tampa da válvula da árvore de cames de apoio (1 e 5) - Seal

 -  AT motores, excepto RSH

 -  Produto usado

 -  Vedação pasta para motores → Capítulo

   

Corpo > Chemicals manual > Dados técnicos > Reparação Grupo 15 - cabeça dos cilindros, o mecanismo de controle de válvulas > tampa de apoio da válvula Camshaft (1º e 5º) - Seal

Corpo > Manual de Produtos Químicos > Dados técnicos > Reparação Grupo 17 - Sistema de lubrificação > cárter do motor - Encher / nível de óleo do topo para cima

   

cárter do motor - Encher / nível de óleo do topo para cima

1
  -  Produto usado

 -  Motores - Todos até 11.02, exceto ► Passat 2001

 -  Motor de lubrificação multi-usos, como por VW 501 01 padrão → Capítulo

 -  Motores - Para Passat 2001 ► e tudo a partir de 12.02

 -  Motor de óleo lubrificante com alta capacidade de lubrificação, de acordo com VW 502 00 padrão → Capítulo

 -  Motores - 2.4 Caravelle e Eurovan

 -  Óleo lubrificante para motores a diesel - de acordo com a norma VW 505 00 → Capítulo

 -  Motores - 2.0 T Amarok

 -  Óleo lubrificante para motores a diesel - de acordo com a norma VW 505 01 → Capítulo

   

Corpo > Manual de Produtos Químicos > Dados técnicos > Reparação Grupo 17 - Sistema de lubrificação > cárter do motor - Encher / nível de óleo do topo para cima

Corpo > Chemicals manual > Dados técnicos > Reparação Grupo 17 - Sistema de lubrificação > cárter do motor - selo

   

cárter do motor - selo

2
  -  Motores sem junta do cárter sólida

 -  Produto usado

 -  Selante de silicone para o motor → Capítulo

   

Corpo > Chemicals manual > Dados técnicos > Reparação Grupo 17 - Sistema de lubrificação > cárter do motor - selo

Corpo > Chemicals manual > Dados técnicos > Reparação Grupo 19 - Sistema de refrigeração > sistema de refrigeração G 12 - preenchimento / ajuste aditivo proporção.

   

G sistema de refrigeração 12 - preenchimento / ajuste aditivo proporção.

3
  -  motores refrigerados a água
*
 Para veículos fabricados a partir de 2000/05/02

 -  Produto usado

 -  Aditivo de refrigeração - G12 → Capítulo

   

Corpo > Chemicals manual > Dados técnicos > Reparação Grupo 19 - Sistema de refrigeração > sistema de refrigeração G 12 - preenchimento / ajuste aditivo proporção.

Corpo > Chemicals manuais > Dados técnicos > Grupo Repair 20 - Sistema de Abastecimento - tanque, bomba de combustível > eixo do pedal do acelerador - Lubrifique

   

eixo do pedal do acelerador - lubrificar

4
  -  Todos (exceto veículos Kombi e E-gás)

 -  Produto usado

 -  Branco graxa lubrificante → Capítulo

   

Corpo > Chemicals manuais > Dados técnicos > Grupo Repair 20 - Sistema de Abastecimento - tanque, bomba de combustível > eixo do pedal do acelerador - Lubrifique

Corpo > Chemicals manual > Dados técnicos > Grupo Repair 30 - sistema de controle - Clutch > garfo de embreagem, entre em contato com rolamento - lubrificar

   

garfo de embreagem, entre em contato com rolamento - lubrificar

5
  -  Transmissions
013-1,0 L
013-1,6, 1,8 e 2,0 L

 -  Produto usado

 -  Pasta lubrificante para juntas homocinéticas → Capítulo

   

Corpo > Chemicals manual > Dados técnicos > Grupo Repair 30 - sistema de controle - Clutch > garfo de embreagem, entre em contato com rolamento - lubrificar

Corpo > Chemicals manual > Dados técnicos > Grupo Repair 30 - sistema de controle - Clutch > bungs garfo de embreagem - lubrifique

   

bungs garfo de embreagem - Lubrifique

6
  -  Transmissions
013-1,0 L
013-1,6, 1,8 e 2,0 L

 -  Produto usado

 -  Pasta lubrificante para juntas homocinéticas → Capítulo

   

Corpo > Chemicals manual > Dados técnicos > Grupo Repair 30 - sistema de controle - Clutch > bungs garfo de embreagem - lubrifique

Corpo > Manual de Produtos Químicos > Dados técnicos > Grupo Repair 30 - sistema de controle - Clutch > anel de vedação para o guia de-embreagem rolamento - lubrificar para a montagem

   

Anel de vedação para o guia de-embreagem rolamento - lubrificar para a montagem

7
  -  transmissões -
   MQ 200
   MQ 250

 -  Produto usado

 -  Multi-purpose graxa → Capítulo

   

Corpo > Manual de Produtos Químicos > Dados técnicos > Grupo Repair 30 - sistema de controle - Clutch > anel de vedação para o guia de-embreagem rolamento - lubrificar para a montagem

Body > Chemicals Manual > Technical data > Repair Group 30 - Clutch - control system > Primary shaft splines - lubricate

   

Primary shaft splines - lubricate

8
  -  Transmissions -
   013 - 1.0 L
   013 - 1.6, 1.8 and 2.0 L

 -  Product used

 -  Multi-purpose grease → Chapter

   

Body > Chemicals Manual > Technical data > Repair Group 30 - Clutch - control system > Primary shaft splines - lubricate

Body > Chemicals Manual > Technical data > Repair Group 30 - Clutch - control system > Clutch fork contact with the hydraulically activated cylinder of the transmission clutch - lubricate

   

Clutch fork contact with the hydraulically activated cylinder of the transmission clutch - lubricate

9
  -  Transmission -

 -  Product used

 -  Copper grease → Chapter

   

Body > Chemicals Manual > Technical data > Repair Group 30 - Clutch - control system > Clutch fork contact with the hydraulically activated cylinder of the transmission clutch - lubricate

Body > Chemicals Manual > Technical data > Repair Group 30 - Clutch - control system > Fastening flange for the hydraulically activated slave cylinder of the clutch - seal

   

Fastening flange for the hydraulically activated slave cylinder of the clutch - seal

10
  -  Transmission - → Item

 -  Product used

 -  Sealing paste → Chapter

   

Body > Chemicals Manual > Technical data > Repair Group 30 - Clutch - control system > Fastening flange for the hydraulically activated slave cylinder of the clutch - seal

Body > Chemicals Manual > Technical data > Repair Group - 34 - Drive, housing > Gearshift lever bearing

   

Gearshift lever bearing

11
  -  Gol, Parati, Saveiro and Santana

 -  Product used

 -  Special lubrification grease → Chapter

   

Body > Chemicals Manual > Technical data > Repair Group - 34 - Drive, housing > Gearshift lever bearing

Body > Chemicals Manual > Technical data > Repair Group - 34 - Drive, housing > Plastic bungs for the linkage rod coupling system / linkage rod / supports (on the transmission) - lubricate

   

Plastic bungs for the linkage rod coupling system / linkage rod / supports (on the transmission) - lubricate

12
  -  Gol, Parati, Saveiro and Santana

 -  Product used

 -  Molybdenum bisulphate lubricating grease → Chapter

   

Body > Chemicals Manual > Technical data > Repair Group - 34 - Drive, housing > Plastic bungs for the linkage rod coupling system / linkage rod / supports (on the transmission) - lubricate

Body > Chemicals Manual > Technical data > Repair Group - 34 - Drive, housing > Transmission cushion - lubricate

   

Transmission cushion - lubricate

13
  -  Mechanical transmission, for Fox and Polo

 -  Product used

 -  Silicone based grease → Chapter

   

Body > Chemicals Manual > Technical data > Repair Group - 34 - Drive, housing > Transmission cushion - lubricate

Corpo > Chemicals manual > Dados técnicos > Repair Group - 47 - Travões - sistema hidráulico do freio Servo > pin Guia para o apoio do cilindro de freio a disco dianteiro (fabricado pela Varga) - lubrificar

   

Guia pinos para o apoio do freio a disco dianteiro do cilindro (fabricado pela Varga) - lubrificar

14
  -  Gol, Parati, Saveiro e Santana

 -  Produto usado

 -  Graxa para roda dianteira do cilindro de pino guia de suporte → Capítulo

   

Corpo > Chemicals manual > Dados técnicos > Repair Group - 47 - Travões - sistema hidráulico do freio Servo > pin Guia para o apoio do cilindro de freio a disco dianteiro (fabricado pela Varga) - lubrificar

Body > Chemicals Manual > Technical data > Repair Group - 57 - Front doors / components / central lock > Front door lock - lubricate

   

Front door lock - lubricate

15
  -  Gol, Parati, Saveiro and Santana

 -  Product used

 -  Multi-purpose grease → Chapter

   

Body > Chemicals Manual > Technical data > Repair Group - 57 - Front doors / components / central lock > Front door lock - lubricate

Engine > 4-cylinder injection engine > Technical data > Technical data > Engine number

   
Engine number
 
Engine code and engine number can be found on the sticker -arrow- on the toothed belt guard.

The engine code is also on the vehicle data plate and on the crankcase above the gearbox.

The engine number consists of up to nine characters (alphanumeric). The first part (maximum 3

characters) makes up the “engine code”, and the second part (6 characters), 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.

Engine code AUA AUB BBY BBZ BKY

Manufactured 11.01 ► 11.01 ► 11.01 ► 05.02 ► 05.04 ►

Capacity cm3 1390 1390 1390 1390 1390

Output kW at rpm 55/5000 74/6000 55/5000 74/6000 55/5000

Torque Nm at rpm 126/3800 128/4400 126/3800 128/4400 126/3800

Bore Ø mm 76.5 76.5 76.5 76.5 76.5

16
 Stroke mm 75.6 75.6 75.6 75.6 75.6

Compression ratio 10.5 10.5 10.5 10.5 10.5

Valves per cylinder 4 4 4 4 4

RON min. 95 unleaded → Note 98 unleaded → Note 95 unleaded → Note 98 unleaded→ Note 95 unleaded → Note

Injection, ignition 4MV 4MV 4MV 4MV 4TV

Knock control yes yes yes yes yes

Lambda regulation yes yes yes yes yes

Catalytic converter yes yes yes yes yes

Exhaust gas recirculation yes yes yes yes yes

1)
   
  In exceptional circumstances min. 91 RON, however with reduced performance.
2)
  In exceptional circumstances min. 95 RON, however with reduced performance.

Engine > 4-cylinder injection engine > Technical data > Technical data > Engine number

Engine > 4-cylinder injection engine > Enginecrankshaft group, pistons > Dismantling and assembling engine > Assembly overview - parts l and ll

   
Assembly overview - parts l and ll
  Note
Secure engine  on engine  and gearbox support -VAS 6095- to carry out repairs.

  Note
  If metal shavings or larger quantities of metal particles or other deposits (caused for example,
by partial seizure of the conrod  bearings) are found in the engine  oil when making repairs, clean
the oil passages thoroughly and renew the oil filter in order to prevent further damage from
occurring later.
  All bearing and running surfaces must be oiled before assembly.
Repair Manual  

Manuals  

Car repair manual  

Engine
Workshop Manuals  

Free car repair manuals  

Assembly

17
    

Engine > 4-cylinder injection engine > Enginecrankshaft group, pistons > Dismantling and assembling engine > Assembly overview - parts l and ll

Engine > 4-cylinder injection engine > Engine cooling > Dismantling and assembling parts of cooling system > Assembly overview - parts of cooling system - body side

   

Assembly overview - parts of cooling system - body side

18
 1 -  Radiator
   Removing and installing → Chapter.
   After renewing, renew entire coolant.

2 -  O-ring
   Renew.

3 -  Top coolant hose

   Secured to radiator with retaining clip.
   Check for secure seating.
   Coolant hose schematic diagram → Chapter.

4 -  Air ducting

5 -  10 Nm

6 -  Additional fan

   Only vehicles with optional equipment.

7 -  Securing clip

   Check for secure seating.

8 -  Bracket
   For electric fan.

9 -  Connector

10 -  Radiator fan

11 -  To thermostat housing

   Coolant hose schematic diagram → Chapter.

12 -  Expansion tank

   Test for leaks in cooling system using cooling system tester -V.A.G 1274- and adapter -V.A.G 1274/8-.

13 -  Cap
   Check using cooling system tester -V.A.G 1274- and adapter -V.A.G 1274/9-.
   Test pressure: 1.4...1.6 bar.

14 -  Bracket
   For radiator fan connector

15 -  Bottom coolant hose

   Secured to radiator with retaining clip.
   Check for secure seating.
   Coolant hose schematic diagram → Chapter.

16 -  Radiator fan thermal switch -F18-, 35 Nm

   For electric fan.
Switching temperatures
   1st stage on 92...97 °C, off 84...91 °C
   2nd stage on 99...105 °C, off 91...98 °C

17 -  Bracket
   For radiator.
   Note installation position.
   Note various versions.

18 -  10 Nm

   

Engine > 4-cylinder injection engine > Engine cooling > Dismantling and assembling parts of cooling system > Assembly overview - parts of cooling system - body side

Engine > 4-cylinder injection engine > Engine cooling > Dismantling and assembling parts of cooling system > Assembly overview - parts of cooling system - engine side

   
Assembly overview - parts of cooling system - engine side
Thermostat side

19
 1 -  Connection

2 -  Self-tapping bolt, 9 Nm

3 -  O-ring

4 -  Thermostat
   Check function: Heat up thermostat in water. The pin of the thermal element must move out.

5 -  To heat exchanger.

   Coolant hose schematic diagram → Chapter.

6 -  From expansion tank

   Coolant hose schematic diagram → Chapter.

7 -  Thermostat housing

8 -  From heat exchanger.

   Coolant hose schematic diagram → Chapter.

9 -  Coolant pipe
   Coolant hose schematic diagram → Chapter.

10 -  Seal
   Renew.

11 -  Coolant pump housing on cylinder block

12 -  Securing clip

   Check for secure seating.

13 -  10 Nm

14 -  Plug
   If necessary, release pressure in cooling system before removing.

15 -  Coolant temperature sender -G62-

   If necessary, release pressure in cooling system before removing.

16 -  Securing clip

   Check for secure seating.

17 -  Self-tapping bolt, 6 Nm

18 -  Bracket

19 -  To bottom of radiator

   Coolant hose schematic diagram → Chapter.
20
 20 -  From top of radiator
   Coolant hose schematic diagram → Chapter.

   
Coolant pump side

1 -  Main drive toothed belt

   Mark direction of rotation before removing.
   Check for wear.
   Do not kink.
   Toothed belt routing → Fig..
   Removing, installing and tensioning → Chapter.

2 -  Coolant pump
   Check for ease of movement.
   If damaged or leaking, renew complete.
   Removing and installing → Chapter.

3 -  10 Nm

4 -  Rear toothed belt guard

5 -  Upper toothed belt guard

6 -  Lower toothed belt guard

7 -  Pulley
   When installing note fixing arrangement.
   Removing and installing poly V-belt → Chapter.

8 -  90 Nm + 1/4 turn (90°) further

   Renew.
   Oil before installing.
   Turning further can be done in several stages.
   The extra turn angle can be checked using a commercial protractor e.g. Hazet 6690.

9 -  12 Nm
   Renew.

10 -  50 Nm

11 -  Idler roller

21
 12 -  20 Nm

13 -  Crankshaft pulley
   When installing note fixing arrangement.

   

Engine > 4-cylinder injection engine > Engine cooling > Dismantling and assembling parts of cooling system > Assembly overview - parts of cooling system - engine side

Engine > 4-cylinder injection engine > Engine cooling > Dismantling and assembling parts of cooling system > Coolant hose schematic diagram

   

Coolant hose schematic diagram

1 -  Expansion tank

2 -  Coolant pipe

   Bolted to camshaft housing.

3 -  Heater unit heat exchanger

4 -  Gearbox oil cooler

   Only with automatic gearbox.

5 -  Bottom coolant hose

6 -  Radiator

7 -  Top coolant hose

8 -  Thermostat housing

9 -  Coolant pipe

10 -  Cylinder head/cylinder block

11 -  Coolant pump

12 -  Intake pipe

   

Engine > 4-cylinder injection engiEngine > 4-cylinder injection engine > Engine cooling > Dismantling and assembling parts of cooling system > Draining and filling coolant

   

22
Draining and filling coolant

Special tools and workshop equipment required

t  Refractometer -T10007-
t  Spring-type clip pliers -VAS 5024A-
t  Cooling system charge unit -VAS 6096-

   
Draining

    WARNING
Steam may escape when expansion tank is opened. Wear protective glasses
and  clothingto avoid eye injuries and scalding. Cover cap with  cloth  and open carefully.

–  Remove cap from coolant expansion tank.

–  Remove engine splash guard.

 
–  To drain coolant from radiator, open drain plug -arrow-.

  Note
Observe environmental regulations for disposal.

Filling

  Note
t  Only use  coolant  additive G 12 in accordance with TL “VW  774  F”. Identification: purple  colour.
t  G 12 purple (in accordance with TL “VW 774 F”) can be mixed with the previous  coolantadditive
G 12 red!
t  G 12 and  coolant  additives marked "Conforming to TL  “VW  774  F”" prevent frost and corrosion
damage, scaling and also raise  boiling point  of  coolant. Therefore, the system must be filled  all
year  round with frost and corrosion protection additives.
t  Because of its high  boiling point, the  coolant  improves engine reliability under heavy loads,
particularly in countries with tropical  climates.
t  Frost protection is required down to about -25 °C (in countries with arctic  climates: down to
about -35 °C).
t  The  coolant  concentration  must not be reduced by adding water even in warmer seasons and in
warmer countries. The anti-freeze must be at least 40% of mixture.
t  If for climatic reasons greater frost protection is required, the amount of G 12 can be increased,
but only up to 60% (frost protection to about -40°C). Otherwise frost protection and cooling
23
 effectiveness are reduced again.
t  If radiator, heat exchanger, cylinder head or cylinder head gasket is renewed, do not reuse
oldcoolant.

Recommended mixture proportions:

Frost Anti-freeze quantity G 12 → Note Water → Note

protection to

-25 °C 40 % 2.25 l 3.35 l

-35 °C 50 % 2.8 l 2.8 l

1)
   
  The quantity of coolant can vary depending upon vehicle equipment.

 
–  Screw drain plug into radiator.

–  Install engine splash guard.

With cooling system charge unit -VAS 6096-

–  Fill coolant circuit using cooling system charge unit -VAS 6096-. See → operating instructions for

cooling system charge unit 6096.

Without cooling system charge unit -VAS 6096-

 
–  Fill with coolant up to max. mark on expansion tank.

With or without cooling system charge unit -VAS 6096-

–  Fit expansion tank cap.

–  Turn heater control to off position.

–  Start engine and maintain an engine speed of about 2000 rpm for about 3 minutes.

–  Run engine until radiator fan cuts-in.

    WARNING
Steam may escape when expansion tank is opened. Wear protective glasses
and  clothingto avoid eye injuries and scalding. Cover cap with  cloth  and open carefully.

–  Check coolant level and top up if necessary. When the engine is at normal operating

temperature, the coolant level must be on the max. mark; when the engine is cold, between the
min. and max. marks.

Engine > 4-cylinder injection engine > Engine cooling > Dismantling and assembling parts of cooling system > Draining and filling coolant

ne > Engine cooling > Dismantling and assembling parts of cooling system > Coolant hose schematic diagram

Engine > 4-cylinder injection engine > Fuel supply, gas operation > Removing and installing parts of fuel supply system > Assembly overview - fuel tank with attachments

   

Assembly overview - fuel tank with attachments

24
 1 -  Securing clip

2 -  Cap

3 -  Seal
   Renew if damaged.

4 -  Securing bolt

5 -  Tank flap unit

   With rubber cup.
   Removing and installing → General body repairs, exterior; Rep. Gr.55.

6 -  Gravity valve

   To remove valve unclip upwards out of support.
Check valve for through-flow.
   Valve vertical: open.
   Valve tilted 45 °: closed.

7 -  Earth connection

   Check for secure seating.

8 -  Breather line
   Check for secure seating.

9 -  Active charcoal filter
   Location: in front right wheel housing.

10 -  10 Nm

11 -  Breather line
   Clipped onto fuel tank.
   Check for secure seating.

12 -  25 Nm

13 -  Fuel tank

   When removing, support using engine and gearbox jack -V.A.G 1383 A-.
   Removing and installing → Chapter.
   Fuel system must be bled if fuel tank is renewed → Chapter.

14 -  Securing strap

15 -  Breather line
   Check for secure seating.
25
16 -  Securing clip
   Check for secure seating.

17 -  Fuel filter

   Installation position: arrow points in direction of flow.
   Fuel system must be bled if fuel filter is renewed → Chapter.

18 -  Supply line

   Black
   Check for secure seating.
   To fuel rail.

19 -  Seal
   Renew if damaged.

20 -  O-ring
   Renew.

21 -  Fuel pressure regulator

22 -  5 Nm
   For fuel filter clamp.

23 -  Seal
   Renew if damaged.
   When installing, insert seal dry into fuel tank opening.
   Moisten with fuel only when installing flange.

24 -  Fuel gauge sender

   Removing and installing → Chapter.
   Adjusting → Current flow diagrams, Electrical fault finding and Fitting locations.

25 -  Fuel delivery unit
   Removing and installing → Chapter.
   Clean strainer if soiled.
   Checking fuel pump → Chapter.
   Note installation position on fuel tank → Fig..
   Fuel system must be bled if fuel delivery unit is renewed → Chapter.

26 -  Return line

   Blue
   Clipped onto side of fuel tank.
   Check for secure seating.

27 -  Supply line

   Black
   Clipped onto side of fuel tank.
   Check for secure seating.

28 -  Union nut, 80 Nm

   Remove and install using union nut tool -3217-.

29 -  10 Nm

30 -  Breather valve
   Checking → Fig..
   To remove pull locking latch lightly to inside -arrow- and pull valve out.

   

26
  
Installation position of fuel delivery unit flange

Marking on sender must align with the marking on fuel tank -arrows-.

Return line -1- (blue or with blue marking) to connection marked -R-.

Black supply line -2- to connection marked -V-.

  Note
After installing fuel delivery unit flange, check that supply, return and breather lines are still clipped
onto fuel tank.

 
Checking breather valve

Lever in rest position: closed.

Lever pushed in direction of arrow: open.

  Note
Before installing  breather  valve remove fuel tank cap.

Engine > 4-cylinder injection engine > Fuel supply, gas operation > Removing and installing parts of fuel supply system > Assembly overview - fuel tank with attachments

Engine > 4-cylinder injection engine > Fuel supply, gas operation > Removing and installing parts of fuel supply system > Removing and installing fuel delivery unit > Removing

   
Removing
–  Note safety precautions before starting work → Chapter.

–  Observe rules for cleanliness → Chapter.

–  First check whether a coded radio is fitted. If so, obtain anti-theft coding.

–  With the ignition switched off, disconnect battery earth strap.

–  Fold rear seat forwards.

–  Remove cover from fuel delivery unit.

   WARNING
Fuel supply lines are under pressure! Wear protective glasses and gloves to avoid injuries
and skin contact. Before loosening hose connections, wrap a  cloth around the
connection. Then release pressure by carefully pulling hose off connection.
 
–  Pull connector -1- and supply and return lines -2- and -3- off flange.

  Note
Press in safety ring to release fuel lines.

27
  
–  Unscrew union nut with union nut tool -3217-.

–  Pull fuel delivery unit and seal out of the opening in fuel tank.

  Note
If delivery unit is to be renewed, drain old delivery unit before disposal.

Engine > 4-cylinder injection engine > Fuel supply, gas operation > Removing and installing parts of fuel supply system > Removing and installing fuel delivery unit > Removing

Engine > 4-cylinder injection engine > Fuel supply, gas operation > Removing and installing parts of fuel supply system > Removing and installing fuel delivery unit > Installing

   
Installing
–  Installation of fuel delivery unit is carried out in reverse order.

  Note
  When inserting fuel delivery unit, ensure that fuel gauge sender is not bent.
  Insert seal for fuel delivery unit dry into opening of fuel tank.
  Moisten seal with fuel only when installing fuel delivery unit.
  Note  installation  position of fuel delivery unit flange: mark on flange must align with mark  -  
arrows- on fuel tank.
  Ensure that fuel hoses are tight.
  Do not interchange supply and return lines.
  After installing fuel delivery unit, check that supply, return and  breather  lines are still clipped
onto fuel tank.
  Fuel system must be bled  if fuel delivery unit is renewed  →  Chapter.

Engine > 4-cylinder injection engine > Fuel supply, gas operation > Removing and installing parts of fuel supply system > Removing and installing fuel delivery unit > Installing

Engine > 4-cylinder injection engine > Fuel supply, gas operation > Removing and installing parts of fuel supply system > Removing and installing fuel gauge sender

   
Removing and installing fuel gauge sender
Removing

–  Remove fuel delivery unit → Chapter.
 
–  Release connector lugs on lines -3- and -4- and pull off.

–  Raise retaining tabs -1- and -2- using a screwdriver and pull fuel gauge sender off downwards-
arrows-.

Installing

–  Insert fuel gauge sender into guides on fuel delivery unit and press upwards until it engages.

Engine > 4-cylinder injection engine > Fuel supply, gas operation > Removing and installing parts of fuel supply system > Removing and installing fuel gauge sender

Engine > 4-cylinder injection engine > Fuel supply, gas operation > Removing and installing parts of fuel supply system > Removing and installing fuel tank > Removing

28
    
Removing
–  Note safety precautions before beginning work → Chapter.

–  First check whether a coded radio is fitted. If so, obtain anti-theft coding.

–  With the ignition switched off, disconnect battery earth strap.

–  Unscrew securing bolts and remove tank flap unit.

–  Drain fuel tank and clean fuel filler neck and surrounding area.

–  Fold rear seat bench forwards.

–  Remove cover from fuel delivery unit.

–  Pull 4-pin connector off flange.

–  Remove right rear wheel.

–  Remove rear right wheel housing liner: → General body repairs, exterior; Rep. Gr.66

–  Remove active charcoal filter.

–  Unbolt filler pipe from body.

–  Unscrew all rear exhaust system retainers from body. Support lowered exhaust system on body
with suitable wire.

–  Remove rear axle: → Running gear, axles, steering; Rep. Gr.42

   WARNING
Fuel supply lines are under pressure! Wear protective glasses and gloves to avoid injuries
and skin contact. Before loosening hose connections, wrap a cloth around the
connection. Then release pressure by carefully pulling hose off connection.
 
–  Disconnect supply line -1- (black) and breather line -2- (white) at connecting point.

–  Remove securing strap bolt and securing strap. When doing this, support fuel tank with engine
and gearbox jack -V.A.G 1383 A-.

–  Lower fuel tank.

Engine > 4-cylinder injection engine > Fuel supply, gas operation > Removing and installing parts of fuel supply system > Removing and installing fuel tank > Removing

Engine > 4-cylinder injection engine > Fuel supply, gas operation > Checking electronic power control (EPC) > Assembly overview

   

Assembly overview

29
 1 -  Mounting bracket

2 -  Connector
   Black, 6-pin.

3 -  Accelerator pedal position sender -G79- and accelerator position pedal sender 2 -G185-

4 -  10 Nm

   

Engine > 4-cylinder injection engine > Fuel supply, gas operation > Checking electronic power control (EPC) > Assembly overview

Engine > 4-cylinder injection engine > Fuel supply, gas operation > Active charcoal filter system > Assembly overview - parts of active charcoal filter system

   

Assembly overview - parts of active charcoal filter system

30
 1 -  Breather line
   Check for secure seating.

2 -  Pressure retention valve with connecting hose

   Check for secure seating.
   From gravity valve on fuel tank.

3 -  Breather connection
   Visible from below.

4 -  10 Nm

5 -  Throttle valve control module -J338-

   With vacuum union.

6 -  Active charcoal filter solenoid valve 1 -N80-

   Valve closed with ignition switched off.
   When engine is warm, valve will be activated (pulsed) by engine control unit.

7 -  Connector

8 -  Active charcoal filter
   Location: in front right wheel housing.

   

Engine > 4-cylinder injection engine > Fuel supply, gas operation > Active charcoal filter system > Assembly overview - parts of active charcoal filter system

Engine > 4-cylinder injection engine > Mixture preparation system, electronic inj.,Gas > Repairing injection system > Assembly overview - fuel rail with injectors

   

Assembly overview - fuel rail with injectors

31
 1 -  Supply line
   Black with white markings
   Check for secure seating.
   Secure with spring-type clips.
   From fuel filter.

2 -  10 Nm

3 -  Fuel rail

   Removing and installing → Chapter.
   Checking fuel pressure regulator → Chapter.

4 -  Breather valve
   For fuel system.
   Bleeding fuel system → Chapter.

5 -  Securing clip

   Check for secure seating.
   Ensure correct seating on injector and fuel rail.

6 -  O-ring
   Renew.
   Before installing moisten with clean engine oil.

7 -  No. 4 cyl. injector -N33-

   No. 1 cyl. injector -N30-
   No. 2 cyl. injector -N31-
   No. 3 cyl. injector -N32-
   Resistance 12...17 Ω

   

Engine > 4-cylinder injection engine > Mixture preparation system, electronic inj.,Gas > Repairing injection system > Assembly overview - fuel rail with injectors

Engine > 4-cylinder injection engine > Exhaust system > Removing and installing parts of exhaust system > Assembly overview - exhaust system with attachments

   

Assembly overview - exhaust system with attachments

32
 1 -  Warm air collector plate

2 -  10 Nm
   Note tightening sequence → Fig..

3 -  40 Nm

4 -  Bracket

5 -  Exhaust manifold

6 -  Gasket
   Renew.

7 -  Lock nut, 25 Nm

   Renew.

8 -  Lambda probe -G39-, 50 Nm

   Grease only the threads with “G 052 112 A”; “G 052 112 A” must not get into the slots on the probe body.
   Remove and install with lambda probe open ring spanner set -3337-.
   If seal is leaking, nip open and renew.

9 -  Connector
   Black, 6-pin.
   For lambda probe -G39- and lambda probe heating -Z19-.

10 -  Connector
   Black, 4-pin.
   For lambda probe after catalytic converter -G130- and lambda probe heating 1 after catalytic converter -Z29-.

11 -  Lambda probe after catalytic converter -G130-, 50 Nm

   Grease only the threads with “G 052 112 A”; “G 052 112 A” must not get into the slots on the probe body.
   Remove and install with lambda probe open ring spanner set -3337-.
   If seal is leaking, nip open and renew.

12 -  Double clamp

13 -  To front silencer

14 -  25 Nm

15 -  Front exhaust pipe with catalytic converter

   Observe part number.

16 -  Retainer

33
    Renew if damaged.

17 -  40 Nm
   Renew.

18 -  Gasket
   Renew.

   
 
Tightening sequence warm air collector plate to exhaust manifold

1 -  Tighten bolt -1-, 10 Nm

2 -  Tighten bolt -2-, 10 Nm
3 -  Tighten bolt -3-, 10 Nm

Engine > 4-cylinder injection engine > Exhaust system > Removing and installing parts of exhaust system > Assembly overview - exhaust system with attachments

Engine > 4-cylinder injection engine > Exhaust system > Removing and installing parts of exhaust system > Assembly overview - silencer with mountings

   

Assembly overview - silencer with mountings

1 -  Front silencer

2 -  25 Nm

3 -  Mounting
   Note installation position.

4 -  Separating point

   Marked by impressions on connecting pipe

34
    During production, front and rear silencers are installed as a single component. In repair cases, the front exhaust pipe and rear silencer are supplied individually with a
double clamp for connecting together.
   Cut through connecting pipe with body saw e.g. body saw -V.A.G 1523A- at right angles at the separating point → Fig.

5 -  Rear silencer

   
 
Separating point on exhaust pipe

–  Separate exhaust pipe at right angles at separating point -arrow 2-.

–  When installing fit repair double clamp -4- at side markings -arrows 1 and 3-. Torque setting:
25 Nm.

Engine > 4-cylinder injection engine > Exhaust system > Removing and installing parts of exhaust system > Assembly overview - silencer with mountings

Engine > 4 - Cyl. injection engine (4-valve, rolling rockers) > Engine assy,cylinder block,crankcase > Engine - remove and install > Motopropelling group support > Tightening torque

   
Tightening torque

  Note
Fastening bolts  of accessory case are expanding  bolts and must be replaced.
 
Engine accessory case.

A = 20Nm + 90° B = 30Nm + 90° - Replace.

 
Transmission accessory case.

A = 50Nm + 90° B = 40Nm + 90° - Replace.

35
  
Pendular support.

A = 30Nm + 90° . B= 40Nm + 90°. - Replace.

Engine > 4 - Cyl. injection engine (4-valve, rolling rockers) > Engine assy,cylinder block,crankcase > Engine - remove and install > Motopropelling group support > Tightening torque

Vehicle electrics > Electrical system > Starter-current supply-CC > Battery > BatteryA - disconnect and connect

   
Battery -A- - disconnect and connect
  Note
The Battery -A- earth wire fastening should not be removed from the vehicle body.

   WARNING
To avoid accident risks, always disconnect first the terminal  connected to the negative
pole of the Battery -A-.

Depending on the year and engine, the vehicle may be equipped with one of the fuse holders
identified below:
 
  Vehicles with fuse holder coupled to the Battery -A- cover (version 1) → Chapter.

  Vehicles with fuse holder coupled to the Battery -A- cover (version 2) → Chapter.  

36
  Vehicles with fuse holder fastened to the Battery -A- console base (version 3) → Chapter.  

  Vehicles with fuse holder fastened to the Battery -A- console base (version 4) → Chapter.  

  Vehicles with fuse holder fastened to the Battery -A- console base (version 5) → Chapter.  

Vehicle electrics > Electrical system > Starter-current supply-CC > Battery > BatteryA - disconnect and connect

Vehicle electrics > Electrical system > Starter-current supply-CC > Battery > BatteryA console - remove and install > BatteryA console (version 1) - remove and install

   
Battery -A- console (version 1) - remove and install
Removal:

–  Turn off the ignition and all electrical equipment, and remove the key from ignition.

–  Disconnect and remove Battery -A- → Chapter.

37
  
–  Remove the plastic strap -1- that fastens the cables on the front part of the Battery -A-console.

 
–  Loosen the securing nuts -1- (16 Nm) and fastening screw -2- (16 Nm) from the Battery -A-
console-3-.

–  Remove the flexible rubber draining tube from the lower part of the Battery -A-console.

–  Remove the Battery -A-console-3- from its housing.

Installation:

Installation is performed in reverse sequence to the removal, considering the following:

 
–  Tighten the securing nuts -1- and the fastening screw -2- to the specified torque → Chapter.

–  After installing, check correct seating of the Battery -A- on its console.

Vehicle electrics > Electrical system > Starter-current supply-CC > Battery > BatteryA console - remove and install > BatteryA console (version 1) - remove and install

ehicle electrics > Electrical system > Starter-current supply-CC > Battery > Tightening torques - Battery

   
Tightening torques - battery
Location Tightening torques

Terminals in battery poles 6 Nm

Auxiliary terminal to battery terminal 6 Nm

Fastening support screw 25 Nm

securing nut for battery console 16 Nm

Fastening screw for battery console 16 Nm

   

Vehicle electrics > Electrical system > Starter-current supply-CC > Battery > Tightening torques - Battery

Heating, ventilation, air conditioning > Heating, air conditioning > Heating > Heating - passenger compartment components

38
    

Heating - passenger compartment components

   WARNING
Before working on the heater and air conditioning system, it is necessary to disconnect
the battery earth wire Battery -A-  →  Electrical equipment;  Rep. gr.27.

  Note
  Check whether the vehicle has a coded  radio. If so, request the anti-theft code before
disconnecting the Battery -A- earth wire.
  Upon reconnecting the Battery -A-, check the vehicle equipment (radio, clock, power locks
andwindows, etc.) according to the Workshop  Manual and/or instructions for use.

1 -  Upper air duct

   Installed on the cross support of instrument panel.
   Remove and install → Chapter.

2 -  Air duct for baffles

   Installed on the instrument panel → General body repairs, interior; Rep. gr.70.

3 -  Ventilation adjustment mechanism

   Remove and install → Chapter.

4 -  Air baffles (sides)

   Remove and install → Chapter.

5 -  Air baffles (central)

   Remove and install → Chapter.

6 -  Transverse support on instrument panel

   Remove and install → Body - Internal assembly works; Rep. gr.70.

7 -  Plenum chamber (heating system)

   Remove and install → Chapter.

8 -  Front right feet air duct

   Remove and install → Chapter.

9 -  Command cable

   For the ventilation adjustment mechanism.
   For the heating adjustment mechanism.

10 -  Ventilation adjustment mechanism frame

39
 11 -  Coupling for the rear air duct

12 -  Rear air duct

   Remove and install → Chapter.

13 -  Rear right feet air duct

   Remove and install → Chapter.

14 -  Rear left feet air duct

   Remove and install → Chapter.

15 -  Front left feet air duct

   Remove and install → Chapter.

16 -  Heat exchanger/engine compartment partition panel sealing

   Replace if damaged
   Observe the installation position → Chapter.

17 -  dash panel

   Remove and install → Body - Internal assembly works; Rep. gr.70.

   

Heating, ventilation, air conditioning > Heating, air conditioning > Heating > Heating - passenger compartment components

Heating, ventilation, air conditioning > Heating, air conditioning > Heating > Heating - passenger compartment components > Heat exchanger/engine compartment partition panel sealing

   
Heat exchanger/engine compartment partition panel sealing
For vehicles equipped with a ventilation / heating system.

  Vehicles with air conditioning system → Chapter.

1 -  Plenum chamber (Ventilation / Heating)

   Remove and install → Chapter.

2 -  Heat exchanger

   Remove and install → Chapter.

3 -  Heat exchanger sealing

   Replace if damaged.

4 -  Engine compartment's partition panel

   

Heating, ventilation, air conditioning > Heating, air conditioning > Heating > Heating - passenger compartment components > Heat exchanger/engine compartment partition panel sealing

Heating, ventilation, air conditioning > Heating, air conditioning > Heating > Heating - passenger compartment components > Natural air fanV2 > Fresh air fanV2 (version 1) - remove and install

   
Fresh air fan -V2- (version 1) - remove and install
Removal:

–  Remove the glove box → General body repairs, interior; Rep. gr.68.

–  Disconnect the connector -2-.

40
  
–  Carefully cut cable fastening -1- and -3- .

–  Disengage and remove connector -4- from fan case -5-.

–  Remove fastening screws -arrows- and remove fan housing -5-.

 
–  Use a small screwdriver to carefully release the locks -2- on the connector in the direction of
the -arrows- and push connector -1- down.

–  Press locks -3- with a screwdriver inwards and downwards.

–  Remove the Natural air fan -V2- from fan case.

Installation:

Installation is performed in reverse sequence to the removal, observing the following:

  The Natural air fan -V2- is different for the heater and air conditioning equipment - check the part
number.
  The connector shall be connected correctly.
  Tighten fastening screws to a torque of (1 Nm).
  Locks -3- must leave completely the fan case.
  Check fan operation before installing fan case → Chapter.

Heating, ventilation, air conditioning > Heating, air conditioning > Heating > Heating - passenger compartment components > Natural air fanV2 > Fresh air fanV2 (version 1) - remove and install

Heating, ventilation, air conditioning > Heating, air conditioning > Heating > Heating - passenger compartment components > Natural air fanV2 > Fresh air fanV2 (version 2) - remove and install

   
Fresh air fan -V2- (version 2) - remove and install
Removal:

–  Remove the glove box → General body repairs, interior; Rep. gr.68.

–  Disconnect the connector -1-.

–  Carefully cut the cable fastenings.

 
–  Remove the fastening screws -arrows- and remove fan case.

41
  
–  By using a small screwdriver, release carefully the locks -2- from the connector towards the -
arrows- and push connector -1- downwards.

–  Press locks -3- with a screwdriver inwards and downwards.

–  Remove the Natural air fan -V2- from fan case.

Installation:

Installation is performed in reverse sequence to the removal, observing the following:

  The Natural air fan -V2- is different for the heater and air conditioning equipment - check the part
number.
  The connector shall be connected correctly.
  Tighten fastening screws to a torque of (1 Nm).
  Locks -3- must leave completely the fan case.
  Check fan operation before installing fan case → Chapter.

Heating, ventilation, air conditioning > Heating, air conditioning > Heating > Heating - passenger compartment components > Natural air fanV2 > Fresh air fanV2 (version 2) - remove and install

Heating, ventilation, air conditioning > Heating, air conditioning > Heating > Heating - passenger compartment components > Dust and pollen filter - remove and install > Removal

   
Removal
 
–  Join the dust and pollen filter cover locks -arrows-.

 
–  Remove dust and pollen filter from the ventilation case -arrow-.

42
  
–  Remove the filtering element from framework.

Heating, ventilation, air conditioning > Heating, air conditioning > Heating > Heating - passenger compartment components > Dust and pollen filter - remove and install > Removal

43