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Service Department. Technical Information

 Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups

Repair Group
00 - General, Technical Data
10 - Engine Assembly
13 - Crankshaft, Cylinder Block
15 - Cylinder Head, Valvetrain
17 - Lubrication
19 - Cooling System
20 - Fuel Supply
21 - Turbocharger, Supercharger
26 - Exhaust System, Emission ControlsAG. Volkswagen A
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2014 Volkswagen AG, Wolfsburg D3E8001FB4E

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

Contents

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ag. e.n.A.G.. V. o. lk. s.w.a.ge. n. A. G. d. o. . . . . . . . . . . . . . 2
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2.1 Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . y.V.o.lk.s . . . . . . . . . . . . . . . . . . . .no. t .gu. . . . . . . . . 2
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10 - Engine Assembly . . . . . . . . . . . . . . . a.ut.h . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . e.or.a . . 3
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1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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1.1 Engine and Transmission Mount, Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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2.1 Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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3.1 Additional Information for Vehicles with Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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3.2 Engine, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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3.3 Engine, Securing to Assembly Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4 Engine, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
l purpos

13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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1.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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1.2 Injection Pump Sprocket Bolt Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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2.1 Drive and Toothed Belt Overviews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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2.2 Sealing Flanges and Dual Mass Flywheel/Drive Plate Overview . . . . . . . . . . . . . . . . . . . . 17
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2.3 Piston and Connecting Rod Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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2.4 Crankshaft Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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3.1 Piston and Cylinder Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cted
24
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3.2 Crankshaft Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.1 Semi-Automatic Toothed Belt Tensioner, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2 Piston Position, Checking at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1 Ribbed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.2 Idler Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.3 Sealing Flange Oil Seal, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.4 Sealing Flange, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.5 Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.1 Cylinder Head Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.2 Valvetrain Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.3 Valve Seat, Refacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.1 Compression, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Contents i
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

3.2 Valve Guide, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3.3 Hydraulic Valve Lifter, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.1 Toothed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.2 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.3 Valve Guide, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.4 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.5 Valve Stem Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.1 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.2 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.1 Lubrication System Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.2 Oil Filter Bracket Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.3 Oil Supply Line Overview . . . . . . . . . . . . . . . . A. G . ..V.o.lk.sw. a. g.e.n . . . . . . . . . . . . . . . . . . . . . . . . 68
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4 Diagnosis and Testing . . . .s a.u.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o.r a.c. . . . . . . . . 70
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4.1 Oil Pressure and Switch, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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5.1 Oil Supply Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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5.2 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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19 - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.1 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

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1.2 Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
l purpos

2.1 Coolant Hose Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

2.2 Cooling System Component Overview, Body Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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2.3 Cooling System Component Overview, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

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3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
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3.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

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4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

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4.1 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
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4.2 Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

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4.3 Coolant Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
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20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.2 Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.3 Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.1 Fuel Tank and Attachments Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.2 Fuel Filter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.3 Accelerator Mechanism with Adjustable Throttle Position Sensor, Overview . . . . . . . . . . 95
2.4 Accelerator Mechanism with Non-Adjustable Throttle Position Sensor, Overview . . . . . . 96
2.5 Throttle Position Sensor, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

ii Contents
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.1 Throttle Position Sensor, with Adjustable Sensor, Checking . . . . . . . . . . . . . . . . . . . . . . . . 99
4.2 Throttle Position Sensor with Non-Adjustable Sensor, Checking . . . . . . . . . . . . . . . . . . . . 101
5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.1 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

21 - Turbocharger, Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.2 Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.3 Charge Air System and Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.1 Turbocharger and Attachments Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.2 Charge Air Cooler Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.1 Boost Pressure Regulation, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.2 Wastegate Bypass Regulator Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.1 Hose Connections with Connector Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.2 Line Connections to Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.3 Turbocharger and Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.4 Charge Air Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
AG. Volkswagen AG d
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26 - Exhaust System, Emission Controls . . . . . . . . . . . .es.no.t .gu. . . . . . . . . . . . . . . . . . . 120
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1 General Information .or.ise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .an.te.e . . . . . . . . . . . . . . . . . . . 120
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1.1 Exhaust System .s a.u. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c . . . . . . . . . . . . . . . . . 120
s
1.2 Exhaust Gas Recirculation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
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2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

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2.1 Front Exhaust Pipe and Catalytic Converter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

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2.2 Muffler and Mount Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

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2.3 Exhaust Gas Recirculation (EGR) System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

h re
hole

2.4 Vacuum Hose Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

spec
es, in part or in w

3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
t to the co

3.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
rrectness of i

4.1 EGR Vacuum Regulator Solenoid Valve N18 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 127

4.2 Exhaust Gas Recirculation, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
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5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

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5.1 Front Exhaust Pipe and Catalytic Converter with Attachments . . . . . . . . . . . . . . . . . . . . . . 131
orm

5.2 Exhaust Gas Recirculation (EGR) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

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atio
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6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

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7 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

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Contents iii
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

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iv Contents
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

00 – General, Technical Data

1 General Information
(Edition 02.2010)
⇒ “1.1 Engine Number”, page 1

1.1 Engine Number

The engine number (“engine code” and “serial number”) are lo‐
cated at the engine/transmission joint -arrow-.
The engine number consists of up to nine alphanumeric charac‐
ters. The first part (maximum 3 letters) represents the engine
code , the second (six digit) is the serial number. If more than
999,999 engines with the same engine code are produced, the
first of the six characters is replaced with a letter.
In addition, a sticker with the engine code and serial number is
affixed to the toothed belt guard.
The engine code is also included on the vehicle data label.

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1. General Information
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 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

2 Specifications
⇒ “2.1 Engine Data”, page 2

2.1 Engine Data

Code Letter ALH
Manufactured From 10/1997
Emission values in accordance with D3 standard
Displacement agen
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Output yV
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kW at RPM ot gu66 at 3750
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Torque rise Nm at RPM 210ntat
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Bore ss
a Diameter in mm 79.5ac

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Stroke mm 95.5
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Compression ratio 19.5

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Fuel meeting DIN EN 590

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Ignition sequence 1-3-4-2

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Catalytic converter x
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Exhaust Gas Recirculation (EGR) x

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Turbocharger x
Charge Air Cooler (CAC) x

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2 Rep. Gr.00 - General, Technical Data

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

10 – Engine Assembly
1 General Information
⇒ “1.1 Engine and Transmission Mount, Aligning”, page 3

1.1 Engine and Transmission Mount, Align‐

ing

WARNING

Before loosening the bolts, secure the assembly using the en‐
gine support bridge - 10-222 A- .

Engine Mount
a = 14.0 mm
b = minimum 10.0 mm
Both bolt heads -1- must be flush with the edge -c-.

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Transmission Mount
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Edges -a and b- must be parallel to each other.

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1. General Information 3
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

2 Specifications
⇒ “2.1 Tightening Specifications”, page 4

2.1 Tightening Specifications

Component Fastener Size Nm
Bolts and Nuts
M6 10
M8 20
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Front Exhaust Pipe to Turbocharger Nut horis - nte
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Engine Mount

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Engine mount to body bolt -1-. Tighten to 40 Nm + 90° (1/4) ad‐
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ditional turn. 1
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Bracket to engine mount/body bolt -2-. Tighten to 25 Nm. 1
hole

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Engine mount to engine mount bracket bolt -3-. Tighten to 100

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Nm. 1

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Transmission Mount
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Transmission mount to body bolt -1-. Tighten to 40 Nm + 90° (1/4)
com

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Transmission mount to body bolt -2-. Tighten to 25 Nm. 1

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Transmission mount to transmission mount bracket bolt-3-. Tight‐

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Pendulum Support
Pendulum support to transmission bolt -1-. Tighten to 50 Nm.
Pendulum support to transmission bolt -2-. Tighten to 50 Nm.
Pendulum support to subframe bolt -3-. Tighten to 25 Nm.
• 1 Always replace

4 Rep. Gr.10 - Engine Assembly

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

3 Removal and Installation

⇒ “3.1 Additional Information for Vehicles with Air Conditioning ”,
page 5
⇒ “3.2 Engine, Removing”, page 5
⇒ “3.3 Engine, Securing to Assembly Stand”, page 8
⇒ “3.4 Engine, Installing”, page 9

3.1 Additional Information for Vehicles with

Air Conditioning

WARNING
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The Air Conditioning d by V(A/C) refrigerant circuit must t gnot
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To prevent damage to the A/C condenser and also to the refrig‐

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erant lines/hoses, ensure that the lines and hoses are not stretch‐

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ed, kinked or bent.
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To facilitate removal and installation of the engine without having
to open the refrigerant circuit:
– Remove the retaining clamp(s) from the refrigerant lines.
rrectness of i

– Remove the ribbed belt, refer to

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⇒ “5.1 Ribbed Belt”, page 28 .

– Remove the A/C compressor, refer to ⇒ Refrigerant R134a;
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Rep. Gr. 00 ; Removal and Installation .

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– Secure the A/C compressor to the tow hook so that the refrig‐
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erant lines/hoses are not under a load.

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Shield the bumper from damage using adhesive tape.
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3.2 Engine, Removing

Special tools and workshop equipment required
♦ Engine Sling - 2024 A-
♦ Engine/Transmission Support - T10012-
♦ Holding Fixture - VW313-
♦ Holding Fixture - VW540-
♦ Shop Crane - VAG1202 A-
♦ Drip Tray - VAG1306-
♦ Torque Wrench (5-50 Nm) - VAG1331-

3. Removal and Installation 5

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

♦ Torque Wrench (40-200 Nm) - VAG1332-

♦ Engine/Transmission Jack - VAG1383A-
♦ Hose Clip Pliers - VAG1921-
♦ Step Ladder - VAS5085-

Note

♦ To perform this procedure, the ground cable must be discon‐

nected from the battery. If a coded radio is installed, obtain the
anti-theft code beforehand.
♦ The engine is removed downward together with the transmis‐
sion.
♦ All tie straps which are opened or cut off when removing the
engine, must be replaced in the same position when installing
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When doing any repair work, especially in the engine compart‐
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ment, pay attention to the following due to clearance issues:

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♦ Route lines of all types (for example, fuel, hydraulic, Evap‐
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and vacuum) and electrical wiring so that the original path
hole

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es, in part or in w

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♦ Ensure sufficient clearance to all moving or hot compo‐
nents.

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Removing
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– Disconnect the battery Ground (GND) cable with the ignition

turned off.
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– All tie straps which are opened or cut off when removing the
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engine, must be replaced in the same position when installing

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– Remove the engine cover.

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– Remove the battery and battery tray.

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– Remove the air filter. C py
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– Remove the charge air cooler connecting pipe between the
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WARNING

♦ The fuel or fuel lines for the fuel system can become very
hot (danger of scalding)!
♦ In addition, the fuel system is under pressure! Before
opening the system, place a cloth around the connection
area and release the pressure by carefully loosening the
connection!
♦ Wear protective goggles and protective gloves when
working on the fuel system!

– Clamp off the fuel supply and return lines at the fuel filter.

6 Rep. Gr.10 - Engine Assembly

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010
AG. Volkswagen AG d
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With a Manual d byTransmission
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– Remove ut
ho the hydraulic clutch slave cylinder, refer toee⇒or Manual
Transmission;
ss
a Rep. Gr. 30 ; Description and Operation ac .

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– Remove the selector mechanism from the transmission, refer

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to ⇒ Manual Transmission; Rep. Gr. 34 ; Removal and In‐
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With a Automatic Transmission

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– Disconnect the selector lever cable from the transmission, re‐
hole

spec
fer to ⇒ Automatic Transmission; Rep. Gr. 37 ; Removal and
es, in part or in w

Installation .

t to the co
Continuation for All

rrectness of i
– Remove the left, right and center noise insulation, refer to ⇒
Body Exterior; Rep. Gr. 50 ; Description and Operation .
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– Drain the coolant.

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– Disconnect the connector from the thermal switch and the ra‐

or
diator fan.

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– Disconnect the coolant hoses from the engine using the -

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VAG1921- .

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– Remove the pendulum support bolts -arrows- and pendulum o

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– Disconnect the vacuum and vent hoses from the engine.t. Cop py
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– Disconnect and lay aside all electrical harnesses from the
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– Remove the front exhaust pipe.
– Remove the ribbed belt, if necessary.
– Remove the power steering pump from the bracket and move
it to the side. The hose remains connected, refer to ⇒ Sus‐
pension, Wheels, Steering; Rep. Gr. 48 ; Removal and In‐
stallation .
– Disconnect all electrical connections as necessary from the
engine and lay aside.
– Remove the right drive axle and disconnect the left drive axle
from the transmission, refer to⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 40 ; Removal and Installation .
– Remove the securing clamps for the power steering pressure
line.
– Install the -T10012- to the -VAG1383 A- .

– Install the -T10012- to the cylinder block with a nut and bolt
M10 x 25/ 8.8 and tighten to approximately 40 Nm.
– Gently lift the engine and transmission using the -VAG1383A- .

3. Removal and Installation 7

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Remove the engine mount to engine mount bracket bolts

-arrows-.

Note

Use the -VAS5085- to remove the bolts.

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– Remove the transmission mount to transmission
rised
mount brack‐ nte
et bolts -arrows-. aut
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– Carefully lower the engine with transmission.

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Carefully guide the engine with transmission, when lowering, to

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prevent damage to the bodywork.

spec
urposes, in part or in wh

t to the co
rrectne
3.3 Engine, Securing to Assembly Stand

s
Special tools and workshop equipment required

s o
cial p

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♦ Engine Sling - 2024 A-

form
mer

♦ Holding Fixture - VW313-

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♦ Holding Fixture - VW540-

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♦ Shop Crane - VAG1202 A-

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♦ Engine/Transmission Jack - VAG1383A-

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Secure the engine to the -VW313- of the assembly stand using C py
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– Remove the transmission.

– On vehicles with a automatic transmission, secure the torque
converter to prevent it from falling out after the engine and
transmission are separated.

8 Rep. Gr.10 - Engine Assembly

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Install the -2024 A- as follows and lift the engine from the -
VAG1383A- using the workshop crane.
Belt pulley side: second hole in the -2024 A- , position 2.
Dual mass flywheel: last hole in the -2024 A- , position 8.

WARNING

Use securing pins -arrows- at the hooks and pins.

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♦ The peg positions on the -2024 A- marked 1 to 4 face the belt

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pulley.

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♦ The bores in the hole rail are counted from the hook.
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– Fasten the engine with the -VW540- to the -VW313- .

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3.4 Engine, Installing
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Installation is performed in the reverse order of removal, noting

the following:
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– Check the clutch release bearing for wear and replace if nec‐
essary.
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– Lightly grease the clutch release bearing, guide sleeve for the
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release bearing and input shaft splines with grease - G 000

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– Make sure centering sleeves for the engine to transmission

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are installed in the cylinder block. Install if necessary.
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– When installing the engine/transmission, ensure clearance to
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the drive axles.
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– Align the engine and transmission mounts, refer to
⇒ “1.1 Engine and Transmission Mount, Aligning”, page 3 .
– Install the drive axles, refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 40 ; Removal and Installation .
– Install the front exhaust pipe, refer to
⇒ “1.1 Exhaust System”, page 120 .
With a Manual Transmission
– Install the slave cylinder for the hydraulic clutch, refer to ⇒
Manual Transmission; Rep. Gr. 30 ; Description and Opera‐
tion .
– Install the selector mechanism and, if necessary, adjust the
selector lever cable, refer to ⇒ Manual Transmission; Rep.
Gr. 34 ; Removal and Installation
With a Automatic Transmission
– Install the selector lever cable to transmission and, if neces‐
sary, adjust it, refer to ⇒ Automatic Transmission; Rep. Gr.
37 ; Removal and Installation .

3. Removal and Installation 9

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

Continuation for All

– Install the power steering pump, refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 48 ; Removal and Installation .
– Install the charge air cooler connecting pipe between the
charge air cooler and the intake manifold.
– Electrical connections and routing, refer to ⇒ Electrical Equip‐
ment; Rep. Gr. 97
– Install the Air Conditioning (A/C) compressor, if applicable, re‐
fer to ⇒ Refrigerant R134a; Rep. Gr. 00 ; Removal and
Installation .
– Install the ribbed belt, refer to
⇒ “5.1 Ribbed Belt”, page 28 .
– Install the left, right and center noise insulation, refer to ⇒ Body
Exterior; Rep. Gr. 50 ; Description and Operation .
– Fill the cooling system, refer to
⇒ “1.2 Draining and Filling”, page 76 .
Tightening Specifications
Bolted Connections Tightening
Specifications
Bolts and Nuts M6 10 Nm
M8 20 Nm
G. Volkswagen AG
wagM10 45 Nm
en A does
olks not
byV M12 60 Nm gu
ara
ed
ris n tee
deviation from ut
ho or
s a ac
Front exhaust pipe tos turbocharger 25 Nm
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

10 Rep. Gr.10 - Engine Assembly

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

4 Special Tools

Special tools and workshop

equipment required
♦ Engine Sling - 2024 A-
♦ Engine/Transmission Sup‐ n AG. Volkswagen AG do
swage es n
port - T10012- byV
olk ot g
ua
d ran
ir se
♦ Holding Fixture - VW313- tho tee
or
au ac
♦ Holding Fixture - VW540- ss

ce
e
nl

pt
du
♦ Shop Crane - VAG1202 A-

an
itte

y li
erm

ab
♦ Drip Tray - VAG1306-

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4. Special Tools 11
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

♦ Torque Wrench (5-50 Nm) -

VAG1331-
♦ Torque Wrench (40-200
Nm) - VAG1332-
♦ Engine/Transmission Jack
- VAG1383A-
♦ Hose Clip Pliers -
VAG1921-
♦ Step Ladder - VAS5085-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

12 Rep. Gr.10 - Engine Assembly

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

13 – Crankshaft, Cylinder Block

1 General Information
⇒ “1.1 Engine”, page 13
⇒ “1.2 Injection Pump Sprocket Bolt Versions”, page 13

1.1 Engine

Note

♦ If large quantities of metal particles or other deposits such as

those caused by partial seizure of the crankshaft or connecting
rod damage are found in the engine oil, cleanathe oilG.passages
gen A
Volkswagen AG
does
thoroughly and replace the engine oil cooler
Volkswto prevent further not
gu
damage. isedb
y ara
n
r tee
ho
♦ Defective fuel injectors can lead
au to strong knocking of the en‐
t or
ac
gine, resulting in bearing damage.
ss If malfunctions exist, allow

ce
le

the engine to run at idle and loosen the fuel injection line union
un

pt
nuts in a row. If the knocking disappears after loosening an

an
d
itte

y li
injector line union nut, this indicates a malfunctioning injector.
rm

ab
pe

ility
ot

wit
Fuel injector servicing, refer to ⇒ Fuel Injection and Glow Plug;
, is n

h re
Rep. Gr. 23 .
hole

spec
1.2 Injection Pump Sprocket Bolt Versions
es, in part or in w

t to the co
Version -A-: Bolt with a Clearance Cut on the Threaded Shaft and
a Point -arrows-

rrectness of i
Fuel injection pump sprocket part number: 038 130 111 A
l purpos

– Tightening specification: 20 Nm + 90° (1/4) additional turn.

nform
ercia

– Replace the bolts.

m

a
com

tion in

Note
r
te o

thi
s
iva

do

Bolt -A- is designed as a bolt with a reduced shank and must

r
rp

cum

always be replaced.
fo

en
ng

t.
yi Co
op py
Version -B-: Bolt without a Clearance Cut on the Threaded Shaft t. C rig
gh ht
and no Point pyri by
Vo
o
by c lksw
cted
Fuel injection pump sprocket part number: 038 130 111 B
agen
Prote AG.

– Tightening specification: 25 Nm
– Do not replace the bolts.

1. General Information 13
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

2 Description and Operation

wage
n AG. Volkswagen AG do
e ks s no
Vol t gu
⇒ “2.1 Drive and Toothed Belt Overviews”,
ed
by page 14 ara
is nte
or
⇒ “2.2 Sealing Flanges and au Dual Mass Flywheel/Drive Plate
th eo
ra
Overview”, page 17 ss c

ce
le
un

pt
⇒ “2.3 Piston and Connecting Rod Overview”, page 19

an
d
itte

y li
⇒ “2.4 Crankshaft Overview”, page 21
rm

ab
pe

ility
ot

2.1 Drive and Toothed Belt Overviews

wit
, is n

h re
hole

spec
es, in part or in w

Part I -

t to the co
⇒ “2.1.1 Ribbed Belt”,
page 15

rrectness of i
Part II -
⇒ “2.1.2 Toothed Belt”,
l purpos

page 16

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

14 Rep. Gr.13 - Crankshaft, Cylinder Block

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

2.1.1 Ribbed Belt agen

AG. Volkswagen AG d
oes
olksw not
y V gu
d b ara
ise nte
1 - Ribbed Belt thor eo
au ra
❑ Mark the direction of ro‐ ss c
tation before removing.

ce
e
nl

pt
du

an
❑ Removing and instal‐

itte

y li
ling, refer to
erm

ab
⇒ “5.1 Ribbed Belt”,

ility
ot p

page 28 .

wit
, is n

h re
❑ Vehicles with Air Condi‐
hole

spec
tioning (A/C) have an
es, in part or in w

additional idler roller.

t to the co
Removing and instal‐
ling, refer to
⇒ “5.2 Idler Roller”, page

rrectness of i
29 .
l purpos

2 - Bolt
❑ 10 Nm + 90° (1/4) addi‐

nf
ercia

tional turn

orm
m

atio
3 - Vibration Damper
om

n in
c

❑ It is possible to install in
or

thi
one position only, the
te

sd
iva

holes are offset.

o
r
rp

cu
o

m
f

4 - Bolt

en
ng

t.
yi Co
op
❑ 25 Nm C py
t. rig
gh ht
yri
5 - Belt Tensioner
p by
co Vo
by lksw
cted agen
6 - Generator
Prote AG.

7 - Accessory Bracket
❑ For the injection pump,
generator, and power
steering pump.
❑ For vehicles without A/
C.
❑ Removing and instal‐
ling; refer to ⇒ Heating,
Ventilation and Air Con‐
ditioning; Rep. Gr. 87 ; Description and Operation .
8 - Bolt
❑ 45 Nm
9 - Banjo Bolt
❑ 30 Nm
10 - Seal
❑ Replace
11 - Pressure Line
12 - Power Steering Pump
❑ Removing and installing, refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 48 ; Removal and Instal‐
lation .
13 - Power Steering Pump Pulley

2. Description and Operation 15

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

2.1.2 Toothed Belt

1 - Bolt
❑ 120 Nm + 90° (1/4) ad‐
ditional turn.
❑ Replace
❑ Use spur belt spreading
- 3099- when loosening
or tightening.
❑ Do not additionally oil or
grease the threads or
collar.
❑ The additional rotation
can occur in several
stages.
2 - Bolt
❑ 40 Nm + 90° (1/4) addi‐
tional turn.
❑ Replace
3 - Bolt
❑ 15 Nm
4 - Nut
❑ 22 Nm
5 - Toothed Belt Guard, Lower
6 - Bolt
❑ 10 Nm
7- n AG. Volkswagen AG do
Toothed Belt Guard, Center lkswage es n
o ot g
byV ua
8 - Bolt ir se
d ran
tee
ho
❑ 45 Nm aut or
ac
ss
9 - Engine Mount Bracket
ce
e
nl

pt
du

an
itte

10 - y li
erm

Toothed Belt Guard, Upper ab

ility
ot p

wit
11 - Toothed Belt
, is n

h re

❑ Mark the direction of rotation before removing.

hole

spec

❑ Check for wear.

es, in part or in w

t to the co

❑ Do not kink.
❑ Removing, installing and tensioning, refer to ⇒ “4.1 Toothed Belt”, page 48 .
rrectness of i

12 - Idler Roller
l purpos

❑ Replace
13 - Bolt
nform
ercia

❑ For the injection pump sprocket.

m

at

❑ Note the different versions and tightening specifications, refer to

om

io

⇒ “1.2 Injection Pump Sprocket Bolt Versions”, page 13 .

n
c

in t
or

his
e

14 - Nut
at

do
priv

❑ 20 Nm
um
for

en
ng

t.
yi
15 - Bolt
Co
Cop py
.
❑ 20 Nm
t rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

16 Rep. Gr.13 - Crankshaft, Cylinder Block

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

16 - Bolt
❑ 45 Nm
17 - Camshaft Sprocket
❑ Use puller - T40001- for removal.
18 - Tensioner
❑ Checking the semi-automatic toothed belt tensioner, refer to
⇒ “4.1 Semi-Automatic Toothed Belt Tensioner, Checking”, page 26 .
19 - Idler Roller
20 - Injection Pump Sprocket
❑ Two piece.
❑ Note the different versions (part numbers), refer to
⇒ “1.2 Injection Pump Sprocket Bolt Versions”, page 13 .
21 - Bolt
❑ 30 Nm
22 - Toothed Belt Guard, Rear
23 - Coolant Pump
❑ Removing and installing, refer to ⇒ “4.2 Coolant Pump”, page 85 .
24 - Idler Roller
❑ To remove, the coolant pump needs to be removed.
❑ Removing and installing ⇒ “4.2 Coolant Pump”, page 85 .
25 - Crankshaft Toothed Belt Gear
26 - Bushing
27 - Injection Pump
❑ Removing and installing, refer to ⇒ Fuel Injection and Glow Plug; Rep. Gr. 23 ; Removal and Installation .
28 - Accessory Bracket
❑ For the injection pump, wgenerator,
agen
AG. Volkand
swagpower
en AG steering pump.
does
lks not
❑ For vehicles without db
y V Air Conditioning (A/C).
o gu
ara
e nte
❑ Removing and horis
installing; refer to ⇒ Heating, Ventilation and
e o Air Conditioning; Rep. Gr. 87 ; Description
aut
and Operation . ra
s s c
ce
le

29 - Bolt
un

pt
an
d

❑ 45 Nm
itte

y li
erm

ab
ility
ot p

wit
is n

2.2 Sealing Flanges and Dual Mass Fly‐

h re
ole,

spec

wheel/Drive Plate Overview

urposes, in part or in wh

t to the co

Note
rrectne

Servicing the clutch, refer to ⇒ Manual Transmission; Rep. Gr.

30 .
ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2. Description and Operation 17

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

1 - Cylinder Block
2 - Pressure Plate/Drive Plate
❑ Does not apply to the
US/Canadian market.
3 - Washer
❑ Note the installed posi‐
tion.
4 - Bolt
❑ 60 Nm + 90° (1/4) addi‐
tional turn.
❑ Replace
5 - Flywheel/Drive Plate AG. Volkswagen AG d
agen oes
❑ To remove and install olksw not
V gu
the flywheel, secure us‐ d by ara
ise nte
ing the flywheel retainer ut
hor eo
- 3067- . ss a ra
c
❑ Drive plate, removing

ce
e
nl

pt
du

and installing, refer to

an
itte

y li
⇒ “5.5 Drive Plate”,
erm

ab
page 33 .

ility
ot p

wit
, is n

6 - Intermediate Plate

h re
hole

❑ Must be located on the

spec
alignment bushings.
es, in part or in w

t to the co
❑ Do not damage or bend
when doing assembly
work.

rrectness of i
7 - Bolt
l purpos

❑ 15 Nm
8 - Sealing Flange with Seal

nf
ercia

or
❑ Note the different ver‐

m
m

atio
sions.
om

n in
c

❑ Only replaced as a com‐

or

thi
e

plete unit.
t

sd
iva

o
r

❑ Lightly lubricate the sealing lip of the seal.

rp

cu
o

m
f

en
ng

❑ Sealing flange with a Polytetrafluoroethylene (PTFE) seal: identification without an inner hose spring -
t.
yi Co
replace the entire part only do not lubricate or grease the sealing lip on the oil seal. Cop py
t. rig
gh
❑ Before installing, remove any remaining oil from the crankshaft with a clean cloth.
ht
pyri by
Vo
o
by c lksw
❑ Use the support sleeve provided with it when installing. Prote
cted AG.
agen

❑ Supporting sleeve may only be removed after the sealing flange has been slid onto the crankshaft.
9 - Seal
❑ Note the different versions.
❑ PTFE version of the seal, without internal ring spring.
❑ Replacing, refer to ⇒ “5.3 Sealing Flange Oil Seal, Belt Pulley Side”, page 29 .
10 - Sealing Flange
❑ Must be located on the alignment bushings.
❑ Removing and installing, refer to ⇒ “5.4 Sealing Flange, Belt Pulley Side”, page 31 .

18 Rep. Gr.13 - Crankshaft, Cylinder Block

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

2.3 Piston and Connecting Rod Overview

1 - Piston Rings
❑ Offset gaps by 120°
❑ Use piston ring pliers for
removal and installa‐ AG. Volkswagen AG d
tion. agen oes
olksw not
yV gu
❑ “TOP” faces toward pis‐ rised b ara
nte
ton crown. ut
ho eo
ra
a
❑ Checking ring gap, s refer
s c

ce
e

to ⇒ page 20 .
nl

pt
du

an
❑ Checking piston ring
itte

y li
erm

groove clearance, refer

ab
ility
to ⇒ page 20 .
ot p

wit
, is n

2 - Piston

h re
hole

spec
❑ With the combustion
es, in part or in w

chamber.

t to the co
❑ Mark the installed posi‐
tion and cylinder alloca‐
tion.

rrectness of i
❑ Installed position and al‐
l purpos

location, piston/cylin‐
der, refer to
⇒ page 21 .

nform
ercia

❑ Arrow on piston face

m

at
points toward the belt
om

ion
pulley side.
c

in t
or

his
e

❑ Install with piston ring

at

do
riv

compressor.
p

cum
for

❑ Replace if piston skirt is

en
ng

t.
yi
cracked.
Co
Cop py
ht. rig
❑ Checking piston posi‐ rig ht
py by
tion at Top Dead Center co Vo
by lksw
cted
(TDC), refer to
agen
Prote AG.
⇒ “4.2 Piston Position,
Checking at TDC”, page
26 .
3 - Piston Pin
❑ If difficult to move, heat piston to 60 °C (140 °F).
❑ Remove and install using the pilot drift - VW222 A- .
4 - Circlip
5 - Connecting Rod
❑ Only replace as set.
❑ Mark affiliation to the cylinder -A-.
❑ Installed position: the marks -B- face the belt pulley side.
6 - Alignment Pin
❑ The alignment pins must fit securely inside the connecting rod and not in the cap.
7 - Bearing Shell
❑ Note the installed position.
❑ Do not interchange used bearing shells.
❑ Check for a secure fit in the retaining tabs.
❑ Axial play wear limit: 0.37 mm
❑ Measure the radial play using a Plastigage: wear limit: 0.08 mm at the radial play, do not turn the crank‐
shaft.

2. Description and Operation 19

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

8 - Cylinder Block
❑ Checking cylinder bore, refer to ⇒ page 21 .
❑ Piston and cylinder dimensions, refer to ⇒ “3.1 Piston and Cylinder Dimensions”, page 24 .
9 - Connecting Rod Bearing Cap
❑ Note the installed position.
10 - Oil Spray Jet
❑ For piston cooling. agen
AG. Volkswagen AG d
oes
olksw not
V gu
11 - Bolt d by ara
rise nte
❑ 25 Nm utho eo
ra
a c
❑ Install without sealant. ss

ce
le
un

pt
12 - Bolt

an
d
itte

y li
❑ 30 Nm + 90° (1/4) additional turn.
erm

ab
ility
ot p

❑ Replace

wit
is n

❑ Lubricate the threads and contact surface.

h re
ole,

spec
❑ Use the old bolt to measure radial play.
urposes, in part or in wh

t to the co
Piston Ring Gap, Checking

rrectne
– Insert ring into lower cylinder bore at a right angle from above,
approximately 15 mm from cylinder edge.

ss o
Piston Ring New Wear limit
cial p

f in
Dimensions in mm

form
mer

1. Compression ring 0.20 to 0.40 1.,0

atio
om

n
c

2. Compression ring 0.20 to 0.40 1.0

i
or

n thi
e

Oil scraping ring 0.25 to 0.50 1.0

t

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
Piston Ring Groove Clearance, Checking gh ht
pyri by
Vo
co lksw
by
Clean the ring groove before checking. Prote
cted AG.
agen

Piston Ring New Wear limit

Dimensions in mm
1. Compression ring 0.06 to 0.09 0.25
2. Compression ring 0.05 to 0.08 0.25
Oil scraping ring 0.03 to 0.06 0.15

20 Rep. Gr.13 - Crankshaft, Cylinder Block

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

Cylinder Bore, Checking

Special tools and workshop equipment required

♦ Internal Dial Gauge 50-100 mm
– Measure diagonally at 3 positions transversely -A- and longi‐
tudinally -B-. Deviation from nominal dimension: <ax. 0.10 mm

Note

Cylinder bore measurement must not be performed if cylinder

block is secured to assembly stand using the holding fixture -
VW540- , since inaccurate measurements are possible.
gen AG
. Volkswagen AG
d
wa oes
olks not
yV gu
ris
ed
b
Installed Position of Piston and Piston/Cylinder Allocation ara
nte
tho eo
Pistons in cylinder 1 and 2: au ra
c
ss
ce
e

Large valve pocket for intake valve toward flywheel side

nl

pt
du

-arrows-
an
itte

y li
erm

ab

Pistons in cylinder 3 and 4:

ility
ot p

wit

Large valve pocket for intake valve toward belt pulley side
, is n

h re

-arrows-
hole

spec
es, in part or in w

t to the co

Note

♦ On new pistons, the cylinder allocation is stamped on the pis‐

rrectness of i

ton face in paint.

l purpos

♦ Piston for cylinders 1 and 2: identification 1/2

♦ Piston for cylinders 3 and 4: identification 3/4
nf
ercia

orm
m

atio
om

2.4 Crankshaft Overview

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Description and Operation 21

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

1 - Bearing Shells 1, 2, 4 and 5

❑ For bearing cap without
oil groove. agen
AG. Volkswagen AG d
oes
olksw not
❑ For cylinder block with d byV gu
ara
oil groove. orise nte
eo
h
ut
❑ Do not interchange ss a ra
c
used bearing shells.

ce
e
nl

pt
du

an
2 - Bolt
itte

y li
erm

ab
❑ 65 Nm + 90° (1/4) addi‐

ility
ot p

tional turn.

wit
, is n

❑ Replace

h re
hole

❑ Tighten to 65 Nm to

spec
es, in part or in w

measure radial play, do

t to the co
not turn further.
3 - Bearing Cap

rrectness of i
❑ Bearing cap 1: belt pul‐
ley side.
l purpos

❑ Bearing cap 3 with

notches for thrust wash‐

nf
ercia

ers.

orm
m

❑ Retaining tabs of bear‐

atio
m

ing shells and cylinder

o

n in
or c

block/bearing caps

thi
e

must lie above one an‐

t

sd
iva

o
other.
r
rp

cu
o

m
f

en
ng

4 - Bearing Shell 3
t.
yi Co
op py
❑ For bearing cap without
. C rig
ht ht
rig
oil groove. py by
co Vo
by lksw
❑ For cylinder block with cted agen
Prote AG.
oil groove.
5 - Thrust Washer
❑ For bearing cap 3.
❑ Observe locating point.
6 - Sensor Wheel
❑ For the speed sensor.
❑ Replace if damaged.
7 - Bolt
❑ 10 Nm + 90° (1/4) additional turn
❑ Replace
8 - Alignment Pin
❑ Check projection from crankshaft, refer to ⇒ page 23 .
9 - Crankshaft
❑ Axial play new: 0.07 to 0.17 mm, wear limit: 0.37 mm
❑ Check radial clearance with Plastigage, new: 0.03 to 0.08 mm, wear limit: 0.17 mm
❑ Do not turn the crankshaft when measuring radial play.
❑ Crankshaft dimensions, refer to ⇒ “3.2 Crankshaft Dimensions”, page 24 .
10 - Thrust washer
❑ For cylinder block, bearing 3.

22 Rep. Gr.13 - Crankshaft, Cylinder Block

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

Check Projection of Alignment Pin from Crankshaft

Alignment pin projection -3- from crankshaft a = 2.5 to 3.0 mm

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2. Description and Operation 23

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

3 Specifications
⇒ “3.1 Piston and Cylinder Dimensions”, page 24
⇒ “3.2 Crankshaft Dimensions”, page 24
⇒ “3.3 Fastener Tightening Specifications”, page 24

3.1 Piston and Cylinder Dimensions

Honing Dimen‐ Piston Diame‐ Cylinder Bore Diame‐
sion ter ter
Basic dimen‐ mm 79.47 79.51
sion
1st oversize mm 79.72 79.76
2nd oversize mm 79.97 80.01

3.2 Crankshaft Dimensions

(Dimensions in mm)
Honing Dimen‐ Crankshaft Bearing Connecting Rod Pins-
sion Pins-Diameter Diameter
-0.022 -0.022
Basic dimension -54.00 -47.80
-0.042 -0.042
-0.022 -0.022
1st oversize -53.75 -47.55
-0.042 -0.042
-0.022 -0.022
2nd oversize -53.50 -47.30
-0.042 -0.042
-0.022 -0.022
AG. Volkswagen AG d
agen
Stage III -53.25 -47.05 Volksw
oes
not
by gu
-0.042 -0.042rise d ara
nte
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u ra
3.3 Fastener Tightening Specifications s a c
s
ce
e
nl

pt
du

Component Fastener Size Nm

an
itte

y li
erm

ab

Accessory Bracket to Cylinder Block Bolt - 45

ility
ot p

Belt Tensioner to Accessory Bracket Bolt - 25

wit
, is n

h re

Camshaft Sprocket to Camshaft Bolt - 45

hole

spec

Center Toothed Belt Guard to Cylinder Block Bolt - 10

es, in part or in w

t to the co

Connecting Rod Cap to Connecting Rod Bolt 1 - 30 + 90°

Coolant Pump to Cylinder Block Bolt - 15
rrectness of i

Crankshaft Bearing Cap to Cylinder Block Bolt 1 - 65 + 90°

l purpos

Crankshaft Toothed Belt Gear to Crankshaft Bolt 1 - 120 + 90°

Engine Mount Bracket to Cylinder Block Bolt - 45
nf
ercia

1 - 60 + 90°
r

Flywheel/Drive Plate to Crankshaft Bolt

m
m

atio
m

Generator to Accessory Bracket Bolt - 25

o

n in
or c

Idler Roller (Ribbed Belt) to Accessory Bracket Bolt - 25

thi
te

sd
iva

Idler Roller (Toothed Belt) to Cylinder Block Bolt 2 - 20

o
r
rp

cu
o

m
f

Idler Roller (Toothed Belt) to Cylinder Block Bolt 2 - 40 +90°

en
ng

t.
yi Co
op
Idler Roller (Toothed Belt) to Cylinder Block Nut - 22
C py
t. rig
gh ht
pyri by
Vo
o

24
c by lksw
cted agen
Rep. Gr.13 - Crankshaft, Cylinder Block Prote AG.
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

Component Fastener Size Nm

Injection Pump to Accessory Bracket Bolt - 30
Injection Pump Sprocket to Injection Pump Bolt
– With a Clearance Cut on the Threaded Shaft and
swa
ga
enPoint
AG. Volkswagen AG d
oes - 20 + 90°
olk not
yV gu
1 edb ara
ris nte
ho eo
– Without a Clearance Cut on the and no Point aut
Threaded Shaft - ra 25
ss c
Oil Spray Jet to Cylinder Block Bolt - 25

ce
e
nl

pt
du

an
Lower Toothed Belt Guard to Cylinder Block Bolt - 10
itte

y li
erm

ab
Power Steering Pump to Accessory Bracket Bolt - 25

ility
ot p

Power Steering Pump Pulley to Power Steering Pump Bolt - 25

wit
, is n

h re
Pressure Line to Power Steering Pump Banjo Bolt - 30
hole

spec
Rear Toothed Belt Guard to Cylinder Head Bolt 3 - 30
es, in part or in w

t to the co
Rear Toothed Belt Guard to Cylinder Head Bolt 3 - 10
Sealing Flange to Cylinder Block Bolt - 15

rrectness of i
Sensor Wheel to Crankshaft Bolt 1 - 10 + 90°
l purpos

Tensioner (Toothed Belt) to Cylinder Head Nut - 20

Vibration Damper to Crankshaft Bolt - 10 + 90°

nf
ercia

orm
• 1 Always replace
m

atio
om

n in
c

• 2For bolt clarification, refer to -items 2 and 15- in

or

thi
e

⇒ “2.1.2 Toothed Belt”, page 16

t

sd
iva

o
r
rp

cu
• 3For bolt clarification, refer to -items 6 and 21- in
o

m
f

en
ng

⇒ “2.1.2 Toothed Belt”, page 16

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3. Specifications 25
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

4 Diagnosis and Testing

⇒ “4.1 Semi-Automatic Toothed Belt Tensioner, Checking”, page
26
⇒ “4.2 Piston Position, Checking at TDC”, page 26

4.1 Semi-Automatic Toothed Belt Tension‐

er, Checking
– Place a load on the toothed belt with strong thumb pressure.
Notch and protrusion -arrow- must be shifted.
– Release the load on the toothed belt again. The tensioner must
return to its initial position. (Notch and protrusion are aligned
again.)

Note

After releasing tension, the tensioner does not return to its initial
position.

4.2 Piston Position, Checking at TDC

⇒ “4.2.1 Cylinder Head Gasket Identification”, page 27
Special tools and workshop equipment required
♦ Measuring Bar - VW382/7-
♦ Magnetic Plate 50 mm Dia. - VW385/17-
Sequence
When installing new pistons or working with a partial motor, all of
the pistons must be checked for piston position at Top Dead Cen‐
ter (TDC). Depending on the pistonAG. Vprojection,
olkswagen AGinstall the corre‐
agenaccording to the
sponding cylinder head ogasket following
does table.
lksw no t gu
yV
db ara
ir se nte
ho eo
Note aut ra
c
ss
ce
e
nl

To measure the piston position at TDC, rotate the engine in clock‐

pt
du

an

wise direction.
itte

y li
erm

ab
ility
ot p

Piston Projection Identification

wit
, is n

Notches/Holes
h re
hole

spec

0.91 to 1.00 mm 1
es, in part or in w

t to the co

1.01 to 1.10 mm 2
1.11 to 1.20 mm 3
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co

26
by lksw
cted agen
Rep. Gr.13 - Crankshaft, Cylinder Block Prote AG.
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

4.2.1 Cylinder Head Gasket Identification

♦ Part number = -arrow 1-
♦ Control code = -arrow 2-
♦ Holes = -arrow 3-
AG. Volkswagen AG d
agen oes
lksw not
Note by
Vo gu
ara
ed
ris nte
o eo
If varying values occur when measuring the projection, use the
h
aut ra
gasket for the largest value. ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4. Diagnosis and Testing 27

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

5 Removal and Installation

⇒ “5.1 Ribbed Belt”, page 28
⇒ “5.2 Idler Roller”, page 29
⇒ “5.3 Sealing Flange Oil Seal, Belt Pulley Side”, page 29
⇒ “5.4 Sealing Flange, Belt Pulley Side”, page 31
⇒ “5.5 Drive Plate”, page 33

5.1 Ribbed Belt

Removing
– Remove the right noise insulation, refer to ⇒ Body Exterior;
Rep. Gr. 50 ; Description and Operation .
– Remove the connecting tube between the charge air cooler
and turbocharger, refer to
⇒ “2.2 Charge Air Cooler Components Overview”,
page 110 .
– Mark the direction of rotation of the ribbed belt.
– Using a flat 16 mm box end wrench on the tensioner, pivot the
tensioner in the -direction of the arrow-.
AG. Volkswagen AG d
– Remove the ribbed belt. agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
Note s au ra
c
s

ce
e
nl

pt
♦ On vehicles without Air Conditioning (A/C), remove ribbed belt
du

an
itte

from generator first and install the ribbed belt to the generator
y li
erm

last. ab
ility
ot p

♦ On vehicles with A/C, remove the ribbed belt from the idler wit
, is n

h re
roller first and install the ribbed belt to the idler roller last.
hole

spec

♦ When installing the ribbed belt ensure that the belt is seated
es, in part or in w

t to the co

correctly in the belt pulleys.

Installing
rrectness of i

– Installation is the reverse of the removal procedure, note the

l purpos

following:
nform
ercia

Ribbed Belt Routing, without A/C

m

1 - Vibration damper
at
om

ion
c

2 - Tensioner
in t
or

his
ate

3 - Generator pulley
do
priv

cum
or

4 - Ribbed belt
f

en
ng

t.
yi Co
op
5 - Power steering pump pulley C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

28 Rep. Gr.13 - Crankshaft, Cylinder Block

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

Ribbed Belt Routing, with A/C

1 - Vibration damper
2 - Tensioner
3 - Generator pulley
4 - Power steering pump pulley
5 - Idler roller
6 - Ribbed belt
7 - A/C compressor pulley

5.2 Idler Roller

Only for Vehicles with Air Conditioning (A/C)
Removing
– Remove the right noise insulation, refer to ⇒ Body Exterior;
Rep. Gr. 50 ; Description and Operation .
– Remove the ribbed belt, refer to
⇒ “5.1 Ribbed Belt”, page 28 .
AG. Volkswagen AG d
agen oes
– Pry off the cover -1- with a screwdriver. yV
olksw not
gu
d b ara
e
– Remove the bolt -2- and remove the idler roller -3-.horis nte
eo
aut ra
Installing ss c

ce
e
nl

pt
– Set the idler roller -3- in place and install the bolt -2-. Tightening
du

an
itte

specification: 25 Nm.

y li
erm

ab
ility
– Install the ribbed belt, refer to ⇒ “5.1 Ribbed Belt”, page 28 .
ot p

wit
, is n

– Install the noise insulation, refer to ⇒ Body Exterior; Rep. Gr.

h re
hole

50 ; Description and Operation .

spec
es, in part or in w

5.3 Sealing Flange Oil Seal, Belt Pulley Side t to the co

Special tools and workshop equipment required

rrectness of i

♦ Sleeve - 2080 A-
l purpos

♦ Seal Remover - 3203-

nf
ercia

♦ Counter Support - 3415-

orm
m

atio

♦ Seal Installer - 3265-

om

n in
c

♦ Assembly Tool - T10053-

or

thi
te

sd
a

♦ Torque Wrench (5-50 Nm) - VAG1331-

iv

o
r
rp

cu
o

m
f

♦ Torque Wrench (40-200 Nm) - VAG1332-

en
ng

t.
yi Co
op
Removing
C py
ht. rig
rig ht
py by
– Remove the ribbed belt, refer to co Vo
by lksw
⇒ “5.1 Ribbed Belt”, page 28 .
cted agen
Prote AG.

– Remove the toothed belt, refer to

⇒ “4.1 Toothed Belt”, page 48 .

5. Removal and Installation 29

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Remove the crankshaft toothed belt gear. To do this, secure

the gear using the -3415- .
– To guide the seal remover, thread the central bolt into the
crankshaft by hand until seated.
– Remove the inner portion of the -3203- two rotations (approx‐
imately 3 mm) from the outer portion and secure with the
knurled bolt.

– Lubricate the threaded head of the seal remover, place against

the seal, and with strong force screw it into the seal as far as
possible.
– Loosen the knurled bolt and turn the inner portion against the
crankshaft until the seal is pulled out.
Installing
Phased in introduction of Polytetrafluoroethylene (PTFE) seals
(Distinguishing feature: without inner ring spring, sealing lip de‐
signed wider). The sealing lip of this seal may not be oiled or
greased. An oil seal of the old version (with inner ring spring) can
be replaced by a PTFE seal - but not the other way around.
Installing the PTFE version seal, refer to ⇒ page 30 .
– Lightly lubricate the sealing lip of the seal.

– Position the -2080 A- on the crankshaft.

– Push the seal over the -2080 A- .

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

– Using the -3265- , press the seal, using the center bolt -1- ap‐
wit
, is n

proximately 2 to 3 mm deep into the sealing flange.

h re
hole

spec

– Install the toothed belt, refer to

es, in part or in w

⇒ “4.1 Toothed Belt”, page 48 .

t to the co

– Install the ribbed belt, refer to ⇒ “5.1 Ribbed Belt”, page 28 .

rrectness of i

PTFE Seal, Installing

l purpos

Note
nform
ercia

The sealing lip of the seal may not be additionally be oiled or

m

at

greased.
om

ion
c

in t
or

his
e

– Before installing, remove any remaining oil from the end of the
at

do
riv

crankshaft with a clean cloth.

p

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
30
AG.
Rep. Gr.13 - Crankshaft, Cylinder Block
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Position the guide sleeve from the -T10053- on the crankshaft.

– Slide the oil seal over the -T10053- onto the crankshaft.

– Press in the oil seal using the -T10053- and -T10053/2- (M16
x 1.5 x 60) until seated.
– Install the toothed belt, refer to
⇒ “4.1 Toothed Belt”, page 48 .
– Install the ribbed belt, refer to ⇒ “5.1 RibbedaBelt”,
gen AG page 28 .n AG do
. Volkswage
w es n
olks ot g
byV ua
ed ran
ris tee
tho or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

5.4 Sealing Flange, Belt Pulley Side

wit
, is n

h re
hole

Special tools and workshop equipment required

spec
es, in part or in w

♦ Sleeve - 2080 A-

t to the co
♦ Counter Support - 3415-

rrectness of i
♦ Torque Wrench (5-50 Nm) - VAG1331-
l purpos

♦ Torque Wrench (40-200 Nm) - VAG1332-

♦ Assembly Tool - T10053-
nform
ercia

♦ Hand Drill with Plastic Brush Attachment

m

at
om

♦ Flat Scraper
on
c

in t
or

♦ Silicone Sealant - D 176 404 A2-

his
ate

do
riv

Removing
p

cum
for

en
ng

– Remove the ribbed belt, refer to

t.
yi Co
op
⇒ “5.1 Ribbed Belt”, page 28 .
C py
ht. rig
rig ht
py by
– Remove the toothed belt, refer to co Vo
by lksw
⇒ “4.1 Toothed Belt”, page 48 . cted agen
Prote AG.

– Remove the crankshaft toothed belt gear. To do this, secure

the gear using the -3415- .
– Drain the engine oil.
– Remove the oil pan, refer to ⇒ “5.2 Oil Pan”, page 73 .
– Remove the front sealing flange bolts.
– Remove the sealing flange, and if necessary loosen by apply‐
ing light strikes with a rubber mallet.
– Remove the sealant residue from the cylinder block with a flat
scraper.
– Cover the seal with a clean cloth.

5. Removal and Installation 31

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Remove the sealant residue from the sealing flange using a

rotating plastic brush (wear safety glasses).
– Clean the sealing surfaces. They must be free of oil and
grease.
Installing

Note

♦ Note the expiration date of the sealant.

♦ The sealing flange must be installed within 5 minutes after ap‐
plication of silicone sealant.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by

32
co Vo
by lksw
Rep. Gr.13 - Crankshaft, Cylinder Block cted agen
Prote AG.
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Cut the tube nozzle at the front mark (nozzle diameter ap‐
proximately 3 mm).
– Apply the sealant, as shown, to the clean sealing surface wongen AG. Volkswagen AG does
s a
the sealing flange. The sealant bead must be: yV
olk not
gu b ara
ed nte
♦ Sealant bead thickness -arrows-: 2 to 3 mm thoris e or
au ac
ss

ce
le
un
Note

pt
an
d
itte

y li
rm

ab
♦ The sealant bead must not be thicker, otherwise excess seal‐

pe

ility
ant could enter the oil pan and may block the oil suction pipe

ot

wit
, is n
strainer. Likewise, it could drip onto the sealing surface of the

h re
crankshaft seal. hole

spec
es, in part or in w

♦ Before applying the bead of sealant, cover the sealing surface

t to the co
of the seal with a clean cloth.

– Set the sealing flange in place immediately and lightly tighten

rrectness of i
the bolts.
l purpos

Note

nform
mercia

To install the sealing flange with the seal already installed, use

a
com

tio
the -2080 A- .

n in
r
te o

thi
s
iva

Polytetrafluoroethylene (PTFE) Version of Oil Seal

do
r
rp

cum
fo

en
ng

t.
yi Co
Note Cop py
t. rig
gh ht
pyri by
To install the sealing flange with the seal already installed, use
o Vo
by c lksw
cted
the -T10053- .
agen
Prote AG.

Continuation for All Versions

– Tighten the sealing flange bolts in a diagonal sequence. Tight‐
ening specification: 15 Nm.
– Remove the excess sealant.
– Install the oil pan.

Note

After installing, allow the sealant to dry for approximately 30 mi‐

nutes. Only after then may the engine oil be added.

Install the toothed belt and adjust the valve timing, refer to
⇒ “4.1 Toothed Belt”, page 48 .
– Install the ribbed belt, refer to ⇒ “5.1 Ribbed Belt”, page 28 .

5.5 Drive Plate

Special tools and workshop equipment required
♦ Flywheel Lock Adapter - VW558-
♦ Depth Gauge
♦ M8 x 45 Bolt and two M10 Nuts

5. Removal and Installation 33

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

Loosening and Tightening

– Secure the -VW558- to the drive plate with an M8 x 45 bolt.
Insert two M10 nuts between the -VW558- and drive plate. In‐
stalled position of -VW558- -A - to loosen- -B - to tighten-

Installing
– Set the drive plate in place, using the washer with notches
-1-.
– Insert the new bolts -3- and tighten to 30 Nm.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
– Check the dimension -a- at three points and calculate the
ot p

wit
mean value. Specified value: 19.5 to 21.1 mm
is n

h re
ole,

If the specification is not obtained:

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

– Remove the drive plate again and install the shim -2-. Tighten
i
or

n thi
e

the bolts -3- again to 30 Nm.

t

sd
iva

o
pr

– Tighten the bolts -3- to 60 Nm + 90° (1/4) additional turn (the

um
r
fo

additional rotation may occur in several stages).

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

34 Rep. Gr.13 - Crankshaft, Cylinder Block

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

6 Special Tools

Special tools and workshop

equipment required
♦ Sleeve - 2080 A-
♦ Seal Remover - 3203-
♦ Counter Support - 3415-
♦ Seal Installer - 3265-
♦ Assembly Tool - T10053-
♦ Torque Wrench (5-50 Nm) -
VAG1331-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

♦ Torque Wrench (40-200 Nm) - VAG1332-

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

6. Special Tools 35
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

♦ Flywheel Lock Adapter - VW558-

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
♦ Measuring Bar - VW382/7-
♦ Magnetic Plate 50 mm Dia. - VW385/17-

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

36 Rep. Gr.13 - Crankshaft, Cylinder Block

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

15 – Cylinder Head, Valvetrain

1 Description and Operation
⇒ “1.1 Cylinder Head Overview”, page 37
⇒ “1.2 Valvetrain Overview”, page 40
⇒ “1.3 Valve Seat, Refacing”, page 42

1.1 Cylinder Head Overview

Checking compression pressures, refer to
⇒ “3.1 Compression, Checking”, page 46 .

Note

♦ When using an exchanged cylinder head with the camshaft

installed, the contact surfaces between the lifters and cam
lobes must be lubricated before installing the cylinder head
cover.
AG. Volkswagen AG d
agen
♦ The plastic protectors installed to protect the open valvesVomust
lksw
oes
not
only be removed immediately before installing the scylinder
ed
by gu
ara
head. thori nte
eo
au ra
♦ When the cylinder head is replaced, all the coolant
ss must also c

ce
e

be replaced.
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Description and Operation 37

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

1 - Toothed Belt Guard, Upper

2 - Toothed Belt
❑ Mark the direction of ro‐
tation before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing, installing
and tensioning, refer to
⇒ “4.1 Toothed Belt”,
page 48 .
3 - Bolt/Nut
❑ 20 Nm
4 - Bolt
❑ 20 Nm
5 - Bolt
❑ 45 Nm
6 - Camshaft Sprocket
AG. Volkswagen AG d
❑ Use the puller - T40001- agen oes
olksw not
for removal. ed byV gu
ara
ris nte
7 - Tensioner aut
ho eo
ra
s c
❑ Checking the semi-au‐ s

ce
le

tomatic toothed belt ten‐

un

pt
an
d

sioner, refer to
itte

y li
⇒ “4.1 Semi-Automatic
erm

ab
Toothed Belt Tensioner,

ility
ot p

Checking”, page 26 .

wit
is n

h re
ole,

8 - Idler Roller

spec
urposes, in part or in wh

9 - Toothed Belt Guard, Rear

t to the co
10 - Bolt/Nut
❑ 10 Nm

rrectne
11 - Lifting Eye
ss
12 - Bolt
o
cial p

f in

❑ Replace
form
mer

❑ Observe the sequence for loosening and tightening, refer to ⇒ “4.2 Cylinder Head”, page 53 .
atio
om

13 - Oil Deflector
c

i
or

n thi
te

14 - Cylinder Head Cover

sd
iva

o
pr

❑ With vulcanized gasket.

um
r
fo

en
ng

t.
yi
15 - Sealing Sleeve
Co
Cop py
. rig
❑ Replace if damaged
ht ht
rig by
copy Vo
lksw
16 - Cap
by
cted agen
Prote AG.
❑ Replace the seal if damaged.
17 - Ventilation Pipe
18 - Retaining Clip
19 - Pressure Regulator Valve
❑ For the crankcase ventilation.
20 - Gasket
❑ Replace if damaged.

38 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

21 - Bolt
❑ 5 Nm
22 - Injection Lines
❑ Tighten to 25 Nm.
❑ Remove using injector line wrench - 3035- .
❑ Always remove complete set of lines.
❑ Do not change the shape.
23 - Vacuum Pump
❑ For the brake booster.
24 - Gasket
❑ Replace
25 - Fuel Injector AG. Volkswagen AG d
agen oes
olksw refer to ⇒ Fuel Injection
❑ Removing and installing, noand
t gu Glow Plug; Rep. Gr. 23 ; Removal and Installation .
yV b ara
ed
26 - Glow Plug horis nte
eo
ut ra
❑ 15 Nm ss a c

ce
le

❑ Checking, refer to ⇒ Fuel Injection and Glow Plug; Rep. Gr. 28 ; Diagnosis and Testing .
un

pt
an
d
itte

27 - Cylinder Head Gasket

y li
erm

ab
❑ Replace

ility
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wit
❑ Observe the identification, refer to ⇒ page 39 .
is n

h re
ole,

❑ After replacing, replace the entire amount of coolant.

spec
urposes, in part or in wh

Checking Cylinder Head for Distortion t to the co

rrectne
Max. permissible distortion: 0.1 mm
ss

Note
o
cial p

f inform
mer

Remanufacturing diesel cylinder heads is not permitted.

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

cum
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fo

en
ng

t.
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op py
Cylinder Head Gasket Identification t. C rig
gh ht
pyri by
♦ Part number = arrow 1
o Vo
by c lksw
cted agen
Prote AG.
♦ Control code = arrow 2 (ignore this!)
♦ Holes = arrow 3

Note

Depending on piston projection, varying cylinder head gasket

thicknesses can be installed. When replacing a head gasket, in‐
stall a head gasket with the same identification.

1. Description and Operation 39

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

1.2 Valvetrain Overview

AG. Volkswagen AG d
agen
Note Volksw
oes
not
by gu
d ara
ise nte
Cylinder heads with thcracks
or
between the valve seats can continue eo
to be used without
ss a reducing service life, as long as the cracks
u ra
c
have a Max. width of 0.5 mm.

ce
e
nl

pt
du

an
itte

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erm

ab
1 - Bearing Cap

ility
ot p

wit
❑ Installed location, refer
, is n

h re
to ⇒ page 41 .
hole

spec
❑ Installation sequence,
es, in part or in w

refer to

t to the co
⇒ “4.4 Camshaft”,
page 55 .

rrectness of i
2 - Nut
l purpos

❑ 20 Nm
3 - Camshaft

nform
ercia

❑ Checking axial play, re‐

m

fer to ⇒ page 41 .

at
om

io
❑ Removing and instal‐
n
c

in t
or

ling, refer to his

ate

⇒ “4.4 Camshaft”,
do
priv

page 55 .
um
for

en
g

❑ Check radial clearance

n

t.
yi Co
op
with Plastigage, wear C py
t. rig
limit: 0.11 mm
gh ht
pyri by
Vo
co
❑ Runout: maximum 0.01
by lksw
cted agen
mm
Prote AG.

❑ Identification, valve tim‐

ing, refer to
⇒ page 42 .
4 - Valve Lifter
❑ Do not interchange.
❑ With hydraulic valve
clearance compensa‐
tion.
❑ Checking, refer to
⇒ “3.3 Hydraulic Valve
Lifter, Checking”,
page 47 .
❑ Place on running sur‐
face when setting down.
❑ Before installing, check axial play of camshafts, refer to ⇒ page 41 .
❑ Lubricate contact surface.
5 - Valve Retainers
6 - Valve Spring Plate
7 - Valve Spring
❑ Removing and installing: Cylinder head removed: remove using the valve spring compressor - 2037-
cylinder head installed, refer to ⇒ “4.5 Valve Stem Seals”, page 57 .
8 - Valve Stem Seal
❑ Replacing, refer to ⇒ “4.5 Valve Stem Seals”, page 57 .

40 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

9 - Valve Guide AG. Volkswagen AG d

agen oes
ksw
❑ Checking, refer to ⇒ “3.2 Valve Guide, Checking”,
by
Vol page 46 . not
gu
ara
ed
❑ Replacing, refer to ⇒ “4.3 Valve Guide,
horis Replacing”, page 55 . nte
eo
ut
❑ Repair guide with shoulder. ss a ra
c

ce
e
10 - Seal

nl

pt
du

an
itte
❑ Note the different versions

y li
erm

ab
❑ To remove and install, remove the bearing cap.

ility
ot p

wit
❑ Toothed belt, removing and installing, refer to ⇒ “4.1 Toothed Belt”, page 48 . , is n

h re
❑ Polytetrafluoroethylene (PTFE) version of oil seal.
hole

spec
❑ Identification: no inner coil spring.
es, in part or in w

t to the co
❑ Do not additionally oil or grease the sealing lip of the oil seal.
❑ Before installing, remove any remaining oil from the camshaft journal with a clean cloth.

rrectness of i
❑ To install, tape over the groove on the camshaft taper.
l purpos

11 - Cylinder Head
❑ See note in ⇒ “1.2 Valvetrain Overview”, page 40 .

nf
ercia

❑ Reface the valve seats, refer to ⇒ “1.3 Valve Seat, Refacing”, page 42 .

orm
m

atio
12 - Valves
om

n in
c

❑ Dimensions, refer to ⇒ page 42 .

or

thi
te

sd
iva

o
r
rp

cu
o

m
f

Camshaft, Checking Axial Play

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Special tools and workshop equipment required

♦ Dial Gauge Holder - VW387-
♦ Dial Gauge
Measure with valve lifters removed and with first and last bearing
cap installed.
Wear limit: maximum 0.15 mm
Installed Position of Camshaft Bearing Caps
Observe central alignment. Before installing the camshaft, set the
bearing caps in place and determine the installed position.

1. Description and Operation 41

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

Valve Dimensions

Note

Valves must not be reground. Only lapping is permitted.

Dimension Intake Valve Exhaust Valve

Diameter a mm 35.95 31.45
Diameter b mm 6.963 6.943
c mm 96.85 96.85
α ∠° 45 45

Camshaft Identification, Valve Timing

Identification
♦ Base circle of cam lobes: a = 38 mm diameter
♦ Identification of stamped numbers and letters between intake
and exhaust lobes:
Engine Code ALH
Cylinder 1 -arrow A- 38 A
Cylinder 2 -arrow B- DE
AG. Volkswagen AG d
agen
Valve Timing at 1 mm Valve Lift olksw
oes
not
byV gu
ara
ed
Engine Code h
ALH
o ris nte
eo
aut ra
Intake valve opens after Top Dead Center ss 16° c
(TDC)

ce
e
nl

pt
du

an
Intake valve closes after Bottom Dead Cen‐ 25°
itte

y li
ter (BDC)
erm

ab
ility
ot p

Exhaust valve opens before BDC 28°

wit
, is n

h re
Exhaust valve closes before TDC 19°
hole

spec
es, in part or in w

1.3 Valve Seat, Refacing

t to the co
Special tools and workshop equipment required
rrectness of i

♦ Depth Gauge
l purpos

♦ Valve Seat Refacing Tool

nform
ercia

Note
m

at
om

ion
c

♦ When repairing engines with leaking valves, it is not sufficient

in t
or

to reface or replace the valve seats and valves. It is particularly

his
ate

do

important to check the valve guides for wear on engines with

priv

longer running times.

um
for

en
ng

t.
yi
♦ Only reface valve seats enough until a perfect contact pattern
Co
Cop py
is obtained. The maximum permissible refacing dimension ht. rig
rig ht
must be calculated before work is carried out. If the refacing py by
co Vo
lksw
dimension is exceeded, the function of the hydraulic lifters can
by
cted agen
Prote
no longer be guaranteed and therefore the cylinder head
AG.

should be replaced.

The maximum permissible refacing dimension is calculated as

follows:
– Insert the valve and press it firmly against the seat.

42 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

Note

If the valve is to be replaced as part of a repair, use a new valve

for the calculation.

– Measure the distance -a- between the end of the valve stem
and upper edge of the cylinder head.
– Calculate the Max. permissible refacing dimension from the
measured distance -a- and minimum dimension.
Intake valve 35.8 mm Exhaust valve 36.1 mm
Measured distance minus minimum dimension = Max. permissi‐
ble refacing dimension.
Example:

Measured distance 36.5 mm

- Minimum dimension 35.8 mm
= Max. perm. rework dimension 0.7 mm

Refacing Intake Valve Seat n AG. Volkswagen AG do

lkswage es n
o ot g
byV ua
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ir se tee
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a ac
ss

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nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
a = 35.7 mm diameter
b = 1.6 mm

rrectness of i
45° = Valve seat angle
l purpos

nf

Note
ercia

orm
m

atio

The 30° relief milling of the valve seat is always necessary due to
om

n in

flow ratios in the intake passage.

or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Description and Operation 43

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d
Refacing Exhaust Valve Seat o
ir se
ran
tee
th or
au ac
a = 31.4 mm diameter ss

ce
le
b = 2.7 mm

un

pt
an
d
itte
45° = Valve seat angle

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

44 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

2 Specifications
⇒ “2.1 Fastener Tightening Specifications”, page 45

2.1 Fastener Tightening Specifications

Component Fastener Size Nm
Bracket to Engine Mount/Body Bolt 1 - 25
Camshaft Bearing Cap to Cylinder Head Nut 2 - 20
Camshaft Sprocket to Camshaft Bolt - 45
Cylinder Head Cover to Cylinder Head Nut - 10
Engine Mount to Body Bolt 1 - 40 + 90°
Engine Mount Bracket to Cylinder Block Bolt - 45
Engine Mount to Engine Mount Bracket Bolt 1 - 100
Glow Plug to Cylinder Head - 15
Idler Roller (Toothed Belt) to Cylinder Head Bolt - 20
Injection Pump Sprocket to Injection Pump Bolt
– With a Clearance Cut on the Threaded Shaft and a Point - 20 + 90°
1

– Without a Clearance Cut on the Threaded Shaft and no Point - 25

Lifting Eye to Cylinder Head Bolt - 20
Oil Deflector to Cylinder Head Cover Bolt - 5
Rear Toothed Belt Guard to Cylinder Head Bolt - 10
Tensioner (Toothed Belt) to Cylinder Head Nut
AG. Volkswagen AG d
- 20
agen oes
Vacuum Pump to Cylinder
yV
olk Head Bolt
sw not
g - 20
db ua
ran
ise
• 1 Always replace
ho
r tee
ut a
or
ac
• 2 ss
Install and tighten the bearing caps in the following order: 2
ce
e
nl

and 4 alternately and diagonally, then caps 5, 1 and 3

pt
du

an
itte

y li
erm

ab
ility
ot p

Cylinder Head Bolt Tightening Sequence and Specification

wit
, is n

h re

– Tighten the cylinder head bolts in the sequence indicated, in

hole

spec

four passes as follows:

es, in part or in w

t to the co

– 1. Tighten the bolts to 40 Nm .

– 2. Tighten the bolts to 60 Nm.
rrectness of i

– 3. Tighten the bolts an additional 90° (1/4) turn.

l purpos

– 4. Tighten the bolts an additional 90° (1/4) turn.

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2. Specifications 45
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

3 Diagnosis and Testing

⇒ “3.1 Compression, Checking”, page 46
⇒ “3.2 Valve Guide, Checking”, page 46
⇒ “3.3 Hydraulic Valve Lifter, Checking”, page 47

3.1 Compression, Checking

Special tools and workshop equipment required
♦ Hinged Socket - 3220-
♦ Torque Wrench (5-50 Nm) - VAG1331-
♦ Adapter - VAG1381/12-
♦ Compression Tester - VAG1763-
Conditions
• Engine oil temperature a min. 30 °C (86 °F)
. Volkswage
n AG n AG d
wage oes
Sequence y Volks not
gu
d b ar
– Disconnect fuel shut ise valve connector at the injection pump.ante
roff
tho eo
u ra
– sa
Disconnect the squantity adjuster connection from injection c
pump. ce
e
nl

pt
du

an
itte

– Remove all glow plugs using the -3220- . y li

erm

ab
ility
– Install the -VAG1381/12- in place of the glow plugs.
ot p

wit
, is n

– Check the compression pressure using the -VAG1763- .

h re
hole

spec
es, in part or in w

t to the co

Note

Using the -VAG1763- , refer to the operating instructions.

rrectness of i
l purpos

– Operate the starter until the -VAG1763- shows no further pres‐

sure increase.
nform
ercia

Compression Pressure:
m

New: 25 to 31 bar pressure, wear limit: 19 bar pressure

at
om

ion
c

Permissible difference between all cylinders: 5 bar

in t
or

his
ate

– Install the glow plugs using the -3220- tightening specifica‐

do
priv

tions:
um
for

en
ng

t.
yi
– Check the diagnostic Trouble Code (DTC) memory, refer to ⇒
Co
op py
Fuel Injection and Glow Plug; Rep. Gr. 01 ; Diagnosis and t. C rig
gh ht
Testing . yri
p by
co Vo
by lksw
cted agen
Prote AG.

Note

By separating the connectors to the injection pump, DTCs are

stored to memory. Query the fault memory and erase, if neces‐
sary.

3.2 Valve Guide, Checking

Special tools and workshop equipment required
♦ Dial Gauge Holder - VW387-
♦ Dial Gauge

46 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

Sequence
– Insert a new valve into the guide. The end of the valve stem
must be flush with the guide. Due to the slight difference in
stem dimensions, ensure that only an intake valve is used in
the intake guide and an exhaust valve in the exhaust guide.
– Tilt clearance: maximum 1.3 mm

3.3 Hydraulic Valve Lifter, Checking

Special tools and workshop equipment required
♦ Feeler Gauge
♦ Wooden or Plastic Wedge

Note

♦ Replace the complete valve lifter (it cannot be adjusted or

serviced).
olkswagen AG
en AG. V
♦ Irregular valve noises are normal while starting theoengine.
lksw
ag does
not
yV gu
db ara
ir se nte
Sequence ut
ho eo
ra
a c
– Start the engine and let it run until the ss
engine oil temperature

ce
le

has reached min. 80 °C (176 °F).

un

pt
an
d
itte

y li
– Increase engine speed to approximately 2500 RPM for 2 mi‐
erm

ab
nutes.

ility
ot p

wit
is n

If the hydraulic valve lifters are still noisy, determine which lifter is

h re
defective as follows:
ole,

spec
urposes, in part or in wh

– Remove the cylinder head cover.

– Rotate the crankshaft clockwise until the camshaft lobe for the t to the co
valve lifter to be tested is pointing upward.
rrectne

– Check the clearance between the cam lobe and valve lifter.
– If the play is greater than 0.1 mm, replace the valve lifter. If
ss o

minimal play of 0.1 mm or no play is measured, continue the

cial p

f in

procedure as follows:
form
mer

– Press the valve lifter downward using a wood or plastic wedge.

atio
m

If there is a gap of more than 0.1 mm until the valve begins to

o

n
c

open, replace the lifter.

or

n thi
te

sd
iva

o
pr

cum
r
fo

Note
en
ng

t.
yi Co
Cop py
After installing the new valve lifters, the engine may not be started
t. rig
gh ht
yri
for approximately 30 minutes. The hydraulic adjusting elements
p by
co Vo
lksw
must seat themselves (otherwise the valves will seat themselves
by
cted agen
Prote
on the pistons).
AG.

3. Diagnosis and Testing 47

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

4 Removal and Installation

⇒ “4.1 Toothed Belt”, page 48
⇒ “4.2 Cylinder Head”, page 53
⇒ “4.3 Valve Guide, Replacing”, page 55
⇒ “4.4 Camshaft”, page 55
⇒ “4.5 Valve Stem Seals”, page 57

4.1 Toothed Belt

Special tools and workshop equipment required
♦ Adjustment Gauge TDC - 2068 A-
♦ Diesel Injection Pump Locking Pin - 3359-
♦ Camshaft Bar - T10098 A-
♦ Engine Support Bridge - 10-222A-
♦ Bracket for Engine - 10-222A/1-
n AG. Volkswagen AG do
swage es n
♦ Pin Wrench - V159- yV
olk ot g
ua
d b ran
♦ Counter-holder tool - 3036- ir se tee
tho
u or
a ac
♦ Puller - T40001- ss

ce
e
nl

pt
Removing
du

an
itte

y li
erm

– Remove the right headlamp, refer to ⇒ electrical Equipment;

ab
ility
Rep. Gr. 94 ; Removal and Installation .
ot p

wit
, is n

– Remove the connecting pipe between the charge air cooler

h re
hole

and intake manifold, refer to

spec
⇒ “2.2 Charge Air Cooler Components Overview”,
es, in part or in w

t to the co
page 110 .
– Remove the coolant expansion tank and move it to the side.

rrectness of i
– Loosen the power steering fluid reservoir and set aside.
l purpos

– Remove the upper toothed belt guard.

– Remove the vacuum pump for the brake booster.

nform
ercia

– Remove the noise insulation, refer to ⇒ Body Exterior; Rep.

m

at
Gr. 50 ; Description and Operation .
om

ion
c

in t
r

– Remove the ribbed belt, refer to

o

his
te

⇒ “5.1 Ribbed Belt”, page 28 .

a

do
priv

cum
or

– Rotate the crankshaft to Top Dead Center (TDC) for cylinder

f

en
g

1 (vehicles with manual transmission). Engine code ALH -B-

n

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
Note
co lksw
by
cted agen
Prote AG.

To rotate the engine by hand, use the -3098- and place it on the
power steering pump.

48 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Rotate the crankshaft to TDC for cylinder 1 -arrow- (with au‐

tomatic transmission).

Note

♦ To rotate the engine by hand, use the -3098- and place it on

the power steering pump.
♦ With the engine removed:

With a Manual Transmission

– Install the -2068 A- as shown.

– Set the -2068 A- to 96 mm -arrow A-. The left notch of the
vernier scale is the reference point.
– Turn the crankshaft until the TDC mark on the flywheel is
aligned with the tip of the -2068 A- -arrow B-.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
With a Automatic Transmission o
ir se tee
th or
au ac
– Install the -2068 A- as shown. ss

ce
e
nl

– Set the -2068 A- to 30 mm -arrow A-. The left notch of the

pt
du

an
itte

vernier scale is the reference point.

y li
erm

ab
– Turn the crankshaft until the TDC mark on the drive plate is

ility
ot p

aligned with the tip of the -2068 A- -arrow B-.

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
Continuation for All
l purpos

– Install the bolts -1- all the way into the cylinder head by hand.
– Secure the camshaft using the -T10098 A- .
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4. Removal and Installation 49

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Lock the injection pump sprocket using the -3359- .

– Loosen the injection pump sprocket bolts -1-.

Note

♦ Loosen and replace the bolts with a bolt with the clearance cut
on the threaded shaft and a pointed end, one after the other.
( fuel injection pump sprocket - 038 130 111 A- part number).
♦ Do not replace the bolts, with bolts without the clearance cut
on the threaded shaft and no pointed end. ( fuel injection pump
sprocket - 038 130 111 B - part number).
♦ The nut -2- for the hub must not be loosened under any cir‐
cumstances. Basic setting of the injection pump may be al‐
tered and cannot be reset with normal workshop equipment.

– Loosen the tensioner.

– Install the -10-222A- with the -10-222A/1- and support the en‐
gine in the installed position.

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– Remove the engine mount bolts -arrows- and completely
ut
ho re‐ eo
ra
move the engine mount. ss a c

ce
le
un

pt
an
d
itte

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Note
erm

ab
ility
ot p

♦ The subframe may only be removed if the engine is supported wit

is n

using the -10-222A- ! h re

ole,

spec

♦ The engine mount bracket may first be loosened only when

urposes, in part or in wh

the subframe is removed.

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

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te

sd
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pr

cum
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fo

en
ng

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Cop py
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gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

50 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Loosen and remove the engine mount bracket bolts -arrows-.n AG. Volkswagen A
age G do
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b
ed ran
Note horis tee
t or
au ac
ss
♦ To loosen both upper engine mount bracket bolts, the engine

ce
le
must be raised slightly using the -10-222A- .

un

pt
an
d
itte

y li
♦ To loosen the lower engine mount bracket bolt, the engine

rm

ab
must be lowered slightly using the -10-222A- .

pe

ility
ot

wit
, is n

h re
– Remove the vibration damper.

hole

spec
– Remove the lower and middle toothed belt guards. es, in part or in w

t to the co
– Mark the direction of rotation of the toothed belt.
– Remove the toothed belt.

rrectness of i
Installing
l purpos

– Verify that TDC mark on the flywheel and reference mark are
aligned.

nform
ercia

– Loosen the camshaft sprocket bolt one revolution. To loosen

m

a
com

the bolt, counter hold the camshaft sprocket using the -3036- .

tion in
r
te o

thi
s
iva

do
Note
r
rp

cum
fo

en
ng

When loosening and tightening the camshaft sprocket bolt, never

t.
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op
use the -T10098 A- to counter-hold! Use the -3036- .
C py
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pyri by
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by
cted agen
– Install the -T40001- with the -T40001/2- -A- and the - Prote AG.

T40001/3- -B- on the center of the camshaft sprocket and

remove the sprocket. To counter hold, use an open end
wrench -C-.
– Place the toothed belt onto the crankshaft sprocket, idler roller,
injection pump sprocket, coolant pump sprocket and tensioner
(observe direction of rotation).
– Align the injection pump sprocket to the central location in the
slots.

– Install the camshaft sprocket together with toothed belt and fix
them in place with the bolt (camshaft sprocket can still be
turned).
– Tension the toothed belt. Do this by turning the -V159- on the
eccentric in clockwise direction, until the notch and the pro‐
jection -arrows- are aligned.

Note

In case the eccentric was turned past the marks, the tensioner
must be completely relieved of tension, and then be tensioned
again. If turned too far, the eccentric must not just be turned back
again to the passed mark.

– Tighten the tensioner nut. Tightening specification: 20 Nm

4. Removal and Installation 51

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Note ut
ho eo
ra
s a c
s
Make sure the tensioner -arrow- is properly positioned in the rear

ce
e
nl

pt
du
toothed belt guard.

an
itte

y li
erm

ab
ility
– Verify the TDC mark on the flywheel once again.

ot p

wit
, is n
– Tighten the bolt for the camshaft sprocket to 45 Nm.

h re
hole

spec
es, in part or in w

t to the co
Version -A-: Bolt with a Clearance Cut on the Threaded Shaft and

rrectness of i
a Point -arrows-
l purpos

– Install the new bolts for the injection pump sprocket. Tighten‐
ing specification: 20 Nm

nf
ercia

orm
m

atio
m

Note
o

n in
or c

thi
e

♦ After the dynamic test of the start of injection, the bolts must
t

sd
iva

be turned an additional 90° (1/4 turn).

o
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rp

cu
o

m
f

en
ng

♦ The bolts may only be used once, since they are bolts with
t.
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reduced shanks. Cop py
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Version -B-: Bolt without a Clearance Cut on the Threaded Shaft by c lksw
cted agen
and no Point
Prote AG.

– Tighten the old bolts for the injection pump sprocket. Tighten‐
ing specification: 25 Nm

Note

Do not replace the bolts.

Continuation for All Versions

– Remove the -T10098 A- from the camshaft.
– Remove the -3359- .
– Rotate the crankshaft twice in engine running direction and
then set cylinder 1 to TDC again.
– Verify that the TDC mark on the flywheel, the -T10098 A- in
the camshaft, the -3359- in the injection pump, the adjustment
of the tensioner (notch/protrusion) or (notch/arrow) are posi‐
tioned properly.
– If the notch and protrusion or notch and arrow are not aligned,
tension the tensioner again and tighten the nut to 20 Nm.
– Continue rotating the crankshaft two rotations in engine rota‐
tion direction until the crankshaft is again at TDC for cylinder
1.
– Check again.

52 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Set the engine mount bracket in place and install the bolts
-arrows-. Tightening specification: 45 Nm AG. Volkswagen
n AG do
wage es n
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ed ran
Note oris tee
th or
au ac
ss
Before the engine mount can be installed, all bolts for the engine

ce
le
mount bracket must be tightened to specifications.
un

pt
an
d
itte

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erm

ab
– Install the engine mount to the body (use new bolts). Tighten‐

ility
ot p

ing specification: 40 Nm + 90° (1/4) additional turn.

wit
is n

h re
– Align the engine mount, refer to
ole,

spec
⇒ “1.1 Engine and Transmission Mount, Aligning”, page 3 .
urposes, in part or in wh

t to the co
– Tighten the engine mount to engine mount bracket, bringing
the contact surfaces together using the -10-222A- . Tightening
specifications: 100 Nm

rrectne
– Align the engine mount, refer to
⇒ “1.1 Engine and Transmission Mount, Aligning”, page 3 .

ss o
– Install the engine mount/body bracket. Tightening specifica‐
cial p

f in
tions: 25 Nm

form
mer

– Install the coolant expansion tank.

atio
om

n
c

– Install power steering fluid reservoir.

i
or

n thi
te

sd
a

– Install vacuum pump, tightening specification: 20 Nm.

iv

o
pr

cum
r
fo

– Install the toothed belt guard and vibration damper.

en
ng

t.
yi Co
op
– Install the ribbed belt, refer to ⇒ “5.1 Ribbed Belt”, page 28 . C py
t. rig
gh ht
yri by
– Install the noise insulation. cop Vo
by lksw
cted agen
Prote
– Install the connecting pipe between the charge air cooler and
AG.

intake manifold, refer to

⇒ “2.2 Charge Air Cooler Components Overview”,
page 110 .
– Install the right headlamp, refer to ⇒ Electrical Equipment;
Rep. Gr. 94 ; Removal and Installation .
– Check the headlamp adjustment and correct if necessary.
– Check the injection pump for start of injection, refer to ⇒ Fuel
Injection and Glow Plug; Rep. Gr. 23 ; Diagnosis and Testing .

4.2 Cylinder Head

Special tools and workshop equipment required
♦ Drip Tray - VAG1306-
♦ Engine Support Bridge - 10-222A-
♦ Torque Wrench (5-50 Nm) - VAG1331-
♦ Torque Wrench (40-200 Nm) - VAG1332-
♦ Engine Support - T10014-
Removing

Note

Both lifting eyes for the -10-222A- are located on the cylinder
head, for that reason an additional holder to support the engine
must be secured on the cylinder block.

4. Removal and Installation 53

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Install the -T10014- as shown, into the threaded hole of the

cylinder block in the area of the coolant pump. Tightening
specification: 20 Nm.
– Using the spindle -A-, lift the engine slightly until the spindle
-B- is unloaded.
– Remove the spindle -B-.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le

– Follow the sequence for loosening the cylinder head bolts.

un

pt
an
d
itte

y li
Installing
erm

ab
ility
ot p

wit
is n

Note

h re
ole,

spec
urposes, in part or in wh

♦ Always replace the cylinder head bolts.

t to the co
♦ Carefully remove residual sealant from the cylinder head and
cylinder block. Make sure that no long scrapes or scratches
result. When using sand paper, the grit must not be below 100.

rrectne
♦ Thoroughly remove all sanding and grinding residue.
♦ Only unpack the new cylinder head gasket immediately prior ss o
cial p

f i
to installation.
nform
mer

♦ Handle the gasket carefully. Damages to the silicone layer and

atio
m

in the areas of the recesses may result in leaks.

o

n
c

i
or

n thi
te

sd
a

– Before installing the cylinder head, position the crankshaft to

iv

o
pr

the Top Dead Center (TDC) mark.

um
r
fo

en
ng

t.
– Turn back the crankshaft in the opposite direction of engine
yi Co
op
rotation until all pistons align almost evenly below TDC.
C py
t. rig
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– Set the cylinder head gasket in place.
op Vo
by c lksw
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Prote AG.
– Install the cylinder head, install the cylinder head bolts and
tighten by hand.

54 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Tighten the cylinder head bolts in the sequence indicated, in

four passes as follows:
– 1. Tighten the bolts to 40 Nm .
– 2. Tighten the bolts to 60 Nm.
– 3. Tighten the bolts an additional 90° (1/4) turn.
– 4. Tighten the bolts an additional 90° (1/4) turn.

Note

There is no requirement to tighten the cylinder head bolts after

repairs. n AG. Volkswagen AG
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– After tightening the ised cylinder head bolts turn the camshaft
b ara
nte
sprocket so that horthe lobes for cylinder 1 point upward equally.eo
ut
Before installing
ss a the toothed belt, turn the crankshaft in engine ra
c
rotation direction to TDC.

ce
le
un

pt
an
d
itte

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4.3 Valve Guide, Replacing
erm

ab
ility
ot p

Special tools and workshop equipment required

wit
is n

h re
ole,

♦ Drift - 3121-

spec
urposes, in part or in wh

♦ Reamer - 7 mm

t to the co
♦ Cutting Oil
Removing
rrectne
– Cleaning and checking the cylinder head. Cylinder heads, in
s

which the valve seat can no longer be refaced, or cylinder

s o

heads that have been reworked to the minimum dimension,

cial p

f in

are unsuitable for the replacing the valve guides.

form
mer

– Press the worn valve guides out using the -3121- from the
atio
m

camshaft side (valve guide with shouldered repair guides -

o

n
c

i
or

from combustion chamber side).

thi
te

sd
va

Installing
i

o
pr

cum
r
fo

– Using the -3121- , press the new guides, lubricated with oil,
en
ng

t.
yi Co
into the cold cylinder head from the camshaft side up to the Cop py
shoulder. ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.
Note

After the guide with the shoulder is seated, the pressing force may
not be increased over 1.0 t, otherwise the shoulder could break
off.

– Hone the valve guide with a reamer. Always use cutting oil for
this.
– Refacing valve seats, refer to
⇒ “1.3 Valve Seat, Refacing”, page 42 .

4.4 Camshaft
Special tools and workshop equipment required
♦ Retainer - 3036-
♦ Diesel Injection Pump Locking Pin - 3359-
♦ Adjustment Guide - 3418-

4. Removal and Installation 55

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

♦ Puller - T40001-
♦ Pin Wrench - V/159-
♦ Torque Wrench (5-50 Nm) - VAG1331-
Removing
– Remove the upper toothed belt guard, cylinder head cover and
vacuum pump.
– Rotate the crankshaft to Top Dead Center (TDC) for cylinder
1 (on vehicles with manual transmission). -B-

– Rotate the crankshaft to TDC for cylinder 1 -arrow- (with au‐

tomatic transmission).

AG. Volkswagen AG d
agen oes
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– Secure the
ss a camshaft using the -3418- . c
ce
le

– Align the -3418- as follows: Turn the secured camshaft until

un

pt
an
d

the end of the -3418- is seated against the cylinder head. On

itte

y li
erm

the other end of the -3418- , measure the resulting clearance

ab
ility

with feeler gauges. Insert a feeler gauge, with half of the clear‐
ot p

wit

ance dimension, between the -3418- and cylinder head. Turn

is n

h re

the camshaft until the -3418- is seated against the feeler

ole,

spec

gauge. Insert a second feeler gauge with same dimension at

urposes, in part or in wh

the other end between the -3418- and cylinder head.

t to the co

Note
rrectne

The camshaft can also be secured using the -T10098 A- .

ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

56 Rep. Gr.15 - Cylinder Head, Valvetrain

 n AG. Volkswagen AG do
lkswage es n Bora 1999 ➤ , Golf 1998 ➤
o ot g
byV Engine ua Mechanical - Edition 02.2010
ed ra
ris nte
utho eo
– Lock the injection pump
ss sprocket using the -3359- .
a ra
c

ce
e
– Loosen the tensioner nut.

nl

pt
du

an
itte

y li
– Remove the toothed belt.

erm

ab
ility
ot p
– Loosen the camshaft sprocket bolt by one revolution. To loos‐

wit
, is n
en the bolt, counter hold the sprocket using the -3036- .

h re
hole

spec
es, in part or in w

Note

t to the co
When loosening and tightening the camshaft sprocket, never use
the -T10098 A- or the -T10098 A- to counter hold! Use the -3036- .

rrectness of i
l purpos

– Install the -T40001- with the -T40001/2- -A- and the -

T40001/3- -B- on the center of the camshaft sprocket and

nform
ercia

remove the sprocket. To counter hold, use an open end

m

wrench -C-.

at
om

ion
c

– Remove the camshaft sprocket.

in t
or

his
ate

– First remove bearing caps 5, 1 and 3. Loosen bearing caps 2

do
priv

c
and 4 alternately and in a diagonal sequence.

um
for

en
ng

t.
Installing
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note

♦ When installing the camshaft, the cam lobes for cylinder 1

must point upward.
♦ When installing, make sure the bearing cap is centrally posi‐
tioned. Before installing, set the bearing cap in place and
determine the installed position.

– Lubricate the running surfaces of the camshaft.

– Install and tighten the bearing caps 2 and 4 alternately and
diagonally to 20 Nm.
– Install bearing caps 5, 1 and 3 and tighten to 20 Nm.
– Fit bearing cap 5 into place by lightly tapping on the end face
of the camshaft.
– Set the camshaft sprocket in place.
– Install the toothed belt, refer to
⇒ “4.1 Toothed Belt”, page 48 .

Note

After installing new valve lifters, the engine may not be started for
approximately 30 minutes. The hydraulic adjusting elements must
seat themselves (otherwise the valves will seat themselves on the
pistons).

4.5 Valve Stem Seals

Special tools and workshop equipment required
♦ Adjustable Rod - 2036-

4. Removal and Installation 57

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

♦ Slide Hammer - 3047 A-

♦ Seal Driver - 3129-
♦ Valve Lever - VW541/1A-
♦ Press Tool for VW541/1A and 2037 - VW541/5-
Removing
(with cylinder head installed)
– Remove the camshaft, refer to ⇒ “4.4 Camshaft”, page 55 .
– Remove the valve lifters and place them on the running sur‐
face when setting down. Be careful not to switch valve lifters.
– Move the piston for the respective cylinder to the Top Dead
Center (TDC) position.
– Install the -2036- and adjust the mounting to stud height.
– Remove the valve springs using the -541/1A- and the -541/5- .

Note

Support the valves on the piston head while doing this.

– Remove the valve stem seals using the -3047 A- .

Installing

AG. Volkswagen AG d
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erm

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ility
ot p

wit
, is n

– Install the plastic sleeve provided to the respective valve stem.

h re
hole

This will help avoid damage to the new valve stem oil seal.
spec
es, in part or in w

– Install the new valve stem oil seal into the -3129- .
t to the co

– Grease the lip of the valve stem oil seal and carefully slide it
onto the valve guide.
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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cu
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f

en
ng

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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

58 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

5 Special Tools

Special tools and workshop

equipment required
♦ Adjustment Gauge TDC -
2068 A-
♦ Diesel Injection Pump
Locking Pin - 3359-
♦ Camshaft Bar - T10098 A-
♦ Engine Support Bridge -
10-222A-
♦ Pin Wrench - V159- AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
ss c

ce
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nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

5. Special Tools 59
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

♦ Adjustable Rod - 2036-

♦ Slide Hammer - 3047 A-
♦ Seal Driver - 3129-
♦ Valve Lever - VW541/1A- n AG. Volkswagen AG do
lkswage es n
o ot g
yV
♦ Press Tool for VW541/1A d b ua
ran
ir se
and 2037 - VW541/5- tho tee
or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Dial Gauge Holder - VW387-

60 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

♦ Counter-holder tool - 3036-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut ra
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le
un

pt
an
d

♦ Puller - T40001-
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

♦ Drift - 3121-

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Reamer - 7 mm

♦ Bracket for Engine - 10-222A/1-

♦ Hinged Socket - 3220-
♦ Adapter - VAG1381/12-
♦ Compression Tester - VAG1763-
♦ Drip Tray - VAG1306-

5. Special Tools 61
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

♦ Torque Wrench (40-200 Nm) - VAG1332-

♦ Engine Support - T10014-
♦ Camshaft Bar - 3418-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
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rp

cu
o

m
f

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

62 Rep. Gr.15 - Cylinder Head, Valvetrain

 n AG. Volkswagen AG do Bora 1999 ➤ , Golf 1998 ➤
lkswage es n
d byV
o ot g
ua Engine Mechanical - Edition 02.2010
ran
ir se tee
tho
or
au
17 – Lubrication
ac
ss

ce
le
un

pt
an
d
itte

y li
1 General Information
rm

ab
pe

ility
ot

wit
⇒ “1.1 Lubrication System”, page 63
, is n

h re
hole

⇒ “1.2 Engine Oil”, page 63

spec
es, in part or in w

t to the co
1.1 Lubrication System

rrectness of i
Note
l purpos

♦ If large quantities of metal particles or other deposits such as

those caused by partial seizure of the crankshaft or connecting

nform
ercia

rod damage are found in the engine oil, clean the oil passages
thoroughly and replace the engine oil cooler to prevent further
m

a
com

t
damage.

ion in
r
te o

♦ The oil level must not be above the Max. mark, danger of

thi
s
iva

damage to catalytic converter!

do
r
rp

cum
fo

en
g

Oil pressure, checking, refer to

n

t.
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op
⇒ “4.1 Oil Pressure and Switch, Checking”, page 70 . C py
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1.2 Engine Oil
cop Vo
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Prote AG.
Engine Oil Specification: Vehicles without LongLife Service
Use only engine oil in compliance with VWstandard 505 00 or 505
01.
Engine Oil Specification: Vehicles from 05.99 with LongLife Serv‐
ice
Only use engine oil in compliance with VWstandard 506 00.

Note

Engine oil conforming to VWstandard 505 00 or 505 01 may con‐

tinue to be used. The oil must be changed every 12 months or
every 15,000 km and the Service Reminder Indicator (SRI) must
be programmed accordingly.

Oil Capacities
For the capacities, refer to ⇒ Maintenance Intervals; Rep. Gr.
03 .

1. General Information 63
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

2 Description and Operation

⇒ “2.1 Lubrication System Components Overview”, page 64
⇒ “2.2 Oil Filter Bracket Overview”, page 66
⇒ “2.3 Oil Supply Line Overview”, page 68

2.1 Lubrication System Components Overview

1 - Bolt
❑ 15 Nm
2 - Bracket
❑ For the wiring harness
for the oil level thermal
sensor.
❑ There are different ver‐
sions: bolted on or clip‐
ped on.
3 - Bolt
❑ 15 Nm
4 - Oil Dipstick
❑ Oil level must not be
above the Max. mark!
❑ Marks, refer to
⇒ page 67 .
AG. Volkswagen AG d
5 - Inlet Spout agen oes
olksw not
V gu
❑ For extracting oil. d by ara
ise nte
or eo
h
6 - Guide Tube aut ra
c
ss
7 - Fitting Sleeves
ce
e
nl

pt
du

an
itte

8 - O-ring
y li
erm

ab

❑ Replace
ility
ot p

wit
, is n

9 - Bolt
h re
hole

❑ 15 Nm
spec
es, in part or in w

10 - Suction Pipe
t to the co

❑ Clean the strainer if con‐

taminated.
rrectness of i

11 - Splash Wall
l purpos

12 - Bolt
❑ 15 Nm
nf
ercia

or

13 - Bolt
m
m

atio
m

❑ 15 Nm
o

n in
or c

thi

14 - Oil Pan
te

sd
iva

❑ Clean the sealing surface before installing.

o
r
rp

cu
o

m
f

❑ Install using silicone sealant - D 176 404 A2- , refer to ⇒ “5.2 Oil Pan”, page 73 .
en
ng

t.
yi Co
op
15 - Seal
C py
t. rig
gh ht
yri
❑ Replace
p by
o Vo
by c lksw
cted agen
16 - Oil Drain Plug
Prote AG.

❑ 30 Nm
❑ Replace the plug with one with a permanent seal.

64 Rep. Gr.17 - Lubrication

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

17 - Bolt
❑ 10 Nm
18 - Oil Level Thermal Sensor - G266-
❑ Only for vehicles from 05.99.
❑ Checking, refer to ⇒ Wiring diagrams, Troubleshooting & Component locations.
19 - Seal
❑ Replace
20 - Oil Pump
❑ With pressure relief valve 12 bar.
❑ Before installing, check to be sure both alignment bushings are present (for centering oil pump/cylinder
block).
❑ Replace if running surfaces and gears are scored.
21 - Sprocket
22 - Bolt
❑ 20 Nm
23 - Bolt
❑ 15 Nm
24 - Chain
25 - Sealing Flange
❑ With seal.
❑ Removing and installing, refer to ⇒ “5.4 Sealing Flange, Belt Pulley Side”, page 31 .
❑ Install using silicone sealant - D 176 404VoA2- , refer to
lkswagen AG
⇒ “5.4 Sealing Flange, Belt Pulley swageSide”,
n AG. page 31 . does
k not
Vol
❑ Note different versions eof d bseals.
y gu
ara
is nte
❑ Polytetrafluoroethyleneut
hor
(PTFE), version of seal without internal ring
e o spring.
a ra
❑ Seal, belt pulley sside, replacing, refer to ⇒ “5.3 Sealing Flange Oil Seal,
s c Belt Pulley Side”, page 29 .
ce
le
un

pt

26 - Chain Tensioner with Tensioning Rail

an
d
itte

y li

❑ 15 Nm
rm

ab
pe

ility

❑ When installing, pretension the spring and hook in.

ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2. Description and Operation 65

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

2.2 Oil Filter Bracket Overview

1 - Locking Bolt
❑ 25 Nm
AG. Volkswagen AG d
2 - Gasket ksw
agen oes
not
Vol
❑ Replace ed by gu
ara
ris nte
o
3 - Oil Cooler aut
h eo
ra
s c
❑ Ensure sufficient clear‐ s

ce
le

ance to surrounding
un

pt
an
d

components.
itte

y li
erm

ab
❑ See note in

ility
ot p

⇒ “1.1 Lubrication Sys‐

wit
is n

tem”, page 63 .

h re
ole,

spec
4 - Gasket
urposes, in part or in wh

❑ Replace

t to the co
❑ Snaps into the tabs of
the oil cooler.

rrectne
5 - Seal
❑ If the seal is leaking cut

ss
it off and replace it.

o
cial p

f inform
6 - Plug
mer

atio
❑ 10 Nm
om

n
c

i
7 - Plug
or

n thi
te

sd
a

❑ 40 Nm
iv

o
pr

cum
r
fo

8 - Spring
en
ng

t.
yi Co
❑ For pressure relief Cop py
valve, approximately
t. rig
gh ht
yri
5 bar.
p by
o Vo
by c lksw
cted agen
9 - Piston
Prote AG.

❑ For pressure relief

valve, approximately
5 bar.
10 - Oil Pressure Switch - F1- ,
0.7 bar
❑ 25 Nm
❑ Brown
❑ Checking, refer to ⇒ “4.1 Oil Pressure and Switch, Checking”, page 70 .
11 - Gasket
❑ Replace
12 - Bolt
❑ 15 Nm + 90° (1/4) additional turn
❑ Replace
❑ First, tighten the upper left and lower right bolts, and then tighten all four bolts in a diagonal sequence.
13 - Oil Filter Bracket
14 - Seal
❑ Replace
15 - Oil Supply Line
❑ To the turbocharger.
❑ Removing and installing, refer to ⇒ “2.3 Oil Supply Line Overview”, page 68 .

66 Rep. Gr.17 - Lubrication

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

16 - Banjo Bolt
❑ Tightening specification, refer to -item 16- ⇒ page 110 .
17 - Cover
❑ 25 Nm
❑ Loosen and tighten using with oil filter wrench - 3417- .
18 - O-ring
❑ Replace
19 - Oil Filter Element
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
Oil Dipstick Marks orise nte
h eo
ut ra
1 - MAX mark ss a c

ce
e
nl

2 - MIN mark

pt
du

an
itte

y li
a - Area above the hatched field up to the MAX mark: Do not add
erm

ab
oil!

ility
ot p

wit
, is n

b - Oil level in the hatched ares: engine oil can be filled.

h re
hole

spec
c - From the MIN mark up to the hatched field: add maximum 0.5
es, in part or in w

liters oil!

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2. Description and Operation 67

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

2.3 Oil Supply Line Overview

1 - Oil Supply Line

❑ To the turbocharger.
2 - Union Nut
❑ 22 Nm
❑ When loosening and
tightening, counter hold
the connection.
AG. Volkswagen AG d
3 - Seal ksw
agen oes
not
ol
❑ Replace byV gu
ara
ed
ris nte
o
4 - Banjo Bolt aut
h eo
ra
s c
❑ 25 Nm s

ce
e
nl

pt
du

5 - Clamp

an
itte

y li
erm

ab
6 - Bolt

ility
ot p

❑ 10 Nm

wit
, is n

h re
7 - Bracket
hole

spec
es, in part or in w

8 - Nut

t to the co
❑ 25 Nm
❑ Replace

rrectness of i
9 - Bolt
l purpos

❑ 10 Nm
10 - Nut

nform
ercia

❑ 10 Nm
m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

68 Rep. Gr.17 - Lubrication

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

3 Specifications
⇒ “3.1 Fastener Tightening Specifications”, page 69

3.1 Fastener Tightening Specifications

Component Fastener Size Nm
Chain Tensioner with Tensioning Rail to Cylinder Block - 15
Cover to Oil Filter Bracket - 25
Oil Cooler Locking Bolt to Oil Filter Bracket - 25
Oil Drain Plug to Oil Pan - 30
Oil Filter Bracket to Cylinder Block Bolt 1, 2 - 15 + 90°
Oil Level Thermal Sensor to Oil Pan Bolt - 10
Oil Level Thermal Sensor Wiring Harness Bracket Bolt - 15
Oil Pan to Cylinder Block Bolt - 15
Oil Pan to Transmission Bolt - 45
Oil Pressure Switch to Oil Filter Bracket - 25
Oil Supply Line Bracket to Cylinder Block Nut 1 -
. Volkswagen AG
25
agen AG do
Oil Supply Line Clamp to Oil Supply Line Bracket Bolt/NutVolks w
- es no
t gu 10
d by ara
Oil Supply Line Clamp to Cylinder Block Bolt ir se - nte 10
tho eo
Oil Supply Line to Oil Filter Bracket Banjo Bolt s au - r 40
ac
s
Oil Supply Line Union Nut to Oil Filter Bracket - 22

ce
e
nl

pt
du

an
Oil Supply Line Union Nut to Connection - 22
itte

y li
erm

ab
Plug to Oil Filter Bracket - 10

ility
ot p

Pressure Relief Valve Piston/Spring Plug to Oil Filter Bracket - 40

wit
, is n

h re
Sealing Flange to Cylinder Block Bolt - 15
hole

spec
Splash Wall to Cylinder Block Bolt - 15
es, in part or in w

t to the co
Sprocket to Oil Pump Bolt - 20
Suction Pipe to Oil Pump Bolt - 15

rrectness of i
• 1 Always replace
l purpos

• 2 First, tighten the upper left and lower right bolts, and then
tighten all four bolts in a diagonal sequence.
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3. Specifications 69
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

4 Diagnosis and Testing

⇒ “4.1 Oil Pressure and Switch, Checking”, page 70

4.1 Oil Pressure and Switch, Checking

Special tools and workshop equipment required
♦ Oil Pressure Gauge - VAG1342-
♦ Voltage Tester - VAG1527B-
♦ Connector Test Set - 1594 A-

Note

For the functional check and servicing of the optical and acoustic
oil pressure display, refer to ⇒ Wiring Diagrams, Guided Fault
Finding with VAS 5051 . AG. Volkswagen A n G do
wage es n
Volks ot g
Sequence ed
by ua
ran
oris tee
– Remove the oil pressure switch -auF1-
th and install it into the - or
ac
VAG1342- . ss

ce
e
nl

pt
– Thread the -VAG1342- into the oil filter bracket in place of the
du

an
itte

oil pressure switch.

y li
erm

ab
ility
– Connect the brown wire of the -VAG1342- to Ground (GND)
ot p

wit
(-).
, is n

h re
hole

– Connect the -VAG1527B- using adapter cables from the -

spec
V.A.G 1594 A- to the battery positive (+) terminal and the oil
es, in part or in w

t to the co
pressure switch. The Light Emitting Diode (LED) must not light
up.
– If LED lights up, replace the oil pressure switch.
If the LED does not light up: rrectness of i
l purpos

– Start the engine and slowly increase the engine speed. The
LED must illuminate at 0.55 to 0.85 bar. Replace the oil pres‐
nform
ercia

sure switch if it does not.

m

at
om

– Increase engine speed further. At 2000 RPM and an oil tem‐

ion
c

perature of 80 °C (176 °F), oil pressure must be at least 2.0

in t
or

his
e

bar.
at

do
priv

If the specifications are not obtained:

um
for

en
ng

t.
yi
– Correct mechanical damage, for example, bearing damage.
Co
Cop py
t. rig
– Replace the oil filter bracket with pressure valve, or oil pump.
gh ht
pyri by
Vo
co lksw
by
At higher engine speeds oil pressure must not exceed 7.0 bar cted agen
Prote AG.

If the specification is exceeded:

– Check the oil passages.
– If necessary, replace the oil filter bracket with pressure relief
valve.

70 Rep. Gr.17 - Lubrication

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

5 Removal and Installation

⇒ “5.1 Oil Supply Line”, page 71
⇒ “5.2 Oil Pan”, page 73

5.1 Oil Supply Linen AG. Volkswagen A

ge G do
swa es n
Special tools and workshop
by
Vol
k
equipment required ot g
ua
d ran
se
♦ Drip Tray - VAG1306-
tho
ri tee
or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Removing
– Remove the noise insulation.
– Place the -VAG1306- beneath.
– Remove the air filter housing.
– Loosen the union nut -2- or remove the banjo bolt -4- from the
oil filter bracket.
– Remove the bolt -6-.
– Loosen the union nut -2- at the turbocharger.
– Remove the bolt -9- from the bracket -7-.

5. Removal and Installation 71

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Remove the nut -8- and remove the bracket -7-.

– Remove the oil supply line -1-.
AG. Volkswagen AG d
agen oes
Installing Volksw not
gu
by ara
d
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Installation is performed in reverse order. When doing this note

the following:

WARNING

Installation of the oil supply line must be performed as in the

following description.

– Loosely install the bracket -7- with the nut -8- to the exhaust
manifold.
– Hand tighten the union nut -2- or banjo bolt -4- to the oil filter
bracket.
– Hand tighten the union nut -2- to the turbocharger.
– Tighten the union nut -2- or banjo bolt -4- to the oil filter bracket
to specification.

72 Rep. Gr.17 - Lubrication

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Tighten the union nut -2- to the turbocharger to specification

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

– Position the clamp -5- for the oil supply line.

i
or

n thi
te

sd
a

– Tighten the bolts -6 and 9- to specification.

iv

o
pr

cum
r
fo

– Tighten the nut -8- to specification.

en
ng

t.
yi Co
op
5.2 Oil Pan
C py
t. rig
gh ht
pyri by
Vo
o
Special tools and workshop equipment required
c by lksw
cted agen
Prote AG.
♦ Hand Drill with Plastic Brush Attachment
♦ Flat Scraper
♦ Silicone Sealant - D 176 404 A2-
Removing
– Remove the left, right and center noise insulation, refer to ⇒
Body Exterior; Rep. Gr. 50 ; Description and Operation .
– Drain the engine oil.
– Remove the oil pan.
– Loosen the oil pan with light blows from a rubber mallet if nec‐
essary.

5. Removal and Installation 73

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Remove the sealant residue from the cylinder block with a flat
scraper.
– Remove the sealant residue from the pan with a rotating brush,
for example, a hand drill with a plastic brush attachment (wear
eye protection).
– Clean the sealing surfaces. They must be free of oil and
grease.
Installing

Note

♦ Note the expiration date of the sealing compound.

♦ The oil pan must be installed within 5 minutes after application n AG. Volkswagen AG do
of silicone sealant. lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
– Cut the tube nozzle at the front mark (nozzle diameter ap‐
ss
au ac
proximately 3 mm).

ce
e
nl

pt
du

an
– Apply the silicone sealant - D 176 404 A2- , as shown, to the
itte

y li
clean oil pan sealing surface. The sealant bead must be:
erm

ab
ility
ot p

♦ 2 to 3 mm thick

wit
, is n

h re
♦ and run on inside of bolt holes -arrows-
hole

spec
es, in part or in w

t to the co
Note

Sealant bead must not be thicker than specified. Otherwise, ex‐

rrectness of i
cess sealant could get into oil pan and clog the strainer in the
l purpos

suction pipe.

nform
ercia

– Apply silicon sealant - D 176 404 A2- to clean sealing surface

as indicated in illustration. (The fig. shows the location of the
m

at
om

i
sealant bead on the cylinder block.)

on
c

in t
or

– Install the oil pan immediately and tighten all oil pan bolts by

his
ate

hand.

do
priv

cum
for

en
ng

t.
yi Co
op
Note C py
t. rig
gh ht
pyri by
The oil pan must seat flush with the cylinder block.
co Vo
by lksw
cted agen
Prote AG.

– Tighten the oil pan bolts to 15 Nm.

– Tighten the oil pan to transmission bolts to 45 Nm.

Note

After installing the oil pan, allow the sealant to dry for approxi‐
mately 30 minutes. Only after then may the engine oil be added.

The rest of the installation is basically a reverse of the removal

sequence.

74 Rep. Gr.17 - Lubrication

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

6 Special Tools

Special tools and workshop

equipment required
♦ Oil Pressure Gauge -
VAG1342-
♦ Voltage Tester -
VAG1527B-
♦ Connector Test Set - 1594
A-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

♦ Drip Tray - VAG1306-

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

6. Special Tools 75
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

19 – Cooling System
1 General Information
⇒ “1.1 Cooling System”, page 76
⇒ “1.2 Draining and Filling”, page 76

1.1 Cooling System

Note

♦ When the engine is warm the cooling system is under pres‐

sure. If necessary release the pressure before beginning re‐
pair work.
♦ Hoses are secured with spring type clips. In cases of repair,
only use spring type clips. agen
AG. Volkswagen AG d
oes
o lksw not
yV
♦ Hose clip pliers - VAG1921- are recommended for installing
b gu
d ara
e
the spring type clamps. horis nte
eo
aut ra
ss c
Perform a leak test on the cooling system using the cooling sys‐

ce
le
un

pt
tem tester - VAG1274- , adapter - VAG1274/8- and adapter -

an
d
itte

VAG1274/9- .

y li
rm

ab
pe

ility
1.2 Draining and Filling
ot

wit
, is n

h re
Special tools and workshop equipment required
hole

spec
es, in part or in w

♦ Drip Tray - VAG1306-

t to the co
♦ Hose Clip Pliers - VAG1921-
♦ Refractometer

rrectness of i
♦ Cooling System Charge Unit - VAS6096-
l purpos

Draining nform
ercia

– Remove the engine cover.

m

– Remove the coolant expansion tank cap.

com

tion in
r

– Remove the center noise insulation, refer to ⇒ Body Exterior;

te o

thi

Rep. Gr. 50 ; Description and Operation .

s
iva

do
r
rp

cum

– Open the drain plug -arrow- to drain the coolant from the ra‐
fo

en
g

diator.
n

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

76 Rep. Gr.19 - Cooling System

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– In addition, to drain the coolant from the engine, disconnect

the coolant hose -arrow- from the oil cooler.

Note

Observe disposal regulations!

Filling

Note

♦ Only coolant additive G 12 can be used, in compliance with

coolant additive - VW774 F- . Distinguishing feature: purple
color
♦ G 12 purple (conforming to TL coolant additive - VW774 F- )
can be mixed with the previous coolant additive G 12 red!
♦ G12 and coolant additives marked "In accordance with TL
coolant additive - VW774 F- F" prevent frost and corrosion
damage, scaling and also raise the boiling point of the coolant.
For this reason the system must be filled all year round with
frost and corrosion protection additives. G. Volkswagen nA AG do
wage es n
♦ Because of its high boiling point, the coolant improves
yV
olks engine ot g
reliability under heavy loads, particularly in countries with trop‐
b ua
ed ran
ris
ical climates. ut
ho tee
or
sa ac
♦ Protection against frost must be assured
s down to approxi‐

ce
le

mately -25 °C (-13 °F) (in arctic climatic countries down to

un

pt
an
d

approximately -35 °C (-31 °F)).

itte

y li
erm

ab
♦ The coolant concentration must not be reduced by adding wa‐

ility
ot p

ter even in warmer seasons and in warmer countries. The

wit
is n

coolant additive portion must be at least 40%.

h re
ole,

spec
♦ If for climatic reasons a greater frost protection is required, the
urposes, in part or in wh

amount of G 12 can be increased, but only up to 60% (frost

t to the co
protection to about -40 °C (-40 °F)), as otherwise frost protec‐
tion is reduced again and cooling effectiveness is also re‐
duced.

rrectne
♦ If radiator, heater core, cylinder head or cylinder head gasket
is replaced, do not reuse the old coolant. ss o
cial p

f in

Recommended Mixture Ratios:

form
mer

atio

Frost Protection Anti-Freeze G 12 1 Water 1

om

to Portion
c

i
or

n thi
te

-25 °C (-13 °F) 40% 2.4 liters 3.6 liters

sd
iva

o
pr

-35 °C (-31 °F) 50% 3 liters 3 liters

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• 1 The quantity of coolant can vary depending upon the vehicle t. Cop py
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– Close the coolant drain plug. Prote
cted AG.
agen

Using the -VAS6096- :

– Fill the coolant circuit using the -VAS6096- , refer to the oper‐
ating instructions for cooling system charge unit VAS6096.
Without the -VAS6096- :

1. General Information 77
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Fill the coolant to the Max mark on the expansion tank.

– Install the expansion tank cap.
– Allow the engine to run until the fan turns on.
– Check the coolant level and top off if necessary. With the en‐
gine at operating temperature, the coolant level must be at the
Max. mark, with the engine cold, it must be between the Min.
and Max. marks.

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urposes, in part or in wh

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mer

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Cop py
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by
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Prote AG.

78 Rep. Gr.19 - Cooling System

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

2 Description and Operation

⇒ “2.1 Coolant Hose Connection Diagram”, page 79
⇒ “2.2 Cooling System Component Overview, Body Side”,
AG. Volkswagen AG d
page 81 kswagen oes
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⇒ “2.3 CoolingisSystem
ed
b Component Overview, Engine aSide”,
ran page
82 u thor tee
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2.1 Coolant Hose Connection Diagram

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With a Manual Transmission
itte

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ility
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1 - Radiator
, is n

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hole

2 - Engine Oil Cooler

spec
es, in part or in w

3 - Coolant Pump/Thermostat

t to the co
4 - Cylinder Block

rrectness of i
5 - Expansion Tank
l purpos

6 - Intake Manifold
7 - Heater Core

nform
ercia

8 - Coolant Pipe
m

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9 - Transmission Oil Cooler ion

c

in t
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❑ Does not apply to the

o

his
te

US/Canadian market.
a

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10 - Coolant Hose, Upper

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11 - Coolant Hose, Lower t. Cop py
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With a Automatic Transmission

2. Description and Operation 79

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

1 - Radiator
2 - Engine Oil Cooler
3 - Coolant Pump/Thermostat
4 - Cylinder Block
5 - Expansion Tank
6 - Intake Manifold
7 - Radiator
❑ For the Exhaust Gas
Recirculation (EGR)
system
8 - Heater Core
9 - Coolant Pipe
10 - Transmission Oil Cooler
11 - Coolant Hose, Upper
12 - Coolant Hose, Lower

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wit
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urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

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c

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te

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80
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Rep. Gr.19 - Cooling System cted agen
Prote AG.
 n AG. Volkswagen AG do
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ac Bora 1999 ➤ , Golf 1998 ➤
ss Engine Mechanical - Edition 02.2010

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2.2 Cooling System Component Overview, Body Side
itte

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1 - Radiator

h re
hole

❑ Removing and instal‐

spec
ling, refer to
es, in part or in w

t to the co
⇒ “4.1 Radiator”,
page 85 .
❑ After replacing, replace

rrectness of i
the entire amount of
coolant.
l purpos

2 - O-ring

nform
ercia

❑ Replace
m

3 - Coolant Hose, Upper

at
om

ion
❑ Secured to radiator with
c

in t
or

a retaining clip.

his
ate

do
riv

❑ Coolant hose connec‐

p

cum
or

tion diagram, refer to

f

en
ng

⇒ “2.1 Coolant Hose

t.
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op
Connection Diagram”,
C py
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gh
page 79 .
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4 - Fan Shroud
cted agen
Prote AG.

5 - Bolt/Nut
❑ 10 Nm
6 - Coolant Fan
❑ Only on vehicles with
optional equipment.
7 - Bracket
8 - Retaining Clip
❑ Check the clip for se‐
cure seating.
9 - Connector
10 - Coolant Fan
11 - to Coolant Pipe
❑ Coolant hose connection diagram, refer to ⇒ “2.1 Coolant Hose Connection Diagram”, page 79 .
12 - Expansion Tank
❑ Perform a leak test on the tank using cooling system tester - VAG1274- and adapter - VAG1274/8- .
13 - Cap
❑ Check using the cooling system tester - VAG1274- and adapter - VAG1274/9- .
❑ Test pressure 1.4 to 1.6 bar.
14 - Bracket
❑ For the fan electrical connector.
15 - Coolant Hose, Lower
❑ Secured to radiator with a retaining clip.
❑ Coolant hose connection diagram, refer to ⇒ “2.1 Coolant Hose Connection Diagram”, page 79 .
16 - O-ring
❑ Replace
17 - Coolant Fan Control (FC) Thermal Switch - F18-
❑ 35 Nm
❑ For the coolant fan.

2. Description and Operation 81

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010
❑ On/off temperatures:
• 1st speed - On: 92 to 97 °C (197.6 to 206.6 °F) Off: 84 to 91 °C (183.2 to 195.8 °F).
• 2nd speed - On: 99 to 105 °C (210.2 to 221 °F) Off: 91 to 98 °C (195.8 to 208.4 °F).
18 - Bracket
❑ For the radiator.
❑ Note the installed position.
❑ Note the different versions.
19 - Bolt
❑ 10 Nm

2.3 Cooling System Component Overview, Engine Side

1 - Bolt
❑ 15 Nm agen
AG. Volkswagen AG d
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❑ Check for ease of move‐ uthor eo
ment. ss a ra
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❑ Note the installed posi‐

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tion.

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❑ Removing and instal‐
erm

ab
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ling, refer to
ot p

wit
⇒ “4.2 Coolant Pump”,
, is n

h re
page 85 .
hole

spec
3 - O-ring
es, in part or in w

t to the co
❑ Replace
4 - to Radiator, Upper Connec‐ rrectness of i
tion
❑ Coolant hose connec‐
l purpos

tion diagram, refer to

⇒ “2.1 Coolant Hose
nf
ercia

Connection Diagram”,
or

page 79 .
m
m

atio
m

5 - to Cylinder Head
o

n in
or c

❑ Coolant hose connec‐

thi
te

sd
a

tion diagram, refer to

iv

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rp

cu

⇒ “2.1 Coolant Hose

o

m
f

Connection Diagram”,
en
ng

t.
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page 79 . t. Cop py
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6 - to Expansion Tank, Upper yri
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Connection
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❑ Coolant hose connec‐
tion diagram
⇒ “2.1 Coolant Hose
Connection Diagram”,
page 79 .
7 - Upper Coolant Pipe
❑ Clipped to the bulkhead
❑ Coolant hose connection diagram ⇒ “2.1 Coolant Hose Connection Diagram”, page 79 .
8 - O-ring
❑ Replace
❑ Check O-ring for secure seating.

82 Rep. Gr.19 - Cooling System

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

9 - Engine Coolant Temperature (ECT) Sensor - G62-

❑ Checking, refer to ⇒ Fuel Injection and Glow Plug; Rep. Gr. 01 ; Diagnosis and Testing .
❑ With the ECT gauge sensor - G2- .
10 - Retaining Clip
❑ Check the clip for secure seating.
11 - to Heater Core
❑ Coolant hose connection diagram, refer to ⇒ “2.1 Coolant Hose Connection Diagram”, page 79 .
12 - from Heater Core
❑ Coolant hose connection diagram, refer to ⇒ “2.1 Coolant Hose Connection Diagram”, page 79 .
13 - Bolt
❑ 10 Nm
14 - Connecting Piece
15 - Coolant Pipe
❑ Coolant hose connection diagram, refer to ⇒ “2.1 Coolant Hose Connection Diagram”, page 79 .
16 - to Radiator, Upper Connection
❑ Coolant hose connection diagram, refer to ⇒ “2.1 Coolant Hose Connection Diagram”, page 79 .
17 - to Expansion Tank, Bottom Connection
❑ Coolant hose connection diagram, refer to ⇒ “2.1 Coolant Hose Connection Diagram”, page 79 .
18 - to Radiator, Lower Connection
❑ Coolant hose connection diagram, refer to ⇒ “2.1 Coolant Hose Connection Diagram”, page 79 .
19 - Connecting Piece n AG. Volkswagen AG do
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❑ For the thermostat.
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20 - Coolant Thermostat
tho
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❑ Removing ss and installing, refer to ⇒ “4.3 Coolant Thermostat”, page 87 .
ce
le

❑ Observe the installed location, refer to ⇒ “4.3 Coolant Thermostat”, page 87 .

un

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d
itte

❑ Checking: warm the thermostat in water.

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ab

❑ Opening begins approximately 85 °C (185 °F).

pe

ility
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wit

❑ Ends approximately 105 °C (221 °F).

, is n

h re

❑ Opening lift, minimum: 7 mm

hole

spec
es, in part or in w

21 - Engine Oil Cooler

t to the co
rrectness of i
l purpos

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te o

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Prote AG.

2. Description and Operation 83

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

3 Specifications
⇒ “3.1 Fastener Tightening Specifications”, page 84

3.1 Fastener Tightening Specifications

Component Fastener Size Nm
Bracket to Fan Shroud Bolt - 10
Connecting Piece to Cylinder Block Bolt - 10
Coolant Fan to Bracket Nut - 10
Coolant Fan Control Thermal Switch to Radiator - 35
Coolant Pipe to Cylinder Block Bolt - 10
Coolant Pump to Cylinder Block Bolt - 15
Coolant Thermostat Connecting Piece to Cylinder Block Bolt - 15
Expansion Tank to Body Bolt - 10
Fan Shroud to Radiator Bolt - 10
Idler Roller (Toothed Belt) to Cylinder Block Bolt 1 - 40 Nm + 90°
AG. Volkswagen AG d
Radiator to Bracket Bolt lksw
agen - oes
not
10
Vo g
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• 1 Always replace ris
ed nte
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urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
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Prote AG.

84 Rep. Gr.19 - Cooling System

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

4 Removal and Installation

AG. Volkswagen AG d
⇒ “4.1 Radiator”, page 85 agen oes
olksw not
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⇒ “4.2 Coolant Pump”, page 85 rise
d
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⇒ “4.3 Coolant Thermostat”, page 87 ss au ra
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4.1 Radiator

nl

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Special tools and workshop equipment required

erm

ab
ility
ot p
♦ Drip Tray - VAG1306-

wit
, is n

h re
♦ Torque Wrench (5-50 Nm) - VAG1331-
hole

spec
es, in part or in w

♦ Hose Clip Pliers - VAG1921-

t to the co
♦ Refractometer
Removing

rrectness of i
– Drain the cooling system, refer to
l purpos

⇒ “1.2 Draining and Filling”, page 76 .

– Remove the front bumper, refer to ⇒ Body Exterior; Rep. Gr.

nform
ercia

63 ; Removal and Installation .

m

at
om

– Disconnect the coolant hoses from the radiator.

ion
c

in t
or

– Disconnect the connector on the thermal switch and on the

his
ate

radiator fan.

do
priv

cum
or

– Bring the lock carrier into the service position, refer to ⇒ Body
f

en
ng

t.
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Exterior; Rep. Gr. 50 ; Description and Operation .
Co
Cop py
t. rig
– Remove the bolts from the radiator and remove the radiator
gh ht
pyri by
with fans downward.
co Vo
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cted agen
Prote AG.
Vehicles with Air Conditioning (A/C)

WARNING

The A/C refrigerant circuit must not be opened.

Note

To prevent damage to the A/C condenser and also to the refrig‐

erant lines/hoses, ensure that the lines and hoses are not stretch‐
ed, kinked or bent.

– Remove the retaining clamp(s) from the refrigerant lines.

– Remove the A/C condenser from the radiator and secure it to
the lock carrier.
Installing
Installation is performed in the reverse order of removal, noting
the following:
– Fill the cooling system, refer to
⇒ “1.2 Draining and Filling”, page 76 .

4.2 Coolant Pump

Special tools and workshop equipment required
♦ Drip Tray - VAG1306-

4. Removal and Installation 85

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

♦ Torque Wrench (5-50 Nm) - VAG1331-

♦ Hose Clip Pliers - VAG1921-
♦ Refractometer
Removing

Note

♦ Always replace gaskets and seals.

♦ The lower toothed belt guard
agen can remainAinstalled.
AG. Volkswagen G d
o w es n
olks o
♦ The toothed belt
ed
bremains
yV in position on the crankshaft
t gu
arasprock‐
et. ho
ris nte
eo
ut ra
♦ Cover the
ss toothed
belt with a cloth to protect it from coolantc
a
before removing the coolant pump.

ce
le
un

pt
an
d
itte

y li
– Drain the cooling system, refer to
erm

ab
ility
⇒ “1.2 Draining and Filling”, page 76 .
ot p

wit
is n

– Remove the ribbed belt, refer to

h re
ole,

⇒ “5.1 Ribbed Belt”, page 28 .

spec
urposes, in part or in wh

– Remove the right headlamp, refer to ⇒ Electrical Equipment;

t to the co
Rep. Gr. 94 ; Removal and Installation .
– Remove the connecting pipe between the charge air cooler rrectne
and intake manifold, refer to
⇒ “2.2 Charge Air Cooler Components Overview”,
page 110 .
ss o
cial p

– Remove the upper -item 10- ⇒ page 16 and center -item 7-

inform

⇒ page 16 toothed belt guards.

mer

atio
m

– Remove the toothed belt from the camshaft sprocket, injection

o

n
c

pump sprocket and coolant pump sprocket, refer to

i
or

n thi

⇒ “4.1 Toothed Belt”, page 48 .

te

sd
iva

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pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

86 Rep. Gr.19 - Cooling System

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Remove the bolt -1- for the idler roller -2- and press down ap‐
proximately 30 mm.
– Remove the coolant pump bolts -3- and carefully remove the
coolant pump -4- between the engine mount bracket and rear
toothed belt guard.
Installing
Installation is performed in the reverse order of removal, noting
the following:
– Lubricate the new O-ring -5- with coolant.
– Install the coolant pump -4- into the cylinder block and tighten
the bolts -3-. Tightening specification: 15 Nm.

Note

The sealing plug of the coolant pump faces downward.

– Install the idler roller -2- and tighten the new bolt -1-. Tighten‐ agen AG. Volkswagen AG do
ing specification: 40 Nm + 90° (1/4) additional turn. yV
olks
w es n
ot g
b ua
ed ran
– Install the toothed belt, refer to horis tee
⇒ “4.1 Toothed Belt”, page 48 . au
t or
ac
ss
– Install the ribbed belt, refer to ⇒ “5.1 Ribbed Belt”, page 28 .

ce
le
un

pt
an
d
itte

– Install the connecting pipe between the charge air cooler and

y li
rm

ab
intake manifold, refer to
pe

ility
⇒ “2.2 Charge Air Cooler Components Overview”,
ot

wit
page 110 .
, is n

h re
hole

– Install the right headlamp, refer to ⇒ Electrical Equipment;

spec
Rep. Gr. 94 ; Removal and Installation .
es, in part or in w

t to the co
– Check the headlamp adjustment and correct if necessary.
– Fill the cooling system, refer to

rrectness of i
⇒ “1.2 Draining and Filling”, page 76 .
l purpos

4.3 Coolant Thermostat

nform
ercia

Special tools and workshop equipment required

m

a
com

t
♦ Drip Tray - VAG1306-

ion in
r
te o

♦ Torque Wrench (5-50 Nm) - VAG1331- thi

s
iva

do
r

♦ Hose Clip Pliers - VAG1921-

rp

cum
fo

en
ng

♦ Refractometer
t.
yi Co
Cop py
t.
Removing
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note

Always replace gaskets and seals.

– Drain the cooling system, refer to

⇒ “1.2 Draining and Filling”, page 76 .

4. Removal and Installation 87

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Disconnect the coolant hose from the connecting piece -2-.

– Remove the bolts -1- for the connecting piece -2- and remove
the connecting piece -2- with the coolant thermostat -4-.
– Rotate the coolant thermostat -4- 90° (1/4) turn to the left and
remove it from the connecting piece -2-.
Installing
Installation is performed in the reverse order of removal, noting
the following:
– Lubricate the new O-ring -3- with coolant.
– Install the coolant thermostat -4- into the connecting piece
-2- and turn it 90° (1/4) turn to the right.

Note

The clip on the thermostat must be positioned at approximately a

right angle.

– Install the connecting piece -2- with the coolant thermostat

-4- to the cylinder block.

– Tighten the connecting piece bolts -1-. Tightening specifica‐

tion: 15 Nm
– Fill the cooling system, refer to
⇒ “1.2 Draining and Filling”, page 76 .

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
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ab
ility
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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
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or c

thi
te

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iva

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Cop py
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rig ht
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Prote AG.

88 Rep. Gr.19 - Cooling System

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

5 Special Tools

Special tools and workshop

AG. Volkswagen AG d
equipment required ksw
agen oes
not
Vol
y gu
♦ Drip Tray - VAG1306- ise
d b ara
nte
or eo
h
♦ Torque Wrench (5-50 Nm) - s aut ra
c
VAG1331- s

ce
e
nl

pt
du
♦ Hose Clip Pliers -

an
itte

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VAG1921-
erm

ab
ility
ot p
♦ Refractometer

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

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or

his
ate

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for

en
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t.
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Cop py
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Vo
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by
cted agen
Prote AG.

5. Special Tools 89
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

20 – Fuel Supply
1 General Information
⇒ “1.1 Safety Precautions”, page 90
⇒ “1.2 Clean Working Conditions”, page 90
⇒ “1.3 Fuel Supply System”, page 91

1.1 Safety Precautions

WARNING

When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to clearance issues:
♦ Route lines of all types (for example, fuel, hydraulic, Evap‐
orative Emission (EVAP), coolant, refrigerant, brake fluid
and vacuum) and electrical wiring wagso
en Athat
G. Vothe original
lkswagen AG
dpath
oes
is followed. Volks not
gu
by d ara
se nte
♦ Ensure sufficient clearance
tho
ri to all moving or hot compo‐ e or
nents. s au ac
s

ce
le

♦ The fuel or fuel lines in fuel system can become very hot
un

(danger of scalding)! pt
an
d
itte

y li
erm

♦ In addition, the fuel system is under pressure! Before ab

ility
ot p

opening the system, place a cloth around the connection wit

is n

area and release pressure by carefully loosening the con‐ h re

ole,

nection!
spec
urposes, in part or in wh

♦ Wear protective goggles and protective gloves when

t to the co

working on the fuel system!

rrectne

When removing and installing the fuel level sensor from a full or
partially full fuel tank, the following must be observed:
ss

♦ Before starting work, switch the exhaust extraction system on

o
cial p

f i

and place an extraction hose close to the fuel tank installation

nform

opening to extract fuel fumes. If no exhaust extraction system

mer

atio

is available, a radial fan (as long as motor is not in air flow)

om

with a displacement greater than 15 m3/h can be used.

n
c

i
or

n thi
e

♦ Prevent fuel from contacting skin! Wear fuel resistant gloves!

t

sd
iva

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cum
r

1.2 Clean Working Conditions

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op
When working on the fuel supply/injection system, pay careful at‐
C py
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tention to the following “6 rules” of cleanliness:
rig ht
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by lksw
♦ Thoroughly clean all connections and the surrounding area
cted agen
Prote AG.
before disconnecting.
♦ Place parts that have been removed on a clean surface and
cover them. Use lint free cloths.
♦ Carefully cover or seal, opened components, if repairs are not
performed immediately.
♦ Install only clean parts: remove the replacement parts from
their packaging just before installing them. Do not use parts
that have been stored loose (for example, in tool boxes, etc.).
♦ When the fuel system is open: avoid working with compressed
air if possible. Do not move the vehicle unless absolutely nec‐
essary.

90 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

♦ In addition, do not let diesel fuel flow onto coolant hoses. If

necessary, the hoses must be cleaned immediately. Replace
any corroded hoses. en AG. V
olkswagen AG
wag does
olks not
1.3 FuelsedSupply
by
V
System gu
ara
nte
ri
utho eo
ra
a c
ss
Note

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le
un

pt
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d
itte

♦ Hose connections are secured with either screw type or clamp

y li
rm

ab
type clips.
pe

ility
ot

wit
♦ Always replace tensioning clamps with spring type clamps or
, is n

h re
screw type clamps.
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

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en
ng

t.
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Cop py
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Vo
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Prote AG.

1. General Information 91
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

2 Description and Operation

⇒ “2.1 Fuel Tank and Attachments Overview”, page 92
⇒ “2.2 Fuel Filter Overview”, page 94
⇒ “2.3 Accelerator Mechanism with Adjustable Throttle Position
Sensor, Overview”, page 95
⇒ “2.4 Accelerator Mechanism with Non-Adjustable Throttle Po‐
sition Sensor, Overview”, page 96
⇒ “2.5 Throttle Position Sensor, Adjusting”, page 96

2.1 Fuel Tank and Attachments Overview

1 - Cap
2 - Seal
❑ Replace if damaged.
3 - Bolt
4 - Fuel Filler Door Unit
❑ With rubber gasket.
5 - Ground Connection
6 - O-ring
❑ Replace
7 - Breather Valve
❑ To remove the valve,
unclip sideways out of
the support.
❑ Before installing, re‐
move the cap.
❑ Checking, refer to AG. Volkswagen AG d
⇒ page 93 . agen oes
olksw not
V gu
by ara
8 - Bolt rised
nte
ho eo
❑ 10 Nm aut ra
c
ss
9 - Vent Line
ce
le
un

pt
an
d

❑ Ensure the line is se‐

itte

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curely seated.
rm

ab
pe

ility

10 - Lock Washer
ot

wit
, is n

h re

11 - Heat Shield
hole

spec
es, in part or in w

12 - Fuel Tank Cover

t to the co

13 - Bolt
❑ 25 Nm
rrectness of i

14 - Securing Strap
l purpos

❑ Observe the varying lengths.

15 - Fuel Tank
nform
ercia

❑ Support using the engine/transmission jack - VAG1383A- when removing.

m

a
com

ti

❑ Removing and installing, refer to ⇒ “5.1 Fuel Tank”, page 103 .

on in
r
te o

thi

16 - Seal
s
iva

do

❑ Replace if damaged.
r
rp

cum
fo

❑ To install, place into the opening of the fuel tank dry.

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ng

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op
❑ Lubricate with fuel only when installing the fuel delivery unit. C py
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Vo
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92
cted agen
Prote
Rep. Gr.20 - Fuel Supply
AG.
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

17 - Fuel Delivery Unit

❑ Note the installed position on the fuel tank, refer to ⇒ page 93 .
18 - Locking Ring
❑ Use the ring nut spanner - 3217- for removal and installation.
19 - Supply Line
❑ To the fuel filter, refer to ⇒ “2.2 Fuel Filter Overview”, page 94 .
❑ Clipped to the fuel tank.
❑ Ensure the line is securely seated.
❑ Black
❑ To disconnect from the flange, press the release button on the connecting piece.
20 - Return Line
❑ From the fuel filter, refer to ⇒ “2.2 Fuel Filter Overview”, page 94 .
❑ To connection -R-.
❑ Blue or with a blue mark.
n AG. Volkswagen AG do
❑ Clipped to the fuel tank. olkswage es n
ot g
yV
❑ Ensure the line is securely seated. d b ua
ran
ir se tee
❑ To disconnect from the flange, press release the au
tho
button on the connecting piece. or
a
ss c
21 - Gravity/Expansion Valve

ce
e
nl

pt
du

❑ To remove the valve unclip upward out of the support.

an
itte

y li
❑ Check the valve for through flow (valve vertical: open, valve tilted 45°: closed)
erm

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ility
ot p

22 - Angle Piece

wit
, is n

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hole

spec
es, in part or in w

Installed Location of the Fuel Delivery Unit

t to the co
Mark on fuel delivery unit must align with the mark on the fuel tank
-arrows-.

rrectness of i
l purpos

Note

nform
ercia

After installing the fuel delivery unit, check to make sure the fuel
supply line -2- and fuel return line -1- (to connection R) are still
m

at
clipped to the fuel tank.
om

ion
c

in t
or

his
ate

do
priv

cum
for

Breather Valve, Checking

en
ng

t.
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op
Lever in rest position: closed
C py
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Lever pushed in the -direction of the arrow-: open cop Vo
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cted agen
Prote AG.

Note

Before installing the breather valve, remove the cap from the fuel
filler tube.

2. Description and Operation 93

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

2.2 Fuel Filter Overview

1 - Supply Line AG. Volkswagen AG d

agen oes
❑ From the fuel tank. olksw not
V gu
d by ara
e
2 - Return Line horis nte
eo
ut ra
❑ To the fuel tank. ss a c

ce
e
nl
3 - O-ring

pt
du

an
itte
❑ Replace

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erm

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ility
4 - Regulator Valve ot p

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, is n

❑ Installed position: the

h re
arrow points to the fuel
hole

spec
tank.
es, in part or in w

t to the co
❑ When changing the fil‐
ter, remove the retaining
clip and remove the reg‐

rrectness of i
ulator valve with the fuel
lines attached.
l purpos

❑ Below 15 °C (59 °F):

flow to the filter is open.

nform
ercia

❑ Below + 31 °C (87.8 °F):

flow to the filter is
m

at
om

i
closed.

on
c

in t
or

5 - Retaining Clip

his
ate

do
riv

6 - Return Line
p

cum
for

en
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❑ From the injection

n

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pump. Cop py
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7 - Supply Line p by
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cted
❑ To the injection pump.
agen
Prote AG.

8 - Fuel Filter
❑ Before installing, fill with
diesel fuel.
❑ Direction of flow is
marked with arrows.
❑ Do not interchange con‐
nections.
❑ Replace if damaged
9 - Gasket
❑ Replace if damaged.
10 - Water Drain Plug
❑ To vent, remove the retaining clip for the regulator valve and remove the regulator valve with the fuel
lines attached.
❑ loosen and allow approximately 100 cm3 of fluid to drain.

94 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010
G. Volkswage
2.3 Accelerator Mechanism with AdjustableoThrottle
lksw
agen
A
Positionn ASensor,
G do
es n
ot
Overview
yV gu
db ara
rise nte
1 - Bolt tho eo
au ra
c
ss
❑ 10 Nm

ce
le
un

pt
an
2-

d
itte

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Throttle Position (TP) Sensor -

erm

ab
G79-

ility
ot p

wit
❑ Checking, refer to

is n

h re
⇒ “4.1 Throttle Position

ole,

spec
Sensor, with Adjustable

urposes, in part or in wh
Sensor, Checking”,

t to the co
page 99 .
❑ Adjusting, refer to
⇒ “2.5 Throttle Position

rrectne
Sensor, Adjusting”,
page 96 .

ss
❑ To remove, the instru‐

o
cial p

f i
ment panel and pedal

nform
assembly cover needs
mer

to be removed.

atio
om

n
c

3 - Cable Pulley

i
or

n thi
te

sd
a

4 - Spring Washer
iv

o
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fo

5 - Nut

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t.
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❑ 10 Nm Cop py
ht. rig
rig ht
6 - Thread Catch py by
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7 - Bracket Prote AG.

❑ Removing and instal‐

ling, refer to ⇒ Brake
System; Rep. Gr. 46 ;
Removal and Installa‐
tion .

2. Description and Operation 95

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

2.4 Accelerator Mechanism with Non-Adjustable Throttle Position Sensor,

Overview

1 - Nut
❑ 10 Nm
2 - Bracket
❑ For the footwell cover.
❑ Clipped onto the accel‐
erator mechanism.
3 - Nut
❑ 10 Nm
4 - Connector
❑ Black, 6 pin
5- n AG. Volkswagen AG do
Accelerator Mechanism with lkswage es n
o ot g
Throttle Position (TP) Sensor - byV ua
d ran
G79- ir se tee
tho
u or
❑ TP sensor is not adjust‐ ss
a ac
able.

ce
e
nl

pt
du

❑ The TP sensor trans‐

an
itte

y li
mits the driver control to
erm

ab
the Engine Control Mod‐

ility
ot p

ule (ECM).

wit
, is n

h re
❑ Remove the footwell
hole

spec
cover to remove the
es, in part or in w

mechanism.

t to the co
❑ Checking, refer to
⇒ “4.2 Throttle Position
Sensor with Non-Ad‐

rrectness of i
justable Sensor, Check‐
l purpos

ing”, page 101 .

nf
ercia

orm
m

atio
om

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or c

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te

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2.5 Throttle Position Sensor, Adjusting

f

en
ng

t.
yi Co
op py
Only for Vehicles with an Adjustable Throttle Position (TP) Sensor t. C rig
gh ht
pyri by
Procedure
co Vo
by lksw
cted agen
Prote AG.
Adjust the cable pulley:

96 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Install the cable pulley in the indicated position.

– Fasten the TP sensor with the pre-installed cable pulley to the
mounting bracket.
– Connect the 6 pin connector to the sensor.
Fine tune the sensor in the installed condition:
– Press the accelerator pedal by hand until the accelerator pedal
is fully pressed against the stop.

Note

On vehicles with a automatic transmission, the pressure point of

the kick down switch must be noticeable before AG. Volkswagen AG d
swagen the throttle rea‐ oes
ches the wide open stop. by
Vol
k not
gu
a
ed ran
oris tee
h
If the accelerator pedal stop is anot
ut reached and the pressure point or
ac
s
of the kick down switch is not snoticed: turn the sensor in the oblong

ce
le

holes in the mounting bracket.

un

pt
an
d
itte

y li
– Check the position of the sensor using the vehicle diagnostic
rm

ab
tester and -V.A.G 1551/3- , refer to
pe

ility
⇒ “4.1 Throttle Position Sensor, with Adjustable Sensor,
ot

wit
, is n

Checking”, page 99 .

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2. Description and Operation 97

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

3 Specifications
⇒ “3.1 Fastener Tightening Specifications”, page 98

3.1 Fastener Tightening Specifications

n AG. Volkswagen AG do
swage es n
Component byV
olk Fastenerot gSize
ua Nm
d ran
ir se 2 - 10
Accelerator Mechanism with Throttle Position
th Sensor to Body Nut
o tee
or
au ac
Cable Pulley to Bracket Nut 1 ss - 10

ce
le
un

pt
Fuel Filler Tube to Body Bolt - 10

an
d
itte

y li
Securing Strap to Underbody Bolt - 25
erm

ab
ility
ot p

Throttle Position Sensor to Bracket Bolt 1 - 10

wit
is n

• 1 For the accelerator mechanism with adjustable throttle position sensor

h re
ole,

spec
urposes, in part or in wh

• 2 For the accelerator mechanism with non-adjustable throttle position sensor

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

98 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

4 Diagnosis and Testing

⇒ “4.1 Throttle Position Sensor, with Adjustable Sensor, Check‐
ing”, page 99
⇒ “4.2 Throttle Position Sensor with Non-Adjustable Sensor,
Checking”, page 101

4.1 Throttle Position Sensor, with Adjusta‐

ble Sensor, Checking
Special tools and workshop equipment required
♦ Handheld Multi-Meter - VAG1526 A-
♦ Connector Test Set - VAG1594-
n AG. Volkswagen AG do
♦ Adapter - VAG1598/22- lkswage es n
o ot g
byV ua
ed ran
♦ Adapter Cable (121-Point) - VAG1598/31- oris tee
th or
u
♦ Diagnostic Cable Adapter - V.A.G 1551/3-
ss
a ac

ce
le
un

♦ Vehicle Diagnostic Tester

pt
an
d
itte

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♦ Wiring Diagram
rm

ab
pe

ility
Sequence
ot

wit
, is n

h re
– Connect the vehicle diagnostic tester and select the control
hole

spec
module for engine electronics with the “address word” 01. The
es, in part or in w

ignition must be on, refer to ⇒ Fuel Injection and Glow Plug;

t to the co
Rep. Gr. 01 ; Diagnosis and Testing .
Scan tool display: Quick data transfer HELP

rrectness of i
Select function XX
l purpos

– Press buttons 0 and 8 for the function “Reading measuring

value blocks” and press Q button to confirm input.

nform
ercia

Scan tool display: Read measured value block HELP

m

Enter display group number XXX

a
com

tion in
– Press buttons 0 0 and 2 for the “Display group number 2”
r
te o

thi
and press Q button to confirm input.
s
iva

do
r
rp

– Check the reading of the Throttle Position (TP) in display field

um
fo

Read measuring value block 2 ->

en
g

2. The accelerator pedal must not be pressed for this. Speci‐

n

yi 0/min 0,0 % 0 1 0 18,4 °C

t.
Co
fied value 0.0 % Cop py
t. rig
gh ht
yri
– Also, check the reading for the idle switch in display field 3. p by
co Vo
The center position must be set at 1. Display: 010
by lksw
cted agen
Prote AG.
– Slowly press the accelerator pedal and observe the display Read measuring value block 2 ->
fields 2 and 3. 0/min 100.0 % 0 0 0 18,4 °C

♦ Display field 2: TP value must increase continuously. Speci‐

fied value for full throttle position: 100%
♦ Display field 3: The center position must jump to 0. Display:
000

Note

On vehicles with a automatic transmission, the pressure point of

the kick down switch must be noticeable before the throttle rea‐
ches the wide open stop.

If the final specification is not obtained:

– Press the → key.

4. Diagnosis and Testing 99

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Press buttons 0 and 6 for the function “End data transfer” and
press Q button to confirm input.
– Turn off the ignition.
– Adjust the TP sensor, refer to
⇒ “2.5 Throttle Position Sensor, Adjusting”, page 96 .
If the reading does not change or only temporarily:
– Check the TP sensor as follows:
– Press the → key.
– Press buttons 0 and 6 for the function “End data transfer” and
press Q button to confirm input. AG. Volkswagen AG d
agen oes
olksw not
V gu
by
– Turn off the ignition. ised ara
nt
r ee
tho or
– Disconnect the 6 pin connector from the accelerators apedal
u po‐ ac
sition sensor. s

ce
le
un

pt
– Measure the resistance of the sensor between terminals 1 and

an
d
itte

y li
3 of the connector. Specified value: the accelerator pedal is in
rm

ab
the idle position: 0.8 to 1.4 kΩ
pe

ility
ot

wit
, is n

– Measure the resistance of sensor between terminals 2 and 3

h re
of the connector. Specified value: the accelerator pedal is in
hole

spec
the idle position: 0.8 to 1.4 kΩ
es, in part or in w

t to the co
– Check the Closed Throttle Position (CTP) switch - F60- in the
throttle position sensor. For this, measure the resistance be‐
tween terminals 4 and 6 of the connector. Specified value: the

rrectness of i
accelerator pedal is in the idle position: 0.8 to 1.2 kΩ acceler‐
ator pedal pressed: ∞ Ω
l purpos

With a Automatic Transmission

nform
ercia

– Measure the resistance of the sensor between terminals 5 and

6 of the connector. Specified value: with the accelerator pedal
m

a
com

t
in the idle position: ∞ Ω accelerator pedal pressed: 0.8 to 1.2

ion in
kΩ
r
te o

thi
s
iva

Continuation for All

do
r
rp

cum
fo

If the specifications are not obtained:

en
ng

t.
yi Co
op
– Replace the TP sensor -item 2- ⇒ page 95 . C py
t. rig
gh ht
yri
If the specified values are achieved:
p by
o Vo
by c lksw
cted agen
Prote AG.
– Connect the -VAG1598/22- to the control module wiring har‐
ness.

100 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Check for open circuits in the wires between the -

VAG1598/22- and connector according to the wiring diagram.
Terminal 1, socket 24 - terminal 2 socket 11 - terminal 3 socket
23 - terminal 4 socket 12 - terminal 6 socket 25, for vehicles
with a automatic transmission terminal 5 socket 8. Harness
resistance: maximum 1.5 Ω
– Also check the wires for short circuits to each other, to vehicle
Ground (GND) and to B+. Specified value: ∞ Ω
If no fault is detected in the wiring:
– Replace the diesel control module - J248- , refer to ⇒ Fuel
Injection and Glow Plug; Rep. Gr. 23 ; Removal and Installa‐
tion .

4.2 Throttle Position Sensor with Non-Ad‐

justable Sensor,oChecking
lksw
agen
AG. Volkswagen AG d
oes
no
yV t gu
Sequence db ara
rise nte
tho eo
– Connect the vehiclessdiagnostic tester and select the control au ra
c
module for engine electronics with the “address word” 01. The

ce
le
un

ignition must be on, refer to ⇒ Fuel Injection and Glow Plug;

pt
an
d

Rep. Gr. 01 ; Diagnosis and Testing .

itte

y li
erm

ab
Scan tool display:

ility
ot p

Quick data transfer HELP

wit
Select function XX
is n

h re
ole,

– Press buttons 0 and 8 for the function “Reading measuring

spec
urposes, in part or in wh

value blocks” and press Q button to confirm input.

t to the co
Scan tool display: Read measuring value block
Enter display group number XXX

rrectne
– Press buttons 0 0 and 2 for the “Display group number 2”
and press Q button to confirm input. ss o
– Check the reading of the Throttle Position (TP) in display field
cial p

f i

Read measuring value block 2 ->

n

2. The accelerator pedal must not be pressed for this. Speci‐

form

0/min 0,0 % 0 1 0 18,4 °C

mer

fied value 0.0 %

atio
om

– Also, check the reading for the idle switch in display field 3.
n
c

i
or

The center position must be set at 1. Display: 0 1 0

thi
te

sd
va

– Slowly press the accelerator pedal and observe the display

i

o
pr

Read measuring value block 2 ->

um
r

fields 2 and 3.
fo

0/min 100.0 % 0 0 0 18,4 °C

en
ng

t.
yi Co
op
♦ Display field 2: TP value must increase continuously. Speci‐ C py
t. rig
fied value for full throttle position: 100%
gh ht
pyri by
Vo
o
by c lksw
♦ Display field 3: The center position must jump to 0. Display: 0 Prote
cted AG.
agen
00

Note

On vehicles with a automatic transmission, the pressure point of

the kick down switch must be noticeable before the throttle rea‐
ches the wide open stop.

If the specifications are not obtained:

– Press the → key.
– Press buttons 0 and 6 for the function “End output” and press
Q button to confirm input.

– Turn the off ignition.

– Check the wiring for the TP sensor as follows:

4. Diagnosis and Testing 101

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Remove the cover in footwell (driver side).

– Disconnect the 6 pin connector from the accelerator pedal po‐
sition sensor.
– Remove the wiper arms and cowl panel, refer to ⇒ Electrical
Equipment; Rep. Gr. 92 ; Removal and Installation .
Vehicles with a 80 Pin Control Module
– Connect the -VAG1598/22- to the control module wiring har‐
ness.

– Check for open circuits in the wires between the -

VAG1598/22- and connectors according to the wiring diagram.
Terminal 1, socket 11 - terminal 3, socket 23 - terminal 4,
socket 24 - terminal 5, socket 12 - terminal 6, socket 25, and
for vehicles with a automatic transmission, terminal 1, socket
8. Harness resistance: maximum 1.5 Ω
– Also check the wires for short circuits to each other, to vehicle
Ground (GND) and to B+. Specified value: ∞ Ω
Vehicles with a 121 Pin Control Module
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
– Connect -VAG1598/31- to the control module wiring harness.

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Check for open circuits in wires between the -VAG1598/31-

nform

and connectors according to the wiring diagram. Terminal 2,

ercia

socket 12 - terminal 3, socket 50 - terminal 4, socket 69 - ter‐

m

at

minal 5, socket 70 - terminal 6, socket 51 and for vehicles with

om

io

a automatic transmission, terminal 1, socket 63. Harness re‐

n
c

in t
or

sistance: maximum 1.5 Ω

his
ate

do
riv

– Also check the wires for short circuits to each other, to vehicle
p

cum
or

Ground (GND) and to B+. Specified value: ∞ Ω

f

en
ng

t.
yi Co
op
Continuation for All C py
t. rig
gh ht
yri
If no fault is detected in the wiring:
p by
co Vo
by lksw
cted agen
– Replace the TP sensor - G79- -item 5- ⇒ page 96 .
Prote AG.

102 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

5 Removal and Installation

⇒ “5.1 Fuel Tank”, page 103

5.1 Fuel Tank

Special tools and workshop equipment required
♦ Torque Wrench (5-50 Nm) - VAG1331-
♦ Engine/Transmission Jack - VAG1383A-
Removing
n AG . Volkswagen AG
– Read the safety precautions before beginning work, referksto
wage does
not
l
⇒ “1.1 Safety Precautions”, page 90 . by
Vo gu
ara
ed nte
oris eo
th
WARNING ss
au ra
c

ce
e
nl

pt
When doing any repair work, especially in the engine compart‐
du

an
itte

ment, pay attention to the following due to clearance issues:

y li
erm

ab
ility
♦ Route lines of all types (for example, fuel, hydraulic, Evap‐
ot p

wit
orative Emission (EVAP), coolant, refrigerant, brake fluid
, is n

h re
and vacuum) and electrical wiring so that the original path
hole

spec
is followed.
es, in part or in w

t to the co
♦ Ensure sufficient clearance to all moving or hot compo‐
nents.
♦ The fuel or fuel lines in the fuel system can become very

rrectness of i
hot (danger of scalding)!
l purpos

♦ In addition, the fuel system is under pressure! Before

opening the system, place a cloth around the connection

nf
ercia

area and release pressure by carefully loosening the con‐

or
nection!

m
m

atio
m

♦ Wear protective goggles and protective gloves when

o

n in
or c

working on the fuel system!

thi
te

sd
iva

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r
rp

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f

– Check if a coded radio is installed. If so, obtain the anti-theft

en
ng

t.
yi
code, as necessary.
Co
Cop py
t. rig
gh
– Disconnect the battery Ground (GND) strap with the ignition
ht
pyri by
Vo
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turned off. by c lksw
cted agen
Prote AG.
– Remove the rear axle beam, refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 42 ; Removal and Installation .
– Remove the right rear wheel housing liner, refer to ⇒ Body
Exterior; Rep. Gr. 66 ; Removal and Installation .
– Remove the cover retainers -arrows- and cover from the fuel
tank.
– Open the fuel tank flap.
– Drain the fuel tank and clean the fuel filler tube and surround‐
ing area.
– Remove the bolt and remove the fuel flap unit with rubber
gasket.
– Remove the bolts on the filler neck.
– Fold the rear seat bench forward.
– Remove the cover plate from the fuel delivery unit and dis‐
connect the connector from the flange.

5. Removal and Installation 103

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Disconnect the fuel supply line and return line at the right front
of the fuel tank.

Note

Press the buttons on the couplings -arrows- downward to do this.

– Remove the tensioning strap bolts and straps. Support the fuel
tank using the -VAG1383A- when doing this.
– Lower the fuel tank.
Installing
Installation is performed in reverse order. When doing this note
the following:
♦ Route the vent lines free of kinks.
♦ Do not interchange the supply and return lines (return line is
n AG. Volkswagen AG do
blue or with a blue marks, supply line is black). olkswage es n
o V t gu
by ara
♦ Clip the supply and return lines to the fuel tank.
ris
ed nte
tho eo
s au ra
c
s

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nl

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itte

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erm

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ility
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es, in part or in w

t to the co
rrectness of i
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Prote AG.

104 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

6 Special Tools

Special tools and workshop

equipment required
♦ Handheld Multi-Meter -
VAG1526 A- AG. Volkswagen AG d
agen oes
♦ Connector Test olksw-
Set not
y V gu
VAG1594-ris
ed b ara
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tho or
♦ Adapter
s a - VAG1598/22-
u ac
s

ce
e

♦ Adapter Cable (121-Point) -

nl

pt
du

VAG1598/31-

an
itte

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erm

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ility
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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

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mercia

at
om

ion
c

in t
or

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ate

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cum
for

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♦ Torque Wrench (5-50 Nm) - VAG1331-

6. Special Tools 105

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010
AG. Volkswagen AG d
♦ Engine/Transmission Jack - VAG1383A-
lksw
agen oes
not
o
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nl

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es, in part or in w

t to the co
♦ Diagnostic Cable Adapter - V.A.G 1551/3-

rrectness of i
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ion
c

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ate

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for

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Cop py
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co lksw
by
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Prote AG.

106 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

21 – Turbocharger, Supercharger
1 General Information
⇒ “1.1 Safety Precautions”, page 107
⇒ “1.2 Clean Working Conditions”, page 107
⇒ “1.3 Charge Air System and Turbocharger”, page 107

1.1 Safety Precautions

WARNING

When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to clearance issues:
♦ Route lines of all types (for example, fuel, hydraulic, Evap‐
orative Emission (EVAP), coolant, refrigerant, brake fluid
and vacuum) and electrical wiring so that the original path
is followed.
♦ Ensure sufficient clearance to all moving or hot compo‐
nents.

n AG. Volkswagen AG do
If special testing equipment is required during a road test, wage
olksnote
es n
ot g
the following: d byV ua
ran
ir se tee
♦ Test and measuring instruments must be secured
autho
to the rear or
ac
seat and operated by a second person from
ss this location.

ce
e
nl

If the vehicle is involved in a collision while testing and measuring

pt
du

an
itte

equipment is operated from the front passenger seat, the person

y li
erm

ab
sitting in that seat could be seriously injured when the airbag de‐

ility
ot p

ploys.

wit
, is n

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1.2 Clean Working Conditions
hole

spec
es, in part or in w

When working on turbocharger, carefully observe the following

t to the co
rules of cleanliness:
♦ Thoroughly clean all connections and the surrounding area
rrectness of i
before disconnecting.
♦ Place parts that have been removed on a clean surface and
l purpos

cover them. Use lint free cloths.

nform
ercia

♦ Carefully cover or seal opened components, if repairs are not

performed immediately.
m

at
om

io

♦ Install only clean parts: remove the replacement parts from

n
c

in t
r

their packaging just before installing them. Do not use parts

o

his
e

that have been stored loose (for example, in tool boxes, etc.).
at

do
priv

cum

♦ Supplied transport and protective packaging and sealing cover

for

en
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should only be removed immediately before installing.

n

t.
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Cop py
♦ During repairs, clean oil from connections and hose ends.
t. rig
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♦ When the fuel system is open: avoid working with compressed
c by lksw
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air if possible. Do not move the vehicle unless absolutely nec‐
Prote AG.

essary.

1.3 Charge Air System and Turbocharger

Observe the safety precautions, refer to
⇒ “1.1 Safety Precautions”, page 107 .

1. General Information 107

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

Observe the rules for cleanliness, refer to

⇒ “1.2 Clean Working Conditions”, page 107 .
AG. Volkswagen AG d
agen oes
Note olksw not
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♦ Hose connections are secured by clamps and retainingauclips.
tho eo
ra
ss c
♦ Use spring type clip pliers - VAS5024A- to installing spring

ce
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nl
clips.

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♦ Do not install hose connections with lubricants containing oil.

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♦ Charge air system must be properly sealed.

wit
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♦ Before connecting the oil supply line to the turbocharger, fill
hole

spec
the turbocharger with engine oil using the supply line opening. es, in part or in w

t to the co
♦ After installing the turbocharger, let the engine run at idle for
approximately 1 minute and without increasing engine speed.
This ensures that the turbocharger is lubricated.

rrectness of i
♦ Replace the self locking nuts.
l purpos

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108 Rep. Gr.21 - Turbocharger, Supercharger

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

2 Description and Operation

⇒ “2.1 Turbocharger and Attachments Overview”, page 109
⇒ “2.2 Charge Air Cooler Components Overview”, page 110

2.1 Turbocharger and Attachments Overview

1 - Exhaust Manifold
❑ With the turbocharger.
❑ Replace as complete
unit only.
2 - Intake Manifold
3 - from Charge Air Cooler
4 - Gasket
❑ Replace
❑ The coating (bead)
faces to the intake mani‐
fold.
5 - Bolt/Nut
❑ 25 Nm
6 - Gasket
❑ Note the installed posi‐
tion.
7 - Bracket
❑ For the heat shield
-item 9-.
8 - Washer
. Volkswagen AG
a gen AG does
9 - Heat Shield Vol
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❑ Engages in the bracket
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-item 7-. utho eo
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10 - Turbocharger
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❑ Replace as a complete
an
itte

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unit with the exhaust

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ab

manifold only
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❑ Remove the right drive

wit
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axle from the transmis‐

hole

sion, refer to ⇒ Suspen‐

spec

sion, Wheels, Steering;

es, in part or in w

t to the co

Rep. Gr. 40 ; Removal and Installation .

❑ Charge pressure regulation, checking, refer to
⇒ “4.1 Boost Pressure Regulation, Checking”, page 113 .
rrectness of i

11 - Pressure Cell
l purpos

❑ For the boost pressure regulation.

❑ Component of the turbocharger, cannot be replaced.
nform
ercia

12 - from Air Filter Housing

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13 - Gasket
n
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❑ Replace
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14 - Seal
um
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❑ Replace
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Prote AG.

2. Description and Operation 109

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

15 - Oil Return Line

❑ To the cylinder block.
16 -
Banjo Bolt
❑ 40 Nm
17 - Bolt
❑ 15 Nm
18 - Bolt
❑ 40 Nm
19 - Bracket
20 - Bolt
❑ 25 Nm
21 - Gasket
❑ Replace
22 - Front Exhaust Pipe
23 - Connection
❑ 30 Nm
❑ Replace
❑ Lubricate the threads and bolt head contact surface with hot bolt paste - G 052 112 A3- .
❑ Fill the oil supply line with oil before installing it to the connection.
24 - Bolt n AG. Volkswagen AG do
lkswage es n
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❑ 10 Nm byV ua
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ir se tee
o
25 - Oil Supply Line auth or
ac
ss
❑ From the oil filter bracket.
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pt

❑ Fill the oil supply line with oil before installing it to the connection.
du

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itte

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❑ Removing and installing, refer to ⇒ “5.1 Oil Supply Line”, page 71 .

erm

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ility
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2.2 Charge Air Cooler Components Over‐

hole

spec

view
es, in part or in w

t to the co

Note
rrectness of i
l purpos

♦ Charge air system must be properly sealed.

♦ Various hose connections are secured with clamps. For con‐
nform
ercia

nector couplings, always note the following points:

m

at

♦ Release connection by pulling retaining clip -arrow-.

om

ion
c

in t

♦ Disconnect hose/pipe without tools.

or

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ate

do
riv

♦ When assembling, make sure retaining tabs -A- are engaged

p

cum

securely.
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Prote AG.

110 Rep. Gr.21 - Turbocharger, Supercharger

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

1 - Charge Air Cooler

2 - Bolt/Nut
❑ 10 Nm
3 - Bracket
4 - Connecting Hose
5 - Connecting Pipe
❑ Charge air cooler/intake
pipe.
6 - O-ring
❑ Replace if damaged.
7 - Intake Air Temperature
(IAT) Sensor - G72-
❑ From 12.98: on the
charge air cooler.
8 - Bolt
❑ 5 Nm
9 - Connecting Hose
❑ Connecting pipe/intake
pipe.
10 - Connecting Hose wage
n AG. Volkswagen AG do
es n
olks ot g
❑ Charge air pipe/turbo‐ d byV ua
ran
charger. o
ir se tee
th or
u
11 - Charge Air Pipe ss
a ac
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e

❑ With muffler.
nl

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ility
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es, in part or in w

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Prote AG.

2. Description and Operation 111

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

3 Specifications
⇒ “3.1 Fastener Tightening Specifications”, page 112

3.1 Fastener Tightening Specifications

Component Fastener Size Nm
Bracket to Cylinder Block Bolt - 40
Charge Air Cooler Bracket Bolt/Nut - 10
Charge Air Cooler to Bracket Bolt - 10
Charge Air Pipe with Muffler Nut - 10
Connection to Turbocharger 1 - 30
Bracket to Turbocharger Bolt - 25
Front Exhaust Pipe to Turbocharger Nut n AG. Volkswagen AG - 25
age does
Heat Shield to Exhaust Manifold yStud ksw
Vol Nut - 25
not
gu
db ara
Heat Shield Bracket to Exhaust
oris Manifold Stud Nut
e nte
eo - 25
h
ut
Intake Air TemperaturessSensor to Connecting Pipe Bolt
a ra
c - 5

ce
e

Intake Manifold to Cylinder Head Bolt - 25

nl

pt
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an
Oil Return Line to Cylinder Block Banjo Bolt - 40
itte

y li
erm

ab
Oil Return Line to Turbocharger Bolt - 15

ility
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wit
Oil Supply Line Bracket Clamp to Bracket Bolt - 10
, is n

h re
hole

Oil Supply Line Bracket to Cylinder Block Nut - 25

spec
es, in part or in w

• 1

t to the co
Always replace
rrectness of i
l purpos

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ercia

orm
m

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Prote AG.

112 Rep. Gr.21 - Turbocharger, Supercharger

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

4 Diagnosis and Testing

⇒ “4.1 Boost Pressure Regulation, Checking”, page 113
⇒ “4.2 Wastegate Bypass Regulator Valve, Checking”,
page 114

4.1 Boost Pressure Regulation, Checking

Special tools and workshop equipment required
♦ Hand Vacuum Pump - VAG1390-
♦ Handheld Multi-Meter - VAG1526 A-
♦ Connector Test Set - VAG1594 A-
♦ Adapter - VAG1598/22-
♦ Vehicle Diagnostic Tester
. Volkswagen AG
a gen AG does
♦ Diagnostic Adapter Cable Adapter - VAG1551/3-
Vol
ksw not
gu
y
db ara
♦ Adapter Cable (121-Point) - VAG1598/31-
or
ise nte
eo
th
au ra
♦ Wiring Diagram ss c

ce
le
un

Conditions

pt
an
d
itte

y li
• No faults in the Diagnostic Trouble Code (DTC) memory, refer
erm

ab
to ⇒ Fuel Injection and Glow Plug; Rep. Gr. 01 ; Diagnosis

ility
ot p

and Testing .

wit
is n

h re
ole,

• No leaks on the intake or exhaust side.

spec
urposes, in part or in wh

• No malfunctions in the engine/injection system including, start

t to the co
of injection, injector nozzles, compression pressure.
• Engine oil temperature at least 80 °C (176 °F).

rrectne
Sequence

s
If special testing equipment is required during road test, note the

s o
following:
cial p

f inform
♦ Test and measuring instruments must be secured to rear seat
mer

and operated by a second person from this location.

atio
om

n
c

If test and measuring instruments are operated from the front

i
or

n thi
e

passenger seat and the vehicle is involved in an accident, there

t

sd
va

is a possibility that the person sitting in this seat may receive se‐
i

o
pr

cum
r

rious injuries when the airbag is triggered.

fo

en
ng

t.
yi Co
– Connect the vehicle diagnostic tester using the -VAG1551/3- t. Cop py
and select the control module for engine electronics with the
rig
gh ht
yri by
“address word” 01. Engine must run at idle during this, refer to op Vo
by c lksw
⇒ Fuel Injection and Glow Plug; Rep. Gr. 01 ; Diagnosis and cted agen
Prote AG.
Testing .
Scan tool display: Quick data transfer HELP
Select function XX

– Press buttons 0 and 8 for the function “Reading measuring

value blocks” and press Q button to confirm input.
Scan tool display: Read measured value block HELP
Enter display group number XXX

– Press buttons 0 1 and 1 for the “Display group number 11”

and press Q button to confirm input.
– Scan tool display: Read measuring value block 11 ->
840/min 938 mbar 978 mbar 92 %

4. Diagnosis and Testing 113

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Accelerate vehicle in 3rd gear at full throttle from approxi‐

mately 1500 RPM.
– When at 3000 RPM, press the PRINT button on the vehicle
diagnostic tester.
Specified value on the vehicle diagnostic tester: 1700 to 2250 Read measuring value block 11 ->
mbar (in display field 3) 3090/min 1866 mbar 1917 mbar 62 %

If the specification is not obtained:

– Perform output diagnostic test and activate the wastegate by‐
pass regulator valve. Refer to ⇒ Fuel Injection and Glow Plug;
Rep. Gr. 01 ; Diagnosis and Testing .
Scan tool display: Output diagnostic test ->
Wastegate Bypass Regulator Valve N75

The valve must work and thereby it must move the rod of the
vacuum diaphragm for boost pressure regulation on the turbo‐
charger back and forth (at least 34 times, as long as vacuum is
available in the vacuum reservoir).
– If the rod moves and the boost pressure values are not ach‐
ieved, replace the turbocharger.
If the rod does not move because the valve is not working:
– Check the wastegate bypass regulator
AG. Volksvalve
wagen-AN75- , refer to
⇒ “4.2 Wastegate Bypass agen
Regulator
G do
Valve, Checking”,
es n
olksw ot g
page 114 . ed
by
V ua
ra
is nte
or
– Check the vacuum
au
th hoses, refer to eo
ra
⇒ “5.2 Line Connections
ss to Turbocharger”, page 117 . c
ce
le
un

pt

If the rod does not move although the valve is working:

an
d
itte

y li

– Connect the -VAG1390- to the boost pressure regulator valve

rm

ab
pe

ility

and check the free movement of the rod.

ot

wit
, is n

– If the rod does not move freely, replace the turbocharger.

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
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nform
mercia

a
com

tion in
r
te o

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4.2 Wastegate Bypass Regulator Valve,
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Checking
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Prote AG.

– Turn off the ignition.

– Disconnect connector from the wastegate bypass regulator
valve - N75- .

114 Rep. Gr.21 - Turbocharger, Supercharger

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Measure the resistance between the terminals of valve.

Specified value: 14 to 20 Ω.
If the specification is not obtained:
– Replace the wastegate bypass regulator valve.
If the specified value is achieved:
– Turn on the ignition.

– Measure the voltage supply of the valve at connector

-terminal 1- and at engine Ground (GND). Specified value:
approximately battery voltage
If the specification is not obtained:
– Turn off the ignition.

Vehicles with a 80 Pin Control Module

– Connect the -VAG1598/22- to the control module wiring har‐
ness. gen AG
. Volkswagen AG
d wa oes
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
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un

pt
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d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec

– Check for open circuits in the wires between the -

es, in part or in w

VAG1598/22- and connectors according to the wiring diagram.

t to the co

-Terminal 1, sockets 2 and 28- and -terminal 2, socket 15-.

Wiring resistance: Max. 1.5 Ω
rrectness of i

– Also check the wires for short circuits to each other, to vehicle
Ground (GND) and to B+. Specified value: ∞ Ω
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
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cum
fo

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ng

t.
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Cop py
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rig ht
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by lksw
cted agen
Prote AG.

4. Diagnosis and Testing 115

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

Vehicles with a 121 Pin Control Module agen

AG. Volkswagen AG d
oes
olksw not
V gu
– Connect the -VAG1598/31- to the control module ewiring
d by har‐ ara
nte
ness. horis
eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Check for open circuits in the wires between the -
VAG1598/31- and connectors according to the wiring diagram.

rrectness of i
-Terminal 1, sockets 1 and 2- and -terminal 2, socket 62-. Wir‐
ing resistance: Max. 1.5 Ω
l purpos

– Also check the wires for short circuits to each other, to vehicle
Ground (GND) and to B+. Specified value: ∞ Ω

nf
ercia

orm
Continuation for All
m

atio
om

n in
If no fault is detected in the wiring:
or c

thi
te

– Replace the diesel control module - J248- , refer to ⇒ Fuel

sd
iva

o
r

Injection and Glow Plug; Rep. Gr. 23 ; Removal and Installa‐

rp

cu
o

m
tion .
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en
ng

t.
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by lksw
cted agen
Prote AG.

116 Rep. Gr.21 - Turbocharger, Supercharger

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

5 Removal and Installation

⇒ “5.1 Hose Connections with Connector Couplings”, page 117
⇒ “5.2 Line Connections to Turbocharger”, page 117
⇒ “5.3 Turbocharger and Attachments”, page 118
⇒ “5.4 Charge Air Cooler”, page 118

5.1 Hose Connections with Connector Cou‐

plings

Note
AG. Volkswagen AG d
agen oes
ksw
All hose connections for the charge air system are y Vsecured by
ol not
b gu
ara
spring type clamps or by connector couplings. risFor connector cou‐
ed
nte
plings, always note the following points: autho eo
ra
ss c

ce
e

Removing
nl

pt
du

an
itte

y li
– Release the connector coupling by pulling the locking clip
erm

ab
-arrow-.

ility
ot p

wit
, is n

– Separate the hose/tube without using tools.

h re
hole

Installing

spec
es, in part or in w

t to the co
– When installing, make sure that the retaining tabs -A- are se‐
curely engaged.

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
riv

5.2 Line Connections to Turbocharger

p

cum
for

en
ng

t.
yi
1- Wastegate Bypass Regulator Valve - N75-
Co
Cop py
ht. rig
2- To the Exhaust Gas Recirculation (EGR) Vacuum Regulator rig ht
py by
Vo
Solenoid Valve - N18- .
co lksw
by
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3- To the air filter housing.
4- To the vacuum reservoir.
5- Vacuum diaphragm for the charge pressure regulator valve
6- Turbocharger
7- To the Intake Manifold Flap Change-Over Valve - N239- .
8- Check valve, white connection faces toward the Wastegate
Bypass Regulator Valve - N75- .

5. Removal and Installation 117

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

5.3 Turbocharger and Attachments

For removal and installation, refer to the following:
– Turbocharger and attachments, refer to . Volkswagen AG
⇒ “2.1 Turbocharger and Attachments Overview”, page gen A.G
a109 does
lksw n o ot g
yV ua
db
5.4 Charge Air Cooler ho
rise ran
tee
aut or
ac
For removal and installation, refer to the following:
ss

ce
e
nl
– Charge Air Cooler, refer to

pt
du

an
itte
⇒ “2.2 Charge Air Cooler Components Overview”, page 110 .

y li
erm

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ility
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es, in part or in w

t to the co
rrectness of i
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nform
mercia

at
om

ion
c

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or

his
ate

do
priv

cum
for

en
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t.
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pyri by
Vo
co lksw
by
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Prote AG.

118 Rep. Gr.21 - Turbocharger, Supercharger

 n AG. Volkswagen AG do
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auth Borae o1999
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c
ss Engine Mechanical - Edition 02.2010

ce
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un

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6 Special Tools

rm

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ility
ot

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Special tools and workshop
hole

spec
equipment required es, in part or in w

t to the co
♦ Hand Vacuum Pump -
VAG1390-
♦ Handheld Multi-Meter -

rrectness of i
VAG1526 A-
l purpos

♦ Connector Test Set -

VAG1594 A-

nform
ercia

♦ Adapter - VAG1598/22-
m

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com

tion in
r
te o

thi
s
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rp

cum
fo

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t.
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Cop py
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Vo
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Prote AG.

♦ Vehicle Diagnosis Tester

♦ Diagnostic Adapter Cable Adapter - VAG1551/3-
♦ Adapter Cable (121-Point) - VAG1598/31-

6. Special Tools 119

 Bora 1999 ➤ , Golf 1998
AG. V➤
olkswagen AG
agen
Engine Mechanical
ksw - Edition 02.2010 es not
do
Vol
by gu
ara
ed nte
oris eo
26 – Exhaust System, Emission Controls
th
au ra
c
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nl

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1 General Information

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ility
ot p

⇒ “1.1 Exhaust System”, page 120

wit
, is n

h re
⇒ “1.2 Exhaust Gas Recirculation System”, page 120
hole

spec
1.1 Exhaust System
es, in part or in w

t to the co
Note

rrectness of i
l purpos

♦ After exhaust system repairs, make sure the exhaust system

is not under stress and that it has sufficient clearance to the
bodywork. If necessary, loosen the double clamps and align

nform
ercia

and clamp the exhaust pipe so that sufficient clearance is

maintained to the bodywork and the suspended mounts carry
m

at
om

i
the uniform loads.

on
c

in t
or

♦ Replace the self locking nuts.

his
ate

do
priv

cum
or

1.2 Exhaust Gas Recirculation System

f

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Cop py
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rig ht
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Note co Vo
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♦ The direct injection diesel control module - J248- controls the
Exhaust Gas Recirculation (EGR) system via the EGR vac‐
uum regulator solenoid valve - N18- to the EGR vacuum
regulator solenoid valve.
♦ The mechanical EGR valve with cone shaped valve plunger
makes different opening diameters possible at different valve
lifts.
♦ Every relevant valve position is possible via cyclic activation.
♦ Replace the self locking nuts.

120 Rep. Gr.26 - Exhaust System, Emission Controls

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

2 Description and Operation

⇒ “2.1 Front Exhaust Pipe and Catalytic Converter Overview”,
page 121
⇒ “2.2 Muffler and Mount Overview”, page 122
⇒ “2.3 Exhaust Gas Recirculation (EGR) System Overview”, page
123
⇒ “2.4 Vacuum Hose Connection Diagram”, page 125

2.1 Front Exhaust Pipe and Catalytic Converter Overview

1 - From the Turbocharger

2 - Seal
❑ Always replace.
3 - Nut
❑ 25 Nm
4 - Catalytic Converter
5 - To Rear Muffler
n AG. Volkswagen AG do
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6- Suspended Mount Vo lks es n
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or c

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Vo
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by
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Prote AG.

2. Description and Operation 121

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010 AG. Volkswagen AG d
agen oes
olksw not
V gu
2.2 Muffler and Mount Overview orised by ara
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1 - Nut

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un

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an
❑ 40 Nm

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itte

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ab
2 - from Front Exhaust Pipe

pe

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ot

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3 - Double Clamp , is n

h re
hole
❑ Note the installed posi‐

spec
tion, refer to
es, in part or in w

⇒ page 123 .

t to the co
4 - Bolt
❑ 25 Nm

rrectness of i
5 - Suspended Mount
l purpos

❑ Note the installed posi‐

tion, refer to

nform
ercia

⇒ page 123 .
m

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com

t
6 - Suspended Mount

ion in
r

❑ With retaining ring.

te o

thi
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7 - Bracket
r
rp

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fo

8 - Suspended Mount

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9 - Rear Muffler t. C rig
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yri by
❑ Installing the muffler op Vo
by c lksw
free of tension, refer to cted agen
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⇒ page 123 .
10 - Separating Point
❑ For repairs.
❑ Marked by three de‐
pressions around the
circumference of the ex‐
haust pipe.
❑ At the factory, the ex‐
haust pipe and rear muf‐
flers are installed as a
single component. Re‐
placement exhaust pipes and rear mufflers are supplied separately, with a replacement double clamp
for the connecting joint.
❑ Cut through the exhaust pipe using for example the body repair saw - VAG1523A- at a right angle at the
separating point, refer to ⇒ page 123 .
11 - Nut
❑ 20 Nm
12 - Tunnel Bridge

122 Rep. Gr.26 - Exhaust System, Emission Controls

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

Installed Position of the Double Clamp

– Position the double clamp approximately 5 mm from mark A
-arrow 1-.

Note

Mark -A- applies to vehicles with a manual transmission and au‐

tomatic transmission.

Installed Position of Suspended Mounts

– Angled side on the foot of the suspended mount -arrow- faces
the front of the vehicle.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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Separation Point on the Exhaust Pipe h re

hole

spec
– Cut through the exhaust pipe at a right angle at the separating
es, in part or in w

point -2-.
t to the co

– Position the double clamp -4- at the edge marks

-arrows 1 and 3- when installing. Tightening specification: 40
rrectness of i

Nm
.
l purpos

nform
mercia

a
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tion in
r
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thi

Installing Muffler Free of Tension

s
iva

do
r

– Bolt at exhaust pipe must be parallel to the tunnel bridge (di‐

rp

cum
fo

mension -x- same at left and right).

en
ng

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by c lksw
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Prote AG.

2.3 Exhaust Gas Recirculation (EGR) System Overview

2. Description and Operation 123

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

1 - Intake Manifold
2 - O-Ring
❑ Always replace.
3 - Intake Tube
❑ With the exhaust gas re‐
circulation valve and
regulator flap.
4 - EGR Vacuum Regulator
Solenoid Valve - N18-
❑ Component of the in‐
take tube.
❑ Can only be replaced as
a complete unit with the
intake tube.
❑ Checking, refer to
⇒ “4.1 EGR Vacuum
Regulator Solenoid
Valve N18 , Checking”,
page 127 .
❑ Check activation, refer
to ⇒ Fuel Injection and
Glow Plug; Rep. Gr. 01 ;
Diagnosis and Testing .
5 - Bolt
❑ 10 Nm
❑ For the EGR Vacuum
Regulator Solenoid AG. Volkswagen AG d
agen
Valve - N18- -4-. Volksw
oes
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6 - From Charge Air Cooler orise nte
eo
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ut ra
7 - Gasket ss a c
ce
le

❑ Replace
un

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8 - Bolt and Nut

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ab
pe

❑ 25 Nm
ility
ot

wit
, is n

❑ For the Connecting Pipe -10-.

h re
hole

9 - Exhaust Manifold
spec
es, in part or in w

t to the co

10 - Connecting Pipe
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

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rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

124 Rep. Gr.26 - Exhaust System, Emission Controls

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

2.4 Vacuum Hose Connection Diagram

1 - Exhaust Gas Recirculation

(EGR) Vacuum Regulator Sol‐
enoid Valve
2 - EGR Vacuum Regulator
Solenoid Valve - N18-
3 - Non Return Valve
4 - from Brake Booster
5 - Upper Air Filter Housing
6 - Vacuum Pump

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
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nl

pt
du

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itte

y li
erm

ab
ility
ot p

wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
125
AG.
2. Description and Operation
 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

3 Specifications
⇒ “3.1 Fastener Tightening Specifications”, page 126

3.1 Fastener Tightening Specifications

Component Fastener Size Nm
Connecting Pipe to Exhaust Manifold Nut - 25
Connecting Pipe to Intake Tube with Exhaust Gas Recirculation - 25
Valve and Regulator Flap Bolt
Double Clamp Nut - 40
Front Exhaust Pipe and Catalytic Converter Bracket Bolt - 25
Front Exhaust Pipe and Catalytic Converter to Turbocharger Nut - 25
Intake Tube with Exhaust Gas Recirculation Valve and Regulator - 10
Flap to Intake Manifold Bolt
Suspended Mount to Tunnel Bridge Bolt - 25
Suspended Mount to Underbody Bolt - 25
Tunnel Bridge to Underbody Nut - 20

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

126 Rep. Gr.26 - Exhaust System, Emission Controls

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

4 Diagnosis and Testing

⇒ “4.1 EGR Vacuum Regulator Solenoid Valve N18 , Checking”,
page 127
⇒ “4.2 Exhaust Gas Recirculation, Checking”, page 127 AG. Volkswagen AG d
agen oes
lksw not
4.1 EGR Vacuum Regulator Solenoid Valve Vo gu
by ara
d
ise nte
- N18- , Checking author eo
ra
ss c
Special tools and workshop equipment required

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e
nl

pt
du

an
♦ Hand Vacuum Pump - VAG1390-
itte

y li
erm

ab
Sequence

ility
ot p

wit
, is n

– Remove the engine cover.

h re
hole

– Remove the connecting pipe between the charge air cooler

spec
es, in part or in w

and exhaust pipe, at the exhaust pipe.

t to the co
– Disconnect the vacuum hose from the EGR Vacuum Regula‐
tor Solenoid Valve - N18- .

rrectness of i
– Connect the Hand Vacuum Pump - VAG1390- to the EGR
Vacuum Regulator Solenoid Valve - N18- .
l purpos

– Operate the Hand Vacuum Pump - VAG1390- and observe

the diaphragm rod. The rod must move in the direction of the

nform
ercia

-arrow-.
m

at
om

i
– Disconnect the hose from the EGR Vacuum Regulator Sole‐

on
c

in t
noid Valve - N18- . The rod must move back in the opposite
or

his
e

direction of the -arrow- into the output position.

at

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4.2 Exhaust Gas Recirculation, Checking

Special tools and workshop equipment required
♦ Handheld Multi-Meter - VAG1526B-
♦ Connector Test Set - VAG1594C-
♦ Adapter - 1598/22-
♦ Adapter Cable (121-Point) - 1598/31-
♦ Vehicle Diagnostic Tester
♦ Diagnostic Adapter Cable - VAG1551/3C-
♦ Wiring Diagram
Sequence
Checking the Exhaust Gas Recirculation (EGR) function is per‐
formed in Function 04 (basic setting). During the procedure, the
EGR valve will be activated every 10 seconds, so that the extreme
value for the EGR (Mass Airflow (MAF) sensor) can be read in
measuring value block 003 in display field 03.
– Connect the vehicle diagnostic tester with the -VAG1551/3C-
and select the control module for engine electronics with the
“address word” 01. Engine must run at idle during this, refer to
⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and
Testing .

4. Diagnosis and Testing 127

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

Scan tool display: Quick data transfer HELP

Select function XX

– Press buttons 0 and 4 for the function “Initiate basic setting”

and press Q button to confirm input.
Scan tool display: Basic setting HELP
Enter display group number XXX

– Press buttons 0 0 and 3 for the “Display group number 3”

and press Q button to confirm input.
In the display: (1 to 4 = display fields) System in basic setting 3 ->
900/min EGR not active 500 mg/H 0%

The reading in display field 2 must switch between EGR active

and EGR not active every 10 seconds. . Volkswage n AG n AG d
wage oes
The readings in display field 3 and 4 must moveyin Volthe following
ks not
gu
control range: ise
d b ara
nte
r
ho eo
aut ra
ss c
Note

ce
e
nl

pt
du

an
itte

y li
If a constant value of 550 mg/H is displayed in display field 3,
erm

ab
check the MAF sensor, refer to ⇒ Fuel Injection and Glow Plug;

ility
ot p

Rep. Gr. 23 ; Diagnosis and Testing .

wit
, is n

h re
hole

EGR not active

spec
es, in part or in w

t to the co
– Specified value in display field 3 400 - 580 mg/H
– Specified value in display field 4 0 5 %

rrectness of i
EGR active
l purpos

– Specified value in display field 3 150 - 340 mg/H

– Specified value in display field 4 95 100 %

nform
mercia

at
om

Note
ion
c

in t
or

his
e

The readings in display field 3 are dependent on pressure and

at

do
riv

altitude. The displayed values refer to 0 m NN. If the measured

p

cum
or

values strongly differ due to altitude, check in display field 3 if

f

en
ng

t.
there is a difference in specified value of at least 100 mg/H be‐
yi Co
op
tween the readings for EGR active and EGR not active.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
If the specifications are not obtained: Prote
cted AG.
agen

– Mechanical EGR valve, checking, refer to

⇒ “4.1 EGR Vacuum Regulator Solenoid Valve N18 , Check‐
ing”, page 127 .
– Check the vacuum hoses, refer to
⇒ “2.4 Vacuum Hose Connection Diagram”, page 125 .
– Check the EGR vacuum regulator solenoid valve - N18- as
follows:
– Press the → key.
– Press buttons 0 and 6 for the function “End data transfer” and
press Q button to confirm input.
– Turn off the ignition.

128 Rep. Gr.26 - Exhaust System, Emission Controls

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Disconnect the connector -1- from the EGR vacuum regulator

solenoid valve -2-.
– Measure the resistance at valve. Specified value: 14 to 20 Ω.
If the specification is not obtained:
– Replace the EGR vacuum regulator solenoid valve.

Note

Resistance at room temperature is in lower specified range, re‐

sistance at operating temperature is in upper specified range.

If specified value is achieved:

– Turn on the ignition.

– Measure voltage supply of the valve at the connector

-terminal 1- and at engine Ground (GND). Specified value:
approximately battery voltage
If the specification is not obtained:
– Turn off the ignition.
Vehicles with a 80 Pin Control Module

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
s a ac
– Connect the -1598/22- to the control module wiring harness.
s

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness

– Check for open circuits in the wires between the -1598/22- and
o
cial p

harness connectors according to the wiring diagram.

inform

-Terminal 1, sockets 2 and 28- and -terminal 2, socket 29-.

mer

Wiring resistance: Max. 1.5 Ω

atio
om

n
c

– Also check the wires for short circuits to each other, to vehicle
i
or

n thi

Ground (GND) and to B+. Specified value: ∞ Ω

te

sd
iva

o
pr

Vehicles with a 121 Pin Control Module

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4. Diagnosis and Testing 129

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

– Connect the -1598/31- to the control module wiring harness.

– Check for open circuits in the wires between the -1598/31- and
connectors according to the wiring diagram.
-Terminal 1, socket 1-, -Terminal 2, socket 61-. Wire resist‐
ance: Max. 1.5 Ω
– Also check the wires for short circuits to each other, to vehicle
Ground (GND) and to B+. Specified value: ∞ Ω
If no fault is detected in the wiring:
– Replace the diesel control module - J248- , refer to ⇒ Fuel
Injection and Glow Plug; Rep. Gr. 23 ; Removal and Installa‐
tion .

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
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ss
ce
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un

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an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

cum
r
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

130 Rep. Gr.26 - Exhaust System, Emission Controls

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

5 Removal and Installation

⇒ “5.1 Front Exhaust Pipe and Catalytic Converter with Attach‐
ments”, page 131
⇒ “5.2 Exhaust Gas Recirculation (EGR) System”, page 131

5.1 Front Exhaust Pipe and Catalytic Con‐

verter with Attachments

Note

♦ For removing and installing the exhaust manifold, refer to

⇒ “1.3 Charge Air System and Turbocharger”, page 107 , also
for removing and installing turbocharger with attachments.
♦ After exhaust system repairs, make sure exhaust system is
not under stress and that it has sufficient clearance from the
bodywork. If necessary, loosen double clamps and clamp and
align exhaust pipe so that sufficient clearance is maintained to
the bodywork and support rings carry uniform loads.
♦ Replace the self-locking nuts.
Volkswa
For removal and installation of sthe wagFront
en AG. Exhaust Pipe
gen AG
doand
es n Cat‐
alytic Converter with Attachments,
by Volk refer to ot g
ua
⇒ “2.1 Front Exhaust Pipe
ir se and Catalytic Converter Overview”, ante
d r
page 121 . utho eo
r a ac
ss
5.2 Exhaust Gas Recirculation (EGR) Sys‐
ce
e
nl

pt
du

tem
an
itte

y li
erm

ab
ility
ot p

wit
, is n

Note
h re
hole

spec

♦ The Diesel Direct Fuel Injection Engine Control Module - J248-

es, in part or in w

controls the EGR system via the EGR Vacuum Regulator

t to the co

Solenoid Valve - N18- .

♦ The mechanical EGR valve with cone-shaped valve plunger
rrectness of i

makes different opening diameters possible at different valve

lifts.
l purpos

♦ Every relevant valve position is possible via cyclic activation.

nf
ercia

♦ Replace the self-locking nuts.

orm
m

atio
om

For the removal and installation of the Exhaust Gas Recirculation

n in
or c

(EGR) System, refer to

thi
te

⇒ “2.3 Exhaust Gas Recirculation (EGR) System Overview”, page

sd
iva

o
r

123 .
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

5. Removal and Installation 131

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

6 Special Tools
AG. Volkswagen AG d
agen oes
olksw not
V
Special tools and workshop
ed by gu
ara
equipment required horis nte
eo
ut ra
a
♦ Handheld Multi-Meter
ss - c
VAG1526B-

ce
e
nl

pt
du

an
itte

♦ Connector Test Set -

y li
erm

ab
VAG1594C-

ility
ot p

wit
♦ Adapter - 1598/22-
, is n

h re
hole

♦ Adapter Cable (121-Point) -

spec
1598/31-
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
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♦ Hand Vacuum Pump - VAG1390-

♦ Diagnostic Adapter Cable - VAG1551/3C-

Edition: K0051006321 - LF 1055511- 11/03/2014 - ESP

132 Rep. Gr.26 - Exhaust System, Emission Controls

 Bora 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 02.2010

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 Cautions & Warnings

Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer thatn Ayou
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If you lack the skills, tools and equipment, or a suitable workshop for or described in this manual, we
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s or other qualified shop. We especially urge

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you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered

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wholly or in part by any of the extensive warranties issued by Volkswagen.

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•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
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system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.

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•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,

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are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
check with your authorized Volkswagen retailer parts department for the latest information.

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•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
l purpos

reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).

•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support

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a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
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vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
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•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the

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battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
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become inoperable, even if the correct code is used in a later attempt.
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•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
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keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
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starting the vehicle while you are under it. Prote
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•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
being fully alert.

•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.

•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.

•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
injury could result.

•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.

Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
 AG. Volkswagen AG d
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Cautions & Warnings
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•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.

erm

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Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled

ility
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fuel or oil.

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Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
es, in part or in w
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.

t to the co
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.

•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be

rrectness of i
crushed by heavy parts.
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•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the

nform
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
ercia

replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
m

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repairs.
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•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
at

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might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
p

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once, but do not store the oily rags, which can ignite and burn spontaneously.
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•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten t. rig
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fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
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•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
ignited, it will ignite gas trapped in the cells and cause the battery to explode.

•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
govern the disposal of wastes.

•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
automotive chemical refrigerants.

•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
negative terminal (ground strap) and the ABS control module connector.

•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
system pressure and may cause the system to burst.

•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).

•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.

Page 2 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
 Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.

•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.

•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
tire from the rim before attempting any repair.
AG. Volkswagen AG d
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When driving or riding in an airbag-equipped not equipment in your hands or lap while
vehicle, never hold test gu
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vehicle is in motion. Objects betweend you and the airbag can increase rthe
rise nte risk of injury in an accident.
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Page 3 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0