Mechanical,

Engine Code(s): AES, Repair Group 13
13 - Knock sensor (KS) 1 -G61-*

Installation location: cylinder block, exhaust side
Sensor and connector terminals are gold-plated
Knock sensor wiring, checking page 28-29
14 - 100 Nm (75 ft lb)
To remove and install: counter-hold with 24 mm
open end wrench on camshaft
Oil bolt head terminal surface
28-5
15 - Spark plug
25 Nm (18 ft lb)
Remove and install using 3122B spark plug wrench
Technical data page 28-7
16 - Spark plug connector
4 to 6 k
Use tool 3277 A when pulling off or pressing on
To pull off spark plug connector for cylinders 2, 4
and 6, remove radiator grille and fold lock carrier
with radiator out forward
Repair Manual , Body Exterior, Repair Group 66
17 - O-ring
Always replace
Black
For camshaft position (CMP) sensor-G40-
28-6
Safety precautions
To prevent injuries to persons and/or damage to

the fuel injection and ignition system, note the
following:
Do not touch or disconnect ignition wiring when

the engine is running or being turned at starter
speed.
Switch the ignition off before connecting or

disconnecting injection or ignition system wiring
or tester cables.
If the engine requires cranking without starting, e.g. when checking

compression, disconnect the 5-pin harness connector from the ignition coil
(arrow).
WARNING!
Due to weight, size and need for manual operation of test instruments
while vehicle is driven on public roads, instrument must be used only with
a Driver operating the vehicle and an Instrument Operator operating the
test equipment.
Do not use instrument with Driver only. Always use two persons to
conduct testing.
Do not place instrument on lap of Driver or front seat passenger because

emergency stop may dislodge instrument and cause airbag deployment
with risk of injury to Instrument Operator.
28-7
Technical data, spark plugs
Engine code letters AES
Ignition timing1)
Checking Page 24-94 , checking idle speed
Firing order 1-5-3-6-2-4
Spark plugs2)
VW 101 000 035 AH
OEM designation BKR 5 EKUP
Electrode gap 0.7 mm3)
Tightening torque 25 Nm (18 ft lb)
1) Not adjustable
2) Use tool 3277 A to remove and install spark plug connector on. Remove and install spark plugs with 3122 B spark plug wrench.
3) Gap between Ground electrode and center electrode insulation

28-8
Camshaft Position sensor, checking
VAG 1598/18 Test Box
Fluke 83 multimeter (or equivalent)
VW 1594 Adapter kit
Wiring diagram
Test conditions
Perform test when DTC 00513 is recognized
Battery Positive Voltage: 11.5 Volts minimum
Test sequence
- Disconnect 3-pin harness connector from Camshaft position sensor (arrow).

28-9
- Switch Fluke 83 multimeter to 20 Volt DC

range.
- Connect multimeter between harness connector terminals 1 + 3 using jumper

wires from VW 1594 adapter kit.
- Switch ignition on.
specification: 11.5 Volts minimum
- Switch ignition on.
- Connect Test Box VAG 1598/18 to ECM wiring harness.

28-10
- Check for open circuit between Test Box and 3-pin harness connector using
wiring diagram, connecting as follows
terminal 1 + socket 23
Wire resistance: 1.5 maximum
- Check wires for shorting to one another
Specification:
If wiring OK and voltage present between terminals 1 + 3:
- Replace camshaft position (CMP) sensor -G40- Page 28-2 (item 1 ).

28-11
If wiring OK and NO voltage between terminals 1

+ 3:
- Replace Motronic Engine Control Module (ECM)

-J220- page 24-9 (item 3 ).
- Perform Basic setting page 24-134 .
- Read-out Readiness code page 01-61 .
If DTC memory has been erased:
- Create Readiness code page 01-104 .

28-12
Ignition timing, checking
VAG 1551/1552 Scan Tool using VAG 1551/3

adapter cable
Test conditions
Electrical consumers switched off (radiator fan

must not run during checks)
A/C switched off
Test sequence
- Connect VAG 1551 ((VAG 1552) Scan Tool

page 01-8 .
- With engine idling, press buttons -0- and -1- to

select "Engine electronics" address word 01.
Rapid data transfer HELP Display will appear as shown

Select function XX
- Press buttons -0- and -8- to select "Read measuring value block" and press -Q-
button to enter selection.
Read measuring value block HELP Display will appear as shown
Input Display group number XXX
- Press buttons -0-, -1- and -0- to select "Display group number 10".
- Press -Q- button to enter selection.
Read measuring value block 10 Display will appear as shown (1 to 4 Display fields)
1 2 3 4
28-13
- Check ignition specifications (Display fields 3

and 4):
Display fields
1 2 3 4
Display group 10: Ignition 1
Display xxx rpm xx.x ms xx.x xx.x
Indicated Engine speed Engine load Ignition angle (mapped value) Ignition angle
Working range 650 to 6000 rpm 0.0 to 25.0 ms 0.0 to 50.0 BTDC 0.0 to 40.0 BTDC
Spec 650 to 750 rpm 1.5 to 2.5 ms 11.0 to 13.0 BTDC max. 2.0 deviation from display field 3
--- --- Test conditions: Intake Air Temperature 50 C max.
If spec not obtained Page 24-49 , Throttle Valve Control Module checking
- Press button.
- Press buttons -0- and -6- to select "End
output".

28-14
Misfire recognition, checking

adapter cable
Test sequence

page 01-8 .


Select function XX
- Press buttons -0- and -8- to select "Read measuring value block".

1 2 3 4
- Check misfiring recognition spec (Display fields 2 to 4).
28-15
Display fields
1 2 3 4
Display group 110: Misfire recognition 1
Display x.xx ms xxx xxx xxxxxxxx
Indicated Engine load Misfire adversely affecting emissions Misfire adversely affecting catalyst Misfire recognition
level (total) (total) status
Working 0.00 to 25.00 --- --- ---
range ms
Spec 1.00 to 3.00 0 0 00000000
ms
--- If specification not obtained Page 28-16 , evaluating Display group 110
- Press button.

output".
28-16
Evaluating Display group 110
Display group: 110

Display field: 2 + 3 Possible cause Corrective action
More than 25
Ignition coil malfunctiony - Check ignition coil Page 28-20
Ignition cable malfunctiony - Check ignition system components Page 28-2
Spark plug malfunctiony
Fuel injector malfunctiony - Check injectors Page 24-85

Fuel shortage - Check quantity of fuel in tank
28-17
Ignition timing control, checking
Special tools, testers and auxiliary items

adapter cable
Test conditions
Electrical consumers switched off (radiator fan

must not run during check)
A/C switched off
Engine oil temperature 80 C (176 F)

minimum
Test sequence

page 01-8 .


Select function XX

28-18
1 2 3 4
- Check ignition timing control specifications (Display fields 1 to 4):
Display fields
1 2 3 4
Display group 10: Ignition 1
Display xxx rpm xx.x ms xx.x xx.x
Indicated Engine speed Engine load Ignition angle (mapped value) Ignition angle
Working range 650 to 6000 rpm 0.0 to 25.0 ms 0.0 to 40.0 BTDC 0.0 to 40.0 BTDC
Spec 650 to 750 rpm 1.9 to 2.1 ms 11.0 to 13.0 BTDC max. 2.0 display field 3 deviation
2480 to 2520 rpm 1.7 to 1.9 ms 23.0 to 25.0 BTDC Max. 2.0 display field 3 deviation
--- --- Test condition: Intake air temperature 50 C max.
If spec not obtained Page 28-19 , continuation

28-19
Continuation
- Check operating modes page 24-122 .
- Check Throttle Valve Control Module page

24-49 .
- Check Knock sensor and knock contro page

28-25 .
If specification still not obtained:
- Replace Motronic Engine Control Module (ECM)

-J220- page 24-9 (item 3 ).
- Perform Basic setting page 24-134 .

28-20
Ignition coil, checking
VAG 1527B LED Tester
VW 1594 adapter kit
Wiring diagram
Test conditions
Battery Positive Voltage: 11.5 Volts minimum
Engine Speed sensor OK page 24-79 ;

checking
Camshaft Position sensor OK page 28-8 ;

checking
Test sequence
- Disconnect 5-pin harness connector from ignition coil.
28-21
Voltage supply, checking
- Switch Fluke 83 multimeter to 20 Volt DC

range.
- Connect multimeter between terminals 1+5 of disconnected harness connector

using jumper wires from VW 1594 adapter kit.
- Switch ignition on and measure supply voltage.
Must be 11.5 Volts minimum
- Switch ignition off.
If no voltage present:
- Check for open circuit between 5-pin harness connector terminal 1 and Ground
using wiring diagram.
- Check for open circuit between 5-pin harness connector terminal 5 and
fuse/relay panel using wiring diagram.
28-22
Activation, checking
CAUTION!
Do not touch the ignition coil terminals or

test cable attachments during the following
test.
- Remove fuse 18 from fuse/panel.
- Using jumper wires from VW 1594 adapter kit, connect VAG 1527B LED tester
to disconnected connector:
terminals 5 + 2 (ignition output 1)
- Operate starter and check ignition signal from motronic engine control module
(ECM) -J220-.
LED must flicker
- Switch ignition off.
If LED does not flicker:
- Replace motronic engine control module (ECM) -J220- Page 24-9 (item 3 ).
- Perform Basic setting Page 24-134
- Read-out Readiness code Page 01-61 .
28-23
- Create Readiness code Page 01-104 .
If LED flickers:
- Connect Test Box VAG 1598/18 to ECM wiring harness
wiring diagram, connecting as follows:
28-24
- Check wires for shorting to one another as follows:

specification:
If wiring OK and voltage present between terminals 1 + 5:
- Replace ignition coil -N152- page 28-3 (item 7 ).
Secondary winding, checking
- Check secondary winding at terminal 4 between:

Cyl. 1 and Cyl. 6
Cyl. 3 and Cyl. 4
Cyl. 2 and Cyl. 5
specification: 3.6 to 4.4 k
If specifications not obtained:
- Replace ignition coil -N152- page 28-3 (item 7 ).

28-25
Knock control, checking

adapter cable
VW 1594 Adapter kit
Wiring diagram
Test sequence

page 01-8 .


Select function XX
28-26

- Press buttons -0-, -4- and -5- to select "Display group number 45" (Cyl. 1 to 4)
or:
- Press buttons -0-, -4- and -6- to select "Display Group number 46 (Cyl. 5 and 6).
1 2 3 4
Note:
Check must be carried out during road test because knock control is only active
when engine load exceeds 3 ms.
- Road test vehicle and observe knock control specifications on display (2nd
person required). During road test, engine coolant temperature must exceed
80 C.
When the above temperature is reached, the following operating conditions must be
attained several times:
Closed throttle
Partially open throttle
Wide open throttle
Overrun
At wide open throttle, engine rpm must exceed 3500
28-27
Display fields
1 2 3 4
Display group 45: Knock control
Display xx.xx ATDC xx.xx ATDC xx.xx ATDC xx.xx ATDC
Indicated Ignition angle correction Ignition angle correction Ignition angle correction Ignition angle correction
Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4
Working 0.0 to 15.0 ATDC 0.0 to 15.0 ATDC 0.0 to 15.0 ATDC 0.0 to 15.0 ATDC
range
Spec 0.0 to 12.0 ATDC 0.0 to 12.0 ATDC 0.0 to 12.0 ATDC 0.0 to 12.0 ATDC
If specification not obtained Page 28-28 , evaluating Display group 45 and 46
- Press button.

output".
28-28
Evaluating Display group 45 and 46
Display group: 45
Display fields: 1 to 4 Possible cause Corrective action
Display group: 46
Display fields: 1 & 2

All cylinders more than
Knock sensor faulty - Continued Page 28-29
12 ATDC
Connector corroded
Knock sensor not - Loosen knock sensor and tighten to: 20 Nm (15 ft lb)
correctly tightened
Engine auxiliary - Secure auxiliary components

components loose
Poor fuel quality - Change type of fuel
One cyl. deviation

Connector corroded - Continued Page 28-29
greater than others
Engine damage - Check compression pressure Repair Manual , 2.8 Liter VR6 2V Engine
Mechanical, Engine Code(s): AES, Repair Group 13
Engine auxiliary - Secure auxiliary components
components loose
28-29
Knock sensor, checking
VW 1594 Adapter kit
Wiring diagram
Test sequence
- Remove insulation tray.
Repair Manual , Body Exterior, Repair Group

50
- Connect VAG 1598/18 Test Box ECM wiring harness.
Knock sensor (KS) 1 -G61-

- Disconnect white 3-pin harness connector to knock sensor 1 (arrow).
28-30
Knock sensor (KS) 2 -G66-
- Disconnect black 3-pin harness connector to knock sensor 2 (arrow).

- Switch multimeter to resistance range.
- Measure resistance between knock sensor terminals, connecting as follows:

between terminals 1 + 2
Specification:
28-31
wiring diagram, connecting as follows:
-G61- -G66-
terminal 1 + socket 34 57
wire resistance: 1.5 maximum

- Check wires for shorting to one another;
-G61- -G66-
specification:
If wiring OK:
- Loosen appropriate knock sensor and re-torque.

Tightening torque: 20 Nm (15 ft lb)
28-32
- Road test vehicle. During road test, engine

coolant temperature must exceed 80 C.
When the above temperature is reached, the

following operating conditions must be attained
several times:
Closed throttle
Partially open throttle
Wide open throttle
Overrun
At wide open throttle, engine rpm must exceed

3500
- Check DTC memory.
If DTC is still present in DTC memory:
- Replace appropriate knock sensor, -G61- and/or

-G66- Page 28-3

50-1
Body, front
Lock carrier with attached components,
- Remove dampening pan Page 50-7
- Remove front bumper Page 63-1 .
- Remove hex bolts -1- on left and right.

- Fold radiator and lock carrier out forwards -arrow-.
Vehicles up to 09.90
- Remove left and right hex bolts -1-.

- Pull apron -2- with sleeves -3- off pins -4- at left and right.
50-2
Vehicles from 10.91
- Remove left and right combi hex. bolts -1-.
- Pull apron -1- off the pins -3- with the aid of a (locally manufactured) hook -2- (approx. 2
mm dia. wire). Place hook above or below the pins -arrows-.
50-3
Continuation for all vehicles
- Remove headlights and turn signals at left and right (four combi hex. bolts -arrows- and
separate electrical connectors.
- Hook workshop crane onto radiator (VAG 1202A).
- Drive pins out of spreader clips -arrows- at left and right and unclip spreader clips from
radiator brackets.
- Lift radiator with workshop crane.
50-4
- Unbolt cross member -1- together with headlamp bracket -2-.

- Tightening torques:
Bolt -3- = 8 Nm
Bolt -4- = 8 Nm up to8.93
Bolt -4- = 19 Nm from 9.93
- Unclip electrical leads from cross member/headlight bracket.
50-5
Fender, front
Assembly overview from 01.96
1 - Fender
Removing
- Remove front bumper Page 63-1 .
- Remove turn signal.
- Remove hex bolts - 2 - and - 3 -.
- Heat fender in area of wheel arch with a hot air blower
and pull off (if necessary cut through PVC material with
utility knife; second technician necessary).
Note:
PVC must only be heated lightly and briefly.
PVC must not change in color or blister.
50-6
2 - Hex-screw
With small washer
3 - Hex-screw
With large washer
4 - Rib plate
Installed to enable the gaps between fender, front lid and
front door to be adjusted via the oversized holes.
Installing
Before bolting on fender, each point of bolting in area of wheel

housing -A- pillar must be given a zinc packing AKL 381 035 50.
50-7
Sound dampening pan, components
Assembly overview
1 - Hex nut
9 Nm
2 - Bracket
3 - Damping element
4 - Hex nut
9 Nm
5 - Bolt
9 Nm up to 08.93
19 Nm from 09.93
6 - Dampening pan
Removing
- Remove two hex nuts -4- and six bolts -5-.
- Release locking lever -8-, swing down dampening pan
and unhook at brackets -2-.
7 - Damping material
Replacing Page 50-8
8 - Locking hook
50-8
Sound dampening material, replacing
1 - Sound dampening material

On vehicles with automatic transmission or air conditioner,
dampening material must be removed according to
perforation.
2 - Clip
3 - Sound dampening pan
57-1
Front door
Assembly overview
Note:
The assembly overview illustrates a front door with electric windows.

The procedure is similar for doors without electric windows.
1 - Front door
Removing Page 57-6
2 - Inner window slot seal
Pressed into flange
Remove together with door trim (manual windows)
Remove together with door trim (with power windows).
Repair Manual, Body Interior, Repair Group 70
3 - Outer window slot seal
Pressed into flange
4 - Window channel
5 - Door window
Removing Page 57-24
57-2
6 - Sealing profile
Clipped and glued
7 - Trim plate
8 - Lock knob
Screwed on
9 - Outside door handle
Removing Page 57-25
Lock cylinder, removing Page 57-28
10 - Clip
57-3
11 - Clip
12 - Screw
8 Nm
13 - Lock rod
14 - Screw
8.0 Nm (71 in. lb)
15 - Door lock
Removing Page 57-27
16 - Pull rod
17 - Clip
To fasten guide and pull rod
18 - Screw
7.0 Nm (62 in. lb)
Secures regulator rail to window regulator
57-4
19 - Screw
7 Nm
20 - Window regulator
21 - Screw
7 Nm
22 - Window regulator motor
Remove together with window regulator Page 57-15
Remove window regulator crank (front door with manual
regulator) together with window regulator Page 57-15
23 - Cover
Clipped on
24 - Door check strap
25 - Screw
7 Nm
57-5
26 - Lock nut
6.5 Nm
27 - Bolt
28 - Boot
Cover on vehicles with manual window regulator
57-6
Door, removing (up to12.95)
Front door, removing (from 01.96) Page 57-

10
Vehicles with central locking, power

windows, heated outside mirrors and/or door
speakers
- Remove front door trim.

70
Continued, all vehicles
- Locate wiring connectors, disconnect wiring and

remove from door.
- Remove nut -1- and pull out pin.

- Remove hex bolt -2- from upper and lower hinge.
57-7
Door, installing and adjusting (up

to12.95)
Door, installing and adjusting (from 01.96)

Page 57-11
- Install hex bolts -2- into upper/lower door

hinges.
- Adjust door by moving hinges in oversized

holes.
57-8
Door is correctly adjusted if, when closed, has uniform gap all around opening, is not
sunken, does not protrude, matches contour -arrow-.
- Tighten hex bolts -2-. After installation of bolt, tighten nut -1-.
Tightening torques:
Nut -1- = 6.5 Nm (57 in. lb)
Hex bolt -2- = 55 Nm (41 ft lb)
57-9
Striker, adjusting
- After Phillips screws -1- are loosened, striker -2- can be moved horizontally and
vertically -arrows-.
Tightening torque:
Phillips screws -1- = 19 Nm (14 ft lb)
- Adjust striker -1- so recess on door lock turn clip is concentric -arrows- to striker (door
must not be raised or pressed down). Door must not move when closed.
57-10
Door, removing (from 01.96)
Door, removing (up to 12.95) Page 57-6
- Remove door trim Repair Manual

- Disconnect electrical wires, disconnect plug connectors and pull out of door.
- Remove nut -1- and remove bolts.

- Remove screws -2- for upper and lower hinge and remove door.
57-11
Door, installing and adjusting (from

01.96)
Door, installing and adjusting (up to 12.95)

Page 57-7
Note:
Adjust door gap dimensions from fender, to A-

pillar and B-pillar.
- Remove door Page 57-10 .
- Loosen screws -3-, slide hinges and tighten screws again.
Tightening torque: Nut -1- = 6.5 Nm (58 in. lb), Screw -3- = 55 Nm (41 ft lb).
- Install door.
57-12
- Install screws -2- for upper and lower

hinges.
- Adjust door so it is flush with fender, A-pillar

and B-pillar.
- Adjust door within oversized holes in hinge so its flush with fender.
Front door is correctly adjusted when there is a uniform distance from door opening, is not
too low or to high and matches contour -arrows-.
.
57-13
- Tighten bolts -2-, after installation of bolt, tighten nut -1-.
Tightening torques: nut -1- = 6.5 Nm (58 in. lb) , bolt -2- = 55 Nm (41 ft lb).
Striker, adjusting
- After screw -1- are loosened striker -2- can be moved horizontally and vertically -
arrows-.
Tightening torque: = 19 Nm (14 ft lb).
- Tighten bolts in specified sequence.

- Tightening torque: 3.5 Nm (2.6 in. lb).
57-14
- Adjust striker -1- so recess on door lock turn clip is concentric -arrows- to striker (door
must not be raised or pressed down). Door must not move when closed.
57-29
Central locking
Central locking, components
1 - Door lock actuator, right front

2 - Door lock actuator, sliding door
3 - door lock actuator, tailgate
4 - Door lock actuator, left front
5 - Door lock actuator, rear
6 - Control module for central locking
Remove instrument panel to access
57-30
Door lock actuator, removing and

installing (front)
Removing
- Remove door trim.

70
- Disconnect multi-pin connector -1- from actuator.

- Remove screws -2-.
- Disconnect lock rod.
- Remove actuator.
Installing
- Reinstall actuator in reverse sequence.

57-31
Sliding door lock actuator, removing

and installing
Removing
- Remove door trim.

70
- Remove screws -1- and lay actuator aside.
- Disconnect multi-pin connector -1- from actuator.

- Disconnect lock rod.
- Remove actuator.
Installing

57-32
Tailgate lock actuator, removing and

installing
Removing
- Remove tailgate trim.

70
- Disconnect connector -1- from actuator.

- Remove screws -2-.
- Disconnect connecting rod and remove actuator.
Installing

57-33
Double rear door lock actuator,

Removing
- Remove rear double door trim.

70
- Disconnect multi-pin connector from actuator.
- Remove Phillips screws -1-.

- Disconnect connecting rod -2- and remove actuator.
Installing

57-34
Central Locking System (09.98 through 10.00)
For vehicles from 10.00
Repair Manual, Body On Board Diagnostic (OBD), Repair Group

01
Assembly Overview
1 - Front door lock actuator

2 - Sliding door lock actuator
3 - Rear lid door lock actuator
4 - Front door lock actuator
57-35
5 - Double back door lock actuator

Removing and installing, Page 57-33
6 - Central control module
Only on vehicles with radio frequency remote control
central locking
To remove, first remove instrument panel trim
57-36
Central locking system with radio

frequency remote control functions
(05.98 through 10.00)
For vehicles from 10.00
Repair Manual, Body On Board Diagnostic

(OBD), Repair Group 01
Vehicles with radio frequency remote control can

be unlocked or locked without direct activation of
the door locks. The radio frequency remote
control also activates/deactivates the anti-theft
warning system. The following information
describes the additional functions not found in
central locking systems without radio frequency
remote control.
The transmitter unit with batteries is located in

the handle of the vehicle key. The Central
Locking System Control Module -J276- is located
behind the instrument cluster.
The effective range of radio frequency remote

control is 6 - 15 m (20 - 50 ft.). The range
depends on various factors (atmospheric
conditions, metallic materials in the area of the
vehicle, condition of the batteries in the key).
The vehicle will not unlock if the battery is

already considerably discharged. The vehicle
cannot be locked with the radio frequency remote
control and the corresponding key cannot be
synchronized.
57-37
To unlock vehicle:
- Point key toward vehicle within the effective

range and briefly press unlock button -1-.
Opening of vehicle and anti-theft warning
system (if equipped) deactivation are indicated
by emergency flashers lighting up twice.
To lock vehicle:
- Press briefly on lock button -2-. Opening of vehicle and anti-theft warning system (if
equipped) deactivation is indicated by emergency flashers lighting up twice.
If lock button -2- is pressed for at least one second, anti-theft warning system is activated
at same time.
Locking of vehicle and activation of anti-theft warning system will be displayed by

emergency flashers lighting up one time.
When lock button -2- or unlock button -1- is pressed, indicator light -3- in key blinks. If this
light does not blink, batteries in the key may be discharged. If necessary, replace
batteries.
No synchronizing is required after changing batteries.
Each time locks are unlocked or locked using the radio frequency remote control, system
code is changed.
If lock and/or unlock buttons are operated more than 50 times outside system receiving
range, system will not react until button -1- or -2- is pressed quickly two times.
57-38
Radio frequency remote control,

synchronizing (vehicles from 10.00)
For vehicles up to 10.00

(OBD), Repair Group 01
It is necessary to synchronize the radio

frequency remote control key if:
New additional keys (maximum 4 keys) are

obtained for the vehicle and/or defective keys
are replaced.
Central Locking System Control Module

(remote control) -J276- is replaced.
or:
Complete locking system was replaced.
Adaptation of new keys to anti-theft immobilizer

is always performed first.
Repair Manual, Electrical Equipment On

Board Diagnostic (OBD) from August 1998,
Repair Group 01.
Successful synchronizing of a key erases

previous synchronizing (code) of other keys.
Therefore, entire set of keys (maximum 4 keys)

have to be re-synchronized, immediately, one
after another.
57-39
Note:
During synchronizing, no other vehicle with radio

frequency remote control may be within an area
of 20 m (50 ft.). If this condition is not observed, it
is possible synchronizing will be influenced by an
outside vehicle.
- Switch ignition on for maximum 3 seconds with

master key only.
- Switch ignition off and pull out key.
Synchronizing of key must now take place within

20 seconds.
- While holding lock button -2-, press unlock button -1- three times.
- Release lock button -2-. Indicator light -3- in key blinks five times.
If control module has accepted synchronizing of the key, the vehicle locks and unlocks
once and emergency flasher system is activated accordingly.
57-40
Any additional keys must be synchronized within

next 20 seconds after new key is completed To
synchronize additional keys, (maximum 3 more)
hold lock button -2- and press button -1- 3 times.
If control module has accepted synchronizing of

the key, vehicle locks and unlocks once and
emergency flasher system is activated
accordingly.
Synchronizing process ends if 20 second time

limit has been exceeded or ignition was switched
off for at least 5 seconds. If all 4 keys were
synchronized, th synchronizing process
automatically ends.
57-41
Adaptation of ignition keys with radio-

frequency remote control from 05.00
Note:
If new or additional ignition keys are required,

they must be adapted to the electronic controls
of the anti-theft immobilizer and the radio-
frequency remote control.
Generally, all ignition keys, including existing

keys, must be re-adapted.
The number of adapted keys is indicated after

selecting the adaptation function.
Adaptation can be interrupted using the "C"

button of the VAG1551 scan tool.
WARNING!
The Work Shop Code (WSC) of the VAG1551

is stored in the electronic controls of the anti-
theft immobilizer during adaptation of ignition
keys.
57-42
Requirements
All ignition keys available. If there are no old

ignition keys available, see "Procedure for lost
key",

Board Diagnostic (OBD) from August 1998, On
Board Diagnostic (OBD) of anti-theft immobilizer.
Key chain with concealed secret number is

available; if not, see "Determining secret
number",

Board Diagnostic (OBD) from August 1998, On
Board Diagnostic (OBD) of anti-theft immobilizer.
- Insert mechanically appropriate ignition key into

ignition lock.
- Connect Scan Tool (ST)

(OBD), Repair Group 01; On Board Diagnostic
- Initiate On Board Diagnostic (OBD)

(OBD), Repair Group 01; Initiating On Board
Diagnostic (OBD) for central locking system with
radio-frequency remote control
The adaptation shown here is just an example.
Rapid data transfer HELP Indicated on display:

Select function XX
- Press buttons -1- and -0- to select "Adaptation", function 10.
57-43
Rapid data transfer Q Indicated on display:

10 - Adaptation
- Press -Q- button to confirm input.
Adaptation Indicated on display:

Enter channel number XX
- Press buttons -0- and -0- to erase all keys via channel number 00.
Adaptation Q Indicated on display:

Erase adaptation values ?

Adaptation values have been erased
- Press button.

Select function XX

10 - Adaptation
57-44

- Press buttons -0- and -1-. All keys are adapted via channel number 01.

Enter channel number 01
Channel 1......adaptation 1 Indicated on display:

Key 1 <-1 3->
The upper line indicates how many keys are supposed to be adapted (standard = 1).
Select key number using buttons "1" and "3".

Enter adaptation value XXXXX
- Press the -0- button four times and then the total number of keys to be adapted,
including any keys that are present (e.g. 00003), max. 4 keys possible.
Channel 1 adaptation 3 Q Indicated on display: Number of radio-frequency keys to be adapted.

Key 3 <-1 3->
Channel 1 adaptation 3 Q Indicated on display:

Store modified value?
57-45
Channel 1 adaptation 3 Indicated on display:

Modified value has been stored
- Press button.

Select function XX
- Operate the button on each key being adapted for at least 1 second (in the above
example, for 3 keys).
- Switch ignition off and remove ignition key.
- Perform function test of the (e.g. 3) radio-frequency keys.
Note:
All 3 keys (see example) can be adapted in one adaptation procedure.
The adaptation of all keys (pressing button) must not exceed 15 seconds.
A successful adaptation can be recognized via "Read measuring value block" -function 08,
display group number 003. When radio-frequency key(s) is/are operated, the first two
measured values must indicate the status OK At the same time, the position number of the
key must be indicated in the last measured value (first, second, third, fourth key).
If the radio-frequency remote control key is operated repeatedly, the third indication -no
measured value- switches to "OK".
Repair Manual, Body On Board Diagnostic (OBD), Repair Group 01; Initiating On Board
Diagnostic (OBD) for central locking system with radio-frequency remote control
57-46
Adaptation of ignition keys is automatically

terminated if:
The number of keys to be adapted has been

reached.
A button of one of the keys being adapted is

operated repeatedly.
The allotted adaptation time of 15 seconds is

exceeded (a DTC is stored).
- Select "Check DTC memory", function 02. If

there are no DTCs stored, the key adaptation
was completed successfully.
- Press buttons -0- and -6- to end output.
Rapid data transfer Q06 End Output Indicated on display:
Rapid data transfer HELPEnter address word XX Indicated on display:

- Disconnect harness connectors for the VAG1551 scan tool.
57-47
Adapting a new, additional key from

05.00
Using VAG1551 Scan Tool (ST)
- Connect Scan Tool (ST)
Repair Manual, Body On Board Diagnostic;

Repair Group 01; On Board Diagnostic
- Initiate On Board Diagnostic (OBD)

(OBD), Repair Group 01; Initiating On Board
Diagnostic (OBD) for central locking system with
radio-frequency remote control

Select function XX

10 - Adaptation

- Press buttons -0- and -1-.

Enter channel number 01
57-48

Key 1 <-1 3->
The upper line indicates how many keys are supposed to be adapted (1).
- Press button.
Channel 1......adaptation 1 Q Indicated on display:

Enter adaptation value XXXXX
- Press the -0- button four times and then the -1- button.
Channel 1 adaptation 1 Q Indicated on display: Number of radio-frequency keys to be adapted.

Key 1 <-1 3->
Channel 1 adaptation 1 Q Indicated on display:

Store modified value?
Channel 1 adaptation 1 Indicated on display:

Modified value has been stored
- Press button.

Select function XX
- Press one button on the radio-frequency key for at least 1 second within the next 15
seconds.
- Switch ignition off and remove ignition key.
- Perform function test of the radio-frequency key.
57-49
Note:
Initialization is complete when the time of 15

seconds has been exceeded, no free key
positions are available or the key has been
adapted successfully.
Without VAG1551 Scan Tool (ST)
- Insert mechanically appropriate (old) ignition key

into ignition lock.
- Switch on ignition.
- Switch ignition off within 5 seconds.
- Switch ignition on again within 5 seconds.
- Using the new key (being adapted),

mechanically lock the vehicle within 15 seconds
(i.e. driver-side door) or lock it via the internal
locking switch and then operate the radio-
frequency button on the key.
- After a pause of more than one second (but

within 30 seconds), operate the radio-frequency
button on the key a second time.
- The adaptation procedure has been completed

and is confirmed when the vehicle blinks twice.
Note:
This adaptation fills the next free key position, i.e.

the fourth in this example.
57-50
Synchronization of ignition keys with

radio-frequency remote control from
05.00
Synchronization is necessary when the vehicle
does not open or close when radio-frequency
button is operated or when the relevant
malfunction is indicated in the Read measuring
value block function. It is possible that the key
code and control module code no longer match.
This can occur if the send button on the key is
operated frequently outside the operational range
of the system.
The vehicle key(s) must be resynchronized if this

occurs. The synchronization procedure must not
last longer than 15 seconds.
- Insert key into ignition lock.
- Switch on ignition.
- Switch ignition off within 5 seconds.
- Switch ignition on again within 5 seconds.
- Using the new key (being adapted),

mechanically lock the vehicle within 15 seconds
(i.e. driver-side door) or lock it via the internal
locking switch and then operate the radio-
frequency button on the key.
- After a pause of more than one second (but
within 30 seconds), operate the radio-frequency
button on the key a second time.
58-1
Sliding door
Assembly overview (up to 12.95)
Sliding door, components (from 01.96) Page 58-5
1 - Sliding door
Removing Page 58-10
2 - Rubber buffer
3 - Screw
19 Nm (14 ft lb)
4 - Lower roller guide assembly
5 - Screw
19 Nm (14 ft lb)
6 - Center stop
7 - Remote control
8 - Lock rod
9 - Screw
8 Nm (71 in. lb)
58-2
10 - Catch plate
11 - Phillips screw
19 Nm (14 ft lb)
12 - Trim plate
13 - Screw
19 Nm (14 ft lb)
14 - Tension spring
Removing Page 58-39
16 - Inside door handle
17 - Allen screw
8 Nm (71 in. lb)
18 - Lock knob
Screwed into pull rod
19 - Screw
8 Nm (71 in. lb)
58-3
20 - Washer
21 - Upper roller guide assembly
22 - Screw
8 Nm (71 in. lb)
23 - Window frames
Destroyed during removal
24 - Sliding door window
Flush-bonded window Page 64-7
Sliding window, repairing Page 64-31
25 - Rotary switch
Removing Page 58-38
26 - Screw
19 Nm (14 ft lb)
27 - Hinge link
58-4
28 - Seal
29 - Bolt w/washer
54 Nm (40 ft lb)
30 - Pull rod
Connects remote lock to rotary catch
58-5
Assembly overview (from 01.96)
Sliding door, components (up to 12.95) Page 58-1
1 - Window frame
Destroyed during removal
2 - Rubber buffer
Flush bonded widow: removing and installing Page 64-7
Special equipment, sliding window: repairing Page 64-31
4 - Central lock
Removing Page 58-38
5 - Screw
19 Nm (14 ft lb)
58-6
6 - Hinge link
7 - Seal
8 - Screw and washer assembly
54 Nm (40 ft lb)
9 - Pull rod
Connects remote control lock to central lock
10 - Sliding door
Removing Page 58-10
11 - Lock rod
12 - Remote control
13 - Screw
19 Nm (14 ft lb)
14 - Center stop
58-7
15 - Screw
19 Nm (14 ft lb)
16 - Lower roller guide assembly
17 - Latch pin
18 - Screw
19 Nm (14 ft lb)
19 - Striker
20 - B pillar
21 - Right rear door contact switch (sliding door) -F7-
22 - Recessed screw
8 Nm (71 in. lb)
23 - Striker
24 - Screw
19 Nm (14 ft lb)
58-8
25 - Trim plate
26 - Screw
19 Nm (14 ft lb)
27 - Tensioning spring
Removing Page 58-39
30 - Lock knob
Screwed onto pull rod
31 - Recessed screw
12 Nm (9 ft lb)
32 - Washer
33 - Recessed screw
12 Nm (9 ft lb)
58-9
34 - Upper roller guide assembly

35 - Profile seal
Clipped and glued
36 - Clip
58-10
Sliding door, removing
- Remove Phillips screw -1-, pull end piece -2- off guide rail.
- Mark position of lower roller guide.

- Remove Phillips screws -1-.
58-11
- Lower sliding door at front until upper roller guide can be removed from guide rail.
- With second technician, guide sliding door back -arrow- until hinge link -1- is out of
guide rail -2-.
58-12
Sliding door
Assembly overview from 04.01
1 - Window border
is damaged when removed
2 - Rubber buffer
adhered (positive engagement): removing and installing
page 64-8
Special equipment, sliding window: servicing page 64-32
4 - Central lock
removing page 58-24
5 - Bolt
19 Nm
58-13
6 - Hinge armature
7 - Seal
8 - Bolt
Qty. 2
54 Nm
9 - Latch actuator rod
Connection from remote control to central lock
10 - Sliding door
removing Page 58-17
adjusting Page 58-32
11 - Locking rod
12 - Remote control
13 - Bolt
19 Nm
14 - Center stop
58-14
15 - Bolt
19 Nm
16 - Bolt
19 Nm
17 - Lower roller guide
18 - Latch pin
adjusting Page 58-36
19 - Bolt
19 Nm
20 - Catch plate
21 - B-pillar
22 - Right Rear Side/Sliding Door Contact Switch -F7-
23 - Bolt
8 Nm
24 - Catch plate
25 - Bolt
19 Nm
58-15
26 - Collar
27 - Bolt
19 Nm
28 - Tension spring
removing page 58-25
31 - Lock knob
threaded onto pull rod
32 - Bolt
12 Nm
33 - Washer
34 - Bolt
12 Nm
58-16
35 - Upper roller guide

36 - Seal profile
clipped in and adhered
37 - Clip
58-17
Sliding door, removing from 04.01
- Remove screw -1- and pull off end piece -2- from guide rail.
- Mark adjustment of lower roller guide -arrow-.

- Remove bolts -1-
58-18
- Lower sliding door far enough at front, so that the upper roller guide can be removed
from the guide channel.
- With help from a second technician, guide sliding door back until hinge armature -1-
slides out of guide rail -2-.
58-19
Door stop, removing
- If applicable, remove door step insert and Foot

well Light with Delay Switch -W23-, Page 58-
22 .
- Place sliding door in half-opened position.
- Remove screws -1- and pull door stop -2- downward out of guide channel.
Tightening torque:
19 Nm (14 ft lb)
58-20
Sliding door, adjusting (up to 12.95)
Sliding door adjusting (from 01.96) Page

58-25
- Remove sliding door molded trim and/or sliding

door lower trim

70
Hinge link, adjusting
- Loosen striker -1- by loosening screws -2-.
- Close sliding door and loosen bolt -1- from inside vehicle.
- Have a second technician lift sliding door, push hinge fitting with hex bolts -1- and guide
tab -2- as far forward as possible.
- Tighten hex bolt -1-.
Tightening torque:
Bolt -1- = 58 Nm (43 ft lb)
58-21
Lower roller guide, adjusting
Front Height of sliding door incorrect
Sliding door does not match B-pillar outer

contour
- If sliding door height is incorrect, loosen screws -1-, align sliding door as required -
arrow-.
Tightening torque:
Screw -1- = 19 Nm (14 ft lb)
If sliding door does not match B-pillar outer contour adjust with Phillips screws -2- as
follows:
Vehicles without door step insert
- Press plastic cap -1- out of step from below.

58-22
Vehicles with Foot well Light with Delay

Switch -W23-
- If applicable, pry out Foot well Light with Delay Switch -W23- -1- and disconnect
connectors.
- Unclip door step insert -1- from outside -arrows-, installation position, lift upward out of
clips -2-.
58-23
- Loosen Phillips screws -2-, press sliding door against roller guide -1- -arrow-, tighten
only screw -2- on door side.
- Close sliding door carefully.
- Loosen screw -2- carefully while second technician outside indicates when sliding door
is flush with B-pillar.
- Tighten both screws -2-.
Tightening torque:
Screws -2- = 19 Nm (14 ft lb).
Upper roller guide, adjusting
Top front of sliding door does not match outer B-pillar contour.
- Loosen bolt -1- and slide upper roller guide -2- on bracket -3- -arrows- until top front of
sliding door matches outer B-pillar contour.
Tightening torque:
Bolt -1- 8 Nm (71 in. lb).
58-24
Striker, adjusting
- Striker -1- can move horizontally -arrow- after loosening Phillips screw -2-.
Tightening torque:
Screws -2- = 19 Nm (14 ft lb)
- Adjust striker -1- so recess on remote control with turn clip is concentric -arrows- to
striker (door must not be raised or pressed down).
Sliding door must have no free play when closed.
58-25
Sliding door, adjusting (from 01.96)
Sliding door, adjusting (up to 12.95) Page

58-20
- Remove sliding door molded trim and/or remove

lower door trim.

70
Hinge, adjusting
- Loosen latch striker -1- by loosening phillips screws -2-.
- Close sliding door, loosen hex bolts -1- from inside vehicle.
- Have second technician lift sliding door and push hinge as far forward as possible.
- Tighten hex bolts -1-.
Tightening torque:
Bolt -1- = 58 Nm (43 ft lb)
58-26
Sliding door height not correct
Sliding door outer contour does not match B-

pillar
- To adjust height, loosen Phillips screws -1- and align accordingly -arrow-.
Tightening torque:
Phillips screw -1- = 19 Nm (14 ft lb)
If sliding door contour does not match B-pillar, make adjustments with Phillips screws -2-
as follows:
Vehicles without step insert
- Press plastic cap -1- out of step from below.

58-27
Vehicles with step insert
- Pry step light -W23- -1- out, if applicable, disconnect connector.

58-28
- Unclip step trim -1- at outside -arrows-, lift up out of clips -2-.
58-29
With help of second technician
- Loosen Phillips screws -2-, press sliding door against roller guide -1- -arrow-, tighten
one screw -2- next to door.
- Carefully close door.
- Loosen screw -2- enough to adjust contour with outer B-pillar, then tighten both screws
-2-.
Tightening torque:
19 Nm (14 ft lb)
Sliding door top front does not match B-pillar contour
- Loosen hex recess bolt -1-, slide upper roller guide -2- on bracket -3- -arrows- until top
front of sliding door matches outer B-pillar contour. Tightening torque: Recessed bolt -
1- = 8 Nm (71 in. lb).
58-30
Latch striker, adjusting
- Loosen Phillips screws -2-, striker can now slide horizontally -arrow-.
Tightening torque:
- Adjust latch striker -1- so recess on central lock engages with catch in center of striker -
arrow- (door must not be raised or pressed).
Door must have no free play when closed.
58-31
Latch pin, adjusting
Latch pin must face inside of vehicle, when

installing
- Loosen screws -1- enough to move latch pin -2-.
- Close door slowly and check latch pin -1- position to catch plates -2-, latch pins must be
parallel to catch plates.
- Close door completely to confirm adjustment.
- Open door and tighten screws.
Tightening torque:
58-32
Adjusting sliding door from 04.01
- Remove roller guide trim; front frame trim and

cover for sliding door adjustment.
Repair Manual, Body Interior; Repair Group

70; Door trim, sliding door form trim - assembly
overview
Closing force reduction, adjusting
There must be a distance of approx. 1 to 2

mm between catch plate ( pos. 24 ,
Page 58-14 ) and B-pillar pressure plate in
closed condition (visual check).
If this is not the case, all listed work steps must

be performed in the following sequence:
- Adjust hinge armature Page 58-33 .
- Adjust lower roller guide Page 58-33 .
- Adjust upper roller guide Page 58-34 .
- Adjust latch striker Page 58-35 .
- Adjust latch pin Page 58-36 .
- Adjust rubber buffer Page 58-37 .

58-33
Hinge armature, adjusting
- Close sliding door and loosen bolts -1- from vehicle interior.
- Have a second technician lift sliding door and slide hinge armature with bolts as far
forward as possible.
- Tighten bolts -1-.
Tightening torque: Bolt -1- = 54 Nm
Sliding door height at front is not correct
Sliding door is not flush with outside contour of B-pillar

- Remove latch pin on sliding door-side.
- If the height adjustment of the sliding door is not correct, loosen bolts -1- and adjust
sliding door respectively -arrow-.
If the front of the sliding door is not flush with the outside contour of the B-pillar, the
adjustment must be performed via bolts -2- as follows:
58-34
- Loosen bolts -2-, adjust sliding door to roller guide -1- -arrow- and pre-tighten both bolts
slightly.
- Carefully close sliding door and check seating of sliding door from outside. If necessary,
repeat procedure until the sliding door is flush with the outer contour of the B-pillar.
- Carefully open sliding door and tighten both bolts -2-.
Tightening torque: Bolts -2- = 19 Nm
Top front of sliding door is not flush with the outer contour of the B-pillar
- Loosen bolt -1- and then slide upper roller guide -2- on bracket -3- to adjust -arrows-,
until top front of sliding door is flush with the outer contour of B-pillar.
58-35
Latch striker, adjusting
- Latch striker -1- can be adjusted horizontally -arrow- after loosening bolts -2-.
Tightening torque: Bolts -2- = 19 Nm
- Adjust latch striker -1- so that the cutout of the central lock with lock mechanism
engages centrally in latch striker -arrows- (do not lift up or press down on door). Sliding
door must project out approx. 1 to 2 mm and not have any play in closed condition to C-
pillar (wind noise).
58-36
Latch pin, adjusting
- Install latch pin on sliding door-side.
When installing, make sure the points of

latch pin point toward the vehicle interior.
- Loosen bolts -1- until latch pin -2- can be moved.
- Slowly close sliding door and check position of latch pin -1- to catch plates -2- - latch
pins must be parallel to the catch plates -.
- Close sliding door completely, therefore adjusting the latch pins.
- Open sliding door and tighten screws
Tightening torque: Screws -1- = 19 Nm.
- Carefully close sliding door once again to check whether the latch pins run into the
catch plates in a centered manner.
58-37
Rubber buffers, adjusting
- Rubber buffers at rear top and bottom of sliding door must be adjusted by threading in
or out so that they make light contact.
- Do not use the rubber buffers to adjust the sliding door.
58-38
Remote control lock, removing
- Remove sliding door trim and/or remove lower sliding door trim
Repair Manual, Body Interior, Repair Group 70.
- Disconnect pull rod -1- from remote control lock -2-.
- Remove remote control lock -1- by removing screws and disconnecting pull rod -2- at
remote control.
Tightening torque:
Screw = 19 Nm (14 ft lb).
58-39
Outside door handle, removing
- Remove sliding door trim and/or remove lower sliding door trim.
- Loosen inner mechanism by removing bolts -2-, remove by pulling up.
- Remove Bolts and disconnect pull rod -2-. Push remote control to one side.
Tightening torque:
Bolts -1- = 8 Nm (71 in. lb)
58-40
- Remove screw -1- and disconnect tension spring -2-.

Tightening torque:
Screw -1- = 19 nm (14 ft lb)
58-41
Lock cylinder, removing (sliding door)
- Remove sliding door trim and/or remove lower sliding door trim.
Repair Manual, Body Interior, Repair Group 70.
- Remove outer door handle Page 58-39 .
- Remove spring pin -1-.
- Remove casting -2- off four-sided shaft.
- Remove outer spring -3-.
- Remove lock cylinder -4- with key -5- inserted.
58-42
Guide rail, assembly overview
Note:
To remove guide rail: remove sliding door Page 58-10 , if

necessary, molded trim on right rear side panel

1 - Guide rail
Removing: Remove end piece -4-, loosen hex nuts -2-
58-43
2 - Hex nuts
8 Nm (71 in. lb)
3 - Phillips screws
4 - End piece
63-1
Front bumper
Front bumper, removing and installing (from 01.96) (long front

end) Page 63-2
Front bumper, removing and installing (from 01.96) (short front

end) Page 63-4
1 - Cover
2 - Bolt w/washer
10 Nm (7 ft lb)
3 - Front bumper
Removing: Pull/drive pins -4- out and pull bumper parallel
out of guides -5-
Installing: Slide bumper parallel onto guides -5-, secure by
driving in pins -4- flush
4 - Pin
5 - Guide
63-2
Front bumper, removing and installing (from 01.96)

(long front end)
Front bumper, removing and installing (from 01.96) (short front

end) Page 63-4
Front bumper, removing and installing (up to 12.95) Page 63-

1
1 - Cover
- Remove radiator grille with trim frame page 66-2.
- Remove torx screws -2- and -3-.
- Pull cover forward out of guides.
Note center faster (arrow)
2 - Torx screw T 30 (4x)
6 Nm (53 in. lb)
63-3
3 - Torx screw T25 (2x)

1.2 Nm (11 in. lb)
4 - Bumper beam
Disconnect right side then left
5 - Guide bracket
To remove/install bumper beam, push/pull beam straight
(parallel) out of guide bracket
6 - Rivet
7 - Hex screw (4x)
1.5 Nm (13 in. lb)
8 - Cover bracket
63-4
Front bumper, removing and installing (from 01.96)

(short front end)
Front bumper, removing and installing (up to 12.95) Page 63-

1
Front bumper, removing and installing (from 01.96) (long front

end) Page 63-2
1 - Cover
Material - PP/EPDM
Removing
- Pry out caps -9-, remove combination hex screw and
washer assemblies -10-, Torx screws -8-
2 - Bumper bracket
63-5
3 - Bumper guide bracket

4 - Rivet
5 - Blind rivet
6 - Bumper bracket
7 - Cover guide bracket
1.2 Nm (11 in. lb)
9 - Cap, hex screw
10 - Screw / washer assembly
6.5 Nm (58 in. lb)
63-6
Rear bumper
Rear bumper, removing and installing (from 01.96) Page 63-8
1 - Rear bumper
2 - Cover
3 - Bolt w/washer
15 Nm (11 ft lb)
4 - Bolt w/washer
15 Nm (11 ft lb)
5 - Pin
Replacement part includes -5- and -6-
6 - Expanding clip
Replacement part includes -5- and -6-
63-7
7 - Bumper bracket
8 - Bolt w/washer
110 Nm (81 ft lb)
9 - Pin
10 - Guide
To remove and install, push in or slide out bumper parallel
from guide (left and right)
11 - Sealing washer
63-8
Rear bumper, removing and installing (from 01.96)
Rear bumper, removing and installing (up to 12.95) Page 63-

6
1 - Cover
- Remove torx screws -8-, hex screws -7-.
- Remove bumper with rail -3- from guides -6-.
- Remove torx screws -9-.
- Pull cover from rail with brackets -3-.
Note center fastening point
2 - Bumper beam
When removing, disconnect right side then left
3 - Rail with bracket
63-9
4 - Sleeve
5 - Expansion clip
6 - Bumper guide bracket
7 - Hex bolt with washer
15 Nm (11 ft lb)
1.2 Nm (11 in. lb)
9 - Torx screw T30
6 Nm (53 in. lb)

Engine - Repair - 1997-2000 EV Repair Manual

Uploaded by

Engine - Repair - 1997-2000 EV Repair Manual

Uploaded by

10-1

Engine, removing and

VAG 1921 Spring-clip Pliers

VAG 1306 Drip tray

3277A Installation tool

3408 Engine support

VAG 1383 A Engine/transmission jack

G 000 100 Grease (for vehicles with manual

VAG 1331 Torque wrench (5 to 50 Nm)

VAG 1332 Torque wrench (40 to 200 Nm)

- Remove engine/transmission assembly from

Obtain radio code before disconnecting

- Disconnect battery ground cable.

Ignition must be switched OFF

- Always replace cable ties in original position.

- Drain coolant Page 19-14 .

- Remove radiator and radiator cooling fan

- Remove ribbed belt Page 13-22 .

- Detach hose from combi-valve at Air Cleaner upper section -arrow-.

Vehicles with manual transmission:

- Pry off line/hose from slave cylinder on

- Remove transverse support bolts -A- and -B-.

Vehicles with automatic transmission:

- Remove transmission shift cable.

Vehicles with A/C:

- Observe additional information and removal instructions Page 10-

- Remove axle shafts.

Repair Manual, Suspension, Wheels, Brakes,

Repair Manual, Suspension, Wheels, Steering

- Remove right assembly mount bolt -1-.

- Remove left assembly mount bolts -arrows-.

Carefully guide assembly out of vehicle while lowering. Do not allow

Engine, mounting on engine stand

- Mount engine to VW 313 engine stand support

Special tools and equipment

VAG 1202 A Workshop crane

2024 A Lifting tackle

3269 Engine bracket

VW 313 Support clamp

Vehicles with manual transmission

- Attach 2024 A as follows:

Hooks and locating pins must be secured

Positions marked 1 to 4 on bar must face

Holes in hooks are counted up from the hook.

If engine must be separated from transmission,

- Remove 3408 engine bracket from cylinder

- Install 3269 engine bracket on cylinder block

- Install engine in VW 313 support clamp using

Install engine in reverse sequence, note the

Vehicles with manual transmission

- Check clutch release bearing in slave cylinder

- Clean splines of input shaft and lightly grease

- Check if engine/transmission locating dowels

- Install mounting hardware approx. 5 to 6 turns

Vehicles with A/C

- Install A/C compressor.

Repair Manual, Heating & Air Conditioning

Repair Manual, Heating & Air Conditioning

Vehicles with manual transmission

- Connect line/hose on slave cylinder and secure

- Install gearshift mechanism on transmission,

Vehicles with automatic transmission

- Install transmission shift cable on transmission,

Repair Manual, 4 Spd. Automatic

- Install axle shafts.

Repair Manual, Suspension, Wheels, Steering

- Install power steering pump with bracket.

Repair Manual, Suspension, Wheels, Brakes,

Repair Manual, Suspension, Wheels, Steering

- Install front exhaust pipe Page 26-3 , item

- Install intake manifold complete with lower

- Install ribbed belt Page 13-22 .

- Install radiator and radiator fan Page 19-

- Fill system with coolant Page 19-14 .

- Adjust accelerator cable Page 20-25 .

- Re-connect wiring and route as necessary.