Service

Repair Manual
Bora 1999 ➤
Bora Variant 1999 ➤
Golf 1998 ➤
Golf Variant 1998 ➤
Engine Mechanical
Engine ID AWD AWW AWP

Edition 11.2007

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Service Department. Technical Information

 Service
List 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 agen
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26 - Exhaust System,
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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 © 2015 Volkswagen AG, Wolfsburg D3E80022B06

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

Contents

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

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .V.ol.ks.w.a.g. . . . . . . . . . . . . . . . . . . . . . . . 2
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2.1 Engine Data . . . . . . . . . . . . . . . . . . . . . . o.lk.sw
. a. g.e. . . . . . . . . . . . .G.d.oe. s.n.o . . . . . . . . . . . . . . . 2
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10 - Engine Assembly . . . . . . . . . . . . t.ho.ris.e . . . . . . . . . . . . . . . . . . . . . . . . . .nt.ee.o . . . . . . . 3
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1 General Information . . . . . . ................................... . s.s .a . ...... . .ac. 3

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1.1 A/C System Additional Information and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1.2 Engine and Transmission Mountings, Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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2.1 Engine and Transmission Mounts Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . 5

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3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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3.1 Engine, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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3.2 Engine, Securing on Assembly Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Engine, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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1.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
m

2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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2.1 Overview - Belt Drive and Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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2.2 Overview - Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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2.3 Overview - Pistons and Connecting Rods, Engine Code AWD . . . . . . . . . . . . . . . . . . . . . . 24
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2.4 Overview - Pistons and Connecting Rods, Engine Code AWP, AWW . . . . . . . . . . . . . . . . 26

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2.5 Overview - Sealing Flanges and Flywheel/Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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3.1 Crankshaft Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.2 Piston and Cylinder Dimensions, Engine Code AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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3.3 Piston and Cylinder Dimensions, Engine Codes AWP, AWW . . . . . . . . . . . . . . . . . . . . . . 32

4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.1 Crankshaft Seal, Belt Pulley Side, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.2 Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.3 Sealing Flange, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.4 Ribbed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.1 Overview - Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.2 Overview - Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.3 Valve Seats, Reworking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.1 Compression, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.2 Hydraulic Valve Lifter, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.3 Valve Guides, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.4 Camshaft, Checking Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.1 Camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.2 Camshaft Gaskets, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Contents i
 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

3.3 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

3.4 Toothed Belt, Removing, Installing and Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.5 Valve Stem Seals, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4 Special Tools . . . . G
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17 - Lubrication ed b.y .V . . . . . . . . . . . . . . . . . . .o.t g.ua.ra. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1 General
utho Information . . . . . . . . . . . . . . . . . . . .ee. o.r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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1.1 sLubrication System . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

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2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

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2.1 Lubrication System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

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2.2 Overview - Oil Filter Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

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3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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3.1 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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4.1 Oil Pressure and Oil Pressure Switch, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

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5.1 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
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19 - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

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1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
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1.1 Coolant, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
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1.2 Cooling System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

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2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

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2.1 Coolant Hose Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

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2.2 Cooling System Components, Engine Side, Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

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2.3 Overview - Cooling System Components, Body Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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3 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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3.1 After-Run Coolant Pump V51 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

4.1 Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.2 Coolant Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.3 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.1 Electronic Power Control (EPC) Warning Lamp in Instrument Cluster, Meaning . . . . . . . . 113
1.2 EPC System Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.3 Emergency Fuel Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.4 Evaporative Emission (EVAP) System, Function Description . . . . . . . . . . . . . . . . . . . . . . 114
1.5 Guidelines for Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.6 Leak Detection Function Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.7 Safety Precautions, Working on Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.1 EVAP System Overview Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.2 Overview - Electronic Engine Power Regulation (EPC) Components . . . . . . . . . . . . . . . . 118
2.3 Overview - EVAP System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.4 Overview - Fuel Tank with Attachments and Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.1 Accelerator Pedal Position Sensor G79 and Accelerator Pedal Position Sensor 2 G185 ,
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.2 EVAP Canister Purge Regulator Valve 1 N80 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.3 EVAP System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

ii Contents
 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

3.4 Fuel Pump, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

3.5 Leak Detection Pump (LDP), Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.1 Fuel Delivery Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.2 Fuel Level Sensor G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.3 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

21 - Turbocharger, Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.1 Charge Air System with Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.2 Guidelines for Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.3 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2.1 Exhaust Turbocharging System, Engine Code AWD, wage
Overview
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2.2 Exhaust Turbocharging System, Engine Code byVAWP,
o AWW, Overview Plan .ot.g.ua. . . . . . . . . 151
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2.3 Overview - Charge Air Cooler Components ris . . . . . . . . . . . . . . . . . . . . . . . . . . . . . n.te.e . . . . .
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2.4 Overview - Turbocharger with Attachments au . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.ac. . . 154
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3 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

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3.1 Boost Pressure Regulator Valve Vacuum Diaphragm, Checking . . . . . . . . . . . . . . . . . . . . 159

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itte

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3.2 Charge Air Pressure Regulation, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
erm

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3.3 Charge Air Pressure Sensor G31 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

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3.4 Charge Air System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

h re
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3.5 Deceleration Shut-Off Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

spec
es, in part or in w

3.6 Fuel Tank Shut-Off Valve 4 N249 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

t to the co
3.7 Wastegate Bypass Regulator Valve N75 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

rrectness of i
26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
l purpos

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

1.1 Exhaust System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

nf
ercia

o
1.2 Secondary Air Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

rm
m

atio
m

2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

o

n in
c

2.1 Overview - Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

or

thi
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2.2 Overview - Secondary Air Injection System Components . . . . . . . . . . . . . . . . . . . . . . . . . . 174

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3 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
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3.1 Combination Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

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3.2 Secondary Air Injection Pump Motor V101 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
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3.3 Secondary Air Injection Solenoid Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
p by
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3.4 Three Way Catalytic Converter (TWC), Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cted
178
agen
Prote AG.

4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

5 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Contents iii
 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

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iv Contents
 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

00 – General, Technical Data

1 General Information
(Edition 11.2007)
⇒ “1.1 Engine Number”, page 1

1.1 Engine Number

The engine number (“engine code” and “serial number”) are lo‐
cated at the front of the engine/transmission joint.
The engine number consists of up to nine characters (alphanu‐
meric). The first part (maximum three 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.
The engine code is also included on the vehicle data plate.
In addition, a sticker with “engine code” and “serial number” is
affixed to the toothed belt guard -arrow-.

Note

The engine code -arrow- is also stamped on the engine lifting eye.

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1. General Information 1
 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

2 Specifications
⇒ “2.1 Engine Data”, page 2

2.1 Engine Data

Engine code AWD AWW AWP
Manufactured From 11/1999 From 07/2000 From 06/2001
Displacement liter 1.8 1.8 1.8
Output kW at RPM 110/5700 110/5700 132/5500
Torque Nm at RPM 210/1750 to 4600 220/1950 to 4500 235/1950 to 5000
Hole diameter in mm 81.0 81.0 81.0
Stroke mm 86.4 86.4 86.4
Compression ratio 9.5 9.3 9.5
RON 95 unleaded 95 unleaded 98 unleaded
System designation Motronic ME7.1 Motronic ME7.1 Motronic ME7.1
Emission values in accordance with TLEV1) LEV2) LEV2)
Knock control 2 knock sensors 2 knock
agensensors
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G do sensors
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On Board Diagnostics (OBD) OBD II by Vo OBD II OBDotIIgua
ed ra
Oxygen sensor regulation 2 sensorsthoris 2 sensors 2 sensors ntee o
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Catalytic Converter yesss a yes yes c

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Exhaust Gas Recirculation (EGR) no no no

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Intake manifold change-over no no no
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Camshaft adjustment no yes yes

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Turbocharger, yes yes yes

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Electronic Power Control (EPC) yes yes yes
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Boost pressure regulation Yes Yes Yes
es, in part or in w

t to the co
Secondary Air Injection (AIR) System Yes Yes Yes

rrectness of i
1) TLEV = Transitional Low Emission Vehicles (emission values max. 0.125 g/mi
l purpos

HC)
2) LEV = Low Emission Vehicles (emission values max. 0.075 g/mi HC).

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2 Rep. Gr.00 - General, Technical Data

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

10 – Engine Assembly
1 General Information
⇒ “1.1 A/C System Additional Information and Procedures”, page
3
⇒ “1.2 Engine and Transmission Mountings, Aligning”,
page 4

1.1 A/C System Additional Information and

Procedures

WARNING

Do not open the Air Conditioning (A/C) system refrigerant cir‐

cuit. swa
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♦ The refrigerant circuit must only be opened in shops with

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trained personnel and the necessary range of tools and shop

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equipment.

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♦ To prevent damage to condenser and also to the refrigerant
ole,

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

spec
urposes, in part or in wh

ed, kinked or bent.

t to the co
To facilitate removal and installation of the engine without having
to open the refrigerant circuit:

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

ss
– Remove the ribbed belt. Refer to

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f
⇒ “4.4 Ribbed Belt”, page 38 .

inform
mer

– Remove the A/C Compressor. Refer to ⇒ Heating, Ventilation

atio
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and Air Conditioning; Rep. Gr. 87 ; Description and Operation .

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

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Shield bumper from damage using adhesive tape. cop Vo
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Prote AG.

1. General Information 3
 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

1.2 Engine and Transmission Mountings,

Aligning

WARNING

Before loosening bolts, secure the assemblies using the En‐

gine Support Bridge - 10-222A- .

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

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Transmission Assembly Mount

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Edges a and b must be parallel to each other.

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4 Rep. Gr.10 - Engine Assembly

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

2 Specifications
⇒ “2.1 Engine and Transmission Mounts Tightening Specifica‐
tions”, page 5

2.1 Engine and Transmission Mounts Tight‐

ening Specifications
Engine Mount
1- Mounting to body 3) 40 Nm + 90° (1/ 4
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2- Mount/bracket to body 25 Nm byV
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3- Mount to engine bracket 100 Nmhoris tee
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Transmission Assembly Mount

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1- Mounting to body 4) 40 Nm + 90° (1/ 4

t to the co
turn)
2- Mounting to body 25 Nm

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3- Mounting to transmission console 100 Nm
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4) Replace the bolts

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Pendulum Support
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1- Pendulum supports to transmission 40 Nm + 90° (1/ 4

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2- Pendulum supports to transmission 40 Nm + 90° (1/ 4
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3- Pendulum supports to subframe 5) 20 Nm + 90° (1/ 4

turn)
5) Replace the bolts

2. Specifications 5
 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

3 Removal and Installation

⇒ “3.1 Engine, Removing”, page 6
⇒ “3.2 Engine, Securing on Assembly Stand”, page 10
⇒ “3.3 Engine, Installing”, page 11

3.1 Engine, Removing

Special tools and workshop equipment required
♦ Holding Fixture - VW313-
♦ Holding Fixture - VW540-
♦ Engine Sling - 2024A-
♦ Engine Support Bridge Retainer - 3180-
♦ Shop Crane - VAG1202A- or Shop Crane - VAS6100-
♦ Drip Tray - VAG1306- or Shop Crane - Drip Tray - VAS6208-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Torque Wrench 1332 40-200Nm - VAG1332-
♦ Engine and Gearbox Jack - VAS6931- agen
AG. Volkswagen AG d
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♦ Engine/Trans. Support - T10012- byV gu
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♦ Spring Clip Pliers - VAS6499- aut
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♦ Ladder - VAS5085-

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♦ Lubricating Grease - G 000 100- (vehicles with manual trans‐

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♦ M10×25 / 8.8 Bolt

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♦ Cable Tie
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es, in part or in w

– First, check whether a coded radio is installed. If necessary,

t to the co
obtain the anti-theft coding.
– The engine is removed downward together with the transmis‐

rrectness of i
sion.
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– Turn off the ignition and disconnect the Ground (GND) cable
from the battery.
nform
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– All cable ties which are opened or cut open when removing
engine, must be replaced in the same position when installing
m

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– Remove the engine cover.

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Prote AG.

6 Rep. Gr.10 - Engine Assembly

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Remove connecting hoses -arrows- between Secondary Air

Injection (AIR) pump/combination valve and AIR pump/air fil‐
ter.

Note

Press buttons together on hose connections to do so.

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– Remove connector -1- on AIR Vpump.
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– Remove the air filter. Refer rise to ⇒ Fuel Injection and Ignition; nte
Rep. Gr. 24 ; Description tho and Operation . eo
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– Pull vacuum and vent hoses off from the engine.

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WARNING

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The fuel supply line is under pressure. Always wear protective

h re
eyewear and protective clothing to prevent injuries and contact
ole,

spec
with skin. Place a cloth on the connection location before loos‐
urposes, in part or in wh

ening hose connections. Then release pressure by carefully

t to the co
pulling hose off connection.

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3. Removal and Installation 7

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Pull off the supply line -1- (with white marking) and return line
-2- (with blue marking) and catch any released fuel with a shop
rag.
– Remove hose from solenoid valve.

Note

Press buttons together on hose connections to do so.

– Seal the lines so that no dirt can enter the fuel system.
– Remove intake hose between the Mass Airflow Sensor - G70-
and the exhaust turbocharger. Refer to ⇒ Fuel Injection and
Ignition; Rep. Gr. 24 ; Description and Operation .
– Loosen intake hose (between charge air cooler and Throttle
Valve Control Module - J338- ) at Throttle Valve Control Mod‐
ule - GX3- and remove.
Vehicles with Manual Transmission
– Disconnect selector mechanism from the transmission. Refer
to ⇒ Manual Transmission; Rep. Gr. 34 ; Removal and In‐
stallation .
– Remove the hydraulic clutch slave cylinder. Refer to ⇒ Manual
Transmission; Rep. Gr. 30 ; Description and Operation .

Note agen
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Clutch pedal must not be operated. rised ara
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Vehicles with Automatic Transmission
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– Disconnect selector lever cable from the transmission. Refer

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to ⇒ Automatic Transmission; Rep. Gr. 37 ; Removal and

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Installation .
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Continuation for All Vehicles

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– Remove the insulation. Refer to ⇒ Body Exterior; Rep. Gr.

spec
urposes, in part or in wh

50 ; Description and Operation .

t to the co

– Drain the coolant. Refer to

⇒ “1.1 Coolant, Draining and Filling”, page 93 .
rrectne

– Disconnect coolant hoses from radiator at engine.

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Hose Clip Pliers - VAS5024A- or the Hose Clip Pliers - VAG1921-

atio
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are recommended for installing spring-clips.

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8 Rep. Gr.10 - Engine Assembly

 AG. Volkswagen AG d
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ho
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ss Engine Mechanical - Edition 11.2007 c

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– Remove pendulum supports -arrows-.

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– Pull off/disconnect and free up all electrical harnesses from

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transmission, alternator, and starter.

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– Remove the front exhaust pipe. Refer to

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spec
⇒ “1.1 Exhaust System Components”, page 170 .

es, in part or in w

t to the co
– Remove the ribbed belt. Refer to
⇒ “4.4 Ribbed Belt”, page 38 .
– Remove securing clamps for power steering pressure line.

rrectness of i
– Remove the power steering pump at the bracket and move it

l purpos
to the side. The hoses remain connected. Refer to ⇒ Sus‐
pension, Wheels, Steering; Rep. Gr. 48 ; Removal and In‐

nform
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stallation .

at
– Pull off/disconnect as many wires as necessary from the en‐
om

io
gine and free it up.

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– Remove right drive axle and unbolt left drive axle at transmis‐

do
riv
sion. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ;
p

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Removal and Installation .
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– Remove the air conditioner compressor: p by
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– Observe additional information and removal work. Refer to Prote AG.
⇒ “1.1 A/C System Additional Information and Procedures”,
page 3 .
Continuation for All Vehicles

– Attach the Engine/Trans. Support - T10012- to cylinder block

with nut and bolt M10×25/ 8.8 to approximately 40 Nm.
– Lift the engine and transmission gently using the Engine and
Gearbox Jack - VAS6931- .

– Remove engine side of assembly mounting from engine sup‐

port at top -arrows-.

Note

Use Ladder - VAS5085- to remove securing bolts.

3. Removal and Installation 9

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Remove the subframe mount on the transmission side from

the transmission holder -arrows- from above.
– Carefully lower engine with transmission.
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Carefully guided engine with
ss a transmission, when lowering, to pre‐
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vent damage to bodywork.

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3.2 Engine, Securing on Assembly Stand
ole,

spec
urposes, in part or in wh

Special tools and workshop equipment required

t to the co
♦ Holding Fixture - VW540-
♦ Holding Fixture - VW313-

rrectne
♦ Engine Sling - 2024A-

ss
♦ Engine Support Bridge Retainer - 3180-

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♦ Engine and Gearbox Jack - VAS6931-
mer

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♦ Workshop Crane - VAG1202-
om

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Secure engine to Holding Fixture - VW540- of assembly stand

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using Holding Fixture - VW313- when performing repair work.

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– Remove transmission. Cop py
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Vehicles with Automatic Transmission p by
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– After separating engine from transmission, secure the torque Prote AG.
converter to prevent it from “falling out”.
Continuation for All Vehicles
– Engage the Engine Sling - 2024A- with the Engine Support
Bridge Retainer - 3180- as follows and pry out of the Engine
and Gearbox Jack - VAS6931- with the Workshop Crane -
VAG1202- .
Belt pulley side: three holes of the rail with holes in position 1.
Flywheel side: two holes on the rail with holes in position 5.

WARNING

Use securing pins at hooks and pins.

Note

♦ The peg positions on the carrying strap marked 1 to 4 face the

belt pulley.
♦ The bores in the hole rail are counted from the hook.

10 Rep. Gr.10 - Engine Assembly

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Secure the engine with Holding Fixture - VW540- on Holding

Fixture - VW313- .

3.3 Engine, Installing

Install in reverse order of removal. Note the following:

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♦ Route lines of all types (for example for fuel, hydraulic, pt

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♦ To prevent damage to the lines, make sure there is suffi‐

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cient clearance to all moving or hot components.

spec
es, in part or in w

t to the co

– Make sure the alignment bushings for centering the engine/

transmission are installed inside the cylinder block. Install
rrectness of i

them if necessary.
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Cop py
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rig ht
py by
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by lksw
cted agen
Prote AG.

3. Removal and Installation 11

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Engage the intermediate plate with the sealing flange and then
slide it onto the alignment sleeves -arrows-.
Vehicles with Manual Transmission
– If necessary, check the clutch drive plate centering.
– Check clutch release bearing for wear and replace if neces‐
sary.
– Lightly grease the clutch release bearing, release bearing
guide sleeve and driveshaft splines with Grease - G 000 100- .
– Install the hydraulic clutch slave cylinder. Refer to ⇒ Manual
Transmission; Rep. Gr. 30 ; Description and Operation .
– Install the shift mechanism. Refer to ⇒ Manual Transmission;
Rep. Gr. 34 ; Removal and Installation .
– If necessary, adjust the selector lever cable. Refer to ⇒ Man‐
ual Transmission; Rep. Gr. 34 ; General Information .
Vehicles with Automatic Transmission 01M
– To secure torque converter to drive plate, only use nuts ap‐
proved by replacement parts program.
. Volkswagen AG
gen AG does
– Install the selector lever cable on the transmission Vand
olks adjust
wa not
if necessary. Refer to ⇒ Automatic Transmission; ed Rep. Gr.
by gu
ara
37 ; Removal and Installation . ho
ris nte
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t
au ra
– Adapt the automatic transmission controlss module. c

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pt
Vehicles with Automatic Transmission 09A

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d
itte

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– To secure torque converter to drive plate, only use nuts ap‐
erm

ab
ility
proved by replacement parts program.
ot p

wit
is n

– Install the selector lever cable on the transmission and adjust

h re
ole,

if necessary. Refer to ⇒ Automatic Transmission; Rep. Gr.

spec
urposes, in part or in wh

37 ; Removal and Installation .

t to the co
– Adapt the automatic transmission control module.
Continuation for all Vehicles

rrectne
– When installing the assembly, ensure clearance to the drives
axles. ss o
cial p

– Align engine and transmission mountings. Refer to

f in

⇒ “1.2 Engine and Transmission Mountings, Aligning”,

form
mer

page 4 .
atio
om

– Install the drive axles. Refer to ⇒ Suspension, Wheels, Steer‐

n
c

i
or

ing; Rep. Gr. 40 ; Removal and Installation .

thi
te

sd
iva

– Install front exhaust pipe. Refer to

pr

cum
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fo

⇒ “1.1 Exhaust System Components”, page 170 .

en
ng

t.
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op
– Position the intake hose (between charge air cooler and Throt‐ C py
t. rig
tle Valve Control Module - J338- ) at Throttle Valve Control
gh ht
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Module - GX3- and secure. cop Vo
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cted agen
Prote AG.
– Install power steering pump. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 48 ; Removal and Installation .
– Connections and wiring routing. Refer to ⇒ Electrical Equip‐
ment; Rep. Gr. 97 .
– Install the ribbed belt. Refer to
⇒ “4.4 Ribbed Belt”, page 38 .
– Install connecting hoses between Secondary Air Injection
(AIR) pump/combination valve and AIR pump/air filter.
– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.
50 ; Description and Operation .

12 Rep. Gr.10 - Engine Assembly

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Fill with coolant. Refer to gen AG. Volkswagen AG d

a
⇒ “1.1 Coolant, Draining
Vol and Filling”, page 93 .
ksw
oes
not
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– Perform the “Procedure
ris
e
after Voltage Supply Open Circuit”.
an
tee
ho
Refer to ⇒ Fuel
aut Injection and Ignition; Rep. Gr. 24 ; Diagnosis or
ac
and Testing
ss .

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Tightening Specifications

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Bolted Connection Tightening
pe

ility
Specification
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Bolts and Nuts M6 10 Nm
hole

spec
M7 15 Nm
es, in part or in w

t to the co
M8 25 Nm
M10 40 Nm

rrectness of i
Mme. 60 Nm
Deviation from
l purpos

Connecting bolts, engine to transmis‐ M10 45 Nm

sion

nform
ercia

Connecting bolts, engine to transmis‐ Mme. 80 Nm

m

a
sion
com

tion in
Converter to drive plate 60 Nm
r
te o

thi
s
iva

Driveshaft to drive flange/transmis‐ 40 Nm

do
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Note
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Tightening specifications of subframe mount. Refer to Prote AG.
⇒ “2.1 Engine and Transmission Mounts Tightening Specifica‐
tions”, page 5 .

3. Removal and Installation 13

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

4 Special Tools

Special tools and workshop

equipment required wage
n AG. Volkswagen AG do
es n
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♦ Holding Fixture - VW313- byV ua
d ran
ir se tee
o
♦ Holding Fixture - VW540- auth or
ac
ss
♦ Engine Sling - 2024A-

ce
e
nl

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du

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♦ Engine Support Bridge Re‐
itte

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tainer - 3180-
erm

ab
ility
ot p

♦ Shop Crane - VAG1202A-

wit
, is n

or Shop Crane - VAS6100-

h re
hole

spec
♦ Drip Tray - VAG1306- or
es, in part or in w

Shop Crane - Drip Tray -

t to the co
VAS6208-

rrectness of i
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nf
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orm
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or c

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Prote AG.

14 Rep. Gr.10 - Engine Assembly

 Bora 1999 ➤ , Bora Variant 1999 ➤. V,oGolf
n AG lkswag1998
en AG ➤ , Golf Variant 1998 ➤
wage does
y Volks Engine Mechanical not - Edition 11.2007
g b ua
ed ran
oris tee
th or
♦ Torque Wrench 1331 ss
au ac
5-50Nm - VAG1331-

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♦ Torque Wrench 1332

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40-200Nm - VAG1332-

erm

ab
ility
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♦ Engine and Gearbox Jack -

wit
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VAS6931-

h re
hole

spec
♦ Engine/Trans. Support -

es, in part or in w
T10012-

t to the co
♦ Spring Clip Pliers -
VAS6499-

rrectness of i
♦ Ladder - VAS5085-
l purpos

♦ Lubricating Grease - G 000

100- (vehicles with manual

nform
ercia

transmission)
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or

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ate

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Prote AG.

4. Special Tools 15
 AG. Volkswagen AG d
agen oes
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Bora 1999 ➤ , Bora Variant 1999 ➤aut , Golf 1998 ➤ , Golf Variant 1998 ➤
ho eo
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Engine Mechanical - Edition 11.2007 ss c

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13 – Crankshaft, Cylinder Block

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1 General Information

ole,

spec
urposes, in part or in wh
⇒ “1.1 Engine”, page 16

t to the co
1.1 Engine

rrectne
Note

ss o
cial p

f
♦ Secure the engine to the assembly stand using Holding Fixture

inform
- VW540- and Holding Fixture - Spacers - VW540/1B- when
mer

performing repair work.

atio
om

n
c

♦ If large quantities of metal shavings or abraded material are

i
or

n thi
detected during engine repairs, it may mean the crankshaft or
te

sd
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connecting rod bearings are damaged. To prevent subsequent

i

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damage, perform the following steps after the repair:
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♦ Clean the oil channels carefully.
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♦ Replace oil spray jets yri
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♦ Replace the oil cooler
agen
Prote AG.

♦ Oil Filter, Removing and Installing

16 Rep. Gr.13 - Crankshaft, Cylinder Block

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

2 Description and Operation

⇒ “2.1 Overview - Belt Drive and Cylinder Block”, page 17
⇒ “2.2 Overview - Crankshaft”, page 21
⇒ “2.3 Overview - Pistons and Connecting Rods, Engine Code
AWD”, page 24
⇒ “2.4 Overview - Pistons and Connecting Rods, Engine Code
AWP, AWW”, page 26
⇒ “2.5 Overview - Sealing Flanges and Flywheel/Drive Plate”,
page 30

2.1 Overview - Belt Drive and Cylinder Block

AG. Volkswagen AG d
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h re
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spec
urposes, in part or in wh

t to the co
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cial p

f inform
mer

atio
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n
c

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or

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sd
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pr

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Cop py
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by
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Prote AG.

2. Description and Operation 17

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

I ⇒ “2.1.1 Overview - Belt Drive”, page 18

II ⇒ “2.1.2 Cylinder Block and Components”, page 20

2.1.1 Overview - Belt Drive

1 - Bolt
❑ 25 Nm
2 - Ribbed Belt Tensioner
❑ To release tension on
ribbed belt, pivot using a
wrench. Refer to
⇒ “4.4 Ribbed Belt”,
page 38
3 - Toothed Belt Guard Upper
Section
4 - Toothed Belt Guard Center
Part
5 - Bolt
❑ 27 Nm
6 - Idler Roller
7 - Tensioning Roller
❑ Toothed belt, removing,
installing and tension‐
ing. Refer to
⇒ “3.4 Toothed Belt, Re‐
moving, Installing and
Tensioning”, page 67 .
8 - Toothed Belt
❑ Mark direction of travel agen
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oes
before removing olksw not
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❑ Check for wear orise nte
eo
h
ut
❑ Do not kink ss a ra
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❑ Removing and instal‐
ce
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ling, tensioning. Refer to

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itte

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⇒ “3.4 Toothed Belt, Re‐

erm

ab

moving, Installing and

ility
ot p

Tensioning”, page 67 .
wit
is n

h re

9 - Coolant Pump
ole,

spec
urposes, in part or in wh

❑ Check for ease of movement

t to the co

❑ Completely replace if damaged or leaking

❑ Removing and installing. Refer to ⇒ “4.1 Coolant Pump”, page 106 .
rrectne

10 - O-Ring
❑ Replace
ss o

11 - Bolt
cial p

f inform

❑ 15 Nm
mer

atio

12 - Tensioning Device for Toothed Belt

om

n
c

❑ Toothed belt, removing, installing and tensioning. Refer to

i
or

n thi
e

⇒ “3.4 Toothed Belt, Removing, Installing and Tensioning”, page 67 .

t

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13 - Crankshaft Toothed Belt Sprocket

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14 - Bolt
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❑ 15 Nm opyri
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Prote AG.

18 Rep. Gr.13 - Crankshaft, Cylinder Block

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

15 - Bolt
❑ 20 Nm
16 - Bolt
❑ 90 Nm + 1/4 additional turn (90°)
❑ Replace
❑ Use Counterhold - Crankshaft Sprocket - 3415- when loosening or tightening
❑ The threads and shoulder must be free of oil and grease
17 - Toothed Belt Guard Lower Section
18 - Bolt
❑ 10 Nm
❑ Insert with Locking Fluid - D 000 600 A2-
19 - Belt Pulley
❑ For power steering pump
20 - Bolt
❑ 25 Nm
21 - Ribbed Belt
❑ Mark direction of travel before removing
❑ Check for wear
❑ Do not kink
❑ Removing and installing. Refer to ⇒ “4.4 Ribbed Belt”, page 38 .
22 - Bolt
❑ 25 Nm
23 - Belt Pulley/Vibration Damper n AG. Volkswagen AG do
lkswage es n
❑ Only possible to install in one position - Bores b are
yV
o offset ot g
ua
ed ran
❑ Note position when installing toothed belt.thor Refer to
is tee
or
⇒ “3.4 Toothed Belt, Removing, Installing
s au and Tensioning”, page 67 . ac
s

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d
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ab
ility
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h re
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spec
urposes, in part or in wh

t to the co
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cial p

f inform
mer

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n
c

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Cop py
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gh ht
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by
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Prote AG.

2. Description and Operation 19

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

2.1.2 Cylinder Block and Components

1 - Knock Sensor 1 - G61-

❑ Checking. Refer to ⇒
Fuel Injection and Igni‐
tion; Rep. Gr. 28 ; De‐
scription and Opera‐
tion .
2 - 20 Nm
❑ The tightening specifi‐
cations affect function of
the knock sensor
3 - Knock Sensor 2 - G66-
❑ Checking. Refer to ⇒
Fuel Injection and Igni‐
tion; Rep. Gr. 28 ; De‐
scription and Opera‐
tion .
4 - Oil Dipstick
❑ The oil level must not go
above the MAX mark‐ wagen AG. Volkswagen AG does
ing! ks not
Vol gu
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❑ Marks. Refer tooris e nte
eo
⇒ Fig. ““Oil Dipstick
aut
h
ra
Markings”“s , page 84
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5 - Inlet Spout
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❑ For the oil dipstick

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6 - O-Ring
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❑ Replace
hole

spec

7 - Coolant Pipe
es, in part or in w

t to the co

8 - Bolt
❑ 20 Nm
rrectness of i

9 - Oil Filter Bracket

l purpos

❑ Disassembling and as‐

sembling. Refer to ⇒ “2.2 Overview - Oil Filter Housing”, page 84 .
nform
ercia

10 - Bolt
m

❑ 15 Nm + 1/4 (90°) additional turn

at
om

ion
c

❑ Replace
in t
or

his
ate

11 - Oil Cooler
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❑ Coat contact area to oil filter bracket, outside the seal, with AMV 188 100 02 -AMV 188 100 02-
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❑ Make sure there is enough space to the surrounding components
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❑ See note. Refer to ⇒ “1.1 Engine”, page 16 . gh ht
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12 - Bolt Prote
cted AG.
agen

❑ 25 Nm
13 - Oil Filter
❑ Remove with tension strap
❑ Fasten by hand
❑ Observe installation instructions for oil filter
14 - Seal
❑ Replace

20 Rep. Gr.13 - Crankshaft, Cylinder Block

 n AG. Volkswagen AG do
lkswage es n
Vo ot g
Bora 1999 ➤ , BoraedVariant 1999 ➤ , Golf 1998 ➤ , Golf
by uaVariant 1998 ➤
ran
ir s
tho Engine Mechanical - Edition tee
or 11.2007
au ac
ss
15 - Bolt

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❑ 10 Nm

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16 - Engine Speed Sensor - G28-

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❑ Checking. Refer to ⇒ Fuel Injection and Ignition; Rep. Gr. 28 ; Description and Operation .

wit
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17 - Connection

spec
es, in part or in w
18 - Bolt

t to the co
❑ 15 Nm
19 - O-Ring

rrectness of i
❑ Replace
l purpos

20 - Coolant Thermostat
❑ Removing and installing. Refer to ⇒ “4.2 Coolant Thermostat”, page 107 .

nform
ercia

❑ Note the installation position. Refer to ⇒ “4.2 Coolant Thermostat”, page 107 .
m

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❑ Checking: warm the thermostat in water

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❑ Starts to open: approximately 86 °C (186.8 °F)

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❑ Opening lift minimum 7 mm
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21 - Bolt

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❑ 45 Nm C py
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22 - Compact Bracket
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❑ For the generator, Air Conditioning (A/C) compressor and power steering pump
agen
Prote AG.

23 - Right Engine Bracket

2.2 Overview - Crankshaft

Note

♦ Before removing crankshaft, prepare for appropriate storage,

so that sensor wheel (-Item 8- ⇒ Item 8 (page 22) ) does not
make contact or become damaged.
♦ Secure the engine to the assembly stand using Holding Fixture
- VW540- and Holding Fixture - Spacers - VW540/1B- when
performing repair work.

Refer to
⇒ “2.2.1 Vehicles from Approximately 05/2000”, page 23

2. Description and Operation 21

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

1 - Oil Pump with Chain

Sprocket
❑ With pressure relief
valve 12 bar (174 psi)
❑ Before installing, check
to be sure both align‐
ment bushings are
present (for centering oil
pump/cylinder block)
❑ Removing and instal‐
ling. Refer to
⇒ “1.1 Lubrication Sys‐
tem”, page 81 .
2 - Bolt
❑ 15 Nm
3 - Chain Sprocket
❑ For oil pump drive
❑ Check for wear
4 - Bearing Shells 1, 2, 3, 4 and
5
❑ For bearing cap without
oil groove
❑ For cylinder block with
oil groove
❑ Do not interchange
used bearing shells (la‐
bel)
❑ Vehicles from approxi‐ n AG. Volkswagen AG do
wage
mately 05/2000: classi‐ olks es n
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fication for replacement sed b ua
ran
part ordering. Refer toth o
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or
⇒ Fig. ““Cylinder Block
ss
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Crankshaft Bearing
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Shells Identification”“ ,
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page 23 .
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5 - Bolt
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❑ 65 Nm + 90° (1/4) additional turn

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❑ Replace
spec
es, in part or in w

❑ Fully threaded
t to the co

❑ When measuring crankshaft radial clearance, tighten to 65 Nm

6 - Bearing Cap
rrectness of i

❑ Bearing cap 1: belt pulley side

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❑ Retaining tabs of bearing shells and cylinder block/bearing caps must lie above one another
7 - Bearing Shell 3
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or

❑ -Item 4- ⇒ Item 4 (page 22)

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❑ Do not interchange used bearing shells (label)

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8 - Sensor Wheel
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❑ Replace
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❑ For Engine Speed Sensor - G28-

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❑ Only possible to install in one position - Bores are offset C py
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9 - Bolt cop Vo
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❑ 10 Nm + 1/4 (90°) additional turn Prote AG.

❑ Replace

22 Rep. Gr.13 - Crankshaft, Cylinder Block

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

10 - Thrust Washer
❑ For bearing 3
❑ Pay attention to the locating point
11 - Crankshaft
❑ Axial play new: 0.07 to 0.23 mm, wear limit: 0.30 mm
❑ Check radial clearance with Plastigage®, new: 0.01 to 0.04 mm, wear limit: 0.15 mm
❑ Do not turn crankshaft when measuring radial clearance
❑ Crankshaft Dimensions. Refer to ⇒ “3.1 Crankshaft Dimensions”, page 32 .

2.2.1 Vehicles from Approximately 05/2000

Cylinder Block Crankshaft Bearing Shells Identification
From the factory, the upper bearing shells are allocated to the
cylinder block with the correct thickness. Colored dots serve to
identify the bearing shell thickness.

Note

The arrow points in the direction of travel.

The letters marked on the lower sealing surface of the cylinder

block identify which bearing thickness must be installed ingwhich
n AG. Volkswagen AG do
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Color Identification ed nte
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Letter on Cylinder Color ofssBearing c
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G = Yellow
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– The crankshaft bearing shells in the bearing caps are only
es, in part or in w

available as a replacement part with a “yellow” color marking.

t to the co
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Prote AG.

2. Description and Operation 23

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

2.3 Overview - Pistons and Connecting Rods, Engine Code AWD

1 - Piston Rings
❑ Offset gaps by 120°
❑ Use piston ring pliers for
removing and installing
❑ “TOP” faces toward pis‐
ton crown
❑ Checking the ring gap.
Refer to
⇒ Fig. ““Checking the
Piston Ring Gap”“ , agen
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oes
page 25 . olksw not
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❑ Checking the piston ring orise nte
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groove clearance. Refer aut
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to ss c

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⇒ Fig. ““Piston Ring
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Groove Clearance,

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Checking”“ , page 25 .
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❑ Oil scraping ring, 2-part
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or 3-part, mixed installa‐
, is n

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tion is permitted
hole

spec
2 - Piston
es, in part or in w

t to the co
❑ Checking. Refer to
⇒ Fig. ““Pistons, Check‐
ing”“ , page 26 .

rrectness of i
❑ Mark installed position
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and cylinder allocation

❑ Arrow on piston face
points toward belt pulley

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side
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❑ Install with piston ring
com

tion in
compressor
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3 - Connecting Rod
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❑ Always replace as a set.

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❑ Mark which cylinder to
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which it belongs -B-.
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❑ Installed position: markings -A- face the pulley side
py by
co Vo
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cted agen
4 - Connecting Rod Bearing Cap
Prote AG.

❑ Installed position: markings -A- face the pulley side

❑ Mark which cylinder to which it belongs -B-.
5 - Bolt
❑ 30 Nm + 1/4 additional turn (90°)
❑ Replace
❑ Lubricate threads and contact surface
❑ Tighten to 30 Nm for measuring radial clearance, but do not tighten further.
6 - Relief Valve
❑ 27 Nm
❑ Opening pressure: 1.3 to 1.6 bar (18.8 to 23.2 psi)
7 - Oil Spray Jet
For piston cooling

8 - Bearing Shell
❑ Note the installation position

24 Rep. Gr.13 - Crankshaft, Cylinder Block

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007
❑ Do not interchange used bearing shells.
❑ Check for secure fit in retaining tabs
❑ Axial play new: 0.10 to 0.31 mm, wear limit: 0.40 mm
❑ Check radial clearance with Plastigage®, new: 0.01 to 0.05 mm, wear limit: 0.09 mm
❑ Do not turn crankshaft when checking radial clearance
9 - Cylinder Block
❑ Checking the cylinder AG. Volkswagen G d⇒ Fig. ““Checking Cylinder Bore”“ , page 26 .
agen bore. Refer Ato oes
lksw no
❑ Piston and d by cylinder
Vo
dimensions. Refer to t guar
⇒ “3.2
or Piston and Cylinder Dimensions, Engine Code
ise an
tee AWD”, page 32 .
h
ut or
10 - Connecting
ss
a Rod Bolt ac

ce
e

❑ Replace
nl

pt
du

an
itte

11 - Circlip

y li
erm

ab
ility
12 - Piston Pin
ot p

wit
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❑ If difficult to move, heat piston to 60 °C (140 °F)

h re
hole

❑ Remove and install using the Pilot Drift - VW222A-

spec
es, in part or in w

t to the co
Checking the Piston Ring Gap

rrectness of i
l purpos

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ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t.
Special tools and workshop equipment required
rig
gh ht
pyri by
Vo
co
♦ Feeler Gauge
by lksw
cted agen
Prote AG.
– Insert ring into lower cylinder bore at a right angle from above,
approximately 15 mm from cylinder edge.
Piston Ring Gap
New Wear limit
Compression rings mm 0.15 to 0.40 0.8
Oil scraping ring mm 0.25 to 0.50 1.00
Piston Ring Groove Clearance, Checking

Special tools and workshop equipment required

♦ Feeler Gauge

2. Description and Operation 25

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

Clean ring groove before checking.

Piston Ring Ring to Groove Clearance
New Wear limit
Compression rings mm 0.02 to 0.07 0.12
Oil scraping ring mm 0.02 to 0.06 0.12
Pistons, Checking AG. Volkswagen AG d
agen oes
olksw not
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pt
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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
Special tools and workshop equipment required
♦ External micrometer 75 to 100 mm

rrectness of i
Take measurement approximately 10 mm from lower edge of pis‐
l purpos

ton skirt and offset 90° to piston axis.

Deviations from the specified size: maximum 0.04 mm

nf
ercia

orm
Checking Cylinder Bore
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.

Special tools and workshop equipment required

♦ Internal dial gauge 50 to 100 mm
– Measure diagonally at three positions laterally -A- and longi‐
tudinally -B-.
Deviations to the specified size maximum 0.10 mm

Note

Cylinder bore measurement must not be performed if cylinder

block is secured to assembly stand with Holding Fixture -
VW540- , since inaccurate measurements are possible.

2.4 Overview - Pistons and Connecting Rods, Engine Code AWP, AWW

26 Rep. Gr.13 - Crankshaft, Cylinder Block

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

1 - Piston Rings
❑ Offset gaps by 120°
❑ Use piston ring pliers for
removing and installing
❑ “TOP” faces toward pis‐
ton crown
❑ Checking the ring gap.
Refer to
⇒ Fig. ““Checking the
Piston Ring Gap”“ ,
page 25 .
❑ Checking the piston ring
groove clearance. Refer
to
⇒ Fig. ““Piston Ring
Groove Clearance,
Checking”“ , page 25 .
2 - Piston
❑ Checking. Refer to
⇒ Fig. ““Pistons, Check‐
ing”“ , page 26 .
❑ Mark installed position
and cylinder allocation
❑ Arrow on piston face
points toward belt pulley
side
AG. Volkswagen AG d
❑ Install with piston ring agen oes
olksw not
compressor d by V gu
ara
rise nte
3 - Piston Pin autho eo
ra
s c
❑ If difficult to move, heat s

ce
le

piston to 60 °C (140 °F)

un

pt
an
d
itte

❑ Remove and install us‐

y li
rm

ab
ing the Pilot Drift -
pe

ility
VW222A-
ot

wit
, is n

h re
4 - Circlip
hole

spec
5 - Connecting Rod
es, in part or in w

t to the co
❑ Always replace as a set.
❑ Mark which cylinder to which it belongs -B-.
rrectness of i

❑ Installed position: markings -A- face the pulley side

l purpos

6 - Bearing Shell
❑ Note the installation position. Refer to ⇒ Fig. ““Bearing Shells Installed Position”“ , page 29 .
nform
ercia

❑ Do not interchange used bearing shells.

m

❑ Axial play new: 0.05 to 0.31; wear limit: 0.37 mm

a
com

tio

❑ Check radial clearance with Plastigage®, new: 0.01 to 0.06 mm, wear limit: 0.09 mm
n in
r
te o

thi

❑ Do not turn crankshaft when checking radial clearance

s
iva

do
r
rp

7 - Cylinder Block
um
fo

en
ng

t.
❑ Checking the cylinder bore. Refer to ⇒ Fig. ““Checking Cylinder Bore”“ , page 29 .
yi Co
Cop py
❑ Piston and cylinder dimensions. Refer to
t. rig
gh ht
yri
⇒ “3.3 Piston and Cylinder Dimensions, Engine Codes AWP, AWW”, page 32 .
p by
co Vo
by lksw
cted agen
8 - Connecting Rod Bearing Cap
Prote AG.

❑ Note the installation position

9 - Oil Spray Jet
❑ For piston cooling

2. Description and Operation 27

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

10 - Relief Valve
❑ 27 Nm
❑ Opening pressure: 1.3 to 1.6 bar (18.8 to 23.2 psi)
11 - Connecting Rod Bolt
❑ 30 Nm + 1/4 additional turn (90°)
❑ Replace
❑ Lubricate threads and contact surface
❑ Use old bolt to measure radial clearance
❑ Tighten to 30 Nm for measuring radial clearance, but do not tighten further.

Checking the Piston Ring Gap

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

Special tools and workshop equipment required

an
itte

y li
erm

ab
♦ Feeler Gauge
ility
ot p

– Insert ring into lower cylinder bore at a right angle from above,
wit
, is n

approximately 15 mm from cylinder edge. h re

hole

spec
Piston Ring Gap
es, in part or in w

t to the co

New Wear limit

Compression rings mm 0.20 to 0.40 0.8
rrectness of i

Oil scraping ring mm 0.25 to 0.50 0.8

l purpos

Piston Ring Groove Clearance, Checking

nform
mercia

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.

Special tools and workshop equipment required

♦ Feeler Gauge
Clean ring groove before checking.
Piston Ring Ring to Groove Clearance
New Wear limit
Compression rings mm 0.06 to 0.09 0.20
Oil scraping ring mm 0.03 to 0.06 0.15

28 Rep. Gr.13 - Crankshaft, Cylinder Block

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

Pistons, Checking

Special tools and workshop equipment required

♦ External micrometer 75 to 100 mm
Take measurement approximately 10 mm from lower edge of pis‐
ton skirt and offset 90° to piston axis.
Deviations from the specified size: maximum 0.04 mm
Bearing Shells Installed Position
Bearing shell -1- with oil bore -arrow- for connecting rod.
Bearing shell -2- without oil bore for connecting rod cover.
– Place the bearing shells centrally into the connecting rod and
connecting rod cap.
The dimension -a- must be the same at left and right. Maximum
variance: 0.2 mm

Checking Cylinder Bore

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

Special tools and workshop equipment required

orm
m

atio

♦ Internal dial gauge 50 to 100 mm

om

n in
or c

– Measure diagonally at three positions laterally -A- and longi‐

thi
e

tudinally -B-.
t

sd
iva

o
r
rp

cu

Deviation from specified size: maximum 0.08 mm

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 29

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

Note

Cylinder bore measurement must not be performed if cylinder

block is secured to assembly stand with Holding Fixture -
VW540- , since inaccurate measurements are possible.

2.5 Overview - Sealing Flanges and Fly‐

wheel/Drive Plate

Note

Servicing the clutch. Refer to ⇒ Manual Transmission; Rep. Gr.

30 ; Description and Operation .

1 - Bolt
❑ 90 Nm + 1/4 additional
turn (90°)
❑ Replace
❑ Use Counterhold -
Crankshaft Sprocket -
3415- when loosening
or tightening
❑ The threads and shoul‐
der must be free of oil
and grease
2 - Crankshaft Toothed Belt AG. Volkswagen AG d
Sprocket agen oes
olksw not
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3 - Bolt rised
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❑ 15 Nm s aut ra
c
s
4 - Seal
ce
le
un

pt
an
d

❑ Replacing. Refer to
itte

y li

⇒ “4.1 Crankshaft Seal,

erm

ab
ility

Belt Pulley Side, Re‐

ot p

placing”, page 33 .
wit
is n

h re
ole,

5 - Sealing Flange
spec
urposes, in part or in wh

❑ Must be located on
t to the co

alignment sleeves
❑ Clean sealing surface
before installing
rrectne

❑ Insert with Silicone

Sealant - D 176 404
ss

A2- .
o
cial p

f in

❑ Removing and instal‐

form
mer

ling. Refer to
atio

⇒ “4.3 Sealing Flange,

om

Belt Pulley Side”,

c

i
or

page 36 .
thi
te

sd
va

❑ To remove and install,

i

o
pr

cum
r

remove oil pan

fo

en
ng

t.
yi Co
6 - Cylinder Block t. Cop py
rig
gh
❑ Crankshaft, removing and installing. Refer to ⇒ “2.2 Overview - Crankshaft”, page 21 .
ht
pyri by
Vo
o
by c
❑ Piston and connecting rod, disassembling and assembling. Refer to
lksw
cted agen
Prote
⇒ “2.3 Overview - Pistons and Connecting Rods, Engine Code AWD”, page 24 or
AG.

⇒ “2.4 Overview - Pistons and Connecting Rods, Engine Code AWP, AWW”, page 26

30 Rep. Gr.13 - Crankshaft, Cylinder Block

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

7 - Bolt
❑ 60 Nm + 1/4 (90°) additional turn
❑ Replace
8 - Flywheel/Drive Plate
❑ To remove and install flywheel, secure using the Flywheel Retainer - 3067-
❑ Drive plate, removing and installing. Refer to ⇒ “4.2 Drive Plate”, page 35 .
9 - Intermediate Plate
❑ Must be located on alignment sleeves
❑ Be careful not to damage or bend when installing
10 - Sealing Flange with Seal
❑ Replace only as a complete unit.
❑ To remove and install, remove oil pan. Refer to ⇒ “5.1 Oil Pan”, page 89 .
❑ Before installing, remove oil remains from crankshaft journal with a clean cloth
❑ Do not coat the sealing lip on the gasket with oil or grease.
❑ To install, use provided support sleeve
❑ Support sleeve may only be removed after the sealing flange has been slid onto the crankshaft pin.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
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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

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.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
31
by c lksw
cted
2. Description and Operation
agen
Prote AG.
 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

3 Specifications
⇒ “3.1 Crankshaft Dimensions”, page 32
⇒ “3.2 Piston and Cylinder Dimensions, Engine Code AWD”, page
32
⇒ “3.3 Piston and Cylinder Dimensions, Engine Codes AWP,
AWW”, page 32

3.1 Crankshaft Dimensions

(Dimensions in mm)
Honing Dimen‐ Crankshaft Bearing Connecting Rod Bear‐
sion Pin Diameter ing
Pin Diameter
Standard dimen‐ 54.00 -0.017 47.80 -0.022
sion -0.037 -0.042
1st oversize 53.75 -0.017 47.55 -0.022
-0.037 -0.042
2nd oversize 53.50 -0.017 47.30 -0.022
-0.037 -0.042
Stage III 53.25 -0.017 47.05 -0.022
-0.037 -0.042

3.2 Piston and Cylinder Dimensions, Engine

Code AWDgen AG. Volkswagen AG d
a oes
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Vol
Honing Dimen‐ ed b y Piston Diameter Cylinder
gu Bore
ara
sion ris Diameter nte
utho eo
ra
sa
Standardsdimen‐ mm 80.965. Refer to 81.01 c
sion 6)
.
ce
le
un

pt
an
d

1st oversize mm 81.465. Refer to 81.51

itte

y li

.
erm

6)
ab
ility
ot p

6) Measurement without graphite coating (0.02 mm thick), the graphite coating

wit
is n

wears off.
h re
ole,

spec

3.3 Piston and Cylinder Dimensions, Engine

urposes, in part or in wh

t to the co

Codes AWP, AWW

Honing Dimen‐ Piston Diameter Cylinder Bore
rrectne

sion Diameter
Standard dimen‐ mm 80.965. Refer to 81.01
ss

sion 7)
.
o
cial p

f in

1st oversize mm 81.465. Refer to 81.51

form
mer

7)
.
atio
om

7) Measurement without graphite coating (0.02 mm thick), the graphite coating

n
c

i
or

wears off.
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.

32 Rep. Gr.13 - Crankshaft, Cylinder Block

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

4 Removal and Installation

⇒ “4.1 Crankshaft Seal, Belt Pulley Side, Replacing”, page 33
⇒ “4.2 Drive Plate”, page 35
⇒ “4.3 Sealing Flange, Belt Pulley Side”, page 36
⇒ “4.4 Ribbed Belt”, page 38

4.1 Crankshaft Seal, Belt Pulley Side, Re‐

placing
Special tools and workshop equipment required
♦ Puller - Crankshaft Seal - 3203-
♦ Counterhold - Crankshaft Sprocket - 3415-
n AG. Volkswagen AG do
♦ Seal Installer - Crankshaft Sealol-ksT10053-
wage es n
ot g
V
by ua
♦ Torque Wrench 1331 5-50Nm
rised - VAG1331- ran
tee
ho
ut or
♦ Torque Wrench 1332
ss
a 40-200Nm - VAG1332- ac

ce
le

Removing
un

pt
an
d
itte

y li
– Remove ribbed belt and tensioner. Refer to
erm

ab
⇒ “4.4 Ribbed Belt”, page 38 .

ility
ot p

wit
– Remove the toothed belt. Refer to
is n

h re
⇒ “3.4 Toothed Belt, Removing, Installing and Tensioning”,
ole,

spec
page 67 .
urposes, in part or in wh

t to the co
– Remove toothed belt crankshaft sprocket. To do so, lock the
toothed belt sprocket using the Counterhold - Crankshaft
Sprocket - 3415- .
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

– To guide the Puller - Crankshaft Seal - 3203- , thread the cen‐

t.
yi Co
op
tral bolt into crankshaft by hand until stop.
C py
t. rig
gh ht
yri by
– Remove the inner portion of Puller - Crankshaft Seal - 3203- cop Vo
by lksw
nine rotations (approximately 20 mm) from outer panel and cted agen
Prote AG.
secure with knurled bolt.

4. Removal and Installation 33

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Lubricate threaded head of Puller - Crankshaft Seal - 3203- ,

place on the seal, and with strong force screw into the seal as
far as possible.
– Loosen knurled bolt and turn inner portion against crankshaft
until the seal is pulled out.
AG. Volkswagen AG d
agen oes
Installing olksw not
byV gu
ara
ed
ris nte
ho eo
ut ra
Note ss a c

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le
un

pt
Phased in introduction of Polytetrafluoroethylene (PTFE) sealing

an
d
itte
rings (Distinguishing feature: without ring spring, sealing lip de‐

y li
erm

ab
signed wider). The sealing lip of this sealing ring may not be oiled

ility
or greased. A seal of the old version (with ring spring) can be ot p

wit
is n
replaced by a PTFE seal - but not the other way around.

h re
ole,

spec
urposes, in part or in wh

– Wipe off any oil that may still be on the end of the crankshaft

t to the co
with a clean cloth.

– Attach the Seal Installer - Crankshaft Seal Guide Sleeve -

rrectne
T10132/1- guide sleeve on crankshaft pin.
– Slide seal over guide sleeve onto the crankshaft pin.

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
– Press in seal using Seal Installer - Crankshaft Seal - T10053- py by
co Vo
and Seal Installer - Crankshaft Seal Hex Bolt - T10053/2- (M16
by lksw
cted agen
Prote
x 1.5 x 60) up to stop.
AG.

– Install the toothed belt crankshaft sprocket and lock with the
Counterhold - Crankshaft Sprocket - 3415- .
– Tighten new center bolt to 90 Nm and turn an additional 90°
(1/4 turn, additional turn may occur in several stages).

Note

The threads and shoulder must be free of oil and grease.

Refer to
⇒ “3.4 Toothed Belt, Removing, Installing and Tensioning”, page
67 for how to install toothed belt and adjust valve timing
– Installing ribbed belt and tensioner. Refer to
⇒ “4.4 Ribbed Belt”, page 38 .

34 Rep. Gr.13 - Crankshaft, Cylinder Block

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

4.2 Drive Plate

Special tools and workshop equipment required
♦ Flywheel Lock Adapter - VW558-
♦ Hex bolt M8x45 and two M10 hex nuts
♦ Depth Gauge
Drive Plate, Loosening and Tightening
– Secure the Flywheel Lock Adapter - VW558- with M8x45 hex
bolt to the drive plate. Insert two M10 hex nuts between fly‐
wheel lock adapter and drive plate.
Installed location of flywheel retainer:
n AG. Volkswagen AG do
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-A- to loosen olks es n
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d ran
-B- to tighten ir se tee
tho
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a ac
– Loosen drive plate bolts. ss

ce
e
nl

Drive Plate, Installing

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
– Set drive plate in place, using washer with notches -1-.
hole

spec
es, in part or in w

– Install the new bolts -3- and tighten to 30 Nm.

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
a

– Check dimension -a- at three points and calculate mean value.

iv

o
r

Specified value: 19.5 to 21.1 mm

rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
Note
t. rig
gh ht
pyri by
Vo
co lksw
by
This is measured through the hole in the drive plate to the ma‐
cted agen
Prote AG.
chined surface of the cylinder block.

If the specification is not obtained:

4. Removal and Installation 35

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Remove drive plate again and use shim -2-. Tighten bolts
again to 30 Nm.
– Tighten bolt to 60 Nm and turn an additional 90° (1/4 rotation,
additional rotation may occur in several stages).

4.3 Sealing Flange, Belt Pulley Side

Special tools and workshop equipment required
♦ Counterhold - Crankshaft Sprocket - 3415-
♦ Seal Installer - Crankshaft Seal - T10053-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Torque Wrench 1332 40-200Nm - VAG1332-
♦ Hand drill with plastic brush attachment
♦ Silicone Sealant - D 176 404 A2-
♦ Protective eyewear
♦ Flat scraper
Removing
– Remove ribbed belt and tensioner. Refer to
⇒ “4.4 Ribbed Belt”, page 38 .
– Remove the toothed belt. Refer to
⇒ “3.4 Toothed Belt, Removing, Installing and Tensioning”,
page 67 .
n AG. Volkswagen AG do
wage
– Remove toothed belt crankshaft sprocket. To do so, lockVothe lks es n
ot g
toothed belt sprocket using the Counterhold - Crankshaft d by ua
ran
ir se
Sprocket - 3415- . tho tee
or
au ac
– Drain the engine oil. ss
ce
le
un

pt

– Remove the oil pan. Refer to ⇒ “5.1 Oil Pan”, page 89 .

an
d
itte

y li
erm

ab

– Remove the front sealing flange.

ility
ot p

– Remove the sealing flange if necessary use a rubber hammer

wit
is n

h re

and tap it gently.

ole,

spec
urposes, in part or in wh

– Remove the sealant residue from cylinder block with a flat-

blade scraper.
t to the co

– Cover the seal with a clean cloth.

rrectness o
cial p

f inform
mer

atio
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36
co Vo
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Rep. Gr.13 - Crankshaft, Cylinder Block cted agen
Prote AG.
 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Remove any sealant still on the sealing flange using a rotating

plastic brush. Wear protective eyewear.
– Clean sealing surfaces. They must be free of oil and grease.
Installing

Note

♦ Pay attention to the expiration date of the sealant.

♦ The sealing flange must be installed within five minutes after
application of silicon sealant.

– Cut tube nozzle at front marking (nozzle diameter: approxi‐

mately 3 mm).
– Apply silicone sealing compound, as shown, to clean sealing
surface of the sealing flange. The sealing compound bead
must be:
♦ 2 to 3 mm thick
♦ and run on inside of bolt holes -arrows-

Note

♦ The sealing compound bead must not be thicker, otherwise

excess sealing compound could enter the oil pan and may
block the oil suction pipe strainer. Likewise, it could drip onto
the sealing surface of the crankshaft seal.
Volkswagen AG
♦ Before applying the bead of sealant, cover the sealing surface swagen AG. does
on the seal with a clean cloth by
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– Set the sealing flange in place immediately and lightly
au tighten ra
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the bolts. ss

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Use Seal Installer - Crankshaft Seal - T10053/1- to position the
, is n

h re
sealing flange on the installed seal.
hole

spec
es, in part or in w

– Fasten the sealing flange bolts in a diagonal sequence. Tight‐

ening specification: 15 Nm t to the co

– Remove excess sealant.

rrectness of i

– Install the oil pan. Refer to ⇒ “5.1 Oil Pan”, page 89 .

l purpos

nform
ercia

Note
m

After installing, allow sealant to dry for approximately 30 minutes.

com

tion in

Only after then may the engine oil be replenished.

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4. Removal and Installation 37

 AG. Volkswagen AG d
agen oes
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d by ara
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Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤au,t Golf Variant 1998 ➤ ra
c
s
Engine Mechanical - Edition 11.2007 s

ce
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un

pt
an
d
itte
– Install the toothed belt crankshaft sprocket and lock with the

y li
rm

ab
Counterhold - Crankshaft Sprocket - 3415- .

pe

ility
ot
– Tighten new center bolt to 90 Nm and turn an additional 90°

wit
, is n

h re
(1/4 turn, additional turn may occur in several stages).

hole

spec
es, in part or in w

t to the co
Note

The threads and shoulder must be free of oil and grease.

rrectness of i
l purpos
– Install toothed belt and adjust valve timing. Refer to
⇒ “3.4 Toothed Belt, Removing, Installing and Tensioning”,
page 67 .

nform
ercia
– Installing ribbed belt and tensioner. Refer to
m

a
com
⇒ “4.4 Ribbed Belt”, page 38 .

tion in
r
te o

thi
4.4 Ribbed Belt

s
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Special tools and workshop equipment required

en
ng
t.
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op
♦ Locking Pin - T10060A- C py
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– Mark the ribbed belt running direction.
AG.

– Swing tensioner in direction of -arrow- with a wrench until it

can be locked.
– Secure the tensioner using the Locking Pin - T10060A-
-arrow-.
– Remove the sound insulation tray. Refer to ⇒ Body Exterior;
Rep. Gr. 50 ; Description and Operation .

– Remove the ribbed belt.

Installing
– Install in reverse order of removal.

Note

♦ Ensure, before installing ribbed belt, that all ancillaries (alter‐

nator, air conditioner compressor, power steering pump) are
secured tightly.
♦ Note previously marked direction of belt rotation and be sure
that it is seated correctly on pulley.
♦ In vehicles without Air Conditioning (A/C) system, lay ribbed
belt last on the generator.
♦ In vehicles with A/C system, lay ribbed belt last on the A/C
compressor.

After completing repairs always:

– Start the engine and check the belt running.
Ribbed Belt Routing

38 Rep. Gr.13 - Crankshaft, Cylinder Block

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

Belt drive without A/C compressor

Belt drive with A/C compressor

Note

Engines with A/C compressor are equipped with a double ribbed

belt.

AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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ility
ot

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hole

spec
es, in part or in w

t to the co
rrectness of i
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nform
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tion in
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te o

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en
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cted agen
Prote AG.

4. Removal and Installation 39

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

5 Special Tools

♦ Puller - Crankshaft Seal -

3203- en AG. V
olkswagen AG
ag does
ol ksw not
♦ Counterhold - Crankshaft
yV gu
db ara
Sprocket - 3415-
ris
e nte
ho eo
ut
♦ Seal Installer
ss
a - Crankshaft ra
c
Seal - T10053-

ce
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pt
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♦ Torque Wrench 1331

itte

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5-50Nm - VAG1331-
rm

ab
pe

ility
♦ Torque Wrench 1332
ot

wit
, is n

40-200Nm - VAG1332-

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
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nform
mercia

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tion in
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Cop py
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rig ht
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Prote AG.

♦ Locking Pin - T10060A-

40 Rep. Gr.13 - Crankshaft, Cylinder Block

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

♦ Flywheel Lock Adapter - VW558-

AG. Volkswagen AG d
agen oes
olksw not
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an
itte

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hole

spec
es, in part or in w

t to the co
rrectness of i
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at
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ion
c

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or

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Prote AG.

5. Special Tools 41
 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

15 – Cylinder Head, Valvetrain

1 Description and Operation
⇒ “1.1 Overview - Cylinder Head”, page 42
⇒ “1.2 Overview - Valvetrain”, page 44
⇒ “1.3 Valve Seats, Reworking”, page 48

1.1 Overview - Cylinder Head

Note

♦ When using an exchanged cylinder head with camshaft in‐

stalled, the contact surfaces between the lifters and cam lobes
must be lubricated before installing the cylinder head cover.
♦ The plastic protectors installed to protect the open valves must
only be removed immediately before fitting the cylinder head.
♦ If the cylinder head is going to be replaced, then it is also nec‐
essary to replace all the coolant.
♦ Intake manifold, removing and installing. Refer to ⇒ Fuel In‐
jection and Ignition; Rep. Gr. 24 ; Description and Operation .
AG. Volkswagen AG d
agen
Compression pressure, checking. Refer toolks
w oes
not
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⇒ “2.1 Compression, Checking”, pageed51 .
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hole

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es, in part or in w

t to the co
rrectness of i
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at
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ion
c

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or

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ate

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for

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Cop py
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by lksw
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Prote AG.

42 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

1 - Cap
2 - Bolt
❑ 10 Nm
3 - Cylinder Head Cover
4 - Cylinder Head Cover Seal
❑ Replace if damaged
❑ Before installing, coat
contact surfaces of
bearing cap or camshaft
adjuster/chain tensioner
to cylinder head with
Sealant - AMV 174 004
01- . Refer to
⇒ Fig. ““Double Bearing
Cap Contact Surfaces,
Sealing”“ , page 48
and
⇒ Fig. ““Chain Tension‐
er or Camshaft Adjuster/
Cylinder Head Contact
Surfaces, Sealing”“ ,
page 48 .
5 - Oil Deflector
❑ Pay attention to the in‐
stallation position:
above the intake cam‐
shaft
6 - Cylinder Head
❑ Check for distortion. Re‐
fer to
⇒ Fig. ““Checking Cylin‐
der Head for Distor‐
tion”“ , page 44
❑ Resurfacing sealing n AG. Volkswagen AG do
surfaces. Refer to lkswage es n
Vo ot g
⇒ Fig. ““Cylinder Head - Sealing Surface, Resurfacing”“ d , page 47
by ua
ran
ir se tee
❑ Removing and installing. Refer to ⇒ “3.3 CylinderuthHead”, page 64 .
o
or
a ac
❑ After replacing, replace the entire amount of coolant.
ss
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pt
7 - Intake Manifold Gasket an
d
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❑ Replace
rm

ab
pe

ility
❑ Note the installation position
ot

wit
, is n

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8 - Cylinder Head Seal

hole

spec

❑ Replace
es, in part or in w

t to the co

❑ Metal gasket
❑ After replacing, replace the entire amount of coolant.
❑ Pay attention to the installed position: the part number identification must be visible from intake side
rrectness of i

9 - Toothed Belt
l purpos

❑ Mark direction of travel before removing

❑ Check for wear
nform
ercia

❑ Do not kink
m

a
com

ti

❑ Removing and installing, tensioning. Refer to

on in

⇒ “3.4 Toothed Belt, Removing, Installing and Tensioning”, page 67 .

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10 - Gasket for Exhaust Manifold

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❑ Replace
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❑ Note the installation position t. Cop py
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43
by lksw
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Prote 1. Description and Operation
AG.
 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

11 - Cylinder Head Bolt

❑ Replace n AG. Volkswagen AG do
swage es n
❑ Remove and install the Polydrive cylinder
byV
olk
head bolt using Polydrive ot gBit Drive Socket - T10070- or Poly‐
ua
drive Bit Drive Socket - 3452- .rised ran
tee
ho
❑ Sequence for loosening and au tightening. Refer to ⇒ “3.3 Cylinder Head”, page
t or 64
ac
ss
12 - Seal

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an
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❑ Replace if damaged
itte

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ility
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is n

Checking Cylinder Head for Distortion

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

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c

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Special tools and workshop equipment required
te

sd
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♦ Straight Edge
p

cum
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fo

en
ng

♦ Feeler Gauge
t.
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Cop py
. rig
Max. permissible distortion: 0.1 mm
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1.2 Overview - Valvetrain cted agen
Prote AG.

Note

♦ Cylinder heads with cracks between the valve seats, or be‐

tween the valve seat and the spark plug threads, can continue
to be used without reducing the service life, as long as the
cracks have a maximum width of 0.3 mm, or only the first four
threads of the spark plug threads are cracked.
♦ After installing new valve lifters, the engine may not be started
for approximately 30 minutes (otherwise valves will strike pis‐
tons), then turn crankshaft twice around.

44 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

1 - Bolt
❑ 10 Nm
2 - Intake Camshaft
n AG. Volkswagen AG do
❑ Axial play, checking.
olkswage es n
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Refer tod by V ua
ran
⇒ Fig. or ““Camshaft,
ise
tee
Checking
auth
Axial Play”“ , or
ac
spage
s 47 .

ce
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un

❑ Removing and instal‐

pt
an
d

ling. Refer to
itte

y li
erm

⇒ “3.1 Camshafts”,

ab
ility
page 57 .
ot p

wit
is n

❑ Checking radial clear‐

h re
ole,

ance with Plastigage®,

spec
urposes, in part or in wh

wear limit: 0.1 mm

t to the co
❑ Stroke: maximum
0.01 mm

rrectne
3 - Drive Chain
❑ Mark direction of rota‐
tion before removing (in‐

ss o
stallation position). Re‐
cial p

f in
fer to

form
mer

⇒ “3.1 Camshafts”,
atio
page 57
om

n
c

4 - Bolt
or

n thi
te

sd
a

❑ 10 Nm
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5 - O-Ring
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❑ Replace t. Cop py
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❑ Only vehicles with the
ht
pyri by
engine code AWP,
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AWW Prote AG.

6 - Camshaft Adjustment Valve

1 - N205-
❑ Only vehicles with the
engine code AWP, AWW
❑ Camshaft adjustment, checking. Refer to ⇒ “2.4 Camshaft, Checking Adjustment”, page 54 .
7 - Bolt
❑ 3 Nm
❑ Only vehicles with the engine code AWP, AWW
8 - Camshaft Adjuster
❑ Only vehicles with the engine code AWP, AWW
❑ For vehicles with engine code AWD: chain tensioner
❑ Before removing, secure using Bracket For Chain Adjustment - 3366- . Refer to
⇒ “3.1 Camshafts”, page 57 .
❑ Camshaft adjustment, checking. Refer to ⇒ “2.4 Camshaft, Checking Adjustment”, page 54 .
9 - Seal
❑ Rubber/metal seal
❑ Replace
10 - Cylinder Head
❑ Removing and installing. Refer to ⇒ “3.3 Cylinder Head”, page 64 .
❑ Reworking the valve seat. Refer to ⇒ “1.3 Valve Seats, Reworking”, page 48 .
❑ Resurfacing sealing surfaces. Refer to
⇒ Fig. ““Cylinder Head - Sealing Surface, Resurfacing”“ , page 47

1. Description and Operation 45

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007
❑ Sealing contact surfaces. Refer to
⇒ Fig. ““Double Bearing Cap Contact Surfaces, Sealing”“ , page 48 and
⇒ Fig. ““Chain Tensioner or Camshaft Adjuster/Cylinder Head Contact Surfaces, Sealing”“ , page 48
11 - Valves
❑ Do not rework, only lapping is permitted
❑ Valve dimensions. Refer to ⇒ Fig. ““Valve Dimensions”“ , page 48 .
❑ Sodium-filled exhaust valves: pay attention to the disposal notes. Refer to
⇒ Fig. ““Double Bearing Cap Contact Surfaces, Sealing”“ , page 48
12 - Seal
❑ Replacing. Refer to ⇒ “3.2 Camshaft
wage
n AGGaskets,
. VolkswageReplacing”,
n AG d
oe page 60 .
ks s no
Vol t gu
13 - Trim db
y ara
rise nte
❑ For Camshaft Position
tho Sensor - G40- eo
au ra
❑ Observe installed
s location
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14 - Washer

an
d
itte

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❑ Conical
rm

ab
pe

ility
15 - Bolt
ot

wit
, is n

h re
❑ 25 Nm
hole

spec
16 - Camshaft Position Sensor - G40-
es, in part or in w

t to the co
❑ Refer to ⇒ Fuel Injection and Ignition; Rep. Gr. 28 ; Description and Operation
17 - Bolt

rrectness of i
❑ 10 Nm
l purpos

18 - Bolt
❑ 65 Nm
nform
ercia

❑ Use Counterhold - Crankshaft Sprocket - 3036- when loosening or tightening

m

19 - Camshaft Sprocket
com

tion in

❑ Note the installed position: The thin rib of camshaft bearing points outward and cylinder 1 Top Dead
r
te o

thi

Center (TDC) marking is visible.

s
iva

do
r

❑ Note position when installing toothed belt. Refer to

rp

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⇒ “3.4 Toothed Belt, Removing, Installing and Tensioning”, page 67 .

en
ng

t.
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op
20 - Seal
C py
t. rig
gh ht
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❑ Replacing. Refer to ⇒ “3.2 Camshaft Gaskets, Replacing”, page 60 .
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21 - Valve Guide Prote AG.

❑ Checking. Refer to ⇒ “2.3 Valve Guides, Checking”, page 53 .

22 - Valve Stem Seal
❑ Replacing. Refer to ⇒ “3.5 Valve Stem Seals, Replacing”, page 71 .
23 - Valve Spring
❑ Cylinder head removed: remove and install using Valve Spring Compressor - 3362- .
❑ Cylinder head installed. Refer to ⇒ “3.5 Valve Stem Seals, Replacing”, page 71 .
24 - Valve Spring Retainer
25 - Valve Retainers
26 - Valve Lifter
❑ Do not interchange
❑ With hydraulic valve clearance compensation
❑ Checking. Refer to ⇒ “2.2 Hydraulic Valve Lifter, Checking”, page 53 .
❑ Place on running surface when setting down
❑ Before installing, check axial play of camshafts. Refer to
⇒ Fig. ““Camshaft, Checking Axial Play”“ , page 47
❑ Lubricate contact surface

46 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

27 - Bearing Cap for Intake Camshaft

❑ Installation position and installation sequence. Refer to ⇒ “3.1 Camshafts”, page 57
28 - Double Bearing Cap
❑ Must be located on alignment sleeves
❑ Lightly coat the contact surface with Sealant - AMV 174 004 01- and pay attention to the installation
position and installation sequence. Refer to ⇒ “3.1 Camshafts”, page 57 .
❑ Seal the contact surfaces of the double bearing cap/cylinder head. Refer to
⇒ Fig. ““Double Bearing Cap Contact Surfaces, Sealing”“ , page 48 .
29 - Bearing Cap for Exhaust Camshaft
❑ Installation position and installation sequence. Refer to ⇒ “3.1 Camshafts”, page 57
30 - Exhaust Camshaft
❑ Axial Play, Checking. Refer to ⇒ Fig. ““Camshaft, Checking Axial Play”“ , page 47 .
❑ Removing and Installing. Refer to ⇒ “3.1 Camshafts”, page 57 .
❑ Checking radial clearance with Plastigage®, wear limit: 0.1 mm
❑ Stroke: maximum 0.01 mm

Cylinder Head - Sealing Surface, Resurfacing

Resurfacing measurement is made via the holes for cylinder head
bolts.
a = minimum 139.2 mm

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Camshaft, Checking Axial Play
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erm

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es, in part or in w

t to the co
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Special tools and workshop equipment required

nf
ercia

♦ Dial Gauge Holder - VW387-

orm
m

atio

♦ Dial Gauge
om

n in
or c

Measure with valve lifters removed, chain removed and bearing

thi
e

caps 2 and 4 installed.

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rp

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Prote AG.

1. Description and Operation 47

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

Wear limit: maximum 0.2 mm

Valve Dimensions

Note

Valves must not be reworked. Only lapping is permitted.

Dimension Intake Valve Exhaust Valve

Diameter a mm 26.9 29.9
Diameter b mm 5.963 5.943
c mm 104.84 to 105.34 103.64 to 104.14
α ∠° 45 45

Note

Worn sodium-filled exhaust valves must not be scrapped without

first being properly treated. The valves must be cut at the middle
of the shaft using a metal saw. While doing this, do not come into
contact with water. At the very most, throw 10 of the prepared
valves into a bucket filled with water. Then, move quickly away,
because a sudden chemical reaction will occur during which the
sodium is burnt away. The treated parts may then be discarded
through conventional disposal channels. olksw
AG. V agen AG
agen does
olksw not
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Double Bearing Cap Contact Surfaces, db ara
rise Sealing nte
tho eo
– Apply a small amount of Sealant
ss au - AMV 174 004 01-to the ra
c
contact surfaces -arrows- on the double bearing cap.
ce
e
nl

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du

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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

Chain Tensioner or Camshaft Adjuster/Cylinder Head Contact

Surfaces, Sealing
l purpos

– Apply a small amount of Sealant - AMV 174 004 01- to the

chain tensioner/cylinder head or camshaft adjuster/cylinder
nform
ercia

head sealing surfaces -arrows-.

m

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om

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or

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ate

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1.3 Valve Seats, Reworking
by
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Prote AG.

⇒ “1.3.1 Intake Valve Seat, Reworking”, page 50

⇒ “1.3.1 Intake Valve Seat, Reworking”, page 50
Special tools and workshop equipment required
♦ Depth Gauge

48 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

♦ Valve Seat Reworking Tool

Note

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

to rework or replace valve seats and valves. It is also neces‐
sary to check the valve guides for wear. This is particularly
important on high mileage engines. Refer to
⇒ “2.3 Valve Guides, Checking”, page 53 .
♦ Only reface valve seats enough until a perfect contact pattern
is obtained. The maximum permissible reworking dimension
must be calculated before work is carried out. If the reworking
dimension is exceeded, the function of the hydraulic lifters can
no longer be guaranteed and therefore the cylinder head
AG. Volkswagen AG d
should be replaced. lksw
agen oes
n o ot g
yV ua
edb ran
Maximum Permitted Reworking Dimension ho is Calculated
ris as Fol‐ tee
lows: aut or
ac
ss

ce
– Insert valve and press firmly against seat.
le
un

pt
an
d
itte

y li
erm

ab
Note

ility
ot p

wit
is n

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

for the measurement.

spec
urposes, in part or in wh

t to the co
– Measure the distance -a- vertically between the end of the
valve stem and upper edge of cylinder head -1-.

rrectne
– Calculate the maximum permissible reworking dimension from
measured distance and minimum dimension.

ss
Minimum dimension: Outer intake valves 34.0 mm. center intake

o
cial p

f
valves 33.7 mm, exhaust valve 34.4 mm

inform
mer

Measured distance minus minimum dimension = maximum per‐

atio
m

missible reworking dimension.

o

n
c

i
or

n
Example:
thi
te

sd
iva

o
r

Measured distance 34.4 mm

p

cum
r
fo

en
ng

- Minimum dimension 34.0 mm

t.
yi Co
op py
= Maximum permitted reworking dimension. Refer 0.4 mm t. C rig
gh ht
to 8). yri
p by
o Vo
by c lksw
cted agen
8) Maximum permissible reworking dimension is represented in illustrations for Prote AG.
reworking valve seats as dimension “b”.

1. Description and Operation 49

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

1.3.1 Intake Valve Seat, Reworking

Di‐ Intake Valve Seat
men‐
sion
Diam‐ mm 26.2
eter a
b mm Maximum permitted reworking dimension. Re‐
fer to 9).
AG. Volkswagen AG d
c mm 1.5 to 1.8 lksw
agen oes
not
o
yV gu
Z Cylinder Head Lower Edge ed b ara
nte
ris
o
α 45° Valve Seat Angle aut
h eo
ra
s c
β 30° Upper Correction s
Angle

ce
le
un

pt
γ 60° Lower Correction Angle

an
d
itte

y li
erm

ab
ility
ot p

1.3.2 Exhaust Valve Seat, Reworking

wit
is n

h re
ole,

Di‐ Intake Valve Seat

spec
urposes, in part or in wh

men‐
sion

t to the co
Diam‐ mm 29.0
eter a

rrectne
b mm Maximum permitted reworking dimension. Re‐
fer to 9).

ss o
c mm Approximately 1.8
cial p

f inform
Z Cylinder Head Lower Edge
mer

atio
α 45° Valve Seat Angle
om

n
c

β 30° Upper Correction Angle

i
or

n thi
te

sd
γ 60° Lower Correction Angle
iva

o
pr

cum
r
fo

9) How to calculate maximum permissible reworking dimension ⇒ page 49 . en

ng

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

50 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

2 Diagnosis and Testing

⇒ “2.1 Compression, Checking”, page 51
⇒ “2.2 Hydraulic Valve Lifter, Checking”, page 53
⇒ “2.3 Valve Guides, Checking”, page 53
⇒ “2.4 Camshaft, Checking Adjustment”, page 54

2.1 Compression, Checking

Special tools and workshop equipment required
♦ Spark Plug Removal Tool - 3122B- AG. Volkswagen AG d
agen oes
lksw not
♦ Torque Wrench 1331 5-50Nm -bVAG1331-
yV
o gu
ara
d
ise nte
♦ Compression Tester Kit -uVAG1763-
thor eo
a 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

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.

2. Diagnosis and Testing 51

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Remove fuse 32

Note

Voltage supply to the fuel injectors is interrupted when fuse 32 is

removed.

Test Conditions
• Engine oil temperature must be at least 30 °C (86 °F).
AG. Volkswagen AG d
Procedure agen oes
olksw not
y V gu
b ara
– Remove the engine cover. rise
d
nte
tho eo
– Disconnect the ignition coil connectors. ss au ra
c

ce
le
– Remove the ignition coils.
un

pt
an
d
itte

y li
– Remove the spark plugs using Spark Plug Removal Tool -
erm

ab
3122B- .

ility
ot p

wit
– Using a 2nd mechanic, have the accelerator pedal completely
is n

h re
depressed.
ole,

spec
urposes, in part or in wh

– Check compression pressure with Compression Tester Kit -

t to the co
VAG1763- .

rrectne
Note

s
Refer to the Operating Instructions for information on using the

s o
tester.
cial p

f inform
mer

– Operate the starter until tester shows no further pressure in‐

atio
m

crease.
o

n
c

i
or

n thi
Compression Values
te

sd
iva

o
pr

c
New Wear Limit Difference Between

um
r
fo

en
Bar Positive Pres‐ Bar Positive Pres‐ Cylinders
ng

t.
yi Co
sure sure Bar Positive Pres‐ Cop py
sure
t. rig
gh ht
pyri by
Vo
o
10 to 14 bar (145 to 7 bar (101.52 psi) Maximum 3 bar (43
c by lksw
cted agen
203 psi) psi)
Prote AG.

– Install the spark plugs with the Spark Plug Removal Tool -
3122B- and tighten them to 30 Nm.
Vehicles with Engine Code AWD
– Install the ignition coils and tighten them to 10 Nm.
Vehicles with Engines Code AWP, AWW
– Install ignition coils. Ensure ignition coils are seated securely.
Continuation for All Vehicles
– Check the Diagnostic Trouble Code (DTC) memory. Refer to
⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and
Testing .
– Read the readiness code. Refer to ⇒ Fuel Injection and Igni‐
tion; Rep. Gr. 01 ; Diagnosis and Testing .
– If DTC memory was cleared or Engine Control Module (ECM)
disconnected from voltage supply the readiness code must be
regenerated. Refer to ⇒ Fuel Injection and Ignition; Rep. Gr.
01 ; Diagnosis and Testing .

52 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

2.2 Hydraulic Valve Lifter, Checking AG. Volkswagen AG d

agen oes
ksw
Special tools and workshop equipment required by V ol not
gu
ara
ed
is nte
♦ Feeler Gauge hor eo
aut ra
c
♦ Wooden or plastic wedge ss

ce
le
un

pt
an
d
itte

y li
Note

rm

ab
pe

ility
ot

wit
♦ Only replace the entire valve lifter (it cannot be adjusted or
, is n

h re
serviced).
hole

spec
♦ Irregular valve noises are normal while starting the engine.
es, in part or in w

t to the co
Test Sequence

rrectness of i
– Start the engine and let it run until the coolant fan has switched
on once.
l purpos

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

nutes.

nform
ercia

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

a
com

or lifters are defective as follows:

tion in
r
te o

– Remove cylinder head cover.

thi
s
iva

do
– Turn crankshaft clockwise until camshaft lobe for valve lifter to
r
rp

cum
be tested is pointing upward.
fo

en
ng

t.
yi Co
– Measure the play between the camshaft lobe and valve lifter. Cop py
t. rig
gh ht
yri
– If the play exceeds 0.2 mm replace the valve lifter. If minimal p by
o Vo
by c lksw
play of 0.1 mm or no play is measured, continue the procedure Prote
cted agen
as follows:
AG.

– Lightly press the valve lifter downward with a wood or plastic

wedge. If 0.20 mm thick feeler gauge can be inserted between
camshaft and valve lifter, replace valve lifter.

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).

2.3 Valve Guides, Checking

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

2. Diagnosis and Testing 53

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

Test Sequence
– Insert new valve into guide. The end of the valve stem must
be flush with the guide. Due to the slight difference in stem
diameters, use only an intake valve in the intake guide and an
exhaust valve in the exhaust guide.
– Determine the tilt clearance. Wear limit: 0.8 mm
If tilt clearance is exceeded:
– Replace the cylinder head.

2.4 Camshaft, Checking Adjustment

⇒ “2.4.1 Check Activation”, page 54
⇒ “2.4.2 Solenoid Valve, Checking”, page 54
⇒ “2.4.3 Camshaft Adjuster, Checking Function”, page 54
Only Vehicles with Engine Codes AWP, AWW
The camshaft adjustment is load- and RPM dependent. The elec‐
trical valve for camshaft adjustment switches oil pressure onto
camshaft adjuster (mechanical adjustment mechanisms), which
adjusts the camshaft.
Special tools and workshop equipment required
♦ Vehicle Diagnostic Tester
♦ Analog/Digital Multimeter - FLU83III-
AG. Volkswagen AG d
♦ Connector Test Set - VAG1594D- agen oes
olksw not
byV gu
ara
♦ Speed Adjuster Tool - VAG1788/10- orised
nte
h eo
ut ra
2.4.1 Check Activation ss a c
ce
e
nl

pt
du

– Check the activation of the camshaft adjustment solenoid

an
itte

valve via the output Diagnostic Test Mode (DTM).

y li
erm

ab
ility

If control is OK:
ot p

wit
, is n

h re

2.4.2 Solenoid Valve, Checking

hole

spec
es, in part or in w

– Measure resistance between terminals of solenoid valve.

t to the co

Specified value: 10 to 18 Ω (at room temperature)

If no malfunctions are found on valve:
rrectness of i

– Check camshaft adjuster function.

l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

2.4.3 Camshaft Adjuster, Checking Function

f

en
ng

t.
yi Co
op py
Test Conditions
. C rig
ht ht
rig by
py Vo
• Coolant temperature must be at least 85 °C (185 °F), see Dis‐
co lksw
by
cted agen
play group 04, display field 3 Prote AG.

54 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

Test Sequence
– Connect the Vehicle Diagnostic Tester and select the control
module for engine electronics with the “address word 01”. En‐
gine must run at idle for this. Connect the scan tool and select
the engine control module. Refer to ⇒ Fuel Injection and Ig‐
nition; Rep. Gr. 01 ; Diagnosis and Testing .
Scan tool display: Quick data transfer HELP
Select function XX

– Press the buttons 0 and 4 for the function “Initiate basic set‐
ting” and press Q button to confirm the input.
Scan tool display: Initiate basic setting HELP
Enter display group number XXX

– Press the buttons 0 9 and 4 for “Display group number 94”

and confirm entry with the Q button.
Shown on the display: (1 to 4 = display fields)
AG. Volkswagen A
System in basic setting 94 ->
n G do
wage es n 1 2 3 4
Volks ot g
by ua
Engine Code AWW ris
ed ran
tee
tho
or
– Use the Speed Adjuster Tool - VAG1788/10- to au adjust engine ac
ss
speed to 2800 to 3200 RPM.

ce
le
un

pt
an
d

– Hold speed at 1800 to 2200 RPM until display in display field

itte

y li
3 goes from “Test OFF” to “Test ON”.
rm

ab
pe

ility
– Continue to hold speed at 1800 to 2200 RPM until specified
ot

wit
, is n

value “Syst. OK” is shown in display field 3.

h re
hole

spec
Reading results as described:
es, in part or in w

t to the co
– Remove the Speed Adjuster Tool - VAG1788/10- from the ac‐
celerator pedal.
Engine Code AWP rrectness of i

– Press brake pedal and hold firmly.

l purpos

– Press gas pedal into Wide Open Throttle (WOT) position. The
engine speed is raised to approximately 2300 RPM by the En‐
nform
ercia

gine Control Module (ECM).

m

a
com

ti

– Hold the brake pedal and accelerator pedal until display in

on in

display field 3 goes from “Test OFF” to “Test ON”.

r
te o

thi
s
iva

do

– Continue to hold brake and gas pedal until specified value

r
rp

“Syst. OK” is shown in display field 3.

um
fo

en
ng

t.
yi
Reading results as described:
Co
Cop py
ht. rig
– Release brake and gas pedals.
rig ht
py by
co Vo
by lksw
cted
All Engine Codes
agen
Prote AG.

– Press the → -button.

Scan tool display: Quick data transfer HELP
Select function XX

– Press the buttons 0 and 6 for the function “end output” and
press Q button to confirm the input.
– Switch off the ignition.
If “Syst. not OK” is shown in display field 3, read the DTC memory.
Refer to ⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis
and Testing .
The following malfunctions can take place with malfunction code
17927:

2. Diagnosis and Testing 55

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

The camshaft adjuster solenoid valve switches oil pressure cor‐

rectly on mechanical camshaft adjuster but it cannot reach its end
position (for example due to difficulty in moving).
– Replace camshaft adjuster.
– Check the Diagnostic Trouble Code (DTC) memory. Refer to
⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and
Testing .
– Read the readiness code. Refer to ⇒ Fuel Injection and Igni‐
tion; Rep. Gr. 01 ; Diagnosis and Testing .
– If DTC memory was cleared or ECM disconnected from volt‐
age supply the readiness code must be regenerated. Refer to
⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and
Testing .
– Repeat function test.
If specified value is again not obtained:
– Replace the ECM. Refer to ⇒ Fuel Injection and Ignition; Rep.
Gr. 24 ; Removal and Installation .

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

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.

56 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

3 Removal and Installation

⇒ “3.1 Camshafts”, page 57
n AG. Volkswagen A
⇒ “3.2 Camshaft Gaskets,
olks
Replacing”, pageG60
wage does
no
V t gu
by ara
⇒ “3.3 CylinderriseHead”,
d page 64 nte
tho eo
⇒ “3.4 Toothed
ss
au Belt, Removing, Installing and Tensioning”, rpage
ac
67

ce
e
nl

pt
du

an
⇒ “3.5 Valve Stem Seals, Replacing”, page 71
itte

y li
erm

ab
3.1 Camshafts

ility
ot p

wit
, is n

(with cylinder head installed)

h re
hole

spec
Special tools and workshop equipment required
es, in part or in w

t to the co
♦ Wrench - Pin Type - 3036-
♦ Bracket For Chain Adjustment - 3366-

rrectness of i
♦ Torque Wrench 1331 5-50Nm - VAG1331-
l purpos

♦ Torque Wrench 1332 40-200Nm - VAG1332-

♦ Sealant - AMV 174 004 01-

nf
ercia

orm
♦ Sealant - D 454 300 A2-
m

atio
om

Removing n in
or c

thi
te

– Remove the engine cover.

sd
iva

o
r
rp

cu

– Remove the upper toothed belt guard.

o

m
f

en
ng

t.
yi Co
– Set camshaft gear to on the crankshaft on the Top Dead Cen‐ t. Cop py
ter (TDC) marking for cylinder 1. Marking on camshaft gear
rig
gh ht
yri by
must be flush with marking on cylinder head cover. op Vo
by c lksw
cted agen
Prote
– Remove cylinder head cover.
AG.

– Remove toothed belt from camshaft gear. Refer to

⇒ “3.4 Toothed Belt, Removing, Installing and Tensioning”,
page 67 .
– Then, turn the crankshaft back slightly.
– Remove camshaft sprocket. To loosen the bolt, hold the cam‐
shaft sprocket firmly using the Wrench - Pin Type - 3036- .
– Remove the Hall sensor housing.
– Remove washer and cover for Hall sensor.

3. Removal and Installation 57

 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
ed ran
Bora 1999 ➤ , Bora Variant
horis 1999 ➤ , Golf 1998 ➤ , Golf Variant te1998
eo ➤
t
Engine Mechanical au- Edition 11.2007 ra
c
ss

ce
le
un
– Clean the drive chain and camshaft chain sprockets across

pt
an
d
itte
from both arrows on the bearing caps and mark installed po‐

y li
erm

ab
sition with a color marking.

ility
ot p

wit
is n

h re
Note
ole,

spec
urposes, in part or in wh

♦ Do not mark chain using a center punch or similar means!

t to the co
♦ The distance between both arrows or colored markings con‐
sists of drive chain 16 rollers.

rrectness o
cial p

f i
– Secure the camshaft adjuster or camshaft adjuster using the

nform
Bracket For Chain Adjustment - 3366- .
mer

atio
om

n
c

i
or

n
Note

thi
te

sd
iva

o
pr

c
If the Bracket For Chain Adjustment - 3366- is fastened too tightly,

um
r
fo

en
ng

the camshaft adjuster can be damaged.

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

– First remove the bearing covers 3 and 5 for the intake and
exhaust camshaft.
– Remove double bearing cap.
– Remove both bearing caps from chain gears on intake and
exhaust camshafts.
– Remove the camshaft adjuster or chain tensioner bolts.
– Alternating in a diagonal sequence, loosen bearing caps 2 and
4 for the intake and exhaust camshafts and remove.
– Remove intake and exhaust camshafts with camshaft adjuster
or chain tensioner and Bracket For Chain Adjustment - 3366- .
Installing

Note

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

must point upward.
♦ When installing bearing caps, verify marking on cap is reada‐
ble from intake side of cylinder head.

– Place the drive chain onto both camshaft sprockets according

to the color markings.

58 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

Note

♦ When using a new drive chain, distance between notches

-A and B- must be 16 rollers on the chain.
♦ The illustration shows where the first and sixteenth drive chain
rollers must be installed on the chain gears.
♦ Notch -A- is slightly offset inward toward chain roller -1-

– Replace the rubber/metal seal for camshaft adjuster or chain

tensioner and coat the cross-hatched surface with thin coat of
Sealant - D 454 300 A2- .
– Insert the camshaft adjuster or chain tensioner between drive
chain.
– Oil the camshaft running surfaces.
– Insert camshafts with drive chain and camshaft adjuster or
chain tensioner into the cylinder head.
– Tighten camshaft adjuster/chain tensioner to 10 Nm (pay at‐
tention to bushing).

– Alternating in diagonal sequence, tighten bearing caps 2 and

4 of intake and exhaust camshafts and tighten to 10 Nm (pay
attention to bushing).

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

pt
an
d
itte

y li
rm

ab

– Install both bearing caps on chain gears of intake and exhaust

pe

ility

camshafts. Check camshaft for proper adjustment and tighten

ot

wit
, is n

bearing cap to 10 Nm (pay attention to alignment bushing).

h re
hole

spec

– Remove Bracket For Chain Adjustment - 3366-

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

3. Removal and Installation 59

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Coat the hatched surface of double bearing cap lightly using

Sealant - AMV 174 004 01- , install and tighten to 10 Nm (pay
attention to the alignment bushing).
– Install remaining bearing cap and tighten to 10 Nm (pay at‐
tention to alignment bushing).

– Install the camshaft gear (thin rib toward outside -arrow- and
TDC marking visible) and tighten bolt to 65 Nm (use Wrench
- Pin Type - 3036- ).

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
– Check position of camshafts to each other again -arrows-.
erm

ab
ility
ot p

Further assembly is performed the reverse order of the removal.

wit
, is n

h re
Refer to
hole

spec
⇒ “3.4 Toothed Belt, Removing, Installing and Tensioning”, page
es, in part or in w

67 for how to install toothed belt and adjust valve timing

t to the co
Note

rrectness of i
l purpos

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

nf
ercia

pistons).

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
3.2 Camshaft Gaskets, Replacing
gh ht
pyri by
Vo
o
by c lksw
cted
⇒ “3.2.1 Camshaft Gear Gasket”, page 60
agen
Prote AG.

⇒ “3.2.2 Camshaft Position Sensor G40 Gasket, Removing”,

page 62

3.2.1 Camshaft Gear Gasket

Camshaft Position Sensor - G40- gasket, removing and installing.
Refer to
⇒ “3.2.2 Camshaft Position Sensor G40 Gasket, Removing”,
page 62 .
Special tools and workshop equipment required
♦ Puller - Camshaft Seal - 2085-

60 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

♦ Wrench - Pin Type - 3036-

♦ Seal Installer - Camshaft - T10071-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Torque Wrench 1332 40-200Nm - gVAG1332-
en AG. V
olkswagen AG
d a oes
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Removing y Vol gu
b ara
ed nte
ris
– Remove the upper toothed
tho belt guard. eo
au ra
c
ss
– Set camshaft gear to on the crankshaft on the Top Dead Cen‐

ce
e
nl

ter (TDC) marking for cylinder 1. Marking on camshaft gear

pt
du

an
must be flush with marking on cylinder head cover.
itte

y li
erm

ab
– Remove cylinder head cover.

ility
ot p

wit
, is n

– Remove toothed belt from camshaft gear. Refer to

h re
⇒ “3.4 Toothed Belt, Removing, Installing and Tensioning”,
hole

spec
page 67 .
es, in part or in w

t to the co
– Then, turn the crankshaft back slightly.
– Remove camshaft sprocket. To loosen the bolt, hold the cam‐

rrectness of i
shaft sprocket firmly using the Wrench - Pin Type - 3036- .
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
– Insert camshaft gear retaining bolt -arrow- into camshaft by
o

m
f

en
ng

hand to stop to guide seal puller.

t.
yi Co
Cop py
t. rig
– Remove the inner portion of Puller - Camshaft Seal - 2085- yri
gh by
ht
two rotations (approximately 3 mm) from outer portion and cop Vo
by lksw
secure with knurled-head screw. cted agen
Prote AG.

– Grease threaded head of Puller - Camshaft Seal - 2085- , po‐

sition and screw into seal as far as possible with forced pres‐
sure.
– Loosen knurled bolt and turn inner part against camshaft until
seal is removed.
Installing

Note

Phased in introduction of PTFE sealing rings (Distinguishing fea‐

ture: without ring spring, sealing lip designed wider). The sealing
lip of this sealing ring may not be oiled or greased. An seal of the
old version (with ring spring) can be replaced by a PTFE seal -
but not the other way around.

– Clean off any oil on the camshaft pin with a clean cloth.

3. Removal and Installation 61

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Attach the Seal Installer - Crankshaft Seal Guide Sleeve -

T10071/1- on the camshaft bearing.
– Slide seal over guide sleeve onto camshaft pin.

– Press in the seal all the way using the Seal Installer - Camshaft
Guide Sleeve - T10071/3- . Use the Seal Installer - Camshaft
Component 4 - T10071/4- to dosso. n AG. Volkswagen AG do
wage es k not
Vol gu
Further assembly is performed
se
d b in reverse order of the removal.
y ara
nte
ri
ho eo
Refer to ut ra
sa c
⇒ “3.4 Toothed Belt, Removing, Installing and Tensioning”, page
s

ce
le

67 for how to install the toothed belt and adjust valve timing.
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

3.2.2 Camshaft Position Sensor - G40- Gas‐

ket, Removing t to the co
rrectness of i
Special tools and workshop equipment required
l purpos

♦ Puller - Camshaft Seal - 2085-

♦ Seal Installer - Camshaft Installer Kit - 3241- (for standard
nform
ercia

version gasket with ring spring)

m

♦ Seal Installer - Camshaft - T10071- (for PTFE-version gasket)

com

tion in

♦ Torque Wrench 1331 5-50Nm - VAG1331-

r
te o

thi
s
iva

♦ Torque Wrench 1332 40-200Nm - VAG1332-

do
r
rp

cum
fo

♦ Screw M8×60
en
ng

t.
yi Co
op
Removing
C py
ht. rig
rig ht
py by
– Disconnect the connector from the Camshaft Position Sensor co Vo
by lksw
- G40- -arrow-.
cted agen
Prote AG.

– Remove the upper toothed belt guard.

– Remove housing for Hall sensor.
– Remove washer and cover for Hall sensor.

62 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– To guide the Puller - Camshaft Seal - 2085- , thread the Puller

- Camshaft Seal Adapter - 2085/1- all the way in camshaft by
hand.
– Remove the inner portion of Puller - Camshaft Seal - 2085-
two rotations (approximately 3 mm) from outer portion and
secure with knurled-head screw.

AG. Volkswagen AG d
agen oes
olksw not
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– Lubricate threaded headiseof seal extractor, position and with uaran
d b
forced pressure screw
ut
hointo seal as far as possible.
r tee
or
a ac
– ss and turn inner part against camshaft until
Loosen knurled bolt

ce
e

seal is removed.
nl

pt
du

an
itte

y li
Installing
erm

ab
ility
ot p

wit
, is n

Note

h re
hole

spec
Phased in introduction of PTFE sealing rings (Distinguishing fea‐
es, in part or in w

t to the co
ture: without ring spring, sealing lip designed wider). The sealing
lip of this sealing ring may not be oiled or greased. An seal of the
old version (with ring spring) can be replaced by a PTFE seal -

rrectness of i
but not the other way around.
l purpos

PTFE Sealing Ring, Installing

– Clean off any oil on the camshaft pin with a clean cloth.
nform
mercia

at
om

– Attach the Seal Installer - Camshaft Component - T10071/5-

ion
c

on the camshaft bearing.

in t
or

his
ate

– Push the seal over the Seal Installer - Camshaft Component

do
priv

- T10071/5- .
cum
for

en
ng

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

– Press in the seal all the way using the Seal Installer - Camshaft
Guide Sleeve - T10071/3- . Use bolt M8×60 -1- for this.
Sealing Ring, Installing with Ring Spring
– Lightly sealing lip of seal.

3. Removal and Installation 63

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Attach the Camshaft Installer Kit - Sleeve - 3241/2- on the

camshaft bearing.
– Push the gasket over the Camshaft Installer Kit - Sleeve -
3241/2- .

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
– Press in the seal all the way using the Camshaft Installer Kit -
ss

ce
e
Sleeve - 3241/1- . Use the Camshaft Installer Kit - Sleeve -

nl

pt
du
3241/3- to do so.

an
itte

y li
erm

ab
Procedure for All Sealing Rings

ility
ot p

wit
– Insert the Camshaft Position Sensor - G40- trim with notch in
, is n

h re
intake camshaft.
hole

spec
– Install the washer (with the cone outward) and tighten the bolt
es, in part or in w

t to the co
to 25 Nm.
– Install the Camshaft Position Sensor - G40- housing and tight‐
en to 10 Nm.

rrectness of i
– Install the upper toothed belt guard.
l purpos

– Connect the connecting piece from the Camshaft Position

nf
ercia

Sensor - G40- -arrow-.

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
co lksw
by
cted agen
Prote AG.

3.3 Cylinder Head

Special tools and workshop equipment required
♦ Guide Tool - Cylinder Head - 3070-
♦ Drip Tray - VAG1306- or Shop Crane - Drip Tray - VAS6208-
♦ Torque Wrench 1332 40-200Nm - VAG1332-
♦ Spring Clip Pliers - VAS6499-
♦ Polydrive Bit Drive Socket - 3452- or Polydrive Bit Drive Socket
- T10070- (engines with Polydrive cylinder head bolts)
Requirements
• The engine must be no more than warm to touch.
Removing
– Read the safety precautions before starting. Refer to
⇒ “1.7 Safety Precautions, Working on Fuel Supply System”,
page 116 .
– Follow all the guidelines for clean working conditions. Refer to
⇒ “1.5 Guidelines for Clean Working Conditions”, page 115 .

64 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– First, check whether a coded radio is installed. If necessary,

obtain the anti-theft coding.
– Turn off the ignition and disconnect the battery Ground (GND)
cable.
– Remove the engine cover.
– Drain the coolant. Refer to
⇒ “1.1 Coolant, Draining and Filling”, page 93 .

WARNING

The fuel supply line is under pressure. Always wear protective

eyewear and protective clothing to prevent injuries and contact
with skin. Place a cloth on the connection location before loos‐
ening hose connections. Then release pressure by carefully
pulling hose off connection.

– Disconnect the fuel supply and return lines at the connecting

point of the fuel rail.
– Seal the lines so that no dirt can enter the fuel system.
– Remove front exhaust pipe from exhaust manifold or turbo‐
charger.
– Separate all the required connections:
♦ Coolant system
♦ Crankcase ventilation
♦ Secondary Air Injection (AIR) System
♦ Turbocharger/regulation
♦ Fuel injection and ignition system
– Remove the ribbed belt. Refer to
⇒ “4.4 Ribbed Belt”, page 38 . gen AG. Volkswagen AG d
wa oes
olks not
– Remove the ribbed belt
d b tensioning element.
yV gu
ara
e nte
ris
– Remove the upper
ut toothed belt guard.
ho eo
ra
sa c
– Set camshaft sgear to on the crankshaft on the Top Dead Cen‐
ce
e
nl

ter (TDC) marking for cylinder 1. Marking on camshaft gear

pt
du

an

must align with arrow on toothed belt guard.

itte

y li
erm

ab

– Remove toothed belt from camshaft gear. Refer to

ility
ot p

⇒ “3.4 Toothed Belt, Removing, Installing and Tensioning”,

wit
, is n

page 67 .
h re
hole

spec

– Then, turn the crankshaft back slightly.

es, in part or in w

t to the co

– Remove cylinder head cover.

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

65
cted agen
Prote AG.
3. Removal and Installation
 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Loosen and remove cylinder head bolts in specified sequence.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
b ara
Note rise
d
nte
tho eo
au ra
For Polydrive cylinder head bolts, use Polydrive Bit Drive Socket ss c

ce
e
- 3452- or Polydrive Bit Drive Socket - T10070- .

nl

pt
du

an
itte

y li
erm
– Carefully lift cylinder head off.

ab
ility
ot p

Installing

wit
, is n

h re
hole

spec
Note
es, in part or in w

t to the co
♦ There must be no oil or coolant in the blind holes for the cyl‐
inder head bolts in the cylinder block.

rrectness of i
♦ Only remove the new cylinder head gasket from its packing
l purpos

immediately before installing.

♦ Handle the new gasket with extreme care. Damaging will lead

nf
ercia

to leaks.

orm
m

atio
om

– Stuff clean cloths into cylinder so that no dirt or abrasive pow‐

n in
or c

der can get between cylinder wall and piston.

thi
te

sd
iva

– Do not allow dirt or abrasive powder to get into coolant either.

o
r
rp

cu
o

m
f

en
ng

– Carefully clean sealing surfaces on the cylinder head and cyl‐

t.
yi Co
inder block. Avoid introducing scratches or scoring (do not use t. Cop py
sandpaper with grit below 100).
rig
gh ht
pyri by
Vo
co
– Carefully remove metal particles, emery remains and cloths.
by lksw
cted agen
Prote AG.

– Turn crankshaft to set cylinder 1 at TDC.

– Then, turn the crankshaft back slightly.

– To center, install the Guide Tool - Cylinder Head - 3070- in

cylinder head bolts 8 and 10.
– Install new cylinder head gasket. Text (replacement part num‐
ber) must be visible.
– Install cylinder head, insert the remaining eight cylinder head
bolts and hand tighten.
– Remove Guide Tool - Cylinder Head - 3070- through bolt holes
with guide pin handle. Do this by turning the pin handle toward
the left until the pins are free.
– Insert both remaining cylinder head bolts and then fasten them
hand-tight.

66 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Tighten cylinder head in tightening sequence as follows:

– Pre-tighten all the bolts to 40 Nm.
– Then tighten all bolts an additional 1/4 turn (90°) using a rigid
wrench.
– Afterwards, tighten all bolts again 1/4lkturn another 90°
n AG. Vo swagen A ge G do
swa es
Further assembly is performed
by
Vol
k
the reverse order of thenoremoval.
t gu
a d ran
i se
– Install toothed thbelt
or and adjust valve timing. Refer to tee
or
⇒ “3.4 Toothed
ss
au
Belt, Removing, Installing and Tensioning”, ac
page 67

ce
e
nl

pt
du

an
Fill with new coolant. Refer to
itte

y li
⇒ “1.1 Coolant, Draining and Filling”, page 93 .
erm

ab
ility
ot p

– Perform the “Procedure after Voltage Supply Open Circuit”.

wit
, is n

Refer to ⇒ Fuel Injection and Ignition; Rep. Gr. 24 ; Diagnosis

h re
and Testing .
hole

spec
es, in part or in w

t to the co
3.4 Toothed Belt, Removing, Installing and
Tensioning

rrectness of i
⇒ “3.4.1 Toothed Belt, Tensioning”, page 71
l purpos

Special tools and workshop equipment required

♦ Engine Support Bridge - 10-222A- with Engine Support Bridge

nf
ercia

o
- Engine Bracket - 10-222A/1-

rm
m

atio
m

♦ Engine Support Bridge Retainer - 3180-

o

n in
or c

thi

♦ Tensioning Bolt - T10092-

te

sd
iva

o
r

♦ Locking Pin (3 pc.) - T40011-

rp

cu
o

m
f

en
ng

♦ Torque Wrench 1331 5-50Nm - VAG1331-

t.
yi Co
Cop py
t. rig
♦ Torque Wrench 1332 40-200Nm - VAG1332- opyri
gh by
Vo
ht
c lksw
♦ Locking Fluid - D 000 600 A2-
by
cted agen
Prote AG.
Removing
– Read the safety precautions before starting. Refer to
⇒ “1.7 Safety Precautions, Working on Fuel Supply System”,
page 116 .
– Follow all the guidelines for clean working conditions. Refer to
⇒ “1.5 Guidelines for Clean Working Conditions”, page 115 .
– Remove the engine cover.
– Remove the sound insulation tray. Refer to ⇒ Body Exterior;
Rep. Gr. 50 ; Description and Operation .
– Remove the right headlamp. Refer to ⇒ Electrical Equipment;
Rep. Gr. 94 ; Removal and Installation .
– Remove air guide pipe between turbocharger and charge air
cooler -Item 11- ⇒ Item 11 (page 153) .
– Remove the ribbed belt. Refer to
⇒ “4.4 Ribbed Belt”, page 38 .
– Remove the ribbed belt tensioning element.
Engine installed:

3. Removal and Installation 67

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Position crankshaft at Top Dead Center (TDC) cylinder 1 (ve‐

hicles with manual transmissions).

– Position crankshaft at TDC cylinder 1 (vehicles with automatic

transmissions).
With engine removed:

– Position vibration damper at TDC cylinder 1 -arrows-.

– Loosen the coolant expansion tank and set aside.
olksw
– Loosen the power steering
swa
gfluid
en AGreservoir
.V
and dset
agen AG
oes aside.
olk not
V gu
– Remove vacuum edline
by to throttle valve connection. ara
nte
ris
ho eo
– Remove theauupper
t toothed belt guard. ra
c
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

– Insert the Engine Support Bridge - 10-222A- with Engine Sup‐

spec

port Bridge - Engine Bracket - 10-222A/1- .

es, in part or in w

t to the co

– Engage the Engine Support Bridge Retainer - 3180- on right

lifting eye and tighten on the cylinder head and lightly pre-ten‐
sion the engine.
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.

68 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Unfasten bolts from subframe/ engine bracket, subframe/

body and subframe brackets/body -arrows- and completely
remove subframe.
– Remove engine bracket on cylinder block.

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

ce
le

– Remove vibration damper/belt pulley.

un

pt
an
d
itte

y li
– Remove lower and middle toothed belt cover.
erm

ab
ility
ot p

– Mark direction of rotation of toothed belt.

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f
– Screw the Tensioning Bolt - T10092- into tensioning device for
inform

toothed belt.
mer

atio
m

– If necessary, align the pressure piston before tensioning using

o

n
c

needle nose pliers or a thin wire (hole in pressure piston and

i
or

n thi

hole in housing must line up).

te

sd
iva

o
pr

– Tension pressure piston of tensioner just enough that the

um
r
fo

pressure piston can be secured using Locking Pin (3 pc.) -

en
ng

t.
yi
T40011- .
Co
Cop py
t. rig
gh ht
– Remove toothed belt. yri
p by
o Vo
by c lksw
cted
– Then, turn the crankshaft back slightly.
agen
Prote AG.

Installing

Note

When turning camshaft, crankshaft must not be at TDC. Valves

and/or pistons may be damaged.

A - Toothed Belt Completely Removed

If toothed belt was only removed from camshaft gear. Refer to
⇒ page 70
Conditions
• The pistons must not be positioned at TDC.
Procedure

3. Removal and Installation 69

 AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , oGolf
ris
e Variant 1998 ➤ nte
eo
h
Engine Mechanical - Edition 11.2007 s aut ra
c
s

ce
e
nl
– Align marking on camshaft sprocket with marking on cylinder

pt
du

an
head cover.

itte

y li
erm

ab
– Place the toothed belt onto the crankshaft sprocket (observe

ility
ot p
direction of rotation).

wit
, is n

h re
– Install engine bracket on cylinder block. Tightening specifica‐

hole

spec
tion: 45 Nm

es, in part or in w

t to the co
Note

rrectness of i
Before installing engine bracket, insert bolts in bracket.

l purpos
– Install the lower toothed belt guard. (Insert the bolts with Lock‐

nform
ercia
ing Fluid - D 000 600 A2- .) Tightening specification: 10 Nm.
m
– Using a bolt, secure vibration damper/belt pulley (watch locat‐

at
om

io
ing point).

n
c

in t
or

his
ate

do
priv

cum
for

en
ng

– Turn crankshaft to set cylinder 1 at TDC.

t.
yi Co
Cop py
t. rig
– Position toothed belt on coolant pump, tensioning roller and yri
gh by
ht
camshaft gear. cop Vo
by lksw
cted agen
Prote
– Tension the toothed belt. Refer to
AG.

⇒ “3.4.1 Toothed Belt, Tensioning”, page 71 .

B - Toothed Belt Only Removed From Camshaft Gear

– Align marking on camshaft sprocket with marking on cylinder

head cover.
– Turn crankshaft to set cylinder 1 at TDC.
– Place toothed belt on camshaft gear.
– Tension toothed belt
⇒ “3.4.1 Toothed Belt, Tensioning”, page 71

70 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

3.4.1 Toothed Belt, Tensioning

– Tension the toothed belt. To do this, remove the Locking Pin
(3 pc.) - T40011- and unscrew the Tensioning Bolt - T10092- .
– Turn over crankshaft twice and check if the markings on the
camshaft and crankshaft still align with their reference points.
– Install vibration damper and belt pulley tightening specifica‐
tions: 25 Nm
– Install the toothed belt guard center section. (Insert the bolts
with Locking Fluid - D 000 600 A2- .) Tightening specification:
10 Nm.
AG. Volkswagen AG d
– Install the upper toothed belt guard. ksw
agen oes
not
Vol
y gu
– Install engine mount. Tightening specifications.
ise
d bRefer to ara
nte
⇒ “2.1 Engine and Transmission MountsuTightening
thor
Specifi‐ eo
cations”, page 5 . ss a ra
c

ce
le

– Install tensioner for ribbed belt. Tightening specification: 25

un

pt
an
d

Nm
itte

y li
erm

ab
– Install the ribbed belt. Refer to ⇒ “4.4 Ribbed Belt”, page 38 .

ility
ot p

wit
is n

h re
3.5 Valve Stem Seals, Replacing
ole,

spec
urposes, in part or in wh

(with cylinder head installed)

t to the co
Special tools and workshop equipment required
♦ Spark Plug Removal Tool - 3122B-

rrectne
♦ Valve Spring Compressor - 3362- with Valve Spring Com‐

s
pressor - Thrust Piece - 3362/1-

s o
cial p

f i
♦ Puller - Valve Seal - 3364-

nform
mer

♦ Pressure Hose - VW653/3-

atio
om

n
♦ Torque Wrench 1331 5-50Nm - VAG1331-
c

i
or

n thi
te

sd
♦ Torque Wrench 1332 40-200Nm - VAG1332-
iva

o
pr

cum
r

♦ Seal Installer - Valve Stem - 3365-

fo

en
ng

t.
yi Co
Removing Cop py
t. rig
gh ht
yri
– Remove the camshafts. Refer to p by
co Vo
lksw
⇒ “3.1 Camshafts”, page 57 .
by
cted agen
Prote AG.
– Remove the valve lifters and place on running surface when
setting down. Be careful not to switch valve lifters.
– Remove the spark plugs using Spark Plug Removal Tool -
3122B- .
– Set the piston for the respective cylinder to the “Bottom Dead
Center (BDC)” position.

3. Removal and Installation 71

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Now, screw the Pressure Hose - VW653/3- into spark plug

thread.
– Place the Valve Spring Compressor - Thrust Piece - 3362/1-
into the Valve Spring Compressor - 3362- .
– Using retaining bolts bolted in the tool, secure the Valve Spring
Compressor - 3362- to the cylinder head.
– Bring the Valve Spring Compressor - 3362- into the following
position to press valve springs together.
Outer intake valve: lower position
Center intake valve: upper position
Exhaust valve: lower position
– Connect the compressed air hose to a pressure of at least 6
bar (87 psi) and then remove the valve springs.

– Remove the valve stem seals using Puller - Valve Seal -

3364- .
Installing

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

pt
an
d
itte

y li
erm

ab
– Place plastic sleeve -A- on valve stem to prevent damage to ility
ot p

new valve stem seals.

wit
is n

h re

– Oil the sealing lip of valve stem seal -B-, insert into Seal In‐
ole,

spec

staller - Valve Stem - 3365- and carefully slide onto the valve
urposes, in part or in wh

guide.
t to the co

Further assembly is performed the reverse order of the removal.

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

72 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

4 Special Tools

Special tools and workshop

equipment required
♦ Spark Plug Removal Tool -
3122B-
♦ Torque Wrench 1331
5-50Nm - VAG1331- AG. Volkswagen AG d
agen oes
ksw
♦ Compression Tester
by V Kit -
ol not
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ara
VAG1763- ris ed
nte
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aut ra
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un

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an
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itte

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wit
is n

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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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r
fo

en
ng

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

4. Special Tools 73
 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

♦ Wrench - Pin Type - 3036-

♦ Bracket For Chain Adjust‐
ment - 3366-
♦ Torque Wrench 1331
5-50Nm - VAG1331-
♦ Torque Wrench 1332
40-200Nm - VAG1332-

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

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
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pyri by
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o
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cted agen
Prote AG.

74 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

♦ Spark Plug Removal Tool -

3122B-
♦ Valve Spring Compressor -
3362- with Valve Spring
Compressor - Thrust Piece
- 3362/1-
♦ Puller - Valve Seal - 3364-
♦ Pressure Hose - VW653/3-
♦ Torque Wrench 1331
5-50Nm - VAG1331-
♦ Torque Wrench 1332
40-200Nm - VAG1332-

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un

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ab
pe

ility
ot

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

a
com

tion in
r
te o

thi
s
iva

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rp

cum
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en
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Cop py
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cted agen
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4. Special Tools 75
 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

♦ Engine Support Bridge -

10-222A- with Engine Sup‐
port Bridge - Engine Brack‐
et - 10-222A/1-
♦ Engine Support Bridge Re‐
tainer - 3180-
♦ Tensioning Bolt - T10092-
♦ Locking Pin (3 pc.) -
T40011-
♦ Torque Wrench 1331
5-50Nm - VAG1331-
♦ Torque Wrench 1332
40-200Nm - VAG1332-
♦ Locking Fluid - D 000 600
A2-

AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
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nl

pt
du

an
itte

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ab
ility
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wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

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ercia

orm
m

atio
om

n in
or c

thi
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Prote AG.

76 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

♦ Guide Tool - Cylinder Head

- 3070-
♦ Drip Tray - VAG1306- or
Shop Crane - Drip Tray -
VAS6208-
♦ Torque Wrench 1332
40-200Nm - VAG1332-
♦ Spring Clip Pliers -
VAS6499-
♦ Polydrive Bit Drive Socket -
3452- or Polydrive Bit Drive
Socket - T10070- (engines
with Polydrive cylinder
head bolts)

AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
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aut ra
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ce
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nl

pt
du

an
itte

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

4. Special Tools 77
 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

♦ Puller - Camshaft Seal -

2085-
♦ Wrench - Pin Type - 3036-
♦ Seal Installer - Camshaft -
T10071-
♦ Torque Wrench 1331
5-50Nm - VAG1331-
♦ Torque Wrench 1332
40-200Nm - VAG1332-

AG. Volkswagen AG d
agen oes
olksw not
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un

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an
d
itte

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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
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rp

cum
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ng

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Cop py
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by
cted agen
Prote AG.

78 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

Special tools and workshop

equipment required
♦ Puller - Camshaft Seal -
2085-
♦ Seal Installer - Camshaft
Installer Kit - 3241- (for
standard version gasket
with ring spring)
♦ Seal Installer - Camshaft -
T10071- (for PTFE-version
gasket)
♦ Torque Wrench 1331
5-50Nm - VAG1331-
♦ Torque Wrench 1332
40-200Nm - VAG1332-

n AG. Volkswagen AG do
lkswage es n
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ility
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es, in part or in w

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♦ Dial Gauge Holder - VW387-

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
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rp

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by
cted agen
Prote AG.

4. Special Tools 79
 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

♦ Seal Installer - Valve Stem - 3365-

n AG. Volkswagen AG do
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es, in part or in w

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tion in
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by
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Prote AG.

80 Rep. Gr.15 - Cylinder Head, Valvetrain

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

17 – Lubrication
1 General Information
⇒ “1.1 Lubrication System”, page 81

1.1 Lubrication System

Note

♦ If large quantities of metal shavings or abraded material are

detected during engine repairs, it may mean the crankshaft or
connecting rod bearings are damaged. To prevent subsequent
damage, perform the following steps after the repair:
♦ Clean the oil channels carefully.
♦ Replace oil spray jets AG. Volkswagen AG d
agen oes
olksw not
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♦ Replace the oil cooler ised by ara
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♦ Oil filter, removing and installing
h
aut ra
ss c
♦ The oil level must not go above the MAX mark - danger of

ce
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nl

pt
du

causing damage to the catalytic converter! Marks. Refer to

an
itte

⇒ Fig. ““Oil Dipstick Markings”“ , page 84

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Oil pressure and oil pressure switch, checking. Refer to

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h re
⇒ “4.1 Oil Pressure and Oil Pressure Switch, Checking”,
hole

page 87 .

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

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ion
c

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or

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ate

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1. General Information 81
 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

2 Description and Operation

⇒ “2.1 Lubrication System Components”, page 82 .
⇒ “2.2 Overview - Oil Filter Housing”, page 84 .

2.1 Lubrication System Components

AG. Volkswagen AG d
agen
1 - Bolt Volksw
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❑ 15 Nm rised
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2 - Sealing Flange ss a ra
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❑ Must be located on

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alignment sleeves

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❑ Clean sealing surface
erm

ab
before installing

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❑ Insert with Silicone

h re
Sealant - D 176 404
hole

spec
A2- .
es, in part or in w

t to the co
❑ Removing and instal‐
ling. Refer to
⇒ “4.3 Sealing Flange,
Belt Pulley Side”,

rrectness of i
page 36 .
l purpos

3 - Chain Tensioner with Ten‐

sioning Rail,

nform
ercia

❑ 15 Nm
m

at
❑ Check for wear
om

ion
c

❑ when installing, preten‐

in t
or

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e

sion spring and hook in

at

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4 - Chain Sprocket

um
for

en
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❑ For oil pump drive

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❑ Check for wear
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5 - Cylinder Block
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❑ Crankshaft, removing
AG.

and installing. Refer to

⇒ “4.1 Crankshaft Seal,
Belt Pulley Side, Re‐
placing”, page 33 .
❑ Piston and connecting
rod, disassembling and
assembling, Refer to
⇒ “2.3 Overview - Pis‐
tons and Connecting Rods, Engine Code AWD”, page 24 or
⇒ “2.4 Overview - Pistons and Connecting Rods, Engine Code AWP, AWW”, page 26
6 - Oil Dipstick
❑ The oil level must not go above the MAX marking!
❑ Marks. Refer to ⇒ Fig. ““Oil Dipstick Markings”“ , page 84
7 - Inlet Spout
❑ For the oil dipstick
❑ For extracting oil
8 - Guide Tube
9 - Oil Spray Jet
❑ For piston cooling

82 Rep. Gr.17 - Lubrication

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

10 - Relief Valve
❑ 27 Nm
AG. Volkswagen AG d
❑ Opening pressure: 1.3 to 1.6
lksw
bar
agen(18.8 to 23.2 psi) oes
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11 - Bolt ir se
db ran
tee
ho
15 Nm aut or
ac
ss

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12 - Intake Line
un

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❑ Clean the screen if it is dirty.

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ility
13 - O-Ring
ot p

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❑ Replace

h re
ole,

spec
14 - Splash Wall
urposes, in part or in wh

t to the co
15 - Bolt
❑ 15 Nm
❑ Loosen and tighten with the T Bar And Socket - 10mm - 3185- .

rrectne
❑ Remove with the Socket - 3249- .

ss
16 - Oil Pan

o
cial p

f in
❑ Clean sealing surface before installing

form
mer

❑ Insert with Silicone Sealant - D 176 404 A2- .

atio
m

❑ Removing and installing. Refer to ⇒ “5.1 Oil Pan”, page 89 .

o

n
c

i
or

n thi
e

17 - Oil Drain Plug

t

sd
iva

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r

❑ 30 Nm
p

cum
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en
ng

❑ If sealing ring is leaking cut open and replace.

t.
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18 - Seal
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❑ Replace cop Vo
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Prote AG.
19 - Oil Return Line
❑ From turbocharger -Item 36- ⇒ Item 36 (page 156)
20 - Bolt
❑ 10 Nm
21 - Oil Pump
❑ With pressure relief valve 12 bar (174 psi)
❑ 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
22 - Chain Sprocket
❑ For the oil pump
❑ Check for wear
23 - Bolt
❑ 25 Nm
24 - Roller Chain
❑ Mark direction of travel before removing
❑ Check for wear
25 - Alignment Sleeves
❑ Make sure it is secure

2. Description and Operation 83

 n AG. Volkswagen AG do
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Vo ot g
Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998e➤ d , Golf Variant 1998 ➤
by ua
ran
ir s
Engine Mechanical - Edition 11.2007 tho tee
or
au ac
ss
Oil Dipstick Markings

ce
le
un

pt
an
d
1 - MAX marking

itte

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2 - MIN marking

ility
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a - Area above the hatched field up to the MAX mark: Do not add

h re
oil!

hole

spec
es, in part or in w
b - Oil level in the hatched areas: engine oil can be filled.

t to the co
c - From the MIN marking up to the hatched field: add maximum
0.5 liters oil!

rrectness of i
l purpos

2.2 Overview - Oil Filter Housing

nform
mercia

a
com

t
1 - Sealing Plug

ion in
r

❑ 40 Nm
te o

thi
s
iva

do
2 - Seal
r
rp

cum
fo

❑ If sealing ring is leaking

en
ng

t.
yi
cut open and replace.
Co
Cop py
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3 - Spring
ht
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by
❑ For pressure relief Prote
cted AG.
agen
valve, approximately
4 bar (58 psi)
4 - Piston
❑ For pressure relief
valve, approximately
4 bar (58 psi)
5 - Seal
❑ Replace
6 - Return Flow Check Valve
❑ 8 Nm
7 - Seal
❑ Slide on up to collar of
tube
❑ Replace if damaged
8 - Connecting Pipe
❑ For the crankcase ven‐
tilation
9 - Clip
❑ Make sure it is secure
10 - Plug
❑ 15 Nm
11 - Seal
❑ If sealing ring is leaking
cut open and replace.
12 - Bolt
❑ 20 Nm
13 - Oil Supply Line
❑ To turbocharger

84 Rep. Gr.17 - Lubrication

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

14 - Banjo Bolt
❑ 30 Nm
15 - Seal
❑ Replace
16 - Oil Pressure Switch - F1- , 1.4 bar (20.30 psi)
❑ 25 Nm
❑ Black
❑ Checking. Refer to ⇒ “4.1 Oil Pressure and Oil Pressure Switch, Checking”, page 87 .
17 - Seal
❑ If sealing ring is leaking cut open and replace.
18 - Bolt
❑ 15 Nm + 1/4 (90°) additional turn
❑ Replace n AG. Volkswagen AG do
lkswage es n
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19 - Seal d byV ua
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❑ Replace utho
or
a ac
❑ Snaps into the tabs of the oil cooler ss

ce
le
un

pt
20 - Oil Filter

an
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itte

y li
❑ Remove with tension strap
rm

ab
pe

ility
❑ Fasten by hand
ot

wit
, is n

❑ Observe installation instructions for oil filter

h re
hole

spec
21 - Bolt
es, in part or in w

t to the co
❑ 25 Nm
22 - Oil Cooler

rrectness of i
❑ Make sure there is enough space to the surrounding components
❑ See note. Refer to ⇒ “1.1 Lubrication System”, page 81 .
l purpos

❑ Coat the contact surfaces to the oil filter bracket outside of the gasket with Sealing Compound - AMV
188 100 02- .

nform
ercia

23 - Oil Filter Bracket

m

a
com

ti
❑ With pressure relief valve, approximately 4 bar (58 psi)

on in
r
te o

thi
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2. Description and Operation 85

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

3 Specifications olksw
agen
AG. Volkswagen AG d
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⇒ “3.1 Engine Oil”, page 86 rised
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Oil Capacities

du

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Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03

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Engine Oil Specifications

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Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03 hole

spec
es, in part or in w

t to the co
rrectness of i
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nf
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atio
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or c

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Prote AG.

86 Rep. Gr.17 - Lubrication

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

4 Diagnosis and Testing

⇒ “4.1 Oil Pressure and Oil Pressuren ASwitch,
G. VolkswChecking”,
agen AG
page 87 lkswage does
not
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4.1 Oil Pressure
utho
ris and Oil Pressure Switch, tee
or
Checking
ss
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un

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Special tools and workshop equipment required

an
d
itte

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erm

♦ Oil Pressure Gauge Kit - VAG1342-

ab
ility
ot p

♦ Voltage Tester - VAG1527B-

wit
is n

h re
ole,

♦ Connector Test Set - VAG1594D-

spec
urposes, in part or in wh

Test Conditions

t to the co
• Engine oil level OK, checking. Refer to
⇒ Fig. ““Oil Dipstick Markings”“ , page 84 .

rrectne
• Engine oil temperature at least 80 °C (176 °F) (coolant fan
must start up once)

ss o
cial p

f inform
Note
mer

atio
m

Function test and servicing the optical and acoustic oil pressure
o

n
c

i
or

n
gauge. Refer to ⇒ Wiring diagrams, Troubleshooting & Compo‐

thi
te

nent locations.
sd
iva

o
pr

cum
r
fo

en
ng

t.
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Cop py
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by
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4. Diagnosis and Testing 87

 olkswagen AG
en AG. V
Bora 1999 ➤ , Bora ksVariant
wag 1999 ➤ , Golf d1998
oes ➤ , Golf Variant 1998 ➤
not
Vol
Engine Mechanical
ed by - Edition 11.2007 gu
ara
ris nte
utho eo
Test Sequence ss a ra
c

ce
– Remove the Oil Pressure Switch - F1- and install the oil pres‐ e
nl

pt
du

an
sure gauge in its place.
itte

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erm

ab
– Install the Oil Pressure Gauge Kit - VAG1342- into the oil filter

ility
ot p

bracket in place of the oil pressure switch.

wit
, is n

h re
– Connect the brown wire on the tester to the ground (-).
hole

spec
es, in part or in w

– Connect the Voltage Tester - VAS6839- to battery positive (+)

t to the co
and the oil pressure switch using adapter cables from the
Connector Test Set - VAG1594D- . LED must not light up.
– If the LED lights up, replace the 1.4 bar (20.30 psi) Oil Pressure

rrectness of i
Gauge Kit - VAG1342- .
l purpos

If the LED does not light up:

– Let the engine run at idle: the LED must come on at 1.2 to 1.6

nf
ercia

o
bar (17.4 to 23.2 psi) pressure; if not, replace the oil pressure

rm
m

atio
switch.
om

n in
c

– Check oil pressure at different speeds:

or

thi
te

sd
iva

2000 RPM: 2.7 to 4.5 bar (39.16 to 65.26 psi)

o
r
rp

cu
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f

Above 2000 RPM: maximum 7 bar (101.52 psi)

en
ng

t.
yi Co
op
If the specified values are not obtained:
C py
t. rig
gh ht
yri by
– Correct mechanical damage, for example bearing damage. cop Vo
by lksw
cted agen
Prote AG.
– Replace oil filter bracket with pressure relief valve -Item 23-
⇒ Item 23 (page 85) or oil pump -Item 21-
⇒ Item 21 (page 83) .
At higher engine speeds oil pressure must not exceed 7 bar
(101.52 psi)
If the specified value is exceeded:
– Check the oil channels.
– If necessary, replace oil filter bracket with pressure relief valve
-Item 23- ⇒ Item 23 (page 85) .

88 Rep. Gr.17 - Lubrication

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

5 Removal and Installation

⇒ “5.1 Oil Pan”, page 89

5.1 Oil Pan

Special tools and workshop equipment required
♦ T Bar And Socket - 10mm - 3185-
♦ Socket - 3249-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Silicone Sealant - D 176 404 A2-
♦ Hand drill with plastic brush attachment
♦ Protective eyewear
♦ Flat scraper
Removing
– Remove the sound insulation tray. Refer to ⇒ Body Exterior;
Rep. Gr. 50 ; Description and Operation
gen. AG
. Volkswagen AG
d a oes
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– Drain the engine oil. Vol gu
d by ara
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Note ss

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Observe the disposal regulations!

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ab
pe

ility
– Remove turbocharger oil return line from oil pan.
ot

wit
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h re
– Loosen the oil pan bolt with the T Bar And Socket - 10mm -
hole

spec
3185- . (Remove with the Socket - 3249- .)
es, in part or in w

– Remove the oil pan. Loosen oil pan with light blows of a rubber t to the co
headed hammer if necessary.
– Remove the sealant residue from cylinder block with a flat-
rrectness of i

blade scraper.
l purpos

– Remove the sealant residue from pan with a rotating brush,

for example a hand drill with a plastic brush attachment (wear
nform
ercia

eye protection).
m

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

a
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tion in

Installing
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♦ Pay attention to the expiration date of the sealant.
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♦ The oil pan must be installed within five minutes after appli‐
o Vo
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cted agen
cation of silicone sealant. Prote AG.

5. Removal and Installation 89

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Cut tube nozzle at front marking (nozzle diameter: approxi‐

mately 3 mm).
– Apply the silicone seals as illustrated. The sealing compound
bead must be:
♦ 2 to 3 mm thick
♦ And run on inside of bolt holes -arrows-

Note

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

cess sealant could get into oil pan and clog strainer in intake line agen AG. Volkswagen AG do
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– Apply the Silicone-Sealant - D 176 404 A2- au clean
ontossthe ac
sealing surface of the oil pan as shown. (The illustration shows

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pt
the location of the sealant bead on the cylinder block.)
du

an
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– Install the oil pan immediately and tighten all oil pan bolts
erm

ab
ility
lightly.
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Note

spec
es, in part or in w

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

rrectness of i
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– Tighten the oil pan bolts to 15 Nm.

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

nform
ercia

Further assembly is performed the reverse order of the removal.

m

at
om

io
– Tighten oil pan/oil return line screws to 10 Nm.

n
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ate

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Prote AG.

90 Rep. Gr.17 - Lubrication

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

6 Special Tools

Special tools and workshop

equipment required
♦ Oil Pressure Gauge Kit -
VAG1342-
♦ Voltage Tester -
VAG1527B-
♦ Connector Test Set -
VAG1594D-

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♦ T Bar And Socket - 10mm - 3185-

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es, in part or in w

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91
Prote AG.
6. Special Tools
 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

♦ Socket - 3249-

♦ Torque Wrench 1331 5-50Nm - VAG1331-

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Prote AG.

92 Rep. Gr.17 - Lubrication

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

19 – Cooling System
1 General Information
⇒ “1.1 Coolant, Draining and Filling”, page 93
⇒ “1.2 Cooling System Components”, page 96

1.1 Coolant, Draining

en AG. V
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Special tools and workshop equipment required gu
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♦ Refractometer
ut
ho - T10007A-
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♦ Drip Tray
s - VAG1306- or Shop Crane - Drip Tray - VAS6208-

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♦ Spring Clip Pliers - VAS6499-

an
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♦ Cooling System Charge Kit - VAS6096-

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spec
urposes, in part or in wh

WARNING

t to the co
Hot steam may escape when opening the reservoir. Wear pro‐
tective eyewear and protective clothing to prevent eye injury

rrectne
and scalding. Cover the cap with a cloth and open very care‐
fully.
ss o
cial p

f in
– Open cap for coolant expansion tank.
form
mer

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

atio
m

Gr. 50 ; Description and Operation .

o

n
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or

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– Remove the drain plug -arrow- to drain coolant from the radi‐
t

sd
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ator.
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– In addition, to drain the coolant from the engine, disconnect

the coolant hose at the oil cooler -arrow-.

Note

Observe the disposal regulations!

Filling

Caution

Only use tap water for mixing. Well water does not have the
quality necessary to ensure proper coolant function.

1. General Information 93
 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

Note

♦ Only use coolant additive G 12 that conforms to TL VW774 F.

Distinguishing feature: purple color
♦ G 12 lilac (according to TL VW774 F) can be mixed with the
previous coolant additives G 11 and G 12 (red).
♦ G 12 and coolant additives with the note “conforming to TL
VW774 F” prevent frost and corrosion damage, scaling and
also raise boiling point of coolant. For this reason the system
must be filled all year round with frost and corrosion protection
additives.
♦ Because of its high boiling point, the coolant contributes to
engine reliability under heavy engine loads, particularly in
countries with tropical climates.
♦ Freeze protection must be assured to about -25 °C (-13 °F) (in
arctic climatic countries to about -35 °C (-31 °F)).
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The
coolant additive portion must be at least 40%.
♦ If for climatic reasons a greater frost protection is required, the
amount of G 12 can be increased, but only up to 60% (frost
protection to about -40 °C (-40 °F)), as otherwise frost protec‐ wage
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tion is reduced again and cooling effectiveness is also re‐ yV
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♦ The Refractometer - T10007- is recommended for determining
sa
u ac
the freeze protection density. s

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♦ Do not use the old coolant again if replacing the radiator, heat‐

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er core, cylinder head or cylinder head gasket.
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Recommended mixture ratios:
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Frost Protection Anti-Freeze G 12 1) Water 1) 2)
es, in part or in w

to

t to the co
-25 °C (-13 °F) 40% 2 liters (2.1 3 liters (3.1
-35 °C (-31 °F) 50% quarts) quarts)
2.5 liters 2.5 liters

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(2.6 quarts) (2.6 quarts)
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1)The quantity of coolant can vary depending upon the vehicle

equipment.
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2) Only use clean tap water.
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– Install drain plug in radiator.

thi
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Prote AG.

94 Rep. Gr.19 - Cooling System

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Push the coolant hose onto the oil cooler connection and fas‐
ten with spring-type clip.
With Cooling System Charge Kit - VAS6096- :
– Install adapter from the Cooling System Tester - Diesel Adapt‐
er - VAG1274- that is appropriate for vehicle on reservoir.
– Fill the coolant circuit using Cooling System Charge Kit -
VAS6096- . Refer to Operating Instructions for Cooling Sys‐wagen AG. Volkswagen AG does
tem Charge Kit VAS6096. olks not
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Without Cooling System Charge Kit - VAS6096- : thoris e or
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Vehicles from MY 2001 ss

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– Fill the coolant to MAX marking on the expansion tank.

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Vehicles from MY 2002

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– Slowly fill coolant up to top marking of hatched area on ex‐

m

pansion tank.

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Continuation for All Vehicles

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or

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ate

– Seal expansion tank.

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– Switch off the heating and Air Conditioning (A/C) system.

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– Start engine and keep the engine at about 2000 RPM for ap‐
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– Allow engine to run until fan turns on. cted agen
Prote AG.

WARNING

Hot steam may escape when opening the reservoir. Wear pro‐
tective eyewear and protective clothing to prevent eye injury
and scalding. Cover the cap with a cloth and open very care‐
fully.

Vehicles from MY 2001

– Check the coolant level and fill if necessary. With a warm en‐
gine the coolant level must be at the MAX marking, with a cold
engine between Min and Max marking.
Vehicles from MY 2002
With engine at operating temperature, coolant level must lie at top
marking of hatched area.
When engine is cold, the coolant level should be somewhere in
the middle of the hatched area.

1. General Information 95
 AG. Volkswagen AG d
agen oes
olksw not
yV gu
Bora 1999 ➤ , Bora Variant
ised b 1999 ➤ , Golf 1998 ➤ , Golf Variant
ara
nte 1998 ➤
r
Engine Mechanical th-
o Edition 11.2007 eo
s au ra
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s

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1.2 Cooling System Components

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Caution pe

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When doing any assembly work, especially in the engine com‐
hole

partment, pay attention to the following due to the limited

spec
es, in part or in w

space.

t to the co
♦ Route lines of all types (for example for fuel, hydraulic,
Evaporative Emission (EVAP) canister system, coolant
and refrigerant, brake fluid, vacuum) and electrical wiring

rrectness of i
so that the original path is followed.
l purpos

♦ Make sure that there is sufficient clearance to all moving

or hot components.

nform
mercia

a
com

tion in
WARNING
r
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thi
s
iva

do
Hot steam may escape when opening the reservoir. Wear pro‐
r
rp

cum
fo

tective eyewear and protective clothing to prevent eye injury

en
ng

t.
and scalding. Cover the cap with a cloth and open very care‐
yi Co
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fully.
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Note

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

sure. If necessary release pressure before commencing repair
work.
♦ Hoses are secured with spring-type clamps. In cases of repair
only use spring-type clamps.
♦ The Hose Clip Pliers - VAG1921- or the Hose Clip Pliers -
VAS6340- are recommended for installing spring-type clamps.
♦ When installing coolant hoses, make sure they are free of
stress and do not come into contact with other components
(observe markings on coolant connections and hoses).

Perform the leak test of the cooling system using the Cooling
System Tester - VAG1274- , Cooling System Tester - Adapter -
VAG1274/8- and the Cooling System Tester - Adapter -
VAG1274/9- .
Cooling system components, body side. Refer to
⇒ “2.3 Overview - Cooling System Components, Body Side”, page
103 .
Cooling system components, engine side. Refer to
⇒ “2.2 Cooling System Components, Engine Side, Overview”,
page 101 .
Coolant hose connection diagram. Refer to
⇒ “2.1 Coolant Hose Connection Diagram”, page 97 .
Coolant, draining and filling. Refer to
⇒ “1.1 Coolant, Draining and Filling”, page 93 .
Coolant mixture specifications. Refer to
⇒ “1.1 Coolant, Draining and Filling”, page 93 .

96 Rep. Gr.19 - Cooling System

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

2 Description and Operation

⇒ “2.1 Coolant Hose Connection Diagram”, page 97
⇒ “2.2 Cooling System Components, Engine Side, Overview”,
page 101
⇒ “2.3 Overview - Cooling System Components, Body Side”, page
103

2.1 Coolant Hose Connection Diagram

⇒ “2.1.1 Only Vehicles with Engine Code AWD”, page 97
⇒ “2.1.2 Vehicles with Engine Code AWP (manual transmission),
AWW (manual and automatic transmission)”, page 99
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⇒ “2.1.3 Vehicles with Engine Code AWP (automatic transmis‐Vol
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2.1.1 Only Vehicles with Engine Code AWD ss
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Vehicles with engine code AWP (manual transmission), AWW

un

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an
(manual and automatic transmission). Refer to
d
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⇒ “2.1.2 Vehicles with Engine Code AWP (manual transmission),
erm

ab
AWW (manual and automatic transmission)”, page 99

ility
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Vehicles with engine code AWP (automatic transmission). Refer

h re
ole,

to

spec
⇒ “2.1.3 Vehicles with Engine Code AWP (automatic transmis‐
urposes, in part or in wh

sion)”, page 100

t to the co
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2. Description and Operation 97

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

1 - Radiator
2 - Oil Cooler
3 - Coolant Thermostat Hous‐
ing
4 - Cylinder Head/Cylinder
Block
5 - Expansion Tank
6 - Turbocharger
7 - Heater Core for the Heater
8 - Connection
9 - Transmission Fluid Cooler
❑ Only with automatic
transmission
10 - Lower Coolant Line
11 - Intake Manifold
12 - Drain Plug

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Prote AG.

98 Rep. Gr.19 - Cooling System

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

2.1.2 Vehicles with Engine Code AWP (manual transmission), AWW (manual and
automatic transmission)

1 - Expansion Tank
2 - Turbocharger
3 - Intake Manifold
4 - Cylinder Head/Cylinder
Block
5 - Connection
6 - Heater Core for the Heater
7 - Lower Coolant Line
8 - Transmission Fluid Cooler
❑ Only engine code AWW
with automatic trans‐
mission
9 - Upper Coolant Hose
10 - Drain Plug
11 - Radiator
12 - Lower Coolant Hose
13 - Oil Cooler
14 - Coolant Thermostat Hous‐
ing
15 - Coolant Pump AG. Volkswagen AG d
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Prote AG.

2. Description and Operation 99

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

2.1.3 Vehicles with Engine Code AWP (automatic transmission)

1 - Expansion Tank
2 - Turbocharger
3 - Intake Manifold
4 - Cylinder Head/Cylinder
Block
5 - Coolant Pipe
6 - Connection
7 - Heater Core for the Heater
8 - Transmission Fluid Cooler
❑ only with automatic
transmission
9 - Lower Coolant Line
10 - Oil Cooler
11 - Upper Coolant Hose
12 - Radiator n AG. Volkswagen AG do
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13 - Lower Coolant Hose d byV ua
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14 - After-Run Coolant Pump - autho
or
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V51- ss

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15 - Coolant Thermostat Hous‐

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16 - Coolant Pump

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100 Rep. Gr.19 - Cooling System

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007
AG. Volkswagen AG d
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2.2 Cooling System Components, Engine Side, Overview
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❑ 15 Nm
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2 - Toothed Belt
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❑ Check for wear

spec
urposes, in part or in wh

❑ Do not kink

t to the co
❑ Removing and instal‐
ling, tensioning. Refer to
⇒ “3.4 Toothed Belt, Re‐

rrectne
moving, Installing and
Tensioning”, page 67 .

ss
3 - Coolant Pump

o
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❑ Check for ease of move‐

form
mer

ment

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❑ Completely replace if
o

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damaged or leaking

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❑ Removing and instal‐
iva

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ling. Refer to
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⇒ “4.1 Coolant Pump”, en

ng

t.
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page 106 .
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4 - O-Ring rig ht
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❑ Replace
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5 - Coolant Thermostat
❑ Checking: warm the
thermostat in water
❑ Starts to open: approxi‐
mately 87 °C (188.6 °F)
❑ Ends approximately 102
°C (215.6 °F)
❑ Opening lift minimum 7
mm
6 - O-Ring
❑ Replace
7 - Connection
8 - To Heater Core
❑ Coolant hose connection diagram. Refer to ⇒ “2.1 Coolant Hose Connection Diagram”, page 97 .
9 - O-Ring
❑ Replace
10 - Connector
❑ 4-pin
11 - Engine Coolant Temperature Sensor - G62-
❑ With Engine Coolant Temperature Gauge Sensor - G2-
❑ For Engine Control Module (ECM)
❑ If necessary, release the pressure in coolant system before removing
❑ Checking. Refer to ⇒ Fuel Injection and Ignition; Rep. Gr. 24 ; Diagnosis and Testing .
12 - Clip
❑ Make sure it is secure

2. Description and Operation 101

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

13 - Upper Coolant Hose

❑ Secured to radiator with a retaining clip
❑ Make sure it is secure
❑ Coolant hose connection diagram. Refer to ⇒ “2.1 Coolant Hose Connection Diagram”, page 97 .
14 - Lower Coolant Hose
❑ Secured to radiator with a retaining clip
❑ Make sure it is secure
❑ Coolant hose connection diagram. Refer to ⇒ “2.1 Coolant Hose Connection Diagram”, page 97 .
15 - Oil Cooler
❑ Removing and installing. Refer to ⇒ Item 22 (page 85) .
16 - From the Heater Core
❑ Coolant hose connection diagram. Refer to ⇒ “2.1 Coolant Hose Connection Diagram”, page 97 .
17 - Lower Coolant Line
❑ Coolant hose connection diagram. Refer to ⇒ “2.1 Coolant Hose Connection Diagram”, page 97 .
18 - Bolt AG. Volkswagen AG d
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❑ 10 Nm by Vol not
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19 - Cap thor eo
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❑ Check with Cooling System Tester - VAG1274B-
ss and Cooling System Tester - Adapter - VAG1274/9-
c

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e

❑ Test pressure 1.4 to 1.6 bar (20.30 to 23.20 psi) positive pressure
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20 - Seal
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❑ Replace if damaged
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21 - Bolt

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❑ 10 Nm
es, in part or in w

t to the co
22 - Expansion Tank
❑ Perform a leak test with Cooling System Tester - VAG1274- and Cooling System Tester - Adapter -
VAG1274/8- .

rrectness of i
23 - To Turbocharger
l purpos

❑ Coolant hose connection diagram. Refer to ⇒ “2.1 Coolant Hose Connection Diagram”, page 97 .
24 - 15 Nm
nf
ercia

❑ orm
m

atio
om

25 - To the Top Coolant Hose

n in
or c

thi

❑ Only engine code AWP with automatic transmission

te

sd
iva

❑ Coolant hose connection diagram. Refer to ⇒ “2.1 Coolant Hose Connection Diagram”, page 97 .
r
rp

cu
o

m
f

en
ng

26 - After-Run Coolant Pump - V51-

t.
yi Co
op py
❑ Only engine code AWP with automatic transmission t. C rig
gh ht
yri by
❑ Coolant hose connection diagram. Refer to ⇒ “2.1 Coolant Hose Connection Diagram”, page 97 . cop Vo
by lksw
cted agen
❑ Checking. Refer to ⇒ “3.1 After-Run Coolant Pump V51 , Checking”, page 105 . Prote AG.

27 - From the Turbocharger

❑ Only engine code AWP with automatic transmission
❑ Coolant hose connection diagram. Refer to ⇒ “2.1 Coolant Hose Connection Diagram”, page 97 .

102 Rep. Gr.19 - Cooling System

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

2.3 Overview - Cooling System Components, Body Side

1 - Radiator
❑ Removing and instal‐
ling. Refer to
⇒ “4.3 Radiator”,
page 108 .
❑ After replacing, replace
the entire amount of
coolant.
2 - O-Ring
❑ Replace if damaged
3 - Upper Coolant Hose
❑ Secured to radiator with
a retaining clip
❑ Make sure it is secure
❑ Coolant hose connec‐
tion diagram. Refer to
⇒ “2.1 Coolant Hose
Connection Diagram”,
page 97 .
4 - Air Shroud
5 - Bolt
❑ 10 Nm
6 - Auxiliary Fan
❑ Only vehicles with op‐
tional equipment
7 - Fan Ring
8 - Clip
❑ Make sure it is secure
agen
AG. Volkswagen AG d
o
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Vol ot g
9 - Connector d by ua
ran
ise tee
or
10 - Radiatorau
thFan or
ac
ss
11 - Bracket
ce
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un

pt

❑ For fan connector

an
d
itte

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rm

ab

12 - Lower Coolant Hose

pe

ility
ot

❑ Secured to radiator with a retaining clip

wit
, is n

h re

❑ Make sure it is secure

hole

spec

❑ Coolant hose connection diagram. Refer to ⇒ “2.1 Coolant Hose Connection Diagram”, page 97 .
es, in part or in w

t to the co

13 - O-Ring
❑ Replace
rrectness of i

14 - Coolant Fan Control Thermal Switch - F18- , 35 Nm

l purpos

❑ For electric fan

❑ Switch temperatures:
nform
ercia

❑ First stage: on 92 ° to 97 °C (198° to 207 °F), off: 84 ° to 91 °C (183° to 196 °F)

m

❑ Second stage: on 99 ° to 105 °C (210° to 221 °F), off: 91 ° to 98 °C (196° to 208 °F)
a
com

tion in

15 - Bracket
r
te o

thi

❑ For the radiator

s
iva

do
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rp

❑ Note the installation position

um
fo

en
ng

t.
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Cop py
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pyri by
Vo
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by c lksw

103
cted agen
Prote
2. Description and Operation
AG.
 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007
en AG. V
olkswagen AG
ag does
ksw not
Vol gu
16 - Bolt ed
by ara
nte
ris
❑ 15 Nm tho eo
au ra
c
ss

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nl

pt
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itte

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ab
ility
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wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
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nf
ercia

orm
m

atio
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n in
or c

thi
te

sd
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f

en
ng

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

104 Rep. Gr.19 - Cooling System

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

3 Diagnosis and Testing

⇒ “3.1 After-Run Coolant Pump V51 , Checking”, page 105

3.1 After-Run Coolant Pump - V51- , Check‐

ing
Special tools and workshop equipment required
♦ Voltage Tester VAS6839 - VAS6839- AG. Volkswagen AG d
agen oes
lksw not
♦ Connector Test Set - VAG1594D- by Vo gu
ara
d
ise nte
♦ Wiring diagram uthor eo
a ra
s c
Test Conditions s

ce
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nl

pt
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• All fuses must be OK.

an
itte

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ab
Test Sequence

ility
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wit
– Pull off the 2-pin connector from the After-Run Coolant Pump
, is n

h re
- V51- .
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

– Connect the contacts of the After-Run Coolant Pump - V51- to

the battery, using adapter cables from the Connector Test Set
m

at
om

- VAG1594D- . The After-Run Coolant Pump - V51- must start

ion
c

running.

in t
or

his
ate

If the After-Run Coolant Pump - V51- does not start running:

do
priv

cum
or

– Replace the After-Run Coolant Pump - V51- .

f

en
ng

t.
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op
If the After-Run Coolant Pump - V51- starts running: C py
t. rig
gh ht
yri
– Turn the ignition off and then on again.
p by
co Vo
by lksw
cted agen
Prote AG.

– Connect the Voltage Tester - VAS6839- to the removed con‐

nector of the After-Run Coolant Pump - V51- using adapter
cables from the Connector Test Set - VAG1594D- . LED must
light up.

Note

This test must be performed within 5 minutes after the ignition has
been switched off.

If the LED does not light up:

– Locate and repair the open circuit according to the wiring dia‐
gram. Refer to ⇒ Wiring diagrams, Troubleshooting & Com‐
ponent locations.

3. Diagnosis and Testing 105

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

4 Removal and Installation

⇒ “4.1 Coolant Pump”, page 106 AG. Volkswagen AG d
agen oes
ksw
⇒ “4.2 Coolant Thermostat”, page 107 byV
ol not
gu
ara
ed
is nte
⇒ “4.3 Radiator”, page 108 tho r eo
au ra
s c
4.1 Coolant Pump
s

ce
le
un

pt
an
d

Special tools and workshop equipment required

itte

y li
erm

ab
♦ Refractometer - T10007A-

ility
ot p

wit
is n

♦ Drip Tray - VAG1306- or Shop Crane - Drip Tray - VAS6208-

h re
ole,

spec
♦ Torque Wrench 1331 5-50Nm - VAG1331-
urposes, in part or in wh

t to the co
♦ Spring Clip Pliers - VAS6499-

rrectne
Note

♦ Always replace gaskets and seals.

ss o
cial p

f
♦ The lower toothed belt guard can remain installed.

inform
mer

♦ The toothed belt remains in position on the crankshaft sprock‐

atio
m

et.
o

n
c

i
or

n
♦ Cover the toothed belt with a cloth to protect it from coolant

thi
te

sd
a

before removing the coolant pump.

iv

o
pr

cum
r
fo

en
ng

Removing
t.
yi Co
Cop py
.
– Drain the coolant. Refer to
ht rig
rig ht
by
⇒ “1.1 Coolant, Draining and Filling”, page 93 . copy Vo
by lksw
cted agen
Prote
– Remove the ribbed belt. Refer to
AG.

⇒ “4.4 Ribbed Belt”, page 38 .

– Remove the center and upper toothed belt guards. Refer to
⇒ “3.4 Toothed Belt, Removing, Installing and Tensioning”,
page 67 .
– Remove toothed belt from coolant pump toothed belt sprocket.
Refer to
⇒ “3.4 Toothed Belt, Removing, Installing and Tensioning”,
page 67 .

106 Rep. Gr.19 - Cooling System

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Remove the coolant pump bolts -1- and then remove the cool‐
ant pump -2-.
Installing
Install in reverse order of removal while noting the following:
– Moisten new O-ring with coolant.
– Insert coolant pump into cylinder block and tighten securing
bolts. Tightening specification: 15 Nm

Note

The sealing plug of the coolant pump faces downward.

– Install toothed belt and adjust valve timing.waRefer

gen AGto
. Volkswagen AG
does
⇒ “3.4 Toothed Belt, Removing, Installing
y Volksand Tensioning”, not
gu
page 67 isedb ara
n r tee
tho
– Install the ribbed belt. Refer sto
au ⇒ “4.4 Ribbed Belt”, page 38 .
or
ac
s

ce
Fill with new coolant. Refer to
e
nl

pt
du

⇒ “1.1 Coolant, Draining and Filling”, page 93 .

an
itte

y li
erm

ab
ility
4.2 Coolant Thermostat
ot p

wit
, is n

h re
Special tools and workshop equipment required
hole

spec
♦ Refractometer - T10007A-
es, in part or in w

t to the co
♦ Drip Tray - VAG1306- or Shop Crane - Drip Tray - VAS6208-
♦ Torque Wrench 1331 5-50Nm - VAG1331-

rrectness of i
♦ Spring Clip Pliers - VAS6499-
l purpos

Removing

nf
ercia

orm
m

Note
atio
om

n in
or c

Always replace gaskets and seals.

thi
te

sd
iva

o
r
rp

cu

– Drain the coolant. Refer to

o

m
f

en
ng

⇒ “1.1 Coolant, Draining and Filling”, page 93 .

t.
yi Co
Cop py
– Remove the coolant hose from the connection -3-.
t. rig
gh ht
pyri by
Vo
o
– Remove the bolts -4- from the connection -3- and remove the by c lksw
cted agen
connection -3- with the thermostat -1-. Prote AG.

Installing
Install in reverse order of removal while noting the following:
– Coat the new O-ring -2- with coolant.
– Insert the thermostat -1- into the connection -3- and turn it 1/
4 turn (90°) to the right.
– Install the connection -3- and the thermostat -1- in the engine
block.

Note

The clip of thermostat must be positioned at approximately right

angle.

4. Removal and Installation 107

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007
. Volkswage
AG n AG d
agen oes
olksw not
– Tighten the bolts -4-. Tightening
db
yV specification: 15 Nm gu
ara
rise nte
Fill with new coolant. Refer
tho to eo
au ra
⇒ “1.1 Coolant, Draining
ss and Filling”, page 93 . 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
4.3 Radiator

rrectness of i
l purpos

Special tools and workshop equipment required

♦ Refractometer - T10007A-

nf
ercia

o
♦ Drip Tray - VAG1306- or Shop Crane - Drip Tray - VAS6208-

rm
m

atio
m

♦ Torque Wrench 1331 5-50Nm - VAG1331-

o

n in
or c

thi
♦ Spring Clip Pliers - VAS6499-
te

sd
iva

o
r

Removing
rp

cu
o

m
f

en
ng

t.
– Drain the coolant. Refer to
yi Co
op
⇒ “1.1 Coolant, Draining and Filling”, page 93 .
C py
t. rig
gh ht
yri by
– Remove the front bumper. Refer to ⇒ Body Exterior; Rep. Gr. cop Vo
by lksw
63 ; Removal and Installation .
cted agen
Prote AG.

– Pull off coolant hoses from radiator.

– Disconnect harness connector from thermal switch.
– Bring the lock carrier into the service position. Refer to ⇒ Body
Exterior; Rep. Gr. 50 ; Description and Operation .
– Remove bolts from radiator and remove radiator with fans
downward.
Vehicles with air conditioning:
– Observe additional information and removal work. Refer to
⇒ page 108 .
Installing
Install in reverse order of removal while noting the following:
Fill with new coolant. Refer to
⇒ “1.1 Coolant, Draining and Filling”, page 93 .
Air Conditioning (A/C) System Additional Information and Proce‐
dures

WARNING

Do not open the A/C system refrigerant circuit.

Note

To prevent damage to condenser and also to the refrigerant lines/

hoses, ensure that the pipes and hoses are not stretched, kinked
or bent.

108 Rep. Gr.19 - Cooling System

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Remove retaining clamp(s) from refrigerant lines.

– Remove the condenser from radiator and attach it to the lock
carrier. n AG. Volkswagen A G do
wage 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

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.

4. Removal and Installation 109

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

5 Special Tools

Special tools and workshop

equipment required
♦ Refractometer - T10007A-
♦ Drip Tray - VAG1306- or
Shop Crane - Drip Tray -
VAS6208-
♦ Torque Wrench 1331
5-50Nm - VAG1331-
♦ Spring Clip Pliers -
VAS6499-

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
Vo
co lksw
by
cted agen
Prote AG.

110 Rep. Gr.19 - Cooling System

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

♦ Refractometer - T10007A-
♦ Drip Tray - VAG1306- or
Shop Crane - Drip Tray -
VAS6208-
♦ Spring Clip Pliers -
VAS6499-
♦ Cooling System Charge Kit
- VAS6096-

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

♦ Voltage Tester VAS6839 - VAS6839-

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.

5. Special Tools 111

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

♦ Connector Test Set - VAG1594D-

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
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.

112 Rep. Gr.19 - Cooling System

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

20 – Fuel Supply
1 General Information
⇒ “1.1 Electronic Power Control (EPC) Warning Lamp in Instru‐
ment Cluster, Meaning”, page 113
⇒ “1.2 EPC System Function”, page 113
⇒ “1.3 Emergency Fuel Shut-Off”, page 114
⇒ “1.4 Evaporative Emission (EVAP) System, Function Descrip‐
tion”, page 114
⇒ “1.5 Guidelines for Clean Working Conditions”, page 115
⇒ “1.6 Leak Detection Function Description”, page 115
⇒ “1.7 Safety Precautions, Working on Fuel Supply System”,
page 116

1.1 Electronic Power Control (EPC) Warn‐

ing Lamp in Instrument Cluster, Mean‐
ing
⇒ “1.1.1 Indicator Lamp, Function Test”, page 113
olkswagen AG
en AG. V
“EPC” is an abbreviation and stands for Electronic PowerolkControl,
swa
g does
not
also known as electronic performance regulation. ed by V gu
ara
ris nte
After switching on ignition, ECM checks function
aut of all
ho compo‐ eo
ra
nents used by EPC system. ss c

ce
le
un

If malfunctions are detected in the EPC system during engine op‐

pt
an
d
itte

eration, the ECM switches on the EPC warning lamp. (These

y li
rm

ab
Diagnostic Trouble Codes (DTCs) are identified in the DTC ta‐
pe

ility
bles). The malfunction is stored in DTC memory of ECM at the
ot

wit
same time.
, is n

h re
hole

EPC warning lamp location

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

1.1.1 Indicator Lamp, Function Test

r
rp

cum
fo

en
ng

t.
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Refer to ⇒ Rep. Gr. 01 .
Co
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1.2 EPC System Function
ht
pyri by
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cted agen
For EPC, the throttle valve is not operated by a cable from the
Prote AG.

accelerator pedal. There is no mechanical connection between

the gas pedal and the throttle valve.
The position of the accelerator pedal is transmitted to the Engine
Control Module (ECM) via two accelerator pedal position sensors
(adjustable resistances, accommodated in one housing), that are
connected to the accelerator pedal.

1. General Information 113

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

The position of the accelerator pedal (driver controlled) is a main

input for the ECM.
Operation of the throttle valve occurs via an electric motor (throttlegen AG. Volkswagen AG d
a
valve actuator) in the Throttle Valve Control Module. This applies
Vol
ksw
oes
not
gu
across the entire engine speed and engine load spectrum. ed by ara
n is tee
or
The throttle valve is operated by the throttle drive according
au
th to the or
ac
instructions of the ECM. ss

ce
e
nl

pt
With the engine at standstill and the ignition switched on, the ECM

du

an
itte
activates the throttle valve actuator precisely according to the

y li
erm

ab
specifications of the Throttle Position (TP) sensor. This means, if

ility
ot p
the accelerator pedal is depressed half way, the throttle drive

wit
, is n
opens the throttle valve to the same degree. The throttle valve is

h re
then opened approximately half way.
hole

spec
es, in part or in w

With engine running (under load) the ECM can open and close

t to the co
the throttle valve independently of the accelerator pedal position
sensor.

rrectness of i
This means, for example, that the throttle valve could be fully
opened even though the accelerator pedal has only been de‐
l purpos

pressed half way. This has the advantage of preventing torque

losses at the throttle valve.

nform
ercia

Aside from that, it results in clearly better pollutant output and

consumption values under certain load conditions.
m

at
om

io
The necessary engine torque can be produced by the ECM via

n
c

in t
or

the optimal combination of throttle valve profile and charge air

his
ate

pressure.

do
priv

cum
or

It would be incorrect to think that “EPC” consists of only one or

f

en
ng

t.
two components. EPC is much more of a system containing all
yi Co
op
components that contribute to recognizing, controlling and moni‐
C py
t. rig
gh
toring the position of the throttle valve, for example sensor for
ht
pyri by
Vo
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accelerator pedal position, throttle valve control module, EPC
c by lksw
cted agen
warning lamp, ECM. Prote AG.

Follow all safety precautions. Refer to

⇒ “1.7 Safety Precautions, Working on Fuel Supply System”,
page 116 .
Follow the guidelines for clean working conditions. Refer to
⇒ “1.5 Guidelines for Clean Working Conditions”, page 115 .

1.3 Emergency Fuel Shut-Off

Function
Vehicles with an airbag are equipped with an emergency fuel
shut-off system. It reduces the risk of fire in an accident because
the fuel pump relay switches the fuel pump off. This setup also
makes it easier to start the engine. When the door is opened, the
fuel pump is activated for two seconds so that pressure builds in
the fuel system.
When opening the fuel system:
Follow all safety precautions. Refer to
⇒ “1.7 Safety Precautions, Working on Fuel Supply System”,
page 116 .
– Check the fuel pump relay activation according to the wiring
diagram using the Test System - VAG1466 A- . Refer to ⇒ Wir‐
ing diagrams, Troubleshooting & Component locations.

1.4 Evaporative Emission (EVAP) System,

Function Description
Depending upon air pressure and ambient temperature - more or
less fuel vapors will form in the fuel tank.

114 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

The EVAP canister system prevents these HC emissions from

entering the atmosphere.
With quantity restrictions, fuel vapors travel from the highest point
of the tank via the gravity valve (closed at a tilt of 45°) and the
pressure retention valve to the EVAP canister.
The activated charcoal in the canister stores these gases like a
sponge.
While driving, with oxygen sensor control active (engine warm),
EVAP Canister Purge Regulator Valve 1 - N80- , (also called the
regeneration valve) is activated by the Engine Control. Module
AG Volkswagen AG d
(ECM) in pulses dependent on load and engine ksw
speed.
agen The open‐ oes
not
l
ing time is dependent on input signals. by Vo gu
a d ran
ise
When purging (recovery of the activated
ut
ho
r
charcoal), the suction tee
or
tube vacuum sucks fresh air in through
ss a the ventilation opening on ac
the underside of the EVAP canister. The fuel vapors stored

ce
le
un

amongst the activated charcoal and fresh air are proportionately

pt
an
d
itte

supplied to be burned.

y li
erm

ab
The pressure retention valve prevents fuel vapors from being

ility
ot p

sucked out of the tank when the EVAP canister purge regulator

wit
is n

h re
valve is opened and an intake manifold vacuum is present. It
ole,

therefore ensures that the evacuation of the EVAP canister has

spec
urposes, in part or in wh

priority.

t to the co
When no voltage is applied (for example, open circuit), the sole‐
noid valve is closed. The EVAP canister is not purged.

rrectne
The vacuum line from throttle valve control module to EVAP can‐
ister is also connected with crankcase ventilation valve via a

s
bypass. The check-valve integrated there prevents intake air from

s o
entering the crankcase in certain partial throttle ranges. Thereby
cial p

f in
the crankcase ventilation is altogether improved. The bypass en‐

form
mer

sures crankcase ventilation.

atio
om

1.5 Guidelines for Clean Working Condi‐

n
c

i
or

n thi
tions
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When working on the fuel supply/injection system, pay careful at‐

fo

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tention to the following “5 rules” of cleanliness:

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♦ Thoroughly clean the connecting points and the surrounding
rig
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area before loosening. op Vo
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♦ Place the removed parts on a clean surface and cover them.
AG.

Only use lint-free cloths!

♦ Carefully cover or plug unpacked components if repairs can‐
not be 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. If possible do not move vehicle.

1.6 Leak Detection Function Description

The Evaporative Emission (EVAP) system (including the fuel
tank) is equipped with a leak diagnostic that detects leaks in the
system.
The diagnosis operates by pressurizing the system and should
detect leaks where the damage exceeds 1 mm in diameter.
During the diagnostic, the Leak Detection Pump - V144- gener‐
ates a positive pressure of approximately 30 mbar in the EVAP
system. The pump will switch off when the pressure is attained.
When the pressure falls to below a certain figure, the pump will
switch on again. On Board Diagnostics (OBD) monitors the switch

1. General Information 115

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

intervals and stores a Diagnostic Trouble Code (DTC) in DTC

memory if the intervals are too short.

1.7 Safety Precautions, Working on Fuel

Supply System

Caution

When doing any assembly work, especially in the engine com‐

partment, pay attention to the following due to the limited
space.
♦ Route lines of all types (for example for fuel, hydraulic,
Evaporative Emission (EVAP) canister system, coolant
and refrigerant, brake fluid, vacuum) and electrical wiring
so that the original path is followed.
♦ To prevent damage to the lines, make sure there is suffi‐
cient clearance to all moving or hot components.

Always observe the following when removing and installing the

fuel level sensor or the fuel pump from full or partially n AG. Volkswagen AG do
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The fuel supply line is under pressure. Always wear protective

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eyewear and protective clothing to prevent injuries and contact
erm

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with skin. Place a cloth on the connection location before loos‐

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ening hose connections. Then release pressure by carefully

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pulling hose off connection.

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es, in part or in w

t to the co
♦ Before starting work, switch on exhaust extraction system and
place an extraction hose close to the installation opening of
fuel tank to extract escaping fuel fumes. If no exhaust extrac‐

rrectness of i
tion system is available, a radial fan (as long as motor is not
in air flow) with a displacement greater than 15 m3/h can be
l purpos

used.
♦ Do not let fuel come in contact with skin. Wear fuel-resistant
nform
ercia

gloves.
m

at

– For safety reasons, fuse No. 28 must be removed from fuse

om

ion

holder before opening fuel system as fuel pump can be acti‐

c

in t
or

vated by door contact switch in driver's door.

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ate

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116 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

2 Description and Operation

⇒ “2.1 EVAP System Overview Plan”, page 117
⇒ “2.2 Overview - Electronic Engine Power Regulation (EPC)
Components”, page 118
⇒ “2.3 Overview - EVAP System Components”, page 119
⇒ “2.4 Overview - Fuel Tank with Attachments and Fuel Filter”,
page 121

2.1 EVAP System Overview Plan

1 - Fuel Filler Door Unit

2 - Fuel Tank
3 - Fuel Delivery Unit
4 - Intake Hose
5 - Throttle Valve Control Mod‐
ule - J338-
6 - Intake Manifold
7 - Fuel Distributor with Fuel
Injectors
8 - Fuel Pressure Regulator
9 - Fuel Filter
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❑ Installed position: the agen oes
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10 - EVAP Canister Purge ss c
Regulator Valve 1 - N80-

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❑ Check the activation.

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Refer to ⇒ Fuel Injection
rm

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pe

ility
and Ignition; Rep. Gr.
ot

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01 ; Diagnosis and Test‐
, is n

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ing .
hole

spec
❑ Function, checking. Re‐
es, in part or in w

fer to

t to the co
⇒ “3.2 EVAP Canister
Purge Regulator Valve
1 N80 , Checking”, page rrectness of i
128 .
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11 - Test Connection
12 - Gravity/Expansion Valve
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13 - Pressure Retaining Valve

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14 - Switch-Over Valve
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15 - Evaporative Emission (EVAP) Canister

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❑ Under wheel housing liner in right rear wheel housing

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16 - Leak Detection Pump - V144-
Co
Cop py
.
❑ Check the activation. Refer to ⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and Testing .
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17 - Air Filter for Diagnosis Pump
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2. Description and Operation 117

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

2.2 Overview - Electronic Engine Power Regulation

G. Volkswage
(EPC) Components
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1 - Bracket ris
ed nte
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❑ Removing and instal‐ au ra
c
ling. Refer to ⇒ Brake ss

ce
e
System; Rep. Gr. 46 ;

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Removal and Installa‐

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tion .
erm

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2 - Connector

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❑ Black, 6-pin
hole

spec
3 - Bolt
es, in part or in w

t to the co
❑ 10 Nm
4 - Accelerator Pedal Position
Sensor - G79- with Accelerator

rrectness of i
Pedal Position Sensor 2 -
l purpos

G185-
❑ Not adjustable

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❑ The accelerator position

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sensor transmits the
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atio
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driver control to the En‐

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gine Control Module

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❑ To remove, remove in‐
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rp

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strument panel and ped‐
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t.
al assembly cover.
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❑ Checking. Refer to
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cted AG.
agen
and Accelerator Pedal
Position Sensor 2
G185 , Checking”,
page 125 .
❑ Vehicles with automatic
transmission 01M
❑ When replacing, adapt
the automatic transmis‐
sion control module. Re‐
fer to ⇒ Automatic Transmission On Board Diagnostic; Rep. Gr. 01 .
❑ Vehicles with automatic transmission 09A
❑ When replacing, adapt the automatic transmission control module. Refer to ⇒ Automatic Transmission
On Board Diagnostic; Rep. Gr. 01 .
5 - Bracket
❑ For footwell cover
❑ Version through MY 2001 is illustrated
❑ Clipped onto throttle position sensor

118 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

2.3 Overview - EVAP System Components

Note

♦ Hose connections are secured with either springs or hose

clamps.
♦ Always replace clamp-type clips with spring-type clips.
♦ The Hose Clip Pliers - VAG1921- or the Hose Clip Pliers -
VAS6340- are recommended for installing spring-type clamps.

Follow all safety precautions. Refer to

⇒ “1.7 Safety Precautions, Working on Fuel Supply System”,
page 116 .
Follow the guidelines for clean working conditions. Refer to
⇒ “1.5 Guidelines for Clean Working Conditions”, page 115 .

Note

♦ Components marked with * are checked via On Board Diag‐

nostics (OBD). Refer to ⇒ Fuel Injection and Ignition; Rep. Gr.
01 ; Diagnosis and Testing .
AG. Volkswagen AG d
agen oes
♦ Components marked with ** are checked via output diagnostic
olks
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test mode. Refer to ⇒ Fuel Injection and Ignition; isRep.
ed
b
Gr. ara
nte
01 ; Diagnosis and Testing . uthor eo
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ss

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es, in part or in w

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rrectness of i
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2. Description and Operation 119

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

1 - From the EVAP Canister

Purge Regulator Valve 1 -
N80- */**
2 - Seal n AG. Volkswagen AG do
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3 - Breather Line tho tee
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4 - Connection Piece ss

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5 - Connector du

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❑ 3-pin
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6 - Vacuum Line

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❑ To the Throttle Valve
hole

spec
Control Module - J338-
es, in part or in w

-Item 5-

t to the co
⇒ Item 5 (page 117)
7 - Leak Detection Pump -

rrectness of i
V144- */**
❑ Under wheel housing
l purpos

liner in right rear wheel

housing

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❑ Checking. Refer to

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⇒ “3.5 Leak Detection
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Pump (LDP), Check‐

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ing”, page 137 .

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8 - Connecting Hose
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9 - Bolt Cop py
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❑ 3 Nm
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10 - Air Filter for the Leak De‐
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tection Pump - V144-
11 - Connecting Hose
❑ Intake side
12 - Bracket
13 - Bolt
❑ 10 Nm
14 - Evaporative Emission (EVAP) Canister
❑ Under wheel housing liner in right rear wheel housing

120 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

2.4 Overview - Fuel Tank with Attachments

and Fuel Filter

Note

♦ Hose connections are secured with either springs or hose

clamps.
♦ Always replace clamp-type clips with spring-type clips.
♦ Fuel hoses at engine must only be secured with spring-type
clips. The use of clamps or screw-type clamp is not permissi‐
ble.
♦ Spring Clip Pliers - VAS6499- or the Hose Clip Pliers -
VAG1921- are recommended for installing spring-clips.

Overview - fuel tank with attachments and fuel filter. Refer to

⇒ “2.4 Overview - Fuel Tank with Attachments and Fuel Filter”,
page 121 .
Follow all Safety Precautions. Refer to
⇒ “1.7 Safety Precautions, Working on Fuel Supply System”,
page 116 .
Follow the guidelines for clean working conditions. Refer to
⇒ “1.5 Guidelines for Clean Working Conditions”, page 115 .
Volkswa
Observe crash fuel shut-off.swRefer
agen to
AG. gen AG
does
⇒ “1.3 Emergency Fuelby Shut-Off”,
Volk page 114 not
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Electronic enginethopower
r control, checking tee
or
⇒ “3.1 Accelerator
ss
au
Pedal Position Sensor G79 and Accelerator ac
Pedal Position Sensor 2 G185 , Checking”, page 125
ce
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Parts of Evaporative Emission (EVAP) canister system. Refer to

itte

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⇒ “2.3 Overview - EVAP System Components”, page 119

erm

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ility
ot p

wit
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hole

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es, in part or in w

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rrectness of i
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m

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2. Description and Operation 121

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

1 - Cap
2 - Seal
❑ Replace if damaged
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3 - Bolt ksw
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4 - Fuel Filler Door Unit ise
d b ara
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❑ With rubber gasket auth eo
ra
ss c
5 - Breather Line

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pt
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❑ Black

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itte

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❑ Make sure it is secure

ab
ility
ot p

❑ Clipped in at top of fuel

wit
, is n

tank

h re
hole

spec
6 - Ground (GND) Connection
es, in part or in w

❑ Make sure it is secure

t to the co
7 - Breather Line
❑ White

rrectness of i
❑ Make sure it is secure
l purpos

8 - Gravity Valve

nf
ercia

❑ To remove the valve un‐

or
clip upward out of the

m
m

atio
support
om

n in
c

❑ Checking valve for

or

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e

throughput:
t

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❑ Vertical valve: open,

rp

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valve tipped 45°: closed

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9 - Seal C py
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❑ Replace if damaged p by
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10 - Switch-Over Valve Prote AG.

❑ To remove the valve un‐

clip at the sides out of
the support
❑ Before installing, unscrew cap -Item 1- ⇒ Item 1 (page 122)
❑ Checking. Refer to ⇒ Fig. ““Checking Switch-Over Valve”“ , page 124 .
11 - Breather Line
❑ Black
❑ Make sure it is secure
12 - Pressure Retaining Valve
❑ Checking. Refer to ⇒ Fig. ““Checking Pressure Retention Valve”“ , page 124 .
13 - Breather Line
❑ Black
❑ Make sure it is secure
14 - Fuel Tank
❑ Support with the Engine and Gearbox Jack - VAS6931- during removal
❑ Removing and installing. Refer to ⇒ “4.3 Fuel Tank”, page 141 .
15 - Lock Washer
16 - Heat Shield
❑ For the fuel tank
17 - Bolt
❑ 25 Nm

122 Rep. Gr.20 - Fuel Supply

 AG. Volkswagen AG d
agen oes
olksw not
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ed
ris nte
hBora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998
o e o ➤ , Golf Variant 1998 ➤
aut ra
ss Engine Mechanicalc - Edition 11.2007

ce
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un

pt
18 - Locking Nut

an
d
itte

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rm
❑ 2 Nm

ab
pe

ility
ot
19 - Cover for Fuel Tank

wit
, is n

h re
20 - Mounting Strap
hole

spec
❑ Observe varying lengths
es, in part or in w

t to the co
❑ Locating point (hole) points in driving direction
21 - Supply Line

rrectness of i
❑ Black
l purpos

❑ Make sure it is secure

❑ To remove from fuel filter, press release buttons on connecting piece

nform
ercia

❑ To the fuel supply line at the fuel rail. Refer to ⇒ Fuel Injection and Ignition; Rep. Gr. 24 ; Description
and Operation .
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a
com

tion in
22 - Fuel Filter
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thi
❑ Installed position: the arrow points in the flow direction

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23 - Screw-Type Clamp

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24 - Breather Line
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❑ White
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❑ Make sure it is secure by c lksw
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❑ Attached to the side of the fuel tank
25 - Seal
❑ Replace
❑ Install dry into the opening in the fuel tank
❑ Only coat with fuel for installing fuel delivery unit flange
26 - Fuel Delivery Unit
❑ Installation location on fuel tank. Refer to
⇒ Fig. ““Installation Position of Fuel Delivery Unit Flange ”“ , page 124
❑ Removing and installing. Refer to ⇒ “4.1 Fuel Delivery Unit”, page 140 .
❑ Fuel level sensor, removing and installing. Refer to ⇒ “4.2 Fuel Level Sensor G ”, page 141 .
❑ Fuel pump, checking. Refer to ⇒ “3.4 Fuel Pump, Checking”, page 132 .
❑ Clean the screen if it is dirty.
27 - Union Nut
❑ 75 Nm
❑ Use the Wrench - Ring Nut - 3217- for removal and installation.
28 - Supply Line
❑ Black
❑ Make sure it is secure
❑ Attached to the side of the fuel tank
❑ To remove from flange and fuel filter, press release buttons on connecting piece
29 - Return Line
❑ Blue or with blue marking
❑ Attached to the side of the fuel tank
❑ Make sure it is secure
❑ To remove from flange, press release buttons on connecting piece
❑ From the fuel return line at the fuel rail. Refer to ⇒ Fuel Injection and Ignition; Rep. Gr. 24 ; Description
and Operation .
30 - Connector
❑ Black, 4-pin
❑ For Fuel Level Sensor - G- and Transfer Fuel Pump - G6-

2. Description and Operation 123

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

31 - Bolt
❑ 10 Nm

Installation Position of Fuel Delivery Unit Flange

Marking on sensor must align with marking on fuel tank
-arrows-.
Blue or blue-marked return line -1- to connection with identifica‐
tion -R-.
Black supply line -2- to connection with designation -V-.

Note

Make sure the supply, return and breather lines are still clipped
to the fuel tank after the fuel delivery unit flange has been instal‐
led.

Checking Switch-Over Valve

Lever in rest position: closed
Lever pushed in direction of arrow: open

Note

Before installing change-over valve, unscrew cover from fuel

tank.

Checking Pressure Retention Valve

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Canister Purge Regulator Valve 1 - N80- . orise tee
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ut or
It is only opened in one flow direction -arrow 2- on the side
ss of the
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124
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Prote AG.
Rep. Gr.20 - Fuel Supply
 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

3 Diagnosis and Testing

⇒ “3.1 Accelerator Pedal Position Sensor G79 and Accelerator
Pedal Position Sensor 2 G185 , Checking”, page 125
⇒ “3.1 Accelerator Pedal Position Sensor G79 and Accelerator
Pedal Position Sensor 2 G185 , Checking”, page 125
⇒ “3.3 EVAP System, Checking for Leaks”, page 130
⇒ “3.4 Fuel Pump, Checking”, page 132
⇒ “3.5 Leak Detection Pump (LDP), Checking”, page 137

3.1 Accelerator Pedal Position Sensor -

G79- and Accelerator Pedal Position
Sensor 2 - G185- , Checking
Special tools and workshop equipment required
♦ Analog/Digital Multimeter - FLU83III-
♦ Connector Test Set - VAG1594A-norAG.Connector
Volkswagen ATest Set -
VAG1594D- olks
wage
G do
es n
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♦ Test Box Kit - 121 Point
ris
ed Adapter - VAG1598/31- nte
tho eo
♦ Vehicle Diagnostic
ss
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c

ce
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♦ Wiring diagram
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Function
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The Accelerator Pedal Position Sensor - G79- and Accelerator

wit
Pedal Position Sensor 2 - G185- are located on gas pedal and
, is n

h re
transmit the drivers intentions to the Engine Control Module
hole

spec
(ECM) completely independent of one another. Both sensors are
es, in part or in w

integrated into one housing.

t to the co
rrectness of i
l purpos

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orm
m

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Prote AG.

3. Diagnosis and Testing 125

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

Test Conditions
• The fuses must be OK.
• The battery voltage must be at least 11.5V.
Test Sequence
– Connect the Vehicle Diagnostic Tester and select the control
module for engine electronics with the “address word 01”. For
this, the ignition be switched on. Connect the scan tool and
select the ECM. Refer to ⇒ Fuel Injection and Ignition; Rep.
Gr. 01 ; Diagnosis and Testing .
Scan tool display:
Quick data transfer HELP
Select function XX

– Press the buttons 0 and 8 for the function “Read measured

value block” and press Q button to confirm the input.
Scan tool display:
Read measuring value block
Enter display group number XXX

– Press the buttons 0 6 and 2 for the “display group 62” and
press Q button to confirm the input.
Shown on the display: (1 to 4 = display fields)
Read measured value block 62 ->
1 2 3 4

– Check specified value of the Accelerator Pedal Position Sen‐

sor - G79- at idle stop in display field 3.
Specified value: 6 to 96%
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– Check specified value of the Accelerator Pedal Position Sen‐ Vol
ks ot g
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sor 2 - G185- at idle stop in display field 4. ris
ed ran
tee
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Specified value: 3 to 48% s au ac
s
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The ECM converts the angle sensor voltage values based on 5 wit
is n

Volts and shows these in percentage values. (5 Volt voltage sup‐

h re

ply corresponds to 100%).

ole,

spec
urposes, in part or in wh

t to the co

– Slowly press gas pedal to Wide Open Throttle (WOT) position

and observe percentage display in display fields 3 and 4 when
doing so:
rrectne

The percentage displays in display field 3 must increase evenly.

Specified range 6 to 96% is not completely utilized during this.
ss o

The percentage displays in display field 4 must increase evenly.

cial p

f in

Tolerance range 3 to 48 % is not completely utilized during this.

form
mer

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om

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Displayed value in display field 3 must always be approximately

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twice as large as value in display field 4.

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– Press the → -button. t. C rig
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– Press the buttons 0 and 6 for the function “end output” and
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press Q button to confirm the input.
Prote AG.

126 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Switch off the ignition.

If the readings do not result as described:
AG. Volkswagen AG d
agen oes
– Check voltage supply and sensor wiring connections: Volksw not
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d
Voltage Supply and Wiring to Control Module, Checking rise nte
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au ra
– Remove the storage compartment on the driverss side. Refer to c
⇒ Body Interior; Rep. Gr. 68 ; Description and Operation .

ce
le
un

pt
an
d
itte
– Remove 6-pin connector from Accelerator Pedal Position Sen‐

y li
erm

ab
sor - G79- and Accelerator Pedal Position Sensor 2 - G185- .

ility
ot p
– Switch the ignition on.

wit
is n

h re
ole,

spec
– Connect the Analog/Digital Multimeter - FLU83III- for voltage urposes, in part or in wh
measurement to following connector terminals with adapter

t to the co
cables from Connector Test Set - VAG1594D- .
Terminal 1 + Ground

rrectne
Terminals 1 + 5

s
Terminal 2 + Ground

s o
cial p

f i
Terminals 2 + 3

nform
mer

Specified value: minimum 4.5 V

atio
om

n
c

– Switch off the ignition.

i
or

n thi
te

sd
a

If no voltage is present:
iv

o
pr

cum
r
fo

en
ng

– Connect Test Box Kit - 121 Point Adapter - VAG1598/31- to

t.
yi Co
op
the control module wiring harness. The ECM remains discon‐ C py
t. rig
nected.
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pyri by
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cted agen
Prote AG.

3. Diagnosis and Testing 127

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golfge1998
n AG. V➤
olk,sw
Golf
agenVariant
AG do 1998 ➤
wa es n
Engine Mechanical - Edition 11.2007
y Volks ot g
b ua
ed ran
ris tee
– Check the wires between Test Boxth Kit - 121 Point Adapter -
o
or
au
VAG1598/31- and the connector
ss for the short circuit according
ac
to the wiring diagram.

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le
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d
Terminal 1 + socket 72

itte

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rm

ab
pe
Terminal 2 + socket 73

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Terminal 3 + socket 36

h re
hole

spec
Terminal 4 + socket 35
es, in part or in w

t to the co
Terminal 5 + socket 33
Terminal 6 + socket 34

rrectness of i
Wire resistance: maximum 1.5 Ω
l purpos

– Also check wires for short circuit to B+ or Ground.

– Also check wires for short circuit to each other.

nform
ercia

If no fault is detected in the wiring:

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com

tio
– Replace the throttle position sensor -Item 4-

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te o

⇒ Item 4 (page 118) .

thi
s
iva

do
Vehicles with Automatic Transmission 01M
r
rp

cum
fo

en
g

– Adapt the automatic transmission control module. Refer to ⇒

n

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Automatic Transmission On Board Diagnostic; Rep. Gr. 01 . Cop py
t. rig
gh ht
yri
Vehicles with Automatic Transmission 09A p by
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– Adapt the automatic transmission control module. Refer to ⇒ Prote AG.
Automatic Transmission On Board Diagnostic; Rep. Gr. 01 .
Continuation for All Vehicles
– Check the Diagnostic Trouble Code (DTC) memory. Refer to
⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and
Testing .
– Read the readiness code. Refer to ⇒ Fuel Injection and Igni‐
tion; Rep. Gr. 01 ; Diagnosis and Testing .
– If DTC memory was cleared or ECM disconnected from volt‐
age supply the readiness code must be regenerated. Refer to
⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and
Testing .

3.2 EVAP Canister Purge Regulator Valve 1

- N80- , Checking
Solenoid valve is closed when no voltage is present.
Check the activation. Refer to ⇒ Fuel Injection and Ignition; Rep.
Gr. 01 ; Diagnosis and Testing .
Special tools and workshop equipment required
♦ Vehicle Diagnostic Tester

128 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

Test Conditions AG. Volkswagen AG d

agen oes
ksw
• Coolant temperature must be bat y Vleast 80 °C (176 °F), ⇒ Display t gua
ol no
group 04, display field 3 rised ran
tee
tho
or
• Fuse 43 must be OK.ss au ac

ce
e
Function Test
nl

pt
du

an
itte

y li
– Connect the Vehicle Diagnostic Tester and select the control
erm

ab
module for engine electronics with the “address word 01”. En‐

ility
ot p

gine must run at idle for this. Connect the scan tool and select

wit
, is n

the Engine Control Module (ECM). Refer to ⇒ Fuel Injection

h re
and Ignition; Rep. Gr. 01 ; Diagnosis and Testing .
hole

spec
es, in part or in w

Scan tool display:

t to the co
Quick data transfer HELP
Select function XX

rrectness of i
– Press the buttons 0 and 8 for the function “Read measured
l purpos

value block” and press Q button to confirm the input.

Scan tool display:

nf
ercia

orm
m

Read measuring value block

atio
m

Enter display group number XXX

o

n in
or c

– Press the buttons 0 7 and 0 for the “display group 70” and

thi
te

sd
a

press Q button to confirm the input.

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m
Shown on the display: (1 to 4 = display fields)
f

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Cop py
Read measured value block 70 -> t. rig
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1 2 3 4 pyri by
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by
cted
– Press button 4 for “Basic Setting” function (“Tank ventilation
agen
Prote AG.
valve diagnosis” is initiated)

Note

During this diagnosis, engine load must not be generated or di‐

agnosis will be terminated and can only be re-initiated after press‐
ing accelerator pedal.

Shown on the display: (1 to 4 = display fields)

System in basic setting 70 ->
1 2 3 4

If diagnosis is initiated by ECM, display in display field 4 goes from

“Test OFF” to “Test ON”.
– Allow engine to continue running at idle until specified value
“TEV OK” is shown in display field 4.

Note

TEV means tank ventilation valve (solenoid valve 1 for Evapora‐

tive Emission (EVAP) canister)

If “TEV not OK” is shown in display field 4:

– Initiate Diagnostic Output Mode (DTM) and activate EVAP
Canister Purge Regulator Valve 1 - N80- . Refer to ⇒ Fuel
Injection and Ignition; Rep. Gr. 01 ; Diagnosis and Testing .
– Check the Diagnostic Trouble Code (DTC) memory. Refer to
⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and
Testing .

3. Diagnosis and Testing 129

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Read the readiness code. Refer to ⇒ Fuel Injection and Igni‐

tion; Rep. Gr. 01 ; Diagnosis and Testing .
– If DTC memory was cleared or ECM disconnected from volt‐
age supply the readiness code must be regenerated. Refer to
⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and
Testing .
If specified value “TEV OK” is reached:
– Press the → -button.
Scan tool display:
Quick data transfer HELP
Select function XX

– Press the buttons 0 and 6 for the function “end output” and
press Q button to confirm the input.
– Switch off the ignition.

3.3 EVAP System, Checking for Leaks

⇒ “3.3.1 Function Test”, page 130
⇒ “3.3.2 Checking for Leaks”, page 131
Special tools and workshop equipment required
♦ Vehicle Diagnostic Tester
Test Conditions
• Fuse 43 must be OK.
• No faults in Diagnostic Trouble Code (DTC) memory. Refer to
⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and
Testing .
• All electrical consumers such as, for example
wage lights and rear does n
n AG. Volkswagen AG
window heater, must be switched offy Vo lks ot g
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ed
• If vehicle is equipped with an Air
tho
riConditioning
s
(A/C) system, it nte
e or
must be switched off. s au ac
s
ce
e

• Throttle valve angle less than 10° ⇒ Display group 03, display
nl

pt
du

field 3.
an
itte

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erm

ab

• Coolant temperature less than 99 °C (210 °F) ⇒ Display group

ility
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04, display field 3.

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h re

• Intake air temperature less than 95 °C (203 °F) ⇒ Display

hole

spec

group 04, display field 4

es, in part or in w

t to the co

3.3.1 Function Test

– Connect the Vehicle Diagnostic Tester and select the control
rrectness of i

module for engine electronics with the “address word 01”. En‐
l purpos

gine must run at idle for this. Connect the scan tool and select
the engine control module. Refer to ⇒ Fuel Injection and Ig‐
nition; Rep. Gr. 01 ; Diagnosis and Testing .
nf
ercia

or

Scan tool display:

m
m

Quick data transfer HELP

atio
m

Select function XX
o

n in
or c

– Press the buttons 0 and 8 for the function “Read measured

thi
te

sd
a

value block” and press Q button to confirm the input.

iv

o
r
rp

cu
o

m
f

Scan tool display:

en
ng

yi Read measuring value block

t.
Co
op Enter display group number XXX
py
t. C rig
gh ht
– Press the buttons 0 7 and 1 for the “display group 71” and yri
p by
co Vo
press Q button to confirm the input.
by lksw
cted agen
Prote AG.

130 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

Scan tool display Read measured value block 71 ->

Reed open Test OFF

– Press button 4 for “Initiate basic setting” function

Scan tool display System in basic setting 71 ->
Reed open Test ON

Scan tool display System in basic setting 71 ->

Reed closed Test ON

Evaporative Emission (EVAP) canister system test is initiated.

First, the function of the reed contact (in Leak Detection Pump -
V144- ) is checked by the control module.
Scan tool display System in basic setting 71 ->
Reed closed Syst. Test Test ON

After approximately 10 seconds, the Leak Detection Pump - agen AG. Volkswagen AG do
V144- is activated and generates pressure in fuel system.
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ksw es n
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Scan tool display rise nte 71 ->
System in basic setting
tho eo
Reed open Syst. Test Testr ON
s au ac
s

ce
After approximately 50 seconds, the test is initiated (this can take
e
nl

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up to 120 seconds if there is insufficient pressure in the fuel sys‐

an
itte

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tem).
erm

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ility
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Scan tool display System in basic setting 71 ->

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Reed open Measurement Test ON

h re
hole

spec
The Leak Detection Pump - V144- switches off and the time until
es, in part or in w

the reed contact closes is measured by the control module.

t to the co
Scan tool display System in basic setting 71 ->
Reed closed END of measurement Syst. OK

rrectness of i
– Check indication in display fields 3 and 4.
l purpos

Display field specified value 3: message END

nf
Display field specified value 4: system OK
ercia

orm
m

If the specified values are not obtained:

atio
om

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c

– Checking for leaks. Refer to

or

thi
⇒ “3.3.2 Checking for Leaks”, page 131 .
te

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If the specified values are achieved:

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t.
– Press the → -button.
yi Co
Cop py
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gh
– Press the buttons 0 and 6 for the function “end output” and
ht
pyri by
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press Q button to confirm the input.
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Prote AG.
– Switch off the ignition.

3.3.2 Checking for Leaks

If a small or large leak was recognized during the Evaporative
Emission (EVAP) canister system function test, proceed as fol‐
lows.
– Switch off the ignition.
– Check whether the fuel filler cap is completely closed or wheth‐
er the seal leaks, replace if necessary.
– Repeat function test.
If malfunction persists:
– Fold the rear bench seat forward.
– Remove cover under the bench seat.

3. Diagnosis and Testing 131

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Check if the locking ring for the fuel delivery unit is tightened
of if the seal is faulty and if necessary replace it. Tighten the
locking ring with the Wrench - Ring Nut - 3217- . Check supply
and return line to fuel delivery unit for leaks.
– Repeat function test.
If malfunction persists:
– Remove the right rear wheel housing liner. Refer to ⇒ Body
Exterior; Rep. Gr. 66 ; Description and Operation .
– Check pressure hose between diagnostic pump and EVAP
canister for leaks -Item 8- ⇒ Item 8 (page 120) , replace if nec‐
essary.
– Check lines and line connections between EVAP canister and
tank flap unit or tank ventilation valve for leaks. Refer to
⇒ “2.1 EVAP System Overview Plan”, page 117 .
– Repeat function test.
If malfunction persists:
. Volkswagen AG
does gen AG
– Remove EVAP canister and
Vol
kscheck
wa for tears and leaks, nreplace
ot g
if necessary. ed by ua
ra
is nte
or
– Repeat functionautest.
th eo
ra
ss c
3.4 Fuel Pump, Checking
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e
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an
itte

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⇒ “3.4.1 Function and Power Supply, Checking”, page 133
erm

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ility
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⇒ “3.4.2 Delivery Quantity, Checking”, page 134

wit
, is n

h re

⇒ “3.4.3 Fuel Pump Check Valve, Checking”, page 137

hole

spec

Special tools and workshop equipment required

es, in part or in w

t to the co

♦ Wrench - Ring Nut - 3217-

♦ Fuel Injection Gauge Kit - VAG1318-
rrectness of i

♦ Fuel Injection Gauge Kit - Pressure Gauge Adapter -

l purpos

VAG1318/1-
♦ Fuel Injection Gauge Kit - CO Adapter - VAG1318/11-
nform
ercia

♦ Fuel Injection Gauge Kit - Adapter Set - VAG1318/17A-

m

at
om

♦ Fuel Injection Gauge Kit - Adapter 23 - VAG1318/23-

on
c

in t
or

♦ Torque Wrench 1332 40-200Nm - VAG1332-

his
ate

do
priv

♦ Injection Rate Comparison Meter Kit - VAG1348-

um
for

en
ng

t.
♦ Test System - VAG1466A-
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Cop py
t. rig
♦ Voltage Tester - VAS6839-
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pyri by
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by
♦ Connector Test Set - VAG1594A- or Connector Test Set - Prote
cted AG.
agen
VAG1594D-
♦ Analog/Digital Multimeter - FLU83III-
♦ Measuring container
♦ Wiring diagram

132 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

Test Conditions
• Fuse No. 28 is OK
• The battery voltage must be at least 11.5V.
• All electrical consumers such as, for example, lamps and the
rear window defogger, must be off.
• If vehicle is equipped with an Air Conditioning (A/C) system, it
must be switched off.

Note

Note the description of the emergency fuel shut-off function

⇒ “1.3 Emergency Fuel Shut-Off”, page 114 .

3.4.1 Function and Power Supply, Checking

AG. Volkswagen AG d
agen oes
ksw
Note byV
ol not
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ara
ed
ris nte
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In the continuingaut work procedure, it is possibly necessary to dis‐
h
ra
connect the battery
ss
Ground (GND) cable. Check whether a coded c
ce
le

radio is installed. If so, obtain anti-theft coding beforehand.

un

pt
an
d
itte

y li
erm

– Remove the cover from fuel delivery unit. ab

ility
ot p

– Briefly operate the starter. Fuel Pump (FP) must run audibly. wit
is n

h re
ole,

– Turn off the ignition.

spec
urposes, in part or in wh

If fuel pump does not activate:

t to the co

– Remove cover in front of fuse holder.

– Pull fuse No. 28 from the fuse holder.
rrectne

– Connect the Injection Rate Comparison Meter Kit - Remote

s

Cable - VAG1348/3A- to the contact 28a to the fuel pump and

s o

battery positive (+) using the Injection Rate Comparison Meter

cial p

f in

Kit - Adapter - VAG1348/3-2- .

form
mer

– Operate the Injection Rate Comparison Meter Kit - Remote

atio
om

Cable - VAG1348/3A- .
n
c

i
or

n thi
e

If fuel pump is activated:

t

sd
iva

o
pr

– Check the fuel pump relay activation according to the wiring

um
r
fo

en
ng

diagram using the Test System - VAG1466A- . Refer to ⇒ Wir‐

t.
yi Co
ing diagrams, Troubleshooting & Component locations. ht. Cop py
rig
rig ht
If fuel pump is not activated: py by
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cted agen
– Disconnect 4-pin connector from flange at the fuel delivery Prote AG.
unit.

3. Diagnosis and Testing 133

 AG. Volkswagen AG d
agen oes
ksw
Bora 1999 ➤ , Bora Variant 1999 b➤ y V, Golf 1998 ➤ , Golf Variant 1998
o l not
gu ➤
d ara
Engine Mechanical - Edition 11.2007
orise nte
h eo
aut ra
c
– Contact the Voltage Tester - VAS6839-
ss
with the adapter cable

ce
le
from the Connector Test Set - VAG1594D- on the outer con‐

un

pt
an
tact of the connector.

d
itte

y li
erm

ab
– Operate the remote cable. Light Emitting Diode (LED) must

ility
ot p
light up.

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is n

h re
LED does not light up: ole,

spec
urposes, in part or in wh

– Locate and repair open circuit according to the wiring diagram.

t to the co
Refer to ⇒ Wiring diagrams, Troubleshooting & Component
locations.
LED lights up (voltage supply OK):

rrectness
– Use the Wrench - Ring Nut - 3217- to remove the union nut.

o
cial p

f in
– Check if the wiring between the flange and fuel pump is con‐

form
mer

nected.

atio
om

If no open circuits are found:

n
c

i
or

n thi
e

– FP faulty, replace fuel delivery unit. Refer to

t

sd
va

⇒ “4.1 Fuel Delivery Unit”, page 140 .

i

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pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote AG.

3.4.2 Delivery Quantity, Checking

Test Conditions
• Voltage supply OK.
• The Injection Rate Comparison Meter Kit - Remote Cable -
VAG1348/3A- is connected.
Test Sequence
– Remove the fuel cap from the fuel filler tube.

WARNING

The fuel supply line is under pressure. Always wear protective

eyewear and protective clothing to prevent injuries and contact
with skin. Place a cloth on the connection location before loos‐
ening hose connections. Then release pressure by carefully
pulling hose off connection.

– Disconnect fuel supply line -1- and catch escaping fuel using
a rag.

134 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Connect Fuel Injection Gauge Kit - VAG1318- to fuel supply

line using the Fuel Injection Gauge Kit - Adapter 23 -
VAG1318/23- and Fuel Injection Gauge Kit - Adapter Set -
VAG1318/17- .
– Connect Fuel Injection Gauge Kit - Pressure Gauge Adapter
- VAG1318/1- to the Fuel Injection Gauge Kit - CO Adapter -
VAG1318/11- from the Fuel Injection Gauge Kit - VAG1318-
and hold it in a measuring container.
– Open the shut-off valve on the Fuel Injection Gauge Kit -
VAG1318- . Lever will point in direction of flow -A-.
– Operate the Injection Rate Comparison Meter Kit - Remote
Cable - VAG1348/3A- . Slowly close shut-off valve, until pres‐
sure gauge shows 3 bar (43 psi). From this point on do not
move the position of the shut-off valve.
– Empty the measuring container.
– The delivery rate of fuel pump is dependent on battery voltage.
Therefore connect the multimeter with adapter cables from
Connector Test Set - VAG1594D- to the vehicle battery.
– Operate remote control for 30 seconds and measure battery
voltage.

– Compare the quantity of fuel delivered with the specification.

*) Minimum delivery rate cm3/30 s AG. Volkswagen AG d
agen oes
ksw
**) Voltage at fuel pump with engine off and pump by V running (ap‐
ol not
gu
ara
proximately 2 Volts less than battery voltage).
rised
nte
ho eo
ut
Example: ss a ra
c

ce
le

During test, a voltage of 12.5 Volts is measured at battery. Since

un

pt
an
d

the voltage at the pump is approximately 2 Volts less than battery

itte

y li
voltage, there is a minimum delivery rate of 200 cm3/30 s.
rm

ab
pe

ility
ot

If the Minimum Delivery Rate Is Not Attained

wit
, is n

h re
– Check the fuel lines for possible restrictions (kinks) or block‐
hole

spec
ages.
es, in part or in w

t to the co
WARNING
rrectness of i

The fuel supply line is under pressure. Always wear protective

eyewear and protective clothing to prevent injuries and contact
l purpos

with skin. Place a cloth on the connection location before loos‐

ening hose connections. Then release pressure by carefully
nform
ercia

pulling hose off connection.

m

a
com

tion in
r
te o

thi
s
iva

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rp

cum
fo

en
ng

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

3. Diagnosis and Testing 135

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Pull supply hose -1- from inlet to fuel filter.

– Connect the Fuel Injection Gauge Kit - VAG1318- with the
adapter Fuel Injection Gauge Kit - Adapter Set -
VAG1318/17A- in the fuel line.
– Repeat delivery rate check.
If the minimum delivery rate is now obtained:
– Replace the fuel filter:
If minimum delivery rate is again not obtained:
– Remove fuel delivery unit and check filter strainer for dirt.
Only when up to now no malfunction has been detected:
– Fuel Pump (FP) faulty, replace fuel delivery unit. Refer to
⇒ “4.1 Fuel Delivery Unit”, page 140 .
– Check the Diagnostic Trouble Code (DTC) memory. Refer to
⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and
Testing .
– Read the readiness code. Refer to ⇒ Fuel Injection and Igni‐
tion; Rep. Gr. 01 ; Diagnosis and Testing .
– If DTC memory was cleared or Engine Control Module (ECM)
disconnected from voltage supply the readiness code must be
regenerated. Refer to ⇒ Fuel Injection and Ignition; Rep. Gr.
01 ; Diagnosis and Testing .
Delivery rate has been obtained, but malfunctions are still sus‐
pected in the fuel supply, for example sporadic loss of fuel supply:
– Check the current draw of the fuel pump as follows:
. Volkswagen AG
gen AG does
– Reconnect all disconnected
Vol
kswfuel lines.
a
not
by gu
d ara
ise nt
r
– Connect currentuthprobe of Analog/Digital Multimeter - FLU83III-ee or
o
to the wire of sthe
s 4-pin connector contact 1 -arrow- from wiring ac
a
harness.
ce
le
un

pt
an
d

– Start the engine and run at idle speed.

itte

y li
erm

ab

– Measure current draw of fuel pump. Specified value: maxi‐

ility
ot p

mum 8 amps
wit
is n

h re
ole,

spec
urposes, in part or in wh

Note
t to the co

If malfunction in fuel system is sporadic, test can also be per‐

formed during a road test, but a second person is required.
rrectne

If the current draw is exceeded:

ss o

– Fuel Pump (FP) faulty, replace fuel delivery unit. Refer to

cial p

f in

⇒ “4.1 Fuel Delivery Unit”, page 140 .

form
mer

– Check the DTC memory. Refer to ⇒ Fuel Injection and Igni‐

atio
m

tion; Rep. Gr. 01 ; Diagnosis and Testing .

o

n
c

i
or

n thi
e

– Read the readiness code. Refer to ⇒ Fuel Injection and Igni‐

t

sd
va

tion; Rep. Gr. 01 ; Diagnosis and Testing .

i

o
pr

cum
r
fo

– If DTC memory was cleared or ECM disconnected from volt‐

en
ng

t.
yi Co
age supply the readiness code must be regenerated. Refer to Cop py
⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and ht. rig
rig ht
Testing .
py by
co Vo
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cted agen
Prote AG.

136 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

3.4.3 Fuel Pump Check Valve, Checking

Test Conditions
• The Injection Rate Comparison Meter Kit - Remote Cable -
VAG1348/3A- is connected.
• The Fuel Injection Gauge Kit - VAG1318- is still connected.
Test Sequence

Note

This test also checks the connections of the fuel supply line from
fuel delivery unit to connection point of Fuel Injection Gauge Kit -
VAG1318- for leaks.

– Close the shut-off valve on the Fuel Injection Gauge Kit -

VAG1318- (lever perpendicular to direction of flow -B- posi‐
tion).
– Operate the remote cable at short intervals, until a pressure of
approximately 3 bar (43 psi) has built up.

WARNING
olkswagen AG
en AG. V
Danger of spraying when opening shut-off valve; Vwear olks protec‐
wag does
not
tive goggles and protective clothing to prevent d by injuries and gu
ara
ise connection of
contact with skin. Hold container in front ofhorfree nte
eo
the Fuel Injection Gauge Kit - VAG1318- sa
u.
t ra
c
s

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le
un

pt
an
d

– If pressure builds up too high, lower excess pressure by care‐

itte

y li
erm

fully opening the shut-off valve.

ab
ility
ot p

– Watch the pressure drop on gauge. After 10 minutes the pres‐

wit
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sure must not drop below a 2.5 bar (36.25 psi) decrease.

h re
ole,

spec
If the pressure drops further:
urposes, in part or in wh

t to the co
– Check line connections for leaks.
If no fault is detected in the wiring:
rrectne
– Fuel Pump (FP) faulty, replace fuel delivery unit. Refer to
⇒ “4.1 Fuel Delivery Unit”, page 140 .
ss o

– Check the Diagnostic Trouble Code (DTC) memory. Refer to

cial p

f in

⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and

form
mer

Testing .
atio
m

– Read the readiness code. Refer to ⇒ Fuel Injection and Igni‐

o

n
c

i
or

tion; Rep. Gr. 01 ; Diagnosis and Testing .

thi
te

sd
va

– If DTC memory was cleared or Engine Control Module (ECM)

i

o
pr

cum
r

disconnected from voltage supply the readiness code must be

fo

en
ng

regenerated. Refer to ⇒ Fuel Injection and Ignition; Rep. Gr.

t.
yi Co
op
01 ; Diagnosis and Testing . C py
ht. rig
rig ht
py by
co Vo
3.5 Leak Detection Pump (LDP), Checking
by lksw
cted agen
Prote AG.

⇒ “3.5.1 Diagnostic Pump, Checking Electrically”, page 138

⇒ “3.5.2 Power Supply, Checking”, page 138
Special tools and workshop equipment required
♦ Analog/Digital Multimeter - FLU83III-
♦ Voltage Tester - VAS6839-

3. Diagnosis and Testing 137

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

♦ Connector Test Set - VAG1594A-agor Connector

en AG. VolkswageTest
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oes
VAG1594D- Volksw not
g by ua
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♦ Test Box Kit - 121 Point
ho
ris Adapter - VAG1598/31- tee
t or
au ac
♦ Wiring diagram ss

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un

pt
3.5.1 Diagnostic Pump, Checking Electrically

an
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itte

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ab
– Remove the right rear wheel housing liner. Refer to ⇒ Body

ility
ot p

Exterior; Rep. Gr. 66 ; Description and Operation .

wit
is n

h re
– Remove the 3-pin connector Leak Detection Pump - V144- .
ole,

spec
urposes, in part or in wh

– Connect the Analog/Digital Multimeter - FLU83III- for resist‐

t to the co
ance measurement between terminals 1 and 3 on Leak De‐
tection Pump - V144- . Specified value: 640 to 720 Ω.
– Connect the Analog/Digital Multimeter - FLU83III- for resist‐

rrectne
ance measurement between terminals 2 and 3 on Leak De‐
tection Pump - V144- . Specified value: 12.5 to 19.5 Ω.

ss o
If the specified values are not obtained:
cial p

f inform
– Replace the Leak Detection Pump - V144- .
mer

atio
m

– Check theDiagnostic Trouble Code (DTC) memory. Refer to

o

n
c

⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and

i
or

n thi
e

Testing .
t

sd
iva

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pr

c
– Read the readiness code. Refer to ⇒ Fuel Injection and Igni‐
um
r
fo

tion; Rep. Gr. 01 ; Diagnosis and Testing . en

ng

t.
yi Co
op py
– If DTC memory was cleared or Engine Control Module (ECM) t. C rig
gh ht
disconnected from voltage supply the readiness code must be yri
p by
o Vo
regenerated. Refer to ⇒ Fuel Injection and Ignition; Rep. Gr.
c by lksw
cted agen
01 ; Diagnosis and Testing .
Prote AG.

3.5.2 Power Supply, Checking

Test Conditions
• Fuse 43 must be OK.
• The battery voltage must be at least 11.5V.
Test Sequence
– Remove the right rear wheel housing liner. Refer to ⇒ Body
Exterior; Rep. Gr. 66 ; Description and Operation .

138 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Remove the 3-pin connector Leak Detection Pump - V144- .

– Connect the Digital Multimeter - FLU83III- between terminal 3
(positive) on connector and ground.
– Start the engine and let it run at idle: the Light Emitting Diode
(LED) must turn on.
If LED does not light up:
– Switch off the ignition. AG. Volkswagen AG d
agen oes
lksw not
– Check line between terminal d by V3 on connector and central elec‐
o gu
a
tronics for open circuitoraccording
ise to wiring diagram. Wire re‐ rante
sistance: maximumau1.5
th Ω eo
ra
ss c
LED lights up (voltage supply OK):

ce
le
un

pt
an
d
itte

y li
– Connect Test Box Kit - 121 Point Adapter - VAG1598/31- to
erm

ab
the control module wiring harness. The engine control module

ility
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remains disconnected.

wit
is n

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ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

– Check the lines between the Test Box Kit - 121 Point Adapter

atio
m

- VAG1598/31- and 3-pin connector for open circuit according

o

n
c

to wiring diagram. i
or

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sd
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Terminal 1 + socket 80
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fo

Terminal 2 + socket 25
en
ng

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Wire resistance: maximum 1.5 Ω C py
ht. rig
rig ht
by
– Also check wires for short circuit to each other. Specified val‐ copy Vo
by lksw
ue: ∞ Ω cted agen
Prote AG.

If no malfunction is found in the wires and there was voltage be‐

tween terminal 3 and ground:
– Replace the Leak Detection Pump - V144- .
– Check the Diagnostic Trouble Code (DTC) memory. Refer to
⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and
Testing .
– Read the readiness code. Refer to ⇒ Fuel Injection and Igni‐
tion; Rep. Gr. 01 ; Diagnosis and Testing .
– If DTC memory was cleared or Engine Control Module (ECM)
disconnected from voltage supply the readiness code must be
regenerated. Refer to ⇒ Fuel Injection and Ignition; Rep. Gr.
01 ; Diagnosis and Testing .

3. Diagnosis and Testing 139

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

4 Removal and Installation

⇒ “4.1 Fuel Delivery Unit”, page 140
⇒ “4.2 Fuel Level Sensor G ”, page 141
⇒ “4.3 Fuel Tank”, page 141

4.1 Fuel Delivery Unit

Special tools and workshop equipment required
♦ Wrench - Ring Nut - 3217-
♦ Torque Wrench 1332 40-200Nm - VAG1332-
Removing
– Read the safety precautions before starting. Refer to
⇒ “1.7 Safety Precautions, Working on Fuel Supply System”,
page 116 .
– First, check whether a coded radio is installed. If necessary,
obtain the anti-theft coding.
– Turn off the ignition and disconnect the battery Ground (GND)
cable.
– Remove cover under the bench seat.
– Pull off 4-pin connector such as supply and return lines from
flange.

Note

Press buttons together on hose connections to do so.

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WARNING lkswagen
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Fuel supply lines riseare under pressure! Always wear protective nte
ho eo
eyewear ands a protective clothing to prevent injuries and contactr ac
ut
with skin. Place a cloth on the connection location before loos‐
s
ce
le

ening hose connections. Then release pressure by carefully

un

pt
an

pulling hose off connection.

d
itte

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rm

ab
pe

ility
ot

wit

– Use the Wrench - Ring Nut - 3217- to remove the union nut.
, is n

h re
hole

– Pull fuel delivery unit and seal out of the opening in fuel tank.
spec
es, in part or in w

t to the co

Note
rrectness of i

If the delivery unit is to be replaced then drain old delivery unit

before disposal.
l purpos

Installing
nform
ercia

– Installation of the fuel delivery unit is the reverse order of re‐

m

moval.
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
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Cop py
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pyri by
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cted agen
Prote AG.

140 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
EngineolkMechanical
sw
- Edition 11.2007
AG. V agen AG
agen does
olksw not
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Note tho
r eo
au ra
c
ss
♦ When inserting fuel delivery unit, be sure not to bend fuel

ce
le
un

pt
gauge sensor.

an
d
itte

y li
♦ Insert dry flange seal of fuel pump into opening of fuel tank.

erm

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ility
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♦ Only coat seal with fuel when installing fuel delivery unit.

wit
is n

h re
♦ Make sure the fuel hoses are secure.

ole,

spec
urposes, in part or in wh
♦ Pay attention to the position of the fuel delivery unit flange

t to the co
when it is installed: the marking on the flange must align with
the marking on the fuel tank -arrows-.

rrectne
♦ After installing fuel delivery unit, check that the supply, return
and breather lines are still clipped onto the fuel tank.

ss o
– Perform the “Procedure after interrupting voltage supply”. Re‐
cial p

f in
fer to ⇒ Fuel Injection and Ignition; Rep. Gr. 24 ; Diagnosis

form
mer

and Testing .

atio
om

n
c

4.2 Fuel Level Sensor - G-

i
or

n thi
te

sd
va

Removing
i

o
pr

cum
r
fo

en
ng

– Remove fuel delivery unit. Refer to

t.
yi Co
⇒ “4.1 Fuel Delivery Unit”, page 140 . Cop py
t. rig
gh ht
yri
– Disengage connector prongs of wires -3 and 4- and discon‐ p by
o Vo
by c lksw
nect. Prote
cted AG.
agen

– Pry off tabs -1 and 2- using screwdriver and remove sender

for fuel gauge towards bottom -arrows-.
Installing
– Insert fuel level sensor in the guides on the fuel delivery unit
and push up until it engages.
– Install the fuel delivery unit. Refer to
⇒ “4.1 Fuel Delivery Unit”, page 140 .

4.3 Fuel Tank

Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Engine and Gearbox Jack - VAS6931-
Removing
– Read the safety precautions before starting. Refer to
⇒ “1.7 Safety Precautions, Working on Fuel Supply System”,
page 116 .
– First, check whether a coded radio is installed. If necessary,
obtain the anti-theft coding.
– Turn off the ignition and disconnect the battery Ground (GND)
cable.
– Open the fuel filler door.
– Remove the right rear wheel housing liner. Refer to ⇒ Body
Exterior; Rep. Gr. 66 ; Description and Operation .
– Remove the rear subframe. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 42 ; Removal and Installation .

4. Removal and Installation 141

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Drain the fuel tank and clean fuel filler tube and surrounding
area.
– Remove mounting bolt and remove the fuel filler door unit with
rubber gasket.
– Remove securing bolt on filler neck.
– Fold the rear bench seat forward.
– Remove cover plate from fuel gauge sensor and disconnect
the connector.
– Remove covers under fuel tank.

WARNING

Fuel supply lines are under pressure! Always wear protective

eyewear and protective clothing to prevent injuries and contact
with skin. Place a cloth on the connection location before loos‐
ening hose connections. Then release pressure by carefully
pulling hose off connection.

– Separate return line -2- (blue), supply line -1- (black) and
breather line -3- (white) at their connection points.

AG. Volkswagen AG d
agen
Note Volksw
oes
not
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d by ara
ise nte
Press buttons together on hose connections to do so.
or eo
h
aut ra
ss c

ce
le

– Remove the tensioning strap. Support the fuel tank using the
un

pt
Engine and Gearbox Jack - VAS6931- when doing this.

an
d
itte

y li
erm

ab
– Lower the fuel tank.

ility
ot p

wit
Installing
is n

h re
ole,

Install in reverse order of removal while noting the following: spec

urposes, in part or in wh

♦ Make sure ventilation and fuel lines are not kinked when in‐
t to the co

stalled.
♦ Route the fuel hoses kink-free.
rrectne

♦ Make sure the fuel hoses are secure.

ss

♦ Secure fuel hoses with spring-type clamps.

o
cial p

f in

♦ Do not interchange supply and return lines (return line is blue

form
mer

or has blue marking, supply line is black).

atio
om

n
c

i
or

n thi

Note
te

sd
iva

o
pr

cum
r

Make sure the supply, return and breather lines are still clipped
fo

en
ng

to the fuel tank after the fuel tank has been installed.
t.
yi Co
Cop py
t. rig
gh ht
yri
– Perform the “Procedure after interrupting voltage supply”. Re‐ p by
o Vo
by c
fer to ⇒ Fuel Injection and Ignition; Rep. Gr. 24 ; Diagnosis
lksw
cted agen
Prote
and Testing .
AG.

142 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

5 Special Tools

Special tools and workshop

equipment required
♦ Wrench - Ring Nut - 3217-
♦ Fuel Injection Gauge Kit -
VAG1318-
♦ Fuel Injection Gauge Kit -
Pressure Gauge Adapter -
VAG1318/1-
♦ Fuel Injection Gauge Kit -
CO Adapter - VAG1318/11-
♦ Fuel Injection Gauge Kit -
Adapter Set -
VAG1318/17A-
♦ Fuel Injection Gauge Kit -
Adapter 23 - VAG1318/23-

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

pt
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

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.

5. Special Tools 143

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

♦ Torque Wrench 1332

40-200Nm - VAG1332-
♦ Injection Rate Comparison
Meter Kit - VAG1348-
♦ Test System - VAG1466A-
♦ Voltage Tester - VAS6839-
n AG. Volkswagen AG do
swage es n
♦ Connector Test Set - y Vo lk ot g
ua
VAG1594A- or Connector
ir se
d b ran
tee
Test Set - VAG1594D-
utho
or
a ac
ss
♦ Analog/Digital Multimeter -

ce
le

FLU83III-
un

pt
an
d
itte

y li
♦ Measuring Container
erm

ab
ility
ot p

♦ Wiring diagram

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
co lksw
by
cted agen
Prote AG.

144 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007
olkswagen AG
en AG. V
Special tools andolworkshop
ksw
ag does
not
equipment required
ed
by V gu
ara
ris nte
♦ Analog/Digital
au
tho Multimeter - eo
ra
FLU83III-
ss c

ce
le
un

♦ Voltage Tester - VAS6839-

pt
an
d
itte

y li
♦ Connector Test Set -
erm

ab
VAG1594A- or Connector

ility
ot p

Test Set - VAG1594D-

wit
is n

h re
ole,

♦ Test Box Kit - 121 Point

spec
urposes, in part or in wh

Adapter - VAG1598/31-

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.

Special tools and workshop equipment required

♦ Torque Wrench 1331 5-50Nm - VAG1331-

5. Special Tools 145

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

♦ Engine and Gearbox Jack - VAS6931-

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

ce
le
un

pt
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

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.

146 Rep. Gr.20 - Fuel Supply

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

21 – Turbocharger, Supercharger
1 General Information
⇒ “1.1 Charge Air System with Turbocharger”, page 147
⇒ “1.2 Guidelines for Clean Working Conditions”, page 147
⇒ “1.3 Safety Precautions”, page 148

1.1 Charge Air System with Turbocharger

Note

♦ Various hose connections are secured with clamps.

♦ The charge air system must be properly sealed.
♦ Replace the self-locking nuts.
♦ Vacuum hoses and connectors must be free of grease when
reinstalling.
♦ Spring Clip Pliers - VAS6499- or the Hose Clip Pliers -
VAG1921- are recommended for installing spring-clips.

Turbocharger with attachments, assembly overview. Refer to

⇒ “2.4 Overview - Turbocharger with Attachments”, page 154
Components of charge air cooling system, assembly overview.
Refer to
⇒ “2.3 Overview - Charge Air Cooler Components”, page 152
Follow the guidelines for clean working conditions. Refer Ato
G. Volkswagen AG d
agen
⇒ “1.2 Guidelines for Clean Working Conditions”,Volpage
ksw 147 .
oes
not
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db ara
Follow all Safety Precautions. Refer to orise nte
eo
⇒ “1.3 Safety Precautions”, page 148 .auth ra
ss c
Charge pressure system, checking. Refer to
ce
le
un

pt

⇒ “3 Diagnosis and Testing”, page 159

an
d
itte

y li
erm

1.2 Guidelines for Clean Working Condi‐

ab
ility
ot p

tions
wit
is n

h re
ole,

When working on turbocharger, carefully observe the following “5

spec
urposes, in part or in wh

rules” of cleanliness:
t to the co

♦ Thoroughly clean the connecting points and the surrounding

area before loosening.
rrectne

♦ Place the removed parts on a clean surface and cover them.

Only use lint-free cloths!
ss

♦ Carefully cover or plug unpacked components if repairs can‐

o
cial p

not be performed immediately.

inform
mer

♦ Install only clean parts: remove the replacement parts from

atio
m

their packaging just before installing them. Do not use parts

o

n
c

that have been stored loose (for example, in tool boxes etc.).
i
or

n thi
te

sd
a

♦ When the fuel system is open: avoid working with compressed

iv

o
pr

air if possible. If possible do not move vehicle.

um
r
fo

en
ng

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

1. General Information 147

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

1.3 Safety Precautions

Caution

When doing any assembly work, especially in the engine com‐

partment, pay attention to the following due to the limited
space.
♦ Route lines of all types (for example for fuel, hydraulic,
Evaporative Emission (EVAP) canister system, coolant
and refrigerant, brake fluid, vacuum) and electrical wiring
so that the original path is followed.
♦ Make sure that there is sufficient clearance to all moving
or hot components.

Observe the following if test and measuring instruments are re‐

quired during a test drive:
♦ Test and measuring instruments must be secured to rear seat
and operated by a second person from this location.
If test and measuring instruments are operated from the front
passenger seat and the vehicle is involved in an accident, there
is a possibility that the person sitting in this seat may receive se‐
rious injuries when the airbag is triggered.
n AG. Volkswagen AG do
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ir se tee
tho
u or
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e
nl

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itte

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erm

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ility
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, is n

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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
om

n in
or c

thi
te

sd
iva

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rp

cu
o

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f

en
ng

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

148 Rep. Gr.21 - Turbocharger, Supercharger

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

2 Description and Operation

⇒ “2.1 Exhaust Turbocharging System, Engine Code AWD, Over‐
view Plan”, page 149
⇒ “2.2 Exhaust Turbocharging System, Engine Code AWP,
AWW, Overview Plan”, page 151
⇒ “2.3 Overview - Charge Air Cooler Components”, page 152
olkswagen AG
en AG. V
⇒ “2.4 Overview - Turbocharger with Attachments”, page 154
olks
wag does
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2.1 Exhaust Turbocharging System, Engine Code AWD, Overview Plan tho
rise nte
eo
au ra
c
ss

ce
le
1 - Connecting Hose

un

pt
an
d
❑ From the Leak Detec‐ itte

y li
erm

ab
tion Pump - V144-

ility
ot p

wit
2 - Vacuum Reservoir
is n

h re
ole,

❑ Below front right wheel

spec
housing liner
urposes, in part or in wh

t to the co
3 - Check Valve
4 - Turbocharger

rrectne
5 - Check Valve

s
6 - Vacuum Diaphragm

s o
cial p

f
❑ For the charge air pres‐

inform
sure regulator valve
mer

atio
7 - Deceleration Shut-Off
om

n
Valve
c

i
or

n thi
te

8 - Wastegate Bypass Regula‐

sd
iva

o
r

tor Valve - N75-

p

cum
r
fo

en
ng

❑ Valve is activated yi
t.
Co
(pulsed) by Engine Con‐ . Cop py
trol Module (ECM)
ht rig
rig ht
py by
Vo
❑ Check the activation.
co lksw
by
cted agen
Refer to ⇒ Fuel Injection Prote AG.
and Ignition; Rep. Gr.
01 ; Diagnosis and Test‐
ing .
9 - Brake Booster
10 - Check Valve
❑ For the brake booster
11 - Air Filter with Mass Airflow
Sensor - G70-
12 - Pressure Regulator Valve
for the Crankshaft Housing
Ventilation
13 - Combination Valve
❑ For Secondary Air Injection (AIR) system
❑ Checking. Refer to ⇒ “3.1 Combination Valve, Checking”, page 176 .

2. Description and Operation 149

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

14 - Fuel Pressure Regulator

15 - Check Valve
16 - Fuel Tank Shut-Off Valve 4 - N249-
. Volkswagen AG
does gen AG
17 - Secondary Air Injection Solenoid Valve - N112- olks
wa not
yV gu
❑ Checking. Refer to ⇒ “3.3 Secondary Air InjectionriseSolenoid Valve, Checking”, page 177 a.rant
d b
ee
ho
18 - Crankcase Ventilation aut or
ac
ss

ce
e
19 - Check Valve

nl

pt
du

an
itte
20 - Charge Air Pressure Sensor - G31-

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ab
❑ Replace O-ring if damaged

ility
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21 - Secondary Air Injection Pump Motor - V101-

h re
hole

❑ Function, checking. Refer to ⇒ “3.2 Secondary Air Injection Pump Motor V101 , Checking”, page 176 .

spec
es, in part or in w

22 - Charge Air Cooler

t to the co
23 - Vacuum Reservoir

rrectness of i
24 - EVAP Canister Purge Regulator Valve 1 - N80-
❑ Check the activation.
l purpos

❑ Function, checking. Refer to

⇒ “3.2 EVAP Canister Purge Regulator Valve 1 N80 , Checking”, page 128 .

nf
ercia

orm
25 - Connecting Hose
m

atio
m

❑ To the Evaporative Emission (EVAP) canister

o

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or c

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en
ng

t.
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Cop py
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by
cted agen
Prote AG.

150 Rep. Gr.21 - Turbocharger, Supercharger

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

2.2 Exhaust Turbocharging System, Engine Code AWP, AWW, Overview Plan

1 - Connecting Hose
❑ From the Leak Detec‐
tion Pump - V144-
2 - Vacuum Reservoir
❑ Below front right wheel
housing liner
3 - Check Valve
4 - Turbocharger
5 - Vacuum Diaphragm
❑ For the charge air pres‐
sure regulator valve
6 - Deceleration Shut-Off
Valve
7 - Brake Booster
8 - Check Valve
❑ For the brake booster
9 - Wastegate Bypass Regula‐
tor Valve - N75-
❑ Valve is activated
(pulsed) by Engine Con‐ wage
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trol Module (ECM) yV
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ua
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❑ Check the activation. o
ir se
ran
tee
th or
u
10 - Air Filter with Mass Airflow ss
a ac
Sensor - G70-

ce
le
un

pt
an
d

11 - Pressure Regulator Valve

itte

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for the Crankshaft Housing
rm

ab
pe

ility
Ventilation
ot

wit
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12 - Combination Valve

h re
hole

spec
❑ For Secondary Air Injec‐
es, in part or in w

tion (AIR) system

t to the co
❑ Checking. Refer to ⇒ “3.1 Combination Valve, Checking”, page 176 .
13 - Vacuum Reservoir

rrectness of i
14 - Fuel Pressure Regulator
l purpos

15 - Crankcase Ventilation
nform
ercia

16 - Check Valve
m

17 - Fuel Tank Shut-Off Valve 4 - N249-

a
com

tion in

18 - Secondary Air Injection Solenoid Valve - N112-

r
te o

thi
s

❑ Checking. Refer to ⇒ “3.3 Secondary Air Injection Solenoid Valve, Checking”, page 177 .
iva

do
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rp

cum

19 - Suction Jet Pump

fo

en
ng

t.
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20 - Secondary Air Injection Pump Motor - V101- Cop py
t. rig
gh
❑ Function, checking. Refer to ⇒ “3.2 Secondary Air Injection Pump Motor V101 , Checking”, page 176 .
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Description and Operation 151

 olkswagen AG
wag en AG. V
Bora 1999 ➤ , Bora Variant 1999
olks ➤ , Golf 1998 ➤ , Golf sVariant
doe
not 1998 ➤
yV gu
Engine Mechanical - Edition
sed 11.2007
b ara
n ri tee
ho
ut or
21 - Intake Manifold ss
a ac

ce
le
22 - Charge Air Pressure Sensor - G31-

un

pt
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d
itte

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23 - Charge Air Cooler
rm

ab
pe

ility
24 - Check Valve
ot

wit
, is n

h re
25 - EVAP Canister Purge Regulator Valve 1 - N80-
hole

spec
❑ Check the activation.
es, in part or in w

t to the co
❑ Function, checking. Refer to
⇒ “3.2 EVAP Canister Purge Regulator Valve 1 N80 , Checking”, page 128 .
26 - Connecting Hose

rrectness of i
❑ To the Evaporative Emission (EVAP) canister
l purpos

nform
ercia

2.3 Overview - Charge Air Cooler Compo‐

m

a
nents
com

tion in
r
te o

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♦ Various hose connections are secured with clamps.
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♦ The charge air system must be properly sealed. rig ht
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♦ When installing, follow installation marks on hoses and com‐ cted agen
Prote AG.
ponents.
♦ Note installation position of heat shield mats

152 Rep. Gr.21 - Turbocharger, Supercharger

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

1 - Air Guide
2 - Bolt
❑ 10 Nm
3 - Charge Air Pressure Sen‐
sor - G31-
❑ Checking. Refer to
⇒ “3.3 Charge Air Pres‐
sure Sensor G31 ,
Checking”, page 162 .
4 - O-Ring
❑ Replace
5 - Rubber Grommet
AG. Volkswagen AG d
❑ with sleeve agen oes
olksw not
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6 - Bolt rised
nte
ho eo
❑ 10 Nm s aut ra
c
s
7 - Intake Hose

ce
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nl

pt
du

an
❑ Between intake mani‐
itte

y li
fold and charge air cool‐
erm

ab
ility
er
ot p

wit
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8 - Heat Shield Mats

h re
hole

spec
❑ Note the installation po‐
es, in part or in w

sition

t to the co
9 - Screw-Type Clamp
❑ Only vehicles with en‐
gine code AWD rrectness of i
l purpos

❑ Vehicles with engine

code AWP, AWW with
quick-release connec‐
nform
ercia

tion (with O-ring and re‐

taining clip)
m

at
om

ion

10 - Connecting Hose
c

in t
or

his
te

11 - Air Guide Pipe

a

do
priv

cum
or

12 - Bracket
f

en
ng

t.
yi Co
13 - Connecting Hose t. Cop py
rig
gh ht
yri
14 - Charge Air Cooler p by
o Vo
by c lksw
cted agen
Prote AG.

2. Description and Operation 153

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

2.4 Overview - Turbocharger with Attach‐

ments
⇒ “2.4.1 Part I”, page 154
⇒ “2.4.2 Part II”, page 156

2.4.1 Part I

Caution
G. Volkswage
If mechanical damage is found lon kswthe turbocharger, for exam‐
agen
A n AG d
oes
not
ple a destroyed compression by wheel, it is not enough to justguar
Vo
replace the turbocharger.
ris Perform the following steps to pre‐
ed an
tee
vent subsequent damage.
au
tho or
a
ss c
♦ Check the air filter housing, the air filter element and the

ce
e
nl

intake hoses for contamination.

pt
du

an
itte

y li
♦ Check entire charge air circuit and charge air cooler for
erm

ab
foreign objects.

ility
ot p

wit
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If foreign objects are found in charge air circuit, the circuit must

h re
hole

be cleaned and the cooler replaced if necessary.

spec
es, in part or in w

t to the co
1 - Bolt

rrectness of i
❑ 40 Nm
l purpos

❑ Coat threads with Hot

Bolt Paste - G 052 112
A3-
nf
ercia

orm

2 - Seal
m

atio
m

❑ Replace
o

n in
or c

thi
e

3 - Bolt
t

sd
iva

o
r

❑ 10 Nm
rp

cu
o

m
f

en
ng

❑ Must not be loosened

t.
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op py
4 - Vacuum Diaphragm
t. C rig
gh ht
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❑ For the charge air pres‐
op Vo
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cted
sure regulator valve
agen
Prote AG.

❑ Can only be replaced as

together with turbo‐
charger
❑ Charge air pressure
regulation, checking.
Refer to
⇒ “3.2 Charge Air Pres‐
sure Regulation, Check‐
ing”, page 160 .
5 - Retainer
6 - Turbocharger
❑ Charge air pressure
regulation, checking.
Refer to
⇒ “3.2 Charge Air Pres‐
sure Regulation, Check‐
ing”, page 160 .
❑ The charge air pressure
regulator valve and
charge air pressure reg‐

154 Rep. Gr.21 - Turbocharger, Supercharger

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

ulator valve vacuum di‐

aphragm are part of the exhaust turbocharger and cannot be replaced individually.
❑ Before connecting oil supply line, fill turbocharger with oil at filler tube
❑ After installing turbocharger, let engine idle for approximately 1 minute without increasing engine speed.
This ensures adequate oil supply to the turbocharger.
7 - O-Ring
❑ Replace
8 - Bolt
❑ 10 Nm
9 - Intake Manifold
10 - Seal
❑ Replace
❑ Note the installation position
11 - Bolt
❑ 20 Nm
12 - Shield
13 - Bolt
❑ 10 Nm
14 - Banjo Bolt
❑ 30 Nm
AG. Volkswagen AG d
agen
15 - Oil Supply Line olksw
oes
not
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ara
d
16 - Bolt orise nte
eo
h
ut
❑ 30 Nm ss a ra
c
❑ Replace
ce
e
nl

pt
du

an

❑ Coat threads and head contact surfaces with Hot Bolt Paste - G 052 112 A3- .
itte

y li
erm

ab

17 - Exhaust Manifold
ility
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wit
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18 - Seal
h re
hole

❑ Replace
spec
es, in part or in w

❑ Note the installation position

t to the co

19 - Bolt
❑ 20 Nm
rrectness of i

20 - Banjo Bolt
l purpos

❑ 30 Nm
21 - Bolt
nf
ercia

or

❑ 25 Nm
m
m

atio
m

❑ Replace
o

n in
or c

❑ Coat threads with Hot Bolt Paste - G 052 112 A3-

thi
te

sd
iva

22 - Banjo Bolt
r
rp

cu
o

m
f

❑ 35 Nm
en
ng

t.
yi Co
op py
23 - Coolant Supply Line
. C rig
ht ht
rig by
py
24 - Bolt
co Vo
by lksw
cted agen
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❑ 25 Nm
AG.

25 - Spacer Sleeve
26 - Banjo Bolt
❑ 35 Nm

2. Description and Operation 155

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

27 - Bolt
❑ 10 Nm
28 - Coolant Supply Line
29 - Banjo Bolt
❑ 35 Nm
30 - Bolt
❑ 30 Nm
❑ Only use original screw from parts program
31 - Bracket
❑
❑ Between turbocharger and cylinder block
32 - Bolt
❑ 25 Nm
33 - Seal
❑ Replace
34 - Seal
❑ Replace
35 - Bolt
❑ 10 Nm
36 - Oil Return Line
❑ To oil pan n AG. Volkswagen AG do
lkswage es n
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37 - Bolt d byV ua
ran
ir se
❑ 10 Nm utho tee
or
a ac
38 - Bolt ss
ce
le
un

pt

❑ 10 Nm
an
d
itte

y li

❑ Do not change adjustment

erm

ab
ility

❑ Must not be loosened

ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

2.4.2 Part II
t to the co

Note
rrectne

♦ Components marked with * are checked via On Board Diag‐

ss

nostics (OBD). Refer to ⇒ Fuel Injection and Ignition; Rep. Gr.

o
cial p

01 ; Diagnosis and Testing .

inform
mer

♦ Components marked with ** are checked via output diagnostic

atio
m

test mode. Refer to ⇒ Fuel Injection and Ignition; Rep. Gr.

o

n
c

01 ; Diagnosis and Testing .

i
or

n thi
te

sd
a

♦ Note installation position of heat shield mats

iv

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.

156 Rep. Gr.21 - Turbocharger, Supercharger

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

1 - Deceleration Shut-Off
Valve
❑ Checking. Refer to
⇒ “3.5 Deceleration
Shut-Off Valve, Check‐
ing”, page 166 .
2 - Connecting Hose
❑ To the Fuel Tank Shut-
Off Valve 4 - N249- */**
3 - Pressure Regulating Valve
❑ For the crankcase ven‐
tilation
4 - Connecting Hose
❑ From deceleration shut-
off valve to upper air
guide pipe
5 - To Crankcase Housing
Ventilation
6 - From Air Filter
7 - Upper Air Guide Pipe
❑ Note the installation po‐
sition of the heat shield
mat
❑ Vehicles with engine
code AWP, AWW with
quick-release connec‐
tion (with O-ring and re‐ AG. Volkswagen A
taining clip) ksw
agen G do
es n
Vol ot g
❑ Vehicles withseengine
db
y ua
ran
code AWDthowith screw-
ri tee
or
type clamps
s au ac
s
ce
le

8 - Bracket
un

pt
an
d
itte

9 - Bolt
y li
erm

ab

❑ 40 Nm
ility
ot p

wit
is n

10 - Bolt
h re
ole,

❑ 25 Nm
spec
urposes, in part or in wh

t to the co

11 - To Connection Hose for Lower Connection Sleeve/Charge Air Cooler

12 - O-Ring
rrectne

❑ Replace
❑ Only vehicles with engine code AWP, AWW
ss

13 - Retaining Clip
o
cial p

f in

❑ Make sure it is secure

form
mer

❑ Only vehicles with engine code AWP, AWW

atio
om

14 - Bolt
c

i
or

n thi
e

❑ 10 Nm
t

sd
iva

o
pr

15 - From Turbocharger Exhaust Connection

um
r
fo

en
ng

t.
yi
16 - Connecting Hose
Co
Cop py
t. rig
gh
17 - Connecting Hose
ht
pyri by
Vo
co lksw
by
❑ To the charge air pressure regulator valve vacuum diaphragm Prote
cted AG.
agen

18 - Retaining Clip
❑ Make sure it is secure

2. Description and Operation 157

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

19 - O-Ring
❑ Replace
20 - Intake Hose
❑ To intake tube of turbocharger
21 - Wastegate Bypass Regulator Valve - N75- */**
❑ Valve is activated (pulsed) by engine control module
❑ Check the activation. Refer to ⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and Testing .

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
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
co lksw
by
cted agen
Prote AG.

158 Rep. Gr.21 - Turbocharger, Supercharger

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

3 Diagnosis and Testing

⇒ “3.1 Boost Pressure Regulator Valve Vacuum Diaphragm,
Checking”, page 159
⇒ “3.2 Charge Air Pressure Regulation, Checking”, page 160
⇒ “3.3 Charge Air Pressure Sensor G31 , Checking”, page 162
⇒ “3.4 Charge Air System, Checking for Leaks”, page 164
⇒ “3.5 Deceleration Shut-Off Valve, Checking”, page 166
⇒ “3.6 Fuel Tank Shut-Off Valve 4 N249 , Checking”, page 166
⇒ “3.7 Wastegate Bypass Regulator Valve N75 , Checking”, page
167

3.1 Boost Pressure Regulator Valve Vac‐

uum Diaphragm, Checking
Special tools and workshop equipment required
♦ Vehicle Diagnostic Tester
Test Conditions
• Engine oil temperature: minimum 60 °C (140 °F)
• No leaks on intake or exhaust side.
Test Sequence
– Disconnect the connector -2- from the Wastegate Bypass
Regulator Valve - N75- -1-.

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

nform
mercia

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.

3. Diagnosis and Testing 159

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Start engine and increase speed to maximum RPM by de‐

pressing accelerator pedal suddenly. The actuator rod -2- for
the charge air pressure regulator valve must move.
If actuator rod does not move:
– Check lever for the charge air pressure regulator valve -1- for
ease of movement. If rusted in place, replace turbocharger.
If actuator rod does not move through light prying:
n AG. Volkswagen A ge G do
swa es
– Exhaust turbocharger by
Vofaulty,
lk replace it. Refer to not gua
⇒ “2.4 Overviewrise-dTurbocharger with Attachments”, ran
tee
page 154 . utho or
a ac
ss
– Check the Diagnostic Trouble Code (DTC) memory. Refer to

ce
le
un

⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and

pt
an
d

Testing .
itte

y li
erm

ab
– Read the readiness code. Refer to ⇒ Fuel Injection and Igni‐

ility
ot p

tion; Rep. Gr. 01 ; Diagnosis and Testing .

wit
is n

h re
ole,

– If DTC memory was cleared or Engine Control Module (ECM)

spec
disconnected from voltage supply the readiness code must be
urposes, in part or in wh

regenerated. Refer to ⇒ Fuel Injection and Ignition; Rep. Gr.

t to the co
01 ; Diagnosis and Testing .

rrectne
3.2 Charge Air Pressure Regulation, Check‐
ing
ss o
cial p

Special tools and workshop equipment required f inform

mer

♦ Vehicle Diagnostic Tester

atio
m

Test Conditions
o

n
c

i
or

n thi
e

• There must be no malfunctions stored in the Diagnostic Trou‐

t

sd
va

ble Code (DTC) memory. Refer to ⇒ Fuel Injection and

i

o
pr

cum
r

Ignition; Rep. Gr. 01 ; Diagnosis and Testing .

fo

en
ng

t.
yi Co
• No leaks on intake or exhaust side. t. Cop py
rig
gh ht
yri
• Engine oil temperature: minimum 80 °C (176 °F) p by
o Vo
by c lksw
cted agen
Test Sequence Prote AG.

– Charge pressure is measured under Wide Open Throttle

(WOT) while driving or on the roller type test stand.
Follow all applicable safety precautions during a road test. Refer
to ⇒ “1.3 Safety Precautions”, page 148 .
– Connect the Vehicle Diagnostic Tester and select the control
module for engine electronics with the “address word 01”. En‐
gine must run at idle for this. Connect the scan tool and select
the Engine Control Module (ECM). Refer to ⇒ Fuel Injection
and Ignition; Rep. Gr. 01 ; Diagnosis and Testing .
Scan tool display: Quick data transfer HELP
Select function XX

– Press the buttons 0 and 8 for the function “Read measured

value block” and press Q button to confirm the input.
Scan tool display: Read measuring value block
Enter display group number XXX

– Press the buttons 1 1 and 4 for the “display group 114” and
press Q button to confirm the input.
Shown on the display: (1 to 4 = display fields) Read measured value block 114 ->
1 2 3 4

– During a road test or on a test stand, check (at full throttle

between 1800 and 2300 RPM) duty cycle of Wastegate By‐

160 Rep. Gr.21 - Turbocharger, Supercharger

 gen AG. Volkswagen A
Boraolk1999
swa ➤ , Bora Variant d1999
G o
es n ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
ot g
V uEngine
ed by ara Mechanical - Edition 11.2007
ris nte
tho eo
pass Regulator Valve
ss
au
- N75- in display field 4. Specified value: ra
c
5.0 to 95.0%

ce
e
nl

pt
du

an
If specified value is achieved:

itte

y li
erm

ab
– Switch to display group 115 as follows: push the button 3 .

ility
ot p

wit
, is n

Shown on the display: (1 to 4 = display fields)

h re
Read measured value block 115 ->
hole

1 2 3 4

spec
es, in part or in w

– Check charge air pressure actual value with Wide Open Throt‐

t to the co
tle (WOT) in display field 4:
On Dynamometer

rrectness of i
In 3rd gear or in 2nd driving mode
l purpos

While Driving
Vehicles with manual transmission

nf
ercia

orm
– Accelerate vehicle with full throttle in 2nd gear.
m

atio
om

n in
Vehicles with automatic transmission
or c

thi
te

sd
– Manually shift vehicle in 4th gear and accelerate vehicle from
iva

o
r

low speed at WOT (without kick down, transmission does not

rp

cu
o

m
downshift any more).
f

en
ng

t.
yi Co
op
Engine Codes AWD and AWW C py
t. rig
gh ht
yri by
– Press print button between 1800 and 2300 RPM and read out cop Vo
by lksw
charge air pressure actual value in display field 4. Specified cted agen
Prote AG.
value: 1350 to 1750 mbar
Engine Code AWP
– Press print button between 1800 and 2300 RPM and read out
charge air pressure actual value in display field 4. Specified
value: 1700 to 2000 mbar
Continuation for All Vehicles
– Compare the charge air pressure actual value with the charge
air pressure specified value in the display field 4. Difference:
maximum 100 mbar

Note

Repeat measurement if full charge air pressure had not been

reached yet or difference between specified and actual value is
too large.

– Press the → -button.

– Press the buttons 0 and 6 for the function “end output” and
press Q button to confirm the input.
– Switch off the ignition.
If the charge air pressure is exceeded:
– Check the Charge Air Pressure Sensor - G31- . Refer to
⇒ “3.3 Charge Air Pressure Sensor G31 , Checking”,
page 162 .
– Check the Wastegate Bypass Regulator Valve - N75- .
(Throughput in hose from turbocharger via valve to vacuum
diaphragm with connector disconnected)
– Check that vacuum diaphragm for the charge air pressure
regulator valve is securely seated on turbocharger.

3. Diagnosis and Testing 161

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Check the vacuum diaphragm. Refer to

⇒ “3.1 Boost Pressure Regulator Valve Vacuum Diaphragm,
Checking”, page 159 .
– Check the mounting of the charge air pressure regulator valve
shaft in the turbocharger for ease of movement. If rusted in
place, replace turbocharger.
If charge air pressure is exceeded:
– Check the Charge Air Pressure Sensor - G31- . Refer to
⇒ “3.3 Charge Air Pressure Sensor G31 , Checking”,
page 162 .
– Check the Wastegate Bypass Regulator Valve - N75- .
– Check the mounting of the charge air pressure regulator valve
shaft in the turbocharger for ease of movement. If rusted in
n AG. Volkswagen AG do
place, replace turbocharger. olkswage es n
o V t gu
by ara
– Exhaust turbocharger faulty, replace it.risRefer
ed to nte
⇒ “2.4 Overview - Turbocharger withuthAttachments”,
o eo
ra
page 154 . ss
a c

ce
e
nl

– Check the DTC memory. Refer to ⇒ Fuel Injection and Igni‐

pt
du

an
tion; Rep. Gr. 01 ; Diagnosis and Testing .
itte

y li
erm

ab
– Read the readiness code. Refer to ⇒ Fuel Injection and Igni‐

ility
ot p

tion; Rep. Gr. 01 ; Diagnosis and Testing .

wit
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h re
– If DTC memory was cleared or ECM disconnected from volt‐
hole

spec
age supply the readiness code must be regenerated. Refer to
es, in part or in w

⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and

t to the co
Testing .

3.3 Charge Air Pressure Sensor - G31- ,

rrectness of i
Checking
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⇒ “3.3.1 Voltage Supply and Wiring to Control Module, Checking”,

page 163

nform
ercia

⇒ “3.3.2 Checking Function”, page 163

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ion

Special tools and workshop equipment required

c

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or

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te

♦ Analog/Digital Multimeter - FLU83III-

a

do
priv

cum
or

♦ Connector Test Set - VAG1594A- or Connector Test Set -

f

en
g

VAG1594D-
n

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♦ Test Box Kit - 121 Point Adapter - VAG1598/31-
t rig
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♦ Wiring diagram
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Test Conditions
• A malfunction in charge air pressure sensor was detected by
On Board Diagnostics (OBD). Refer to ⇒ Fuel Injection and
Ignition; Rep. Gr. 01 ; Diagnosis and Testing .
• Ignition switched off.

162 Rep. Gr.21 - Turbocharger, Supercharger

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007
. Volkswagen AG
gen AG
3.3.1 Voltage Supply and Wiring olkto
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Module, Checking orised
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– Disconnect the 4-pin connector -2-
ss from the
a
Charge Air Pres‐ c
sure Sensor - G31- -1-.

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rrectne
– Connect multimeter for voltage measurement with adapter ca‐

s
bles from Connector Test Set - VAG1594D- to terminal 1

s o
(ground) + 3 (positive) on Charge Air Pressure Sensor - G31-
cial p

f in
connector.

form
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– Switch the ignition on. Specified value: minimum 4.5 V

atio
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n
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– Switch off the ignition.

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If no voltage is present:
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– Connect Test Box Kit - 121 Point Adapter - VAG1598/31- to
AG.

the control module wiring harness. The Engine Control Module

(ECM) remains disconnected.
– Check the wires between the Test Box Kit - 121 Point Adapter
- VAG1598/31- and the connector for the short circuit accord‐
ing to the wiring diagram.
Terminal 1 + socket 108
Terminal 3 + socket 98
Terminal 4 + socket 101

Wire resistance: maximum 1.5 Ω

– Check wires for short circuit to each other.
If no malfunction is found in the wires and there was voltage be‐
tween terminals 1 + 3:
– Check function. Refer to
⇒ “3.3.2 Checking Function”, page 163 .
If no malfunction is found in the wires and there was no voltage
between terminals 1 + 3:
– Replace the ECM. Refer to ⇒ Fuel Injection and Ignition; Rep.
Gr. 24 ; Removal and Installation .

3.3.2 Checking Function

– Connect Test Box Kit - 121 Point Adapter - VAG1598/31- to
the Engine Control Module (ECM) wiring harness and the
ECM.

3. Diagnosis and Testing 163

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Reconnect connector on the Charge Air Pressure Sensor -

G31- .
– Use adapter cables from Connector Test Set - VAG1594D- to
connect multimeter to sockets 101 (positive) + 108 (ground)
for voltage measurement.
– Start engine and measure voltage. Specified value: 1.80 to
2.00 V
– Increase engine speed by pressing gas pedal suddenly.
Specified value: 2.00 to 3.00 V
If the specified values are not obtained:
– Replace the Charge Air Pressure Sensor - G31- .
– Check the Diagnostic Trouble Code (DTC) memory. Refer to
⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and
Testing .
– Read the readiness code. Refer to ⇒ Fuel Injection and Igni‐
tion; Rep. Gr. 01 ; Diagnosis and Testing .
– If DTC memory was cleared or ECM disconnected from volt‐
age supply the readiness code must be regenerated. Refer to
⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and
Testing .

3.4 Charge Air System, Checking for Leaks

Special tools and workshop equipment required
♦ Turbo System Tester Kit - VAG1687-
♦ Turbo System Tester Kit - Adapter 1 - VAG1687/1-
– Remove intake hose from air filter.
– Remove crankcase ventilation pressure regulator valve
-Item 11- ⇒ Item 11 (page 151) from intake hose.
– Insert the Turbo System Tester Kit - Adapter 1 - VAG1687/1-
into the intake hose and seal the connection for pressure
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regulator valve using Turbo System Tester Kitsw- aAdapter
gen AG 4 - does
VAG1687/4- . Tighten the hose clamps. by V olk not
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Prepare the Turbo System Tester Kit -thVAG1687-
or
i
as follows: tee
or
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– Turn the pressure regulating valve -2- counterclockwise until

t to the co

it stops.
– Close the valves -3 and 4-.
rrectness of i
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Note
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In order to be able to turn pressure regulator valve -2-, the rotary

knob must be pulled upward.
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164
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Rep. Gr.21 - Turbocharger, Supercharger Prote
cted AG.
agen
 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– Connect the Turbo System Tester Kit - VAG1687- as shown:

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– Connect the pressure hose -1- (pressurized air supply) to the
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Turbo System Tester Kit - VAG1687- .

rrectness of i
Note
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If water is located in viewing glass, drain it via the water drain plug
-6-.

nform
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– Open the valve -3-.

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tion in
– Set pressure to 0.5 bar (7.2 psi) using the pressure regulator
r
te o

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valve -2-.
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The pressure must not exceed 0.5 bar (7.2 psi)! A pressure set
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too high may damage the engine.
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– Open valve -4- and wait until testing circuit has filled. If nec‐
essary, continue to regulate the pressure to 0.5 bar (7.2 psi).
– Check the charge air system for leaks by listening, feeling,
using commercially available leak detection spray or by using
the Ultrasonic Measuring Device - VAG1842- .

Note

♦ A minimal amount of air will escape through the turbocharger

into the oil pan. For this reason a pressure retention test is not
possible.
♦ Information on the Ultrasonic Tester - VAG1842S- . Refer to
the Operating Instructions.
♦ If a poorly sealed area is discovered, observe the notes for
charge air system when repairing. Refer to
⇒ “1.1 Charge Air System with Turbocharger”, page 147 .
♦ Before removing adapter, discharge pressure in testing circuit
by pulling off coupling from Turbo System Tester Kit - Adapter
1 - VAG1687/1- .

3. Diagnosis and Testing 165

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

3.5 Deceleration Shut-Off Valve, Checking

Special tools and workshop equipment required
♦ Hand Vacuum Pump - VAG1390-
Test Conditions
• Performance deficiency or load change shocks
Test Sequence

Note

Deceleration shut-off valve is located in front of turbocharger. It

is opened by vacuum during deceleration and at idle.

– Connect the Hand Vacuum Pump - VAG1390- to the vacuum

connection from the deceleration fuel shut-off valve.
– Operate the Hand Vacuum Pump - VAG1390- . Deceleration
shut-off valve must open in direction of -arrow-.
– Operate the breather line on the Hand Vacuum Pump -
VAG1390- . Deceleration shut-off valve must close
If deceleration shut-off valve does not open or does not close,
replace valve.

Note

Connections of deceleration shut-off valve are to be fastened with

screw-type clamps.
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3.6 Fuel Tank Shut-Off Valve 4 - N249- , d b ran
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Checking
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Special tools and workshop equipment required

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♦ Analog/Digital Multimeter - FLU83III-

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ility
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♦ Connector Test Set - VAG1594D-

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♦ Wiring diagram
hole

spec

Test Conditions
es, in part or in w

t to the co

• Output diagnostic test mode performed. Refer to ⇒ Fuel In‐

jection and Ignition; Rep. Gr. 01 ; Diagnosis and Testing .
rrectness of i

Test Sequence
l purpos

– Switch off the ignition.

– Disconnect connector from the Fuel Tank Shut-Off Valve 4 -
nf
ercia

N249- .
orm
m

atio

– Measure resistance between terminals of valve. Specified val‐

om

n in

ue: 27 to 30 Ω
or c

thi
e

If the specification is not obtained:

t

sd
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rp

cu

– Replace the Fuel Tank Shut-Off Valve 4 - N249- .

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– Check the Diagnostic Trouble Code (DTC) memory. Refer to Cop py
⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and
t. rig
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Testing .
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– Read the readiness code. Refer to ⇒ Fuel Injection and Igni‐
Prote AG.

tion; Rep. Gr. 01 ; Diagnosis and Testing .

166 Rep. Gr.21 - Turbocharger, Supercharger

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

– If DTC memory was cleared or Engine Control Module (ECM)

disconnected from voltage supply the readiness code must be
regenerated. Refer to ⇒ Fuel Injection and Ignition; Rep. Gr.
01 ; Diagnosis and Testing .

3.7 Wastegate Bypass Regulator Valve -

N75- , Checking
Special tools and workshop equipment required
♦ Vehicle Diagnostic Tester
♦ Analog/Digital Multimeter - FLU83III-
♦ Connector Test Set - VAG1594D-
Test Conditions
• Output diagnostic test performed . Refer to ⇒ Fuel Injection
and Ignition; Rep. Gr. 01 ; Diagnosis and Testing .
• Ignition switched off.
Test Sequence
– Disconnect the connector -2- from the Wastegate Bypass
Regulator Valve - N75- -1-.

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– Measure resistance between terminals
orise of valve. Specified val‐ nte
eo
ue: 25 to 35 Ω aut
h
ra
ss c
If the specification is not obtained:
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e
nl

pt
du

an

– Replace the Wastegate Bypass Regulator Valve - N75- .

itte

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erm

ab

– Check the DTC memory. Refer to ⇒ Fuel Injection and Igni‐

ility
ot p

tion; Rep. Gr. 01 ; Diagnosis and Testing .

wit
, is n

h re

– Read the readiness code. Refer to ⇒ Fuel Injection and Igni‐

hole

spec

tion; Rep. Gr. 01 ; Diagnosis and Testing .

es, in part or in w

t to the co

– If Diagnostic Trouble Code (DTC) memory was cleared or En‐

gine Control Module (ECM) disconnected from voltage supply
the readiness code must be regenerated. Refer to ⇒ Fuel In‐
rrectness of i

jection and Ignition; Rep. Gr. 01 ; Diagnosis and Testing .

l purpos

If specified value is achieved:

– Check specified values in measured value blocks for the
nform
ercia

charge air pressure regulation: display groups 110 to 119. Re‐

fer to ⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis
m

at
om

and Testing .
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3. Diagnosis and Testing 167

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

4 Special Tools

Special tools and workshop

equipment required
♦ Analog/Digital Multimeter -
FLU83III-
♦ Connector Test Set -
VAG1594A- or Connector
Test Set - VAG1594D-
♦ Test Box Kit - 121 Point
Adapter - VAG1598/31-

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urposes, in part or in wh

♦ Analog/Digital Multimeter - FLU83III- t to the co

rrectness o
cial p

f inform
mer

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n
c

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by
cted agen
Prote AG.

168 Rep. Gr.21 - Turbocharger, Supercharger

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

♦ Hand Vacuum Pump - VAG1390-

♦ Connector Test Set - VAG1594D-

♦ Turbo System Tester Kit - VAG1687-

AG. Volkswagen AG d
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♦ Turbo System Tester Kit - Adapter 1 - VAG1687/1-

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

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4. Special Tools 169

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

26 – Exhaust System, Emission Controls

1 General Information
⇒ “1.1 Exhaust System Components”, page 170
⇒ “1.2 Secondary Air Injection System”, page 170

1.1 Exhaust System Components

Note

♦ After exhaust system repairs, make sure exhaust system is

not under stress and that it has sufficient
swa
gen clearance
AG. Volkswagfrom
en AGthe
doe
bodywork. If necessary, loosenbydouble
Volk clamps and clamp ands not gu
align exhaust pipe so that sufficient
ris
ed clearance is maintained to ara
nte
the bodywork and supportut rings carry uniform loads.
ho eo
r
sa ac
♦ Replace the self-locking
s
nuts.

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♦ Components marked with * are checked via On Board Diag‐

an
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nostic (OBD).
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1.2 Secondary Air Injection System

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Function
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The secondary air injection system blows air behind the exhaust
valves for a maximum of 100 seconds following a cold start (cool‐
ant temperature 5 °C to 35 °C (41 °F to 95 °F)). This produces an
rrectness of i
oxygen rich exhaust gas, causes after burning and reduces the
heating-up phase of the catalytic converter. Activation is triggered
l purpos

by the Motronic Engine Control Module - J220- via the Secondary

Air Injection Pump Relay - J299- to the Secondary Air Injection
nform
ercia

Solenoid Valve - N112- (change-over valve) and combination

valve.
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170 Rep. Gr.26 - Exhaust System, Emission Controls

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

2 Description and Operation

⇒ “2.1 Overview - Exhaust System”, page 171
⇒ “2.2 Overview - Secondary Air Injection System Components”,
page 174

2.1 Overview - Exhaust System

Caution

When doing any assembly work, especially in the engine com‐

partment, pay attention to the following due to the limited
space.
♦ Route lines of all types (for example for fuel, hydraulic,
Evaporative Emission (EVAP) canister system, coolant
and refrigerant, brake fluid, vacuum) and electrical wiring
so that the original path is followed.
♦ To prevent damage to the lines, make sure there is suffi‐
cient clearance to all moving or hot components.

1 - Tunnel Bridge
2 - Center Muffler
❑ As standard, center and
rear mufflers are instal‐ AG. Volkswagen AG d
led as a single compo‐ agen oes
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ara
the center and rear muf‐ horis nte
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fler are supplied individ‐ s aut ra
c
ually and with a double s

ce
le

clamp for connecting.

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❑ Separating point. Refer

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⇒ Fig. ““Separation

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Point on Exhaust

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Pipe”“ , page 173 .
ole,

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urposes, in part or in wh

3 - Mount

t to the co
❑ Note the installation po‐
sition. Refer to
⇒ Fig. ““Installed Loca‐
tion of Mountings”“ , rrectne
page 173 .
ss

4 - Bolt
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❑ 25 Nm
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5 - Nut
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❑ 40 Nm
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❑ Replace
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❑ Replace rig ht
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2. Description and Operation 171

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

8 - Turbocharger
9 - Front Exhaust Pipe with
Catalytic Converter
10 - Heated Oxygen Sensor - G39- *
❑ 50 Nm
❑ Grease only the threads with Hot Bolt Paste - G 052 112 A3- ; Hot Bolt Paste - G 052 112 A3- must not
get into the slots on the sensor body.
❑ Removing and installing with Ring Wrench 7-Piece Set - 3337-
❑ If sealing ring is leaking cut open and replace.
❑ Checking. Refer to ⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Description and Operation .
❑ Connecting piece for engine code AWD: 4-pin gold plated contact
❑ Connecting piece for engine codes AWP and AWW: 6-pin gold plated contact
11 - Oxygen Sensor after Three Way Catalytic Converter - G130- *
❑ 50 Nm
❑ Grease only the threads with Hot Bolt Paste - G 052 112 A3- ; Hot Bolt Paste - G 052 112 A3- must not
get into the slots on the sensor body.
❑ Removing and installing with Ring Wrench 7-Piece Set - 3337-
❑ If sealing ring is leaking cut open and replace. n AG. Volkswagen AG do
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❑ Checking. Refer to ⇒ Fuel Injection and Ignition; d bRep.
yV Gr. 24 ; Description and Operation
ua
ran .
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❑ Connecting piece: 4-pin, terminals 3 and 4 ugold-plated
tho tee
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12 - Double Clamp s

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❑ Note the installation position. Refer to ⇒ Fig. ““Installation Position of Double Clamp”“ , page 173 .
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13 - Nut
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❑ 40 Nm

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14 - Mount
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15 - Bolt
es, in part or in w

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❑ 25 Nm
16 - Rear Muffler

rrectness of i
❑ As standard, center and rear mufflers are installed as a single component. In cases of repair, the center
and rear muffler are supplied individually and with a double clamp for connecting.
l purpos

❑ Separating point. Refer to ⇒ Fig. ““Separation Point on Exhaust Pipe”“ , page 173 .
❑ Installing muffler free of tension ⇒ Fig. ““Installing Muffler Free of Tension”“ , page 173
nform
mercia

17 - Mount
at
om

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18 - Bolt
in t
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❑ 25 Nm
at

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19 - Double Clamp
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20 - Nut t. Cop py
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❑ 40 Nm
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21 - Nut cted agen
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❑ 25 Nm

172 Rep. Gr.26 - Exhaust System, Emission Controls

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

Separation Point on Exhaust Pipe

– Disconnect the exhaust pipe at right angle at the separation
point -arrow 2-.
– Position repair double clamp -4- between -arrow 1- and
-arrow 3- during installation. Tightening specification 40 Nm

Installing Muffler Free of Tension

– Mounting bolt at exhaust pipe must be parallel to tunnel brace
(dimension -x- same at left and right).

Installation Position of Double Clamp

– Position the double clamp approximately 5 mm from mark A
-arrow 1-.

Note

Marking -A- applies to vehicles with Vmanual transmission and au‐

tomatic transmission. swagen AG
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Installed Location of Mountings

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– Angled side at foot of suspended mount -arrow- faces the front

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2. Description and Operation
 n AG. Volkswagen AG do
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Bora 1999 ➤ , Bora Variant th 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤e o
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Engine Mechanical - Edition
ss
a
11.2007 c

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un

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2.2 Overview - Secondary Air Injection Sys‐

an
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erm
tem Components

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Note ole,

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urposes, in part or in wh

t to the co
♦ Components marked with * are checked via On Board Diag‐
nostics (OBD). Refer to ⇒ Fuel Injection and Ignition; Rep. Gr.
01 ; Diagnosis and Testing .

rrectne
♦ Components marked with ** are checked via output diagnostic
test mode. Refer to ⇒ Fuel Injection and Ignition; Rep. Gr.

ss
01 ; Diagnosis and Testing .

o
cial p

f inform
♦ Secondary Air Injection Pump Relay - J299- **
mer

⇒ Fig. ““ Secondary Air Injection Pump Relay -J299- -1- ”“ ,

atio
m

page 175
o

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1 - Combination Valve

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❑ Checking. Refer to
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⇒ “3.1 Combination
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Valve, Checking”,
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2 - Seal
❑ Replace
3 - Connection
❑ Secured to cylinder
head
4 - Bracket
5 - Bolt
❑ 10 Nm
6 - Bracket
❑ Attached to the intake
manifold
7 - To Vacuum Reservoir
8 - Vacuum Hose
9 - Connector
❑ 2-pin
10 - Secondary Air Injection
Solenoid Valve - N112- */**
❑ Tightened to 6 Nm on
bracket
❑ Resistance: 21 to 24 Ω
❑ Checking. Refer to
⇒ “3.3 Secondary Air In‐
jection Solenoid Valve,
Checking”, page 177 .
11 - Intake Hose
❑ For Secondary Air Injection (AIR) pump
❑ Make sure it is secure
❑ Press together at front to release

174 Rep. Gr.26 - Exhaust System, Emission Controls

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

12 - To Air Filter
13 - O-Ring
❑ Replace
14 - Connector
❑ 2-pin
❑ for Secondary Air Injection Pump Motor - V101-
15 - Nut
❑ 10 Nm
16 - Secondary Air Injection Pump Motor - V101-
❑ Function, checking. Refer to ⇒ “3.2 Secondary Air Injection Pump Motor V101 , Checking”, page 176 .
17 - Bolt
❑ 10 Nm
18 - Pressure Hose
❑ Make sure it is secure
❑ Press together at front to release
19 - Nut
❑ 10 Nm
❑ Secured to bracket -Item 6- ⇒ Item 6 (page 174)
20 - Bolt
❑ 10 Nm
21 - Seal
❑ Replace
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Secondary Air Injection Pump Relay - J299- horis -1- nte
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♦ If tools are necessary to pull relays
s or control modules out of
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the relay plate, first disconnect battery Ground (GND) cable.
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2. Description and Operation 175

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

3 Diagnosis and Testing

⇒ “3.1 Combination Valve, Checking”, page 176
⇒ “3.2 Secondary Air Injection Pump Motor V101 , Checking”,
page 176
⇒ “3.3 Secondary Air Injection Solenoid Valve, Checking”,
page 177
⇒ “3.4 Three Way Catalytic Converter (TWC), Checking”,
page 178

3.1 Combination Valve, Checking

Special tools and workshop equipment required
♦ Hand Vacuum Pump - VAG1390-
Test Conditions
• There must be no malfunctions stored in the Diagnostic Trou‐
ble Code (DTC) memory. Refer to ⇒ Fuel Injection and
Ignition; Rep. Gr. 01 ; Diagnosis and Testing .
• The output Diagnostic Test Mode (DTM) is performed. Refer
to ⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and
Testing .
• Vacuum lines and hose connections free of leaks
• Vacuum lines not blocked or kinked.
Test Sequence
– Remove vacuum hose -1- on Secondary Air Injection Solenoid
Valve - N112- -2-.
– Connect the Hand Vacuum Pump - VAG1390- to the vacuum
hose -1-.
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– Disconnect the pressure hose -3- on Secondary Air Injection

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Pump Motor - V101- and blow into it with light pressure

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-arrow-. Combination valve must be closed.

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To disengage, compress the buttons at the hose coupling.

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– Operate the Hand Vacuum Pump - VAG1390- . Valve must

open.
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If the combi-valve does not open:

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– Replace the combination valve.

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3.2 Secondary Air Injection Pump Motor -

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V101- , Checking
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176 Rep. Gr.26 - Exhaust System, Emission Controls

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

♦ Vehicle Diagnostic Tester

Test Conditions
• Secondary Air Injection Pump Relay - J299- fuse -arrow- in
main fuse box on the battery OK.
• There must be no malfunctions stored in the Diagnostic Trou‐
ble Code (DTC) memory. Refer to ⇒ Fuel Injection and
Ignition; Rep. Gr. 01 ; Diagnosis and Testing .
• The battery voltage must be at least 11.5V.
• Secondary Air Injection (AIR) intake hose is not sealed or
kinked.
Test Sequence
– Remove the engine cover.
– Remove the pressure hose on the Secondary Air Injection
Pump Motor - V101- .
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– Activate the Secondary Air Injection Pump Relay - J299- via

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output diagnostic test mode. Refer to ⇒ Fuel Injection and

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Ignition; Rep. Gr. 01 ; Diagnosis and Testing .

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– The Secondary Air Injection Pump Motor - V101- must start in

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intervals and the air must escape at the exhaust connection.
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urposes, in part or in wh

If motor starts, but no air escapes:

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– Continue with output Diagnostic Test Mode (DTM) to end.
– Press the buttons 0 and 6 for the function “end output” and

rrectne
press Q button to confirm the input.
– Switch off the ignition.
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– Replace the Secondary Air Injection Pump Motor - V101- . f inform

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– Check the Diagnostic Trouble Code (DTC) memory. Refer to

atio

⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and

om

Testing .
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– Read the readiness code. Refer to ⇒ Fuel Injection and Igni‐

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tion; Rep. Gr. 01 ; Diagnosis and Testing .

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– If DTC memory was cleared or Engine Control Module (ECM)

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If the AIR pump motor does not start up in intervals:
– Check AIR pump motor activation.

3.3 Secondary Air Injection Solenoid Valve,

Checking
Test Conditions
• Coolant temperature 5 °C to 33 °C (41 °F to 91.4 °F)
• Secondary Air Injection (AIR) pump motor OK
• There must be no malfunctions stored in the Diagnostic Trou‐
ble Code (DTC) memory. Refer to ⇒ Fuel Injection and
Ignition; Rep. Gr. 01 ; Diagnosis and Testing .

3. Diagnosis and Testing 177

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

Test Sequence
– Disconnect vacuum hose at combination valve -arrow-.
– Start engine and let run at idle. Vacuum must be present at
vacuum hose (sense by touch) when Secondary Air Injection
Pump Motor - V101- is running.
If no vacuum can be felt:
– Turn off engine.
– Check the valve activation.

3.4 Three Way Catalytic Converter (TWC),

Checking swage
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♦ Speed Adjuster Tool - VAG1788/10- (only for engine codes

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AWD and AWW)

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Test Sequence

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– Connect the Vehicle Diagnostic Tester and select the control

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module for engine electronics with the “address word 01”. En‐
hole

gine must run at idle for this. Connect the scan tool and select

spec
the Engine Control Module (ECM). Refer to ⇒ Fuel Injection
es, in part or in w

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

rrectness of i
Select function XX

– Press the buttons 0 and 4 for the function “Initiate basic set‐
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ting” and press Q button to confirm the input.

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Scan tool display:

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Initiate basic setting HELP

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Enter display group number XXX
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– Press the buttons 0 3 and 4 for the “display group 34” and

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press Q button to confirm the input.

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Shown on the display: (1 to 4 = display fields)

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– Hold speed at 1800 to 2200 RPM until display in display field

4 goes from “Test OFF” to “Test ON”. Catalytic converter tem‐
perature in display field 2 must be between 350 and 500° C
(662 and 932 °F).
– Continue to hold speed at 1800 to 2200 RPM until specified
value “B1S1 OK” is shown in display field 4.
Engine Code AWP
– Press brake pedal and hold firmly.
– Press gas pedal into Wide Open Throttle (WOT) position. The
engine speed is raised to approximately 2300 RPM by the
ECM.
– Hold the brake pedal and accelerator pedal until display in
display field 4 goes from “Test OFF” to “Test ON”. Catalytic

178 Rep. Gr.26 - Exhaust System, Emission Controls

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

converter temperature in display field 2 must be between 350

and 500° C (662 and 932 °F).
– Continue to hold brake and gas pedal until specified value
“B1S1 OK” is shown in display field 3.
– Release brake and gas pedals.
All Engine Codes
If the reading does not result asendescribed:
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– Check the Diagnostic Vol
by Trouble Code (DTC) memory. Refer to
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⇒ Fuel Injectionrisand
ed
Ignition; Rep. Gr. 01 ; Diagnosis and
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tee
Testing . auth o
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– Read the readiness code. Refer to ⇒ Fuel Injection and Igni‐

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tion; Rep. Gr. 01 ; Diagnosis and Testing .

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– If DTC memory was cleared or ECM disconnected from volt‐
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age supply the readiness code must be regenerated. Refer to

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⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis and

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Reading results as described:
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– Press the C button.
– Press the buttons 0 4 and 6 for the “display group 46” and

rrectness of i
press Q button to confirm the input.
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Shown on the display: (1 to 4 = display fields) Basic setting 46 ->

1 2 3 4

nform
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Engine Codes AWD and AWW

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– Hold speed at 1800 to 2200 RPM until display in display field

ion in

4 goes from “Test OFF” to “Test ON”. Catalytic converter tem‐

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perature in display field 2 must be a minimum of 440 °C (824

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°F).
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– Remove the Speed Adjuster Tool - VAG1788/10- from the ac‐ yri
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celerator pedal.
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Engine Code AWP
– Press brake pedal and hold firmly.
– Press gas pedal into Wide Open Throttle (WOT) position. The
engine speed is raised to approximately 2300 RPM by the
ECM.
– Hold the brake pedal and accelerator pedal until display in
display field 4 goes from “Test OFF” to “Test ON”. The catalytic
converter temperature in display field 2 must be a minimum of
440 °C (824 °F).
– Continue to hold brake and gas pedal until specified value “Kat
B1 OK” is shown in display field 3.
– Release brake and gas pedals.
All Engine Codes
“Catalytic converter B1 not OKB” shown in display field 4:
– Check the DTC memory. Refer to ⇒ Fuel Injection and Igni‐
tion; Rep. Gr. 01 ; Diagnosis and Testing .
– Read the readiness code. Refer to ⇒ Fuel Injection and Igni‐
tion; Rep. Gr. 01 ; Diagnosis and Testing .
– If DTC memory was cleared or ECM disconnected from volt‐
age supply the readiness code must be regenerated. Refer to

3. Diagnosis and Testing 179

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007 AG. Volkswagen A
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⇒ Fuel Injection and Ignition; Rep. Gr. 01 ; Diagnosis
ed
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If specified value “Catalytic converter B1 OK”:
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– Press the → -button.

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Scan tool display:

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Quick data transfer HELP

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Select function XX

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– Press the buttons 0 and 6 for the function “end output” and
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press Q button to confirm the input.
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– Switch off the ignition.

rrectness of i
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180 Rep. Gr.26 - Exhaust System, Emission Controls

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

4 Special Tools
Special tools and workshop equipment required
♦ Hand Vacuum Pump - VAG1390-

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♦ Speed Adjuster Tool - VAG1788/10- (only for engine codes

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AWD and AWW)

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♦ Vehicle Diagnostic Tester

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4. Special Tools 181

 Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Engine Mechanical - Edition 11.2007

5 Revision History
Re Dat Job Type Feedback # Notes Editor
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182 Rep. Gr.26 - Exhaust System, Emission Controls

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Cautions & Warnings ua
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Please read these WARNINGS and CAUTIONS before proceeding with maintenance

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and repair work. You must answer that you have read and you understand these

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WARNINGS and CAUTIONS before you will be allowed to view this information.

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•=
urposes, in part or in wh

If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we

t to the co
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.

rrectne
•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical

s
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.

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f inform
•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
mer

are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always

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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
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reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).

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•= 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
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
become inoperable, even if the correct code is used in a later attempt.

•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
starting the vehicle while you are under it.

•= 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
 Cautions & Warnings
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of anagaccidentally broken
n AG. Volkswagen AG bulb can ignite spilled
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fuel or oil. y Vol not
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•= Friction materials such as brake pads and clutch discs amay
uth contain asbestos fibers. Do not create dustebyor
a
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust. c
ss

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le
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.

un

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•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be

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crushed by heavy parts.

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ole,
•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the

spec
urposes, in part or in wh
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only

t to the co
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
repairs.

rrectne
•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at

ss
once, but do not store the oily rags, which can ignite and burn spontaneously.

o
cial p

f inform
•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
mer

fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque

atio
om

listed.

n
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sd
a

•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
iv

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ignited, it will ignite gas trapped in the cells and cause the battery to explode.
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ng

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•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of C py
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the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that copyri by
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•= 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.

•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.

I have read and I understand these Cautions and Warnings.

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Page 3 of 3
© 2002 Volkswagen of America, Inc.
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