2.8 V6 5V (Aha & Atq)

Technical data Page 1 of 3
00-1
Technical data
Engine identification
The engine code and serial number are located on the flat surface of the
cylinder block in front of the right cylinder head.
The engine code is also listed on the vehicle data label.
Identifying engine with modified oil pump (engine code AHA)
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In vehicles with VINs up to 8D-V-205 000 the oil pump is mounted on the
front of the engine and driven directly by the crankshaft. These engines
can be identified by cylinder head cover -A-.
In vehicles with VINs from 8D-V-205 001 on, the oil pump is driven via a
chain by the crankshaft and mounted inside the oil pan. In addition, oil
supply lines are mounted on the camshaft bearing caps. These engines
can be identified by cylinder head cover -B-.
http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.GE03.00.1 11/21/2002
00-2
Engine specifications
Engine code AHA ATQ

Manufactured 02/97
Displacement liters (cm3) 2771 2771
Output kw @ RPM 142/6000 142/6000
HP @ RPM 190/6000 193/6000
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Torque Nm @ RPM 280/3200 280/3200
Ft lb @ RPM 207/3200 207/3200

Bore diameter mm (in.) 82.5 (3.25) 82.5 (3.25)
Stroke mm (in.) 86.4 (3.40) 86.4 (3.40)
Compression ratio 10.6:1 9.9:1
RON minimum 98 unleaded 1)
Fuel injection and ignition system Bosch Motronic
Knock sensor control Yes Yes
On Board Diagnostic (OBD) Yes Yes
Oxygen sensor control Yes Yes
1) In emergencies, fuel with a RON of 95 may be used. Engine performance will be diminished.
00-3
Engine code AHA ATQ

Exhaust Gas Recirculation (EGR) No No
Three Way Catalytic (TWC) converter Yes Yes
Turbocharger No No
Secondary air injection Yes Yes
Valve timing: at 1 mm valve lift and 0 mm valve lash 2)
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Intake valve opens after TDC 12 12
Intake valve closes after BDC 42 42
Exhaust valve opens before BDC 38 38
Exhaust valve closes before BDC 8 8
2) Camshaft adjustment not active.
Engine, disassembling and assembling Page 1 of 3
13-1
Engine, disassembling and

assembling
Lock carrier, moving into service position
Special tools and equipment
3369 support tool
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1 - Bolts
45 Nm (33 ft lb)
2 - Bolts
45 Nm (33 ft lb)
3 - Bolts
10 Nm (7 ft lb)
4 - Bolts
10 Nm (7 ft lb)
5 - Bore
For 3369 support tool
6 - Lock carrier bore
7 - Fender bore
13-2
- Remove front bumper.
Repair Manual, Body Exterior, Repair Group 63
- Remove 3 quick-release screws on front of noise

insulation panel.
- Unbolt air guide between lock carrier and air
cleaner at lock carrier.
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- If installed, remove retaining clamps for wiring
harness on left side of radiator frame.
- Remove bolt -2- and install 3369 support tool.
- Install 3369 support tool into left bore -5-.
- Remove bolts -1- and -3-.
- Remove bolts -4- and pull lock carrier out to
stop.
- To secure lock carrier, install appropriate M6
bolts into rear bored holes of lock carrier -6- and
fender -7-.
13-3
- After installing lock carrier, check wiring for

proper routing near coolant fan.
- Install front bumper.
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Cylinder block, crankshaft and flywheel, servicing Page 1 of 33
13-4
Cylinder block, crankshaft and

flywheel, servicing
Notes:
Always replace seals and O-rings.
The engine speed sensor is installed in the
transmission bellhousing with a spacer washer
underneath.
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1 - Main bearing cap bolts
Always replace
60 Nm (44 ft lb) + additional 180 (1/2 turn)
2 - Main bearing caps
Always replace bolts
Marking -1- on oil pump side
Checking bearing clearance page 13-25
3 - Connecting rod bearing bolts
Always replace
30 Nm (22 ft lb) + additional 90 (1/4 turn)
When measuring radial clearance, tighten
to 20 Nm (15 ft lb), but do not turn further
13-5
4 - Connecting rod bearings

Do not interchange used bearing shells
Connecting rods, connecting rod bearings
page13-33
5 - Piston rings
Checking page 13-29
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6 - Pistons
Checking page 13-29
7 - Crankshaft
Checking page 13-25
Chain gear for oil pump, removing and
installing page 17-29
For vehicles with automatic transmission,
always install bushing as pilot for converter
Remove bushing using KUKKO 21/2 and
22/1
8 - Oil passage with seal
Always replace seal
9 - Sealing flange, front
10 - Bolt
10 Nm (7 ft lb)
11 - Collar bolt
30 Nm (22 ft lb)
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13-6
12 - Thrust washer
Measuring crankshaft axial clearance
page 13-25
Only on 4th crankshaft bearing
13 - Special bolt (12-sided)
Always replace
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Driveplate: 60 Nm (44 ft lb) + additional
90 (1/4 turn)
Dual-mass flywheel: 60 Nm (44 ft lb) +
additional 180 (1/2 turn)
14 - Dual-mass flywheel or driveplate
Removing and installing page 13-22
Needle bearing, removing and installing
page 13-21
15 - Crankshaft bearing
Axial and radial clearance, checking
page 13-25
16 - Bolt
10 Nm (7 ft lb)
17 - Oil jet
To cool pistons
18 - Seal for rear flange
Replacing page 13-18
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13-7
19 - Bolt
10 Nm (7 ft lb)
20 - Bolt
25 Nm (18 ft lb)
Install hand-tight before fully tightening
21 - Cylinder block
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13-8
Ribbed belt, removing and installing
Lock carrier in service position page 13-1
CAUTION!
Before removing ribbed belt, note direction of

rotation with chalk or felt-tip marker.
Reversing the direction of rotation of a used
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belt can destroy the belt. When installing the
ribbed belt, make sure it is seated correctly
on the pulley.
Removing
- Remove engine cover (arrows).
- Remove noise insulation panel (arrows).
13-9
- Counterhold pulley for viscous fan using 3212 spanner wrench and
remove viscous fan using 3312 open-end spanner (left thread).
- Carefully lift out viscous fan.
Note:
Observe previously marked direction of rotation of belt and that it is

seated correctly on the pulley.
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- To loosen ribbed belt, turn tensioner clockwise using 17 mm box
wrench until two holes are aligned (arrows). Counterhold in position
using 3204 drift.
- Remove ribbed belt.
13-10
Installing
- First install ribbed belt onto crankshaft pulley and idler wheel. Push belt
onto tensioning roller last.
Note:
Observe previously marked direction of rotation of belt and that it is

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Routing of ribbed belt:
D1 - without air conditioning

D2 - with air conditioning
- Remove 3204 drift.
- Install engine cover.
Tightening torque for viscous fan Tightening

torque
1331 torque wrench and 3312 open-end spanner 37 Nm (27 ft lb)
1331 torque wrench without 3312 open-end 70 Nm (52 ft lb)
spanner
13-11
Vibration damper, removing and

installing
Ribbed belt, removing and installing page 13-

8.
Note:
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To remove the vibration damper, it is not
necessary to remove the center bolt.
- Remove vibration damper.
- When installing, make sure notches (arrows) in vibration damper are

aligned with locating lugs on toothed belt sprocket.
Tightening torque (vibration damper to crankshaft): 20 Nm (15 ft lb)
13-12
Toothed belt, removing and installing
Removing
- Remove engine cover.
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Ribbed belt, removing and installing page 13-8 .
- Unclip toothed belt guard on both sides and remove.
13-13
- Turn crankshaft at central bolt of toothed belt gear in direction of

engine rotation to cyl. 1 TDC. Timing marks -A- and -B- must be
aligned.
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- Check position of camshafts. Large holes (arrow) of securing plates on
camshaft sprockets must face toward inside and align.
If not, turn crankshaft one revolution further.
- Remove sealing plug from left-side of cylinder block.
- Top Dead Center (TDC) mark on crankshaft must be visible or be felt
behind bore of removed sealing plug.
WARNING!
DO NOT turn crankshaft while checking for TDC mark. Personal

injury may result.
13-14
- Install 3242 crankshaft holder into sealing plug opening.

- Remove tensioner for ribbed belt.
- Remove center and right toothed belt guards.
CAUTION!
Before removing ribbed belt, note direction of rotation with chalk or

felt-tip marker. Reversing the direction of rotation of a used belt can
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destroy the belt. When installing the ribbed belt, make sure it is
Notes:
The toothed belt tensioner is oil dampened. Compress it by slowly
applying constant pressure.
Use spring clamp from 2024A.
- Using 8 mm hex wrench, turn toothed belt tensioning roller -1- counter-
clockwise, opposite direction shown (arrow), until tensioning lever -2-
compresses tensioner -3- so that spring clamp (2 mm dia.) can be
inserted into bore and lifter.
13-15
- Insert pin and release tension.
- Remove vibration damper page 13-11 .
- Remove idler wheel for ribbed belt (arrows).

- Remove toothed belt.
Installing
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- Install 3391 camshaft locator bar onto camshaft locking plates.
- Loosen both bolts for camshafts and back out bolts approx. 5 turns.
- Remove 3391 camshaft locator bar.
13-16
- Remove both camshaft sprockets using T40001 special tool.

- Reinstall both camshaft sprockets together with locking plates and
hand-tighten.
Note:
The camshaft sprockets should be loose enough on the cone to be

turned, but not so loose as to be tipped.
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- Install toothed belt on all sprockets as shown in illustration.
- Install 3391 camshaft locator bar.
13-17
- Using 8 mm hex wrench, turn toothed belt tensioner roller -1- counter-
clockwise, opposite direction shown (arrow) until tensioning lever -2-
compresses tensioner -3- so that spring clamp can be removed and
then remove clamp.
- Before starting engine, pre-load timing tensioning roller as follows:
- Using a torque wrench with 8 mm hex bit, apply tension to toothed
belt clockwise in direction shown (arrow) until a torque of 15 Nm is
attained. This ensures tensioner has expanded completely and is
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properly engaging toothed belt.
Component Tightening torque

Toothed belt sprocket to camshaft 55 (41 ft lb)
Idler wheel 45 (33 ft lb)
Toothed belt tensioning roller 20 (15 ft lb)
Belt pulley to crankshaft 20 (15 ft lb)
Toothed belt tensioner 10 (7 ft lb)
Center bolt 1) to crankshaft 200 (148 ft lb) + 180 2)
1) Always replace the center bolt.
2) Two turns of 90 are permissible.
13-18
Crankshaft seal, replacing
Toothed belt side
Ribbed belt, removing and installing page 13-

8.
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Toothed belt, removing and installing page 13-
12 .
- Remove sealing plug from left-side of cylinder

block.
- Turn crankshaft to TDC for cylinder 3. The TDC

mark on crankshaft must be visible or felt behind
bore for sealing plug.
- Install 3242 crankshaft holder in bore to secure crankshaft.
13-19
- Remove crankshaft/toothed belt gear.
- Unscrew inner part of 3203 seal puller two turns

(approx. 3 mm) and secure using knurled bolt.
- Grease threaded head of 2085 seal puller, position and with forced
pressure screw into oil seal as far as possible.
- Loosen knurled bolt and turn inner part against crankshaft until oil seal
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is removed.
Installing
- Place 3202/1 guide sleeve on crankshaft pin.

- Slide dry oil seal over guide sleeve.
- Press in oil seal to stop using 3265 seal installer.
The rest of the installation follows is the reverse of removal.
13-20
Dual-mass flywheel
Notes:
Only replace oil seal with sealing flange.
Drain coolant before removing sealing flange

page 19-11 .
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If sealing flange is not available, proceed as
follows:
- Remove clutch and dual-mass flywheel or

driveplate.
- Pry out seal using 10-221 extractor.

- Clean running and sealing surfaces.
- Push seal onto crankshaft using assembly aid.
Notes:
Do not lubricate sealing lip or outer edge of seal before pressing in.
The assembly aid is supplied with the seal.
- Press in seal up to stop using 2003/3 seal installer and bolts for dual-
mass flywheel or driveplate.
13-21
Dual-mass flywheel pilot needle bearing,

removing and installing
- Remove pilot needle bearing using puller -A- (e.g. KUKKO 21/2 and
KUKKO 22/1).
- Install bearing using 3264 bearing driver.
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13-22
Dual-mass flywheel or driveplate,

removing and installing, installation
dimensions
Dual-mass flywheel
- With crankshaft at Top Dead Center (TDC), install 3242 crankshaft

holder.
- Mark position of dual-mass flywheel and engine housing (arrows).
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- Remove bolts and replace.
Note:
A pilot needle bearing is in the dual-mass flywheel and must be inserted

when dual-mass flywheel is replaced.

Dual-mass flywheel to crankshaft 60 Nm (44 ft lb) + 180
Clutch to dual-mass flywheel 20 Nm (15 ft lb)
Note:
Always replace dual-mass flywheel mounting bolts.
13-23
Driveplate
- Hold crankshaft in position using 3242

crankshaft holder page 13-12 .
- Mark hole pattern of driveplate, shim -1- and

washer -2- to crankshaft.
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- Mark positions of shim -1- and washer -2-
(behind driveplate).
- Install driveplate with washer -2- (Part No. 035 105 303 A) and shim -1-
3.0 mm (Part No. 054 105 301) or 4.0 mm (Part No. 054 105 202).
CAUTION!
Part numbers are listed here for reference only. Always check with
your Parts department for the latest information.
Notes:
Short engines and exchange engines are supplied without a bushing
in the crankshaft. Always install a new bushing before installing the
driveplate.
Remove bushing using 21/1 Kukko puller and 21/2 Kukko support.
Always replace driveplate mounting bolts.

Driveplate to crankshaft 30 Nm (22 ft lb) + 90
13-24
- Measure distance -a- at three places and calculate average.

Distance -a-: approx. 12.3 mm.
- If necessary, install different shim.
Note:
Before installing the engine, make sure the engine to transmission

centering sleeves are installed in the engine flange.
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13-25
Crankshaft axial and radial clearance,

measuring
Axial clearance
CAUTION!
Bearing shells must be reinstalled in their

original location and orientation. Always label
the bearing shells according to their installed
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position before removing. Never interchange
used bearing shells.
- Attach dial indicator together with VW387 dial indicator holder to oil
pump and set indicator against crankshaft counterweight.
- Press crankshaft against dial indicator by hand and set indicator to
zero.
- Press crankshaft away from dial indicator.
- Read gauge.
Clearance when new Wear limit

0.07-0.23 mm (0.0028-0.0091 in.) 0.25 mm (0.0098 in.)
13-26
Radial clearance
- Measure radial clearance using Plastigage .
- Read clearance.

0.018-0.045 mm (0.0007- 0.10 mm (0.0039
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0.0018 in.) in.)
CAUTION!
DO NOT turn the crankshaft or allow it to

rotate while measuring with Plastigage in
place.
13-27
Crankshaft bearing cap, installing
Bearing -1- is installed on the oil pump side of the cylinder block, and
bearing -4- on the dual-mass flywheel side of the cylinder block.
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13-28
Crankshaft dimensions
Engine codes AHA, ATQ
Reconditioning dimension Crankshaft journal diameter mm (in.) Connecting rod journal diameter mm (in.)
maximum size (from nominal) -0.022 (0.00087) -0.022 (0.00087)
Standard (nominal dimension) 65.00 (2.559) 54.00 (2.126)
minimum size (from nominal) -0.042 (0.00165) -0.042 (0.00165)
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1st undersize (nominal dimension) 64.75 (2.549) 53.75 (2.116)
2nd undersize (nominal dimension) 64.50 (2.539) 53.50 (2.106)
3rd undersize (nominal dimension) 64.25 (2.530) 53.25 (2.096)
13-29
Pistons and piston rings
Pistons
Installation position: arrow on piston crown must point in driving direction.
- Mark cylinder number on piston crown using waterproof felt pen.
CAUTION!
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DO NOT scratch or scribe on piston crown. The surface has a
coating that must not be damaged.
Checking piston diameter
- Measure pistons approx. 10 mm (3/8 in.) from bottom edge at right

angle (90 ) to piston pin.
Deviation from nominal size: 0.04 mm (0.0016 in.).
13-30
Piston and cylinder bore dimensions
Reconditioning Piston diameter

dimension
Basic dimension 82.48 mm (3.247
in.)
1st oversize 82.74 mm (3.257
in.)
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Checking piston ring side clearance

0.02-0.08 mm (0.0008-0.0031 in.) 0.10 mm (0.004 in.)
13-31
Checking piston ring end gap
- Insert ring at right angle from top and slide down into lower cylinder
opening until approx. 15 mm from lower edge of cylinder.
Piston ring End gap, new mm. (in.) Wear limit mm.
(in.)
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1 0.35-0.50 mm (0.014-0.020 1.0 mm (0.039 in.)
(compression) in.)
2 0.50-0.70 mm (0.020-0.028 1.4 mm (0.043 in.)
(compression) in.)
3 (oil scraper) 0.25-0.50 mm (0.010-0.020 0.8 mm (0.031 in.)
in.)
13-32
Cylinder bore, checking
- Measure at three locations diagonally in crosswise direction -A- and

lengthwise direction -B-.
Inner bore gauge: 50-100 mm (1.96-3.94 in.)
Deviation from nominal size: max. 0.08mm (0.0031 in.)
Piston and cylinder bore dimensions
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Reconditioning Piston diameter Cylinder bore

dimension diameter
Basic dimension 82.48 mm (3.2472 82.51 mm (3.2484
in.) in.)
1st oversize 82.74 mm (3.2575 82.76 mm (3.2578
in.) in.)
Note:
Replacement pistons are only available in the basic dimension.
CAUTION!
DO NOT measure cylinder bore dimensions while the cylinder block

is mounted on the engine stand. The cylinder block is stressed and
deformed by its own weight under these conditions and the
measurements will not be accurate.
13-33
Connecting rod and connecting rod

bearings, checking clearance
Notes:
Replace the connecting rods only as a set.
Do not interchange connecting rod bearings.
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- Mark connecting rod bearing caps with light center punch marks before
removing.
Checking radial clearance
- Remove connecting rod bearing caps. Clean bearing shells and

journals.
- Place Plastigage over entire width of bearing journal or bearing cap.
- Install connecting rod bearing cap and tighten to 20 Nm (15 ft lb).
CAUTION!
DO NOT turn the crankshaft or allow it to rotate while measuring with

Plastigage in place.
- Remove connecting rod bearing cap again.

- Compare width of Plastigage with calibrated scale.
13-34

0.015-0.062 mm (0.0006- 0.12 mm (0.0047
0.0024 in.) in.)
- Always replace connecting rod bolts.
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Valve gear, servicing Page 1 of 62
15-1
Valve gear, servicing

WARNING!
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
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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.
CAUTION!
After installing new hydraulic valve lifters the

engine must not be started for about 30
minutes (otherwise the valves will strike the
pistons). Turn the crankshaft two complete
revolutions by hand before starting.
15-2
Notes:
Cylinder heads with small cracks between the

valve seats that are less than 0.3 mm (0.012
in.) wide and/or between one valve seat and
only the first four threads of the spark plug
thread, can continue to be used without
reduced service life.
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Carefully apply a small amount of sealant D 454
300 A2 at the four end points of the sealing
surfaces on the cylinder head using a small
screwdriver page 15-13 .
CAUTION!
Part numbers are listed here for reference

only. Always check with your Parts
department for the latest information.
15-3
Cylinder head without oil lines to camshaft

bearings
1 - Double bearing cap

Lightly coat with sealant 454 300 02 A2
before installing page 15-36
2 - Bolt
10 Nm (7ft lb)
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3 - Exhaust camshaft bearing cap
Watch guide sleeve
Note installation position and numbering
page 15-36
Lightly coat last bearing cap (after chain)
with D454 300 A2 sealant before installing
4 - Exhaust camshaft
Checking axial clearance page 15-42
Check radial clearance using Plastigage
(hydraulic valve lifters removed):
Wear limit: 0.1 mm (0.004 in.)
Max. run-out: 0.01 mm (0.0004 in.)
15-4
5 - Cap
Always replace
6 - Intake camshaft bearing cap
page 15-36
7 - Intake camshaft
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Max. run-out: 0.01 mm (0.0004 in.)
8 - Drive chain
Installing page 15-36
9 - Bolt
10 Nm (7ft lb)
10 - Mechanical camshaft adjuster
With valve -1- for camshaft adjustment -
N205-
Secure using 3366 bracket tensioner
before removing page 15-31
15-5
11 - Hydraulic valve lifter (intake)

Notes page 15-45
12 - Valve keepers
13 - Valve spring retainer
14 - Valve spring
15 - Valve stem oil seal
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Replacing with cylinder head installed
page 15-47
16 - Rubber/metal seal
Always replace
17 - Seal
Always replace
18 - Cylinder head
Checking for distortion page 15-27
Resurfacing page 15-28
19 - Exhaust valve
20 - Intake valve
21 - Oil seal
Camshaft Position (CMP) sensor side
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15-6
22 - Shutter wheel for Camshaft Position

(CMP) sensor -G40-
Note position (notch on camshaft)
23 - Washer
Conical
24 - Bolt
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25 Nm (18 ft lb)
25 - Camshaft Position (CMP) sensor -G40-
26 - Bolt
10 Nm (7 ft lb)
27 - Bolt
55 Nm (41 ft lb)
28 - Camshaft sprocket
29 - Oil seal
Toothed belt side
30 - Hydraulic valve lifter
Notes page 15-45
Removing and installing with cylinder head
installed page 15-31
15-7
Cylinder head with oil lines to camshaft

bearings
1 - Double bearing cap

Lightly coat with 454 300 02 A2 sealant
before installing page 15-17
2 - Exhaust camshaft bearing cap
With oil line connector
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Watch guide sleeve
page15-31
Lightly coat last bearing cap (after chain)
with D454 300 A2 sealant before installing
3 - Bolt
10 Nm (7 ft lb)
4 - Oil line
Exhaust side
From VIN 8D-W-005 001
For bearing cap lubrication
Note installed position Fig. 4
15-8
5 - Exhaust camshaft
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Max. run-out: 0.01 mm (0.0004 in.)
6 - Cap
Always replace
7 - Oil line
Intake side
From VIN 8D-W-005 001
Note installed position Fig. 3
For bearing cap lubrication
8 - Intake camshaft bearing cap
With oil line connector
page 15-36
15-9
9 - Intake camshaft
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Max. run-out: 0.01 mm (0.0004 in.)
10 - Drive chain
Installing page 15-36
11 - Bolt
10 Nm (7ft lb)
12 - Mechanical camshaft adjuster
With valve -1- for camshaft adjustment -
N205-
Secure using 3366 bracket tensioner
before removing page 15-31
13 - Hydraulic valve lifter (intake)
Refer to notes page 15-45
Removing and installing with cylinder head
installed page15-31
14 - Valve keepers
15-10
15 - Valve spring retainer

16 - Valve spring
17 - Valve stem oil seal
Replacing with cylinder head installed
page 15-47
18 - Rubber/metal seal
Always replace
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19 - Seal
Always replace
20 - Cylinder head
Checking for distortion page 15-27
Resurfacing page 15-28
21 - Exhaust valve
22 - Intake valve
23 - Oil seal
Camshaft Position (CMP) sensor side
15-11
24 - Shutter wheel for Camshaft Position

(CMP) sensor -G40-
Note position (notch on camshaft)
25 - Washer
Conical
26 - Bolt
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25 Nm (18 ft lb)
27 - Camshaft Position (CMP) sensor -G40-
28 - Bolt
10 Nm (7 ft lb)
29 - Bolt
55 Nm (41 ft lb)
30 - Camshaft sprocket
31 - Oil seal
Toothed gear side
15-12
Cylinder head with oil lines on the camshaft

bearings
Fig. 3 Installation position of intake camshaft oil line
If connectors are misaligned, oil line bores are exposed (arrows).
- To install correctly, turn oil line 180 and slide connectors over bores.
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Fig. 4 Installation position of exhaust camshaft oil line
If connectors are misaligned, oil line bores are exposed (arrows).
- To install correctly, turn oil line 180 and slide connectors over bores.
CAUTION!
If the oil lines are incorrectly installed, the camshaft bearings will not
be lubricated and the cylinder head will have to be replaced.
15-13
All models
Sealing contact surfaces between bearing cap and cylinder head
- Carefully apply small amount of sealant D 454 300 A2 at four end

points of sealing surfaces on cylinder head (arrows) using small
screwdriver.
CAUTION!
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Part numbers are listed here for reference only. Always check with
your Parts department for the latest information.
15-14
Cylinder head oil seals, replacing
Oil seal for camshaft drive (left and right

cylinder heads)
- Rotate engine to Top Dead Center (TDC).
- Remove toothed belt page 13-12 .
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- Remove rear toothed belt guard.
- Remove seal using 3240 seal extractor.

- Clean contact surface and sealing surface.
Note:
Do not apply oil to sealing lip or outer circumference of seal.
- Install 3241/2 pull sleeve from 3241/1 press sleeve onto camshaft.
- Press seal flush into cylinder head using 3241/1 press sleeve and
3241/3 bolt.
15-15
Oil seal on Camshaft Position (CMP) sensor

(left and right cylinder head)
- Unbolt Camshaft Position (CMP) sensor.
Tightening torque: 10 Nm (7 ft lb)
- Unbolt shutter wheel for Camshaft Position
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(CMP) sensor and carefully pry out using
screwdriver.
- Screw in bolt from 2085/1 adapter.
- Remove seal using 2085 seal puller and bolt from 2085/1.
- Clean contact surface and sealing surface.
Do not lubricate sealing lip or outer edge of seal before pressing in.
- Install pull sleeve from 3241 seal installer onto camshaft.
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15-16
- Press seal flush using 3241/1 press sleeve and 3241/3 bolt.
Rear sealing flange (left cylinder head)
The sealing flange and rear oil seal on the left cylinder head must be
replaced together as follows:
- Unbolt engine coolant expansion tank from bracket.

- Remove crankshaft ventilation line from cylinder head cover.
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- Unbolt Camshaft Position (CMP) sensor.
- Unbolt shutter wheel for Camshaft Position (CMP) sensor G40 and
carefully pry out using screwdriver.
- Remove cylinder head cover.
- Remove double bearing cap (arrows).

- Remove seal and sealing flange.
- Clean running and sealing surfaces as well as contact surface of
double bearing cap.
15-17
- Apply thin coat of sealant 454 300 A2 to hatched areas on double

bearing cap, install and tighten to 10 Nm (7 ft lb).
- Install pull sleeve from 3241 seal installer onto camshaft.
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- Press seal flush using 3241/1 press sleeve and 3241/3 bolt.
- Carefully drive in sealing flange to stop using 3202 retractor and plastic
hammer.
15-18
Cylinder head, removing and installing
Note:
The following instructions apply to the left

cylinder head.
Removing
Lock carrier in service position page 13-
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1.
- Remove ribbed belt page 13-8 .

- Unbolt left and right-side front exhaust pipes from exhaust manifold.
- Unbolt exhaust system from transmission bracket.
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15-19
- Place VAG1306 drip tray beneath engine.
- Open engine coolant expansion tank cap.
WARNING!
The cooling system is pressurized when the

engine is warm. When opening the expansion
tank, wear gloves and other appropriate
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protection, cover the cap with a cloth and
open carefully to relieve system pressure
slowly.
- With bumper removed, open coolant drain plug (arrow) on lower left of
radiator by turning it counterclockwise. If necessary, attach accessory
hose to connection.
- With bumper installed, pull off retaining clamp for lower right radiator
hose (from radiator to engine) and disconnect radiator hose from
radiator.
- Using 3247 hex ball socket, open coolant drain plug on engine (arrow)
as well.
- Unbolt engine coolant expansion tank from bracket and lay aside
(remove if necessary).
- Disconnect crankshaft housing ventilation line from cylinder head
cover.
- Remove intake air duct between Mass Air Flow (MAF) sensor and
intake air elbow.
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15-20
- Disconnect blue harness connector on Intake Manifold Tuning (IMT)

valve.
- Disconnect black harness connector for intake air temperature sensor
on resonator.
- Cut tie wraps and move wiring to side.
- Disconnect vacuum line at cruise control vacuum diaphragm and at
vacuum booster.
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- Unbolt cruise control vacuum diaphragm and unhook cruise control
vacuum diaphragm linkage at throttle body.
- Disconnect harness connector on throttle body and vacuum lines on
fuel pressure regulator.
- Disconnect harness connectors from camshaft adjustment valve and

from fuel injectors (arrows).
- Disconnect harness connectors from Engine Coolant Temperature
(ECT) sensor and Camshaft Position (CMP) sensor (arrows).
- Cut tie wraps on valve cover.
- Unclip wiring retainer on fuel rail and disconnect crankshaft housing
ventilation lines from left and right-side valve covers. Move hoses and
wiring clear (to rear).
15-21
- Disconnect harness connector for tank diagnostic system in engine

compartment at arrow.
- Remove 4 bolts for fuel rail on intake manifold.
- Unclip fuel supply and return lines from retainer.
- Move fuel rail together with fuel injectors aside. Cover fuel injectors
with clean cloth.
- Install 3391 camshaft locator bar onto camshaft locking plates.
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- Loosen both bolts for camshafts and back out bolts approx. 5 turns.
- Remove camshaft gear using T40001 special tool.

- Disconnect left-side spark plug connectors.
- Unbolt bracket for ignition coils (4 bolts) and move to right side together
with ignition coils.
- Unhook accelerator pedal cable and pull up out of retaining bracket.
15-22
- Disconnect vacuum line at throttle body and line between vacuum

booster and intake air elbow (arrows).
- Remove intake air elbow.
- Remove intake manifold.
- Disconnect heated oxygen sensor harness connector at left-side of
heater core and set aside.
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- Remove left-rear toothed belt guard (arrows).
- Unbolt coolant hose at rear of cylinder head.
15-23
- Unbolt coolant hose at front of cylinder head (arrows).

- Using 3452 polydrive special tool, loosen cylinder head bolts in reverse
order of tightening sequence and remove.
- Carefully lift off cylinder head.
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- When removing and installing, use 3452 polydrive together with
normal commercial 10 mm socket.
15-24
Installing
Notes:
Bolt holes in engine block for cylinder head

bolts must be free of oil and coolant.
Always replace cylinder head bolts.
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Vacuum line connections page 10-23
When installing a new cylinder head:
- Install centering pin for intake manifold.
- Replacement cylinder head may be used to

replace left or right cylinder head. Install sealing
cap at appropriate front end of replacement
cylinder head.
- Coat lip of sealing cap with sealant AMV 188

001 02.
- Using VW295 needle bearing drift press in sealing cap until lip of cap
seals with chamfer end of cylinder head.
- Before installing cylinder head, set crankshaft and camshafts to TDC
for cylinder 3.
- Install cylinder head gasket onto guide sleeves. Marking "oben" or Part
No. must face toward cylinder head.
- Install cylinder head, install cylinder head bolts and tighten hand-tight.
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15-25
- Tighten cylinder head bolts in two stages in sequence shown, as

follows:
Stage 1: 60 Nm (44 ft lb)
Stage 2: additional 1/2 turn (180 ) using rigid wrench (in two 1/4 turns
(90 ) if necessary).
It is not necessary to re-torque cylinder head bolts again after repairs

have been completed.
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Sealing contact surfaces between bearing cap and cylinder head.
- Carefully apply small amount of sealant D 454 300 A2 at four end

points of sealing surfaces on cylinder head using small screwdriver.
15-26
Tightening torques
Component Tightening
torque
Bolts M6 10 Nm (7 ft lb)
Bolts M8 20 Nm (15 ft lb)
Camshaft bearing cap and 10 Nm (7 ft lb)
camshaft adjuster
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Exhaust manifold to cylinder 25 Nm (18 ft lb)
head
Front exhaust pipe to exhaust 25 Nm (18 ft lb)
manifold
Heated Oxygen Sensor 50 Nm (37 ft lb)
(HO2S)
Spark plugs 25 Nm (18 ft lb)
Toothed belt sprocket to 55 Nm (41 ft lb)
camshaft
Intake manifold to cylinder 10 Nm (7 ft lb)
head
Cylinder head cover 10 Nm (7 ft lb)
15-27
Cylinder head, checking for distortion
- Measure at several points using straight-edge.

Maximum permissible distortion: 0.1 mm (0.004 in.)
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15-28
Cylinder head, resurfacing
Resurfacing of the cylinder head is only permissable up to minimum

dimension -a-.
Dimension -a-: 139.25 mm (5.4823 in.).
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15-29
Compression, checking
Test conditions
Engine oil temperature at least 30 C
Battery fully charged
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- Disconnect harness connectors from all 6 fuel
injectors.
- Disconnect 5-pin harness connector from power

output stage of ignition coils.
- Open throttle fully.
- Use VAG1381 or VAG1763 compression tester

to check compression.
- Operate starter until no further pressure

increases are indicated by VAG1381 or
VAG1763 compression tester.
Compression pressure
New Wear Max. permissable

limit difference between
cylinders
9-14 bar 7.5 bar 3 bar (44 psi)

(131-203 (109 psi)
psi)
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15-30
Sealing cap (core plug) in cylinder head,

installing
Cylinder heads supplied as replacement parts

can be used on either the left or right-sides of the
engine. A sealing cap (core plug) must be
installed in the front end of the cylinder head in
each case.
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- Coat outside circumference of sealing cap (core
plug) with sealant AMV 188 001 02.
CAUTION!
Part numbers are listed here for reference

only. Always check with your Parts
department for the latest information.
- Using VW295 needle bearing drift, drive in sealing cap (core plug) until
outside rim is flush with end of chamfer in cylinder head (see inset).
15-31
Camshafts and camshaft adjusters,

Removing

Cylinder head installed
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Left-side cylinder head
- Unbolt engine coolant expansion tank from bracket and lay aside.
- Remove crankshaft housing ventilation line from valve cover.
15-32
Right-side cylinder head
intake air elbow.
- Disconnect EVAP canister purge regulator valve and remove valve
from retainer.
- Disconnect harness connector for mass air flow sensor.
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- Turn connection pipe for secondary air injection pump on air cleaner
45 in clockwise direction and pull forward off air cleaner.
- Unbolt air cleaner and remove.
15-33
All models
- Remove Camshaft Position (CMP) sensor

housing and shutter wheel.
- Unbolt shutter wheel for Camshaft Position

(CMP) sensor -G40- and carefully pry out using
screwdriver.
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Tightening torque: 20Nm (15 ft lb)
- Install 3391 camshaft locator bar into camshaft

locking plates.
- Loosen both bolts for camshafts and back out

bolts approx. 5 turns.
- Remove both camshaft sprockets using T40001 special tool.

- Using screwdriver, carefully lift out oil lines for camshaft bearing
lubrication from camshaft bearings.
When lifting out oil lines, be careful not to damage positioning clips.
15-34
- Secure camshaft adjuster with 3366 bracket tensioner.
Note:
If the bracket tensioner is tightened too far, the camshaft adjuster may be
damaged.
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- Verify that camshafts are at TDC.
Both camshaft markings must align with arrows on bearing caps.
- Clean camshaft drive chain and camshaft chain gears opposite both
arrows on bearing caps. Mark installed position with paint.
15-35
The distance between the two arrows/paint marks is equivalent to 16 drive

chain rollers.
The notch on the exhaust camshaft is slightly offset inward toward chain
roller -1-.
Note:
Do not mark chain using punch, filing a notch or similar.
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- Remove camshaft adjuster retaining bolts.
- Remove bearing caps -1-,-3-,-5- and -7- and lay on a clean surface in
correct order.
- Alternating in diagonal sequence, loosen bearing caps -2- and -4- of
intake and exhaust camshafts and remove.
- Remove both camshafts together with camshaft adjuster.
15-36
Installing
- Replace rubber/metal camshaft adjuster gasket and spread thin layer

of sealant D 454 300 A2 on hatched surface.
- Install drive chain on camshaft chain gear as follows:
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- When installing the old drive chain, line up paint markings (arrows).
15-37
If a new drive chain is installed, distance between notches -A- and -B- on
camshafts must equal the distance between 16 drive chain rollers.
Illustration shows where first and sixteenth drive chain rollers must be
installed on chain gears.
Note:
Notch -A- is slightly offset inward toward drive chain roller -1-.
- Slide in camshaft adjuster between drive chain (second technician
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required).
- Install camshafts with drive chain and camshaft adjuster into cylinder
head.
- Oil camshaft journal surface.
Notes:
Alignment bushings for bearing caps and camshaft adjuster must be
installed in cylinder head.
When installing bearing caps, verify marking on cap is readable from
intake side of cylinder head.
- Tighten camshaft adjuster (pay attention to alignment bushings).
- Tighten bearing caps -2- and -4- in alternating diagonal sequence (pay
attention to alignment bushings).
- Install both bearing caps on chain sprockets of intake and exhaust
camshafts.
15-38
- Verify correct position of both camshafts.
Both camshaft markings must align with arrows on bearing caps

(arrows).
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The distance between the two arrows/paint markings is equivalent to 16
drive chain rollers.
Note:
The notch on exhaust camshaft is slightly offset inward toward drive chain
roller -1-.
15-39
- Lightly coat hatched surface of double bearing cap -1- and bearing cap
-7-...
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- ...with sealant D 454 300 A2 and install bearing cap (pay attention to
alignment bushings).
- Install the other bearing caps (pay attention to alignment bushings).
- Replace oil lines for camshaft bearing lubrication and install.
- Replace oil seal for intake and exhaust camshafts page 15-14 .
- Remove 3366 bracket tensioner.
15-40
CAUTION!
After installing new hydraulic lifters, the

engine must not be started for approx. 30
minutes. The hydraulic valve lifters have to
settle (otherwise valves will strike the
pistons).
After installing the valvetrain and lifters,
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carefully rotate the crankshaft by hand at
least 2 full revolutions before starting to be
sure that valves do not strike the pistons.
Sealing contact surfaces between bearing cap and cylinder head.
- Carefully apply a small amount of sealant D 454 300 A2 at four end

points of sealing surfaces on cylinder head (arrows) using small screw
driver.
- Install cylinder head cover.
- Install toothed belt page 13-15 .
15-41
Tightening torques
torque
Bolts M6 10 Nm (7 ft
lb)
M8 20 Nm (15 ft
lb)
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Except for the following:
Bearing cap to cylinder 10 Nm (7 ft
head lb)
Camshaft adjuster to cylinder 10 Nm (7 ft
head lb)
Shutter wheel for Camshaft 25 Nm (18 ft
Position (CMP) sensor -G40- to lb)
camshaft
Housing for Camshaft Position 10 Nm (7 ft
(CMP) sensor -G40- to cylinder lb)
head
Camshaft gear to 55 Nm (41 ft
camshaft lb)
Camshaft bearing cap and 10 Nm (7 ft
camshaft adjuster lb)
Cylinder head cover 10 Nm (7 ft
lb)
15-42
Camshaft axial play, checking
- Remove camshafts page 15-31 .
- Remove hydraulic valve lifters.
- Install camshafts without chain into cylinder

head and tighten with bearing caps 2 and 4.
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- Secure VW387 dial indicator holder with dial indicator to cylinder head.
- Press camshaft by hand against dial indicator.
- Set dial indicator to zero.
- Press crankshaft away from dial indicator.
- Read clearance.
New Wear limit

0.05-0.15 mm (0.0020-0.0059 in.) 0.20 mm (0.0079 in.)
15-43
Valve dimensions
WARNING!
Valves must not be refaced by cutting or grinding.

Only hand lapping is permitted.
Dimension Intake valve Exhaust valve

Diameter -a- 26.8 - 27.0 mm 29.8 - 30.0 mm
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(1.055 - 1.063 in.) (1.173 - 1.181 in.)
Diameter -b- 5.96 - 5.97 mm 5.94 - 5.95 mm
(.2346 - .2350 in.) (.2338 - .2342 in.)

Length -c- 104.84 - 105.34 mm 103.64 - 104.14 mm
(4.1275 - 4.1472 in.) (4.0803 - 4.0999 in.)

Angle -a- 45 45
15-44
WARNING!
Sodium-filled exhaust valves must not be

scrapped without first being properly treated.
The valves must be cut open using a

hacksaw, by hand, between the valve head
and the middle of the stem.
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The valves must not come into any contact
with water while being cut.
After cutting open the valves, throw not more

than 10 at a time into a bucket of water and
step back. A sudden chemical reaction will
occur during which the sodium filling is
consumed.
Valves that have been treated in this way can

be disposed of as normal waste.
15-45
Hydraulic valve lifters, checking
CAUTION!
After installing new hydraulic valve lifters the

engine must not be started for about 30
minutes. The hydraulic valve lifters must
settle (otherwise valves will strike pistons).
Then turn crankshaft two full revolutions by
hand before starting.
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Notes:
Only replace hydraulic valve lifters in complete

sets. Hydraulic valve lifters cannot be adjusted
or repaired.
Irregular valve noise when starting engine is

normal.
- Start engine and let run until coolant

temperature reaches at least 80 C.
- Increase RPM to 2500 for about 2 minutes. If

necessary, test drive vehicle.
If hydraulic valve lifters are still loud, locate faulty

valve lifter as follows:
- Rotate crankshaft clockwise by turning mounting

bolt for toothed belt sprocket until lobes on
camshaft of hydraulic valve lifters to be checked
are pointing upward.
- Measure clearance between cam and valve

lifter.
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15-46
- Push down on valve lifters using wood or plastic wedge. If 0.20 mm

(0.008 in.) feeler gauge can be inserted between camshaft and valve
lifter, replace valve lifter.
Note:
If irregular valve noise occurs repeatedly during short journeys and

disappears after extended driving, the oil check valves must be replaced
page 17-9 .
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15-47
Valve stem oil seals, replacing
Cylinder head installed
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- Remove camshafts page 15-31 .
- Remove valve lifters (do not interchange) and

lay aside with contact surface facing down.
- Remove spark plugs.
- Move piston for individual cylinder to Bottom

Dead Center (BDC) position.
Note:
Lightly tap valve lever to loosen stuck valve

keepers.
Exhaust side
Note:
Before attaching the adjustable rod, remove the

two studs in the center of the cylinder head and
the three upper studs (intake side) for mounting
the cylinder head cover.
- Install VW653/3 pressure hose together with

seal hand tight into spark plug hole of relevant
cylinder and apply constant pressure (at least 6
bar).
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15-48
- Attach 2036 adjustable rod (as shown in figure) using M6 x 40 bolts

with large washers.
- Remove valve spring using VW541/1 lever and VW541/5 valve spring
tensioner.
- Remove valve spring and valve spring plate.
- Remove valve stem oil seal using 3047A slide hammer.
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- Place plastic sleeve -A- on valve stem to prevent damage to new valve
stem oil seals.
- Lightly lubricate sealing lip with oil.
- Insert valve stem oil seal -B- (without oiling outside of seal) into 3129
seal driver and carefully slide onto valve guide.
- When installing new valve, lightly oil valve stem before installing.
15-49
Intake side
Note:
The intake valves are installed in the cylinder

head at different angles.
3362 valve spring tool can be used in two different positions:
1 - Upper position for center valve
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2 - Lower position for two outer valves
3 - Threaded holes on each side to take M6 x 25 bolts for mounting valve
spring tool to cylinder head.
- Attach 3362 valve spring tool to cylinder head using two bolts supplied
(as shown in figure).
- Screw VW653/3 pressure hose together with seal hand tight into spark
plug hole of relevant cylinder and apply constant pressure (at least 6
bar).
- Set position of valve spring tool for relevant valve and remove valve
spring using threaded spindle.
15-50
- Remove valve stem oil seal using 3364 valve seat tool.
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- Place plastic sleeve -A- on valve stem to prevent damage to new valve
stem oil seals.
- Lightly lubricate sealing lip with oil.
- Insert valve stem oil seal -B- (without oiling outside of seal) into 3365
seal driver and carefully slide onto valve guide.
- When installing new valve, lightly oil valve stem before installing.
15-51
Valves, refacing
WARNING!
Valves must not be refaced by cutting or

grinding.
Only hand lapping is permitted.
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Observe the WARNING regarding proper
disposal of sodium-filled exhaust valves
page 15-44 .
15-52
Valve guides, checking
When servicing engines or cylinder heads with

leaking valves, refacing or replacing valve seats
and valves is not sufficient. Valve guides must be
checked for wear. This is especially important for
engines with high mileage.
- Insert valve into guide.
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Valve shaft edge must seal with guide. Due to differences in valve stem
diameter, make sure only intake valves are used to check intake
guides, and only exhaust valves are used to check exhaust guides.
- Measure axial play.
Wear limit
Intake valve guide Exhaust valve guide

0.8 mm (0.031 in.) 0.8 mm (0.031 in.)
- If wear limit is exceeded, replace cylinder head.
15-53
Valve seats, refacing
Notes:
Only reface valve seats enough until a perfect

contact pattern is obtained.
Before refacing, calculate the maximum

refacing dimension.
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If refaced dimension is exceeded, hydraulic
valve lifter function is no longer guaranteed and
cylinder head must be replaced.
Calculating maximum allowable refacing

dimension
- Insert valve and press firmly against valve

seat.
Note:
If valve is replaced during repair, use a new

valve for measurement.
- Measure distance between end of valve stem and top surface of

cylinder head (four-valve head shown).
- Calculate maximum allowable refacing dimension using distance
measured and minimum dimension.
15-54
Minimum dimensions
Outer intake Center intake Exhaust valve
valve valve
32.2 mm 33.2 mm 33.0 mm (1.299
(1.268 in.) (1.307 in.) in.)
The measured distance minus the minimum

dimension equals the maximum permissible
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refacing dimension.
Example
Outer intake valve
Measured distance 33.0 mm (1.299
in.)
Minimum dimension - 32.2 mm (1.268
in.)
Maximum permissible refacing = 0.8 mm (0.031
dimension in.)
Note:
If the measured distance is less than the

minimum dimension, repeat the measurement
with new valves, or replace the cylinder head.
Lubrication system components, removing and installing Page 1 of 34
17-1
Lubrication system
components, removing and
installing
WARNING!

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again. 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.
CAUTION!
If large quantities of metal particles or other

deposits (caused, i.e. by partial seizure of the
crankshaft or connecting rod bearings) are
found in engine oil, thoroughly clean oil
passages and replace oil cooler to prevent
damage from re-occuring.
Do not overfill with oil past the MAX mark on

the oil dipstick. Damage to the Three Way
Catalytic Converter (TWC) could result.
Checking oil level page 17-32 .
Notes:
Always replace seals and gaskets.
Viscosity classes and oil specifications page

17-31 .
Checking oil pressure page 17-30 .
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17-2
Oil pump, cylinder block breather and oil

spray jets, removing and installing
Oil pan (upper part) and oil pan (lower part),

removing and installing page 17-10 .
1 - Bolt
20 Nm (15 ft lb)
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2 - Washer
3 - Tensioner roller
For toothed belt
4 - Bolt
45 Nm (33 ft lb)
5 - Bolt
10 Nm (7 ft lb)
For toothed belt
6 - Bolt
10 Nm (7 ft lb)
7 - Bolt
10 Nm (7 ft lb)
17-3
8 - Breather housing
9 - Gasket/breather plate
Always replace
10 - Oil check valve
25 Nm (18 ft lb)
11 - Oil seal
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12 - Connector
13 - Bolt
15 Nm (11 ft lb)
14 - 15 Nm
For oil spray jets for piston cooling
15 - Cylinder block
16 - Bolt
10 Nm (7 ft lb)
Use locking fluid D 000 600 A2 when
installing
17 - Oil spray jet
For piston cooling
18 - Gasket
Metal gasket
Always replace
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17-4
19 - Engine oil temperature sensor -G8-

10 Nm (7 ft lb)
For oil temperature gauge
White
If seal is leaking, replace seal
20 - Oil seal
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21 - Tensioner
Compress and secure before removing
page 13-12
22 - 10 Nm
Use locking fluid D 000 600 A2 when
installing
23 - Washer
24 - Bearing bushing
For tensioner lever
25 - Washer
26 - Bolt
25 Nm (18 ft lb)
27 - Tensioning lever
28 - Bearing bushing
For tensioner roller
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17-5
Oil pump, oil pan, oil filter, oil cooler,

1 - Bolt for dipstick tube

25 Nm (18 ft lb)
2 - Dipstick tube
Replace O-ring
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3 - Oil pan (upper part)
No gasket is installed between engine
block and oil pan (upper part)
Only use silicon sealant D 454 300 A2
4 - Bolt
M8
20 Nm (15 ft lb)
5 - Bolt
M6
15 Nm (11 ft lb)
6 - Bolt
M8
20 Nm (15 ft lb)
Bolt is next to coolant drain plug
17-6
7 - Bolt
M6
10 Nm (7 ft lb)
8 - O-ring
Always replace
9 - Gasket for oil pan (lower part)
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Sealing surfaces clean and dry
10 - Oil drain plug
30 Nm (22 ft lb)
11 - Gasket for oil drain plug
Always replace
12 - Bolt
M6
10 Nm (7 ft lb)
13 - Oil pan (lower part)
14 - Bolt
M6
10 Nm (7 ft lb)
15 - Bracket for oil lines
16 - Oil supply line
From pump to oil filter

17 - Oil supply line
From oil filter to engine oil circulation
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17-7
18 - O-ring
Always replace
19 - O-ring
Always replace
20 - Oil filter
21 - Hex nut
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30 Nm (22 ft lb)
Threaded pipe for oil cooler and oil filter
installed in oil pan (upper part) and
tightened to 20 Nm (15 ft lb)
22 - Oil cooler
When installing, make sure O-ring is
seated correctly
23 - Oil pump
Disassembling and assembling Fig. 1
Driven by chain from crankshaft
Tightening torque (chain sprocket to oil
pump): 25 Nm (18 ft lb)
Tightening torque (oil pump to engine
block): 25 Nm (18 ft lb)
17-8
Fig. 1 Removing and installing oil pump

1 - Oil pump
Cannot be disassembled (oil pressure release valve is integrated
with oil pump)
2 - Pressure regulation valve
3 - Tightening torque: 20 Nm (15 ft lb)
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4 - Tightening torque: 25 Nm (18 ft lb)
5 - Chain sprocket
When installing, make sure shaft fits chain sprocket
17-9
Oil check valve, replacing
Note:
If irregular valve noise occurs repeatedly during

short periods of driving and disappears after
extended periods of driving, the oil check valves
must be replaced.
- Remove intake manifold.
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- Remover cover under intake manifold.
- Replace oil check valves -1-.

Note:
The opening also contains distribution line -2- for supplying jets for piston
cooling.
17-10
Oil pan (upper part) and oil pan (lower

part), removing and installing
Special tools and equipment
Drill with plastic brush attachment
Sealant D 454 300 A2
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Torque wrench 10 Nm - 45 Nm
- Switch ignition off and disconnect battery

Ground (GND) strap.
CAUTION!
Before disconnecting the battery, determine

the correct coding for the anti-theft radio.
- Withdraw dipstick.
- Unbolt dipstick tube at right-front of cylinder

head, pull up and remove.
17-11
- Open engine coolant expansion tank cap.
- Place VAG1306 drip tray beneath engine.
- Turn radiator drain plug counterclockwise (arrow). If needed, attach

tube to connection flange.
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- Open coolant pump bearing housing drain plug as well (arrow).
- Drain engine coolant.
- Drain engine oil.
Collect engine oil in appropriate receptacle.
Vehicles with automatic transmission
- Unbolt oil cooler line bracket from right-side of oil pan.
17-12
- Set 10-222A engine support bridge together with 10-222A/3 engine

support adapter on fender mounting edges.
- Attach 2024A engine sling to mounting eyes at front and rear of engine.
- Using 10-222A engine support bridge spindle, lift up engine as far as
possible.
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- Cut tie wraps (arrows), open bracket for starter wiring and remove
wiring.
- Remove torque support at front of engine.
- Unbolt coolant line at front of engine from oil pan.
- Disconnect harness connector from oil pressure switch on left-side of
oil pan.
- Disconnect coolant lines from oil cooler underneath oil filter.
17-13
- Remove left and right nuts from lower engine mount -1-.
- Mark installation positions for threaded assembly -1- and guide sleeves
-2- on left and right lower engine mounts.
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- First remove front bolts -2- and -3- from left and right-sides of
subframe. Then remove bolts -1-.
- Swing stabilizer down.
- Remove starter.
Note:
Only loosen or lower subframe at front to avoid avoid changing wheel

alignment.
17-14
- Remove oil pan (lower part) and oil pan (upper part).
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- Unbolt both oil supply lines. Pull longer of two lines down and off oil
pan (upper part).
17-15
- Unbolt oil pump from engine to allow removal of shorter oil supply line
(do not remove oil pump).
- Remove bolts between oil pan (upper part) and transmission.
- Unbolt oil pan (upper part) from engine.
Note:
Two M6 and two M8 bolts are installed vertically in rear of oil pan (upper
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part) in front of connection between engine and transmission.
17-16
Installing
Installation is the reverse of removal, noting the

following:
- Clean sealing surfaces so they are completely

free of any oil or grease.
WARNING!
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Wear protective glasses.
- Using rotating plastic brush, remove any remaining sealant from oil
pan.
Note:
After applying silicon sealant D 454 300 2, oil pan must be installed within
5 minutes.
- Cut tube jet at front marking (jet diameter approx. 3 mm).

Thickness of sealant: 2-3 mm (0.04-0.12 in.)
Note:
Sealant must not be thicker than 3 mm, otherwise excess sealant may get
into the oil pan and clog the oil intake strainer.
17-17
- Apply silicon sealant to clean sealing surface as shown in illustration.

(The illustration shows placement of sealant on cylinder block.)
Note:
Be especially careful when applying sealant to rear oil seal carrier (arrows
in illustration A17-0041).
- Immediately install oil pan and tighten all bolts between oil pan and
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engine block to 5 Nm (44 in. lb).
- Tighten bolts between oil pan and transmission to 45 Nm (33 ft lb).
- Tighten bolts between oil pan and engine block in 2 stages in diagonal
sequence.
Finally sequence tightening torque: 15 Nm (11 ft lb)
- Tighten M10 bolts between oil pan and cylinder block to 45 Nm (33 ft
lb).
- Clean both sealing surfaces on oil pan (lower part) so they are free of
oil and grease.
Note:
Do not use glue or sealant.
- Install new gasket on oil pan (lower part) and attach to oil pan (upper
part) with two bolts diagonal to each other.
- Tighten all bolts hand tight.
17-18
- Starting in center and moving toward outside,

tighten bolts to 10 Nm (7 ft lb).
- Install new seal on oil drain plug and tighten to

30 Nm (22 ft lb).
Notes:
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When installing oil pan on removed engine,
make sure oil pan is aligned with cylinder block
on flywheel side.
After installing oil pan, allow sealant to dry for

approx. 30 minutes. Only after allowing sealant
to dry may engine oil be added.
- Install subframe.
Repair Manual, Suspension, Wheels,

Steering, Repair Group 40
- Install lock carrier.
17-19
Oil pump, removing and installing

- Drain engine oil.
- Collect engine oil in appropriate receptacle.
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- Unbolt both stabilizer mounting brackets -2- from subframe.
- Lower stabilizer not more than 10 cm (3.94 in.) and secure using wire.
- Unbolt oil cooler line bracket from right-side of oil pan.
17-20
- Remove oil pan (lower part) page 17-10 .
Checking chain tensioner
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- Insert screwdriver between chain and chain tensioner and lift against
chain tensioner.
If no spring tension is evident and chain is not under tension, chain
tensioner is damaged and must be replaced.
- Before replacing chain tensioner, remove front oil seal carrier page
17-26 .
17-21
- Unbolt bracket for oil supply lines (arrows) and pull front oil supply line
(longer line) down and remove.
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- Using Torx T45, unbolt chain sprocket from oil pump and pull off oil
pump.
17-22
- Remove oil pump together with shorter oil supply line.
Installing
Installation is the reverse of removal, noting the following:
- Before installing oil pump, install short oil supply line together with O-
rings into pump and into oil pan (upper part).
- Clean both sealing surfaces on oil pan (lower part) so they are free of
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oil and grease.
Note:
Do not use glue or sealant.
- Install new gasket on oil pan (lower part) and attach to oil pan (upper
part) with two bolts diagonal to each other.
- Tighten all bolts hand tight.
- Starting in the center and moving toward the outside, tighten bolts to 10
Nm (7 ft lb).
- Install new seal on oil drain plug and tighten to 30 Nm (22 ft lb).
17-23
Tightening torques
torque
Oil pan to cylinder block M6 10 Nm (7 ft lb)
M8 20 Nm (15 ft
lb)
Oil pan (lower part) to oil M6 10 Nm (7 ft lb)
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pan (upper part)
Oil pan to transmission M8 25 Nm (18 ft
lb)
M10 45 Nm (33 ft
lb)
Coolant line to oil pan 10 Nm (7 ft lb)
Oil drain plug in oil pan 30 Nm (22 ft
(lower part) lb)
torque
Dipstick tube to cylinder M6 10 Nm (7 ft lb)
head
M8 25 Nm (18 ft
lb)
Oil pump to engine block 25 Nm (18 ft
lb)
Oil supply line for oil pump 10 Nm (7 ft lb)
to oil pan (upper part)

Oil seal carrier, front M6 10 Nm (7 ft lb)
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17-24

Collar screw M8 30 Nm (22 ft lb)
Stabilizer bracket to subframe 1) 25 Nm (18 ft lb)
Coolant drain plug to engine 20 Nm (15 ft lb)
Torque support stop to bracket on engine
25 Nm (18 ft lb)
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Engine mount to subframe 25 Nm (18 ft lb)
Torque support to front side of oil pan 25 Nm (18 ft lb)
Engine mount to engine support 25 Nm (18 ft lb)
Chain sprocket to oil pump 25 Nm (18 ft lb)
1) Replace all self-locking nuts after removal.
17-25
Other tightening torques

Nut for engine mount -1- 25 Nm (18 ft lb)
Bolts -2- and -3- 60 Nm (44 ft lb)
Combination bolt -4- 2) 110 Nm (81 ft lb) + 90
2) Replace combination bolt -4- after removing.
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17-26
Front oil seal carrier and oil pump chain,

Removing
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- Remove oil pan (upper part) and oil pan (lower
part) page 17-10 .
- Before removing front oil seal carrier, remove following components:

1 - Toothed belt tensioner roller
2 - Idler roller
3 - Toothed belt tensioner
4 - Toothed belt tensioner lever
5 - Crankshaft center bolt and toothed belt sprocket
17-27
- Remove front oil seal carrier and remove gasket from front oil seal
carrier (M6 bolts: 10 Nm, 7 ft lb) (Collar screw M8: 30 Nm 22 ft lb).
Replacing oil pump drive chain
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- Using Torx T45, unbolt chain sprocket from oil pump and pull off oil
pump.
17-28
- Remove oil pump together with shorter oil supply line.

- Remove oil pump chain sprocket and remove drive chain from
crankshaft page 17-26 .
Installing
- Remove any remaining sealant from front oil seal carrier and if
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necessary, from cylinder block.
- Clean sealing surfaces so they are completely free of any oil or grease.
Note:
Install gasket for front oil seal carrier dry.
- Tighten bolts for oil seal carrier.

Tightening torque: M6 - 10 Nm (7 ft lb), M8 - 20 Nm (15 ft lb)
Oil pan (upper part) and oil pan (lower part), removing page 17-10 .
17-29
Oil pump chain sprocket on crankshaft,

Removing
Front sealing flange and oil pump chain,

removing and installing page 17-26 .
- Using puller -2-, remove crankshaft chain sprocket, while protecting
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crankshaft end with appropriate washer -1-.
Installing
- Warm chain sprocket in 220 C (428 F) oven for approx. 15 minutes.
WARNING!
Wear protective gloves.
Note:
Installation position: wider collar of chain sprocket points toward engine.
- Using pliers, install chain sprocket on crankshaft end and slide onto
crankshaft to stop using 30-100 press tube. If necessary, carefully tap
with plastic hammer.
Lubrication system components, checking Page 1 of 3
17-30
Lubrication system
components, checking
Oil pressure and oil pressure switch,
checking
Note:
For the functional check and servicing of the

optical and acoustic oil pressure warning
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"Electrical Wiring Diagrams, Troubleshooting
&Component Locations".
Test sequence
- Remove oil pressure switch -F1- and install in tester.

- Install tester into oil pan in place of oil pressure switch.
- Connect brown wire of tester to Ground (GND).
- Using auxiliary cables from VW1594, connect VAG1527B voltage
tester to oil pressure switch and Battery (+).
- Start engine and slowly increase engine speed (RPM).
At 1.2-1.6 bar pressure LED must light up.
- If not, replace oil pressure switch.
- Increase engine speed (RPM) further.
- At 2000 rpm and an oil temperature of 80 C, oil pressure must be at
least 2.0 bar.
17-31
Engine oil
Engine oil capacity (w/filter): 5.7 L (6.0 qt.).
The engine is factory-filled with a high quality

multi-grade oil that can be used as an all-season
oil, except in extremely cold climates.
Viscosity classes and oil specifications
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Select the viscosity according to the chart shown. The oil does not need
to be changed if the outside temperature only briefly exceeds the
specified ranges.
The specifications stated on these pages must be indicated on the

container either individually or in combination with other specifications.
A - Multi-grade oil, specification VW 500 00 1)
B - Multi-grade oil, specification VW 501 01 1)
Multi-grade oil, specification API-SF- or -SG- 2)
1) This VW specification must have a date of 10/91 or later.
2)These oils may only be used in exceptional cases if no approved

engine oil is available.
Mixing oils when topping up is permissible.
17-32
Oil level, checking
Test requirements
Minimum engine oil temperature 60 C
Vehicle must be standing on level ground

when checking oil level
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After stopping engine, wait a few minutes to
allow oil to flow back into oil pan
- Withdraw dipstick, wipe using clean cloth and

reinsert fully.
- Withdraw dipstick again and read oil level.
Range of markings on dip stick:
a - Oil MUST NOT be topped off.

b - Oil may be topped off. After topping off, oil may reach range -a-.
c - Oil MUST BE topped off. After topping off, it is sufficient if oil level is
somewhere in range -b- (shaded area).
CAUTION!
Do not overfill with oil past the MAX mark on the oil dipstick.
Damage to the Three Way Catalytic Converter (TWC) could result.
Cooling system components, removing and installing Page 1 of 40
19-1
Cooling system components,

WARNING!

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slowly.
Notes:
Hoses are secured with spring-type clips. If

servicing, only use the same type of spring-type
clip.
Parts catalog
VAG1921 pliers are recommended when

installing spring-type clips.
The O-rings installed at the quick-release

connections must be replaced if damaged or
leaking.
Seals and gaskets must always be replaced.
When installing coolant hoses, make sure they

are free of stress and do not come into contact
with other components (the arrows which are
located on the coolant pipes and coolant hoses
must be opposite each other).
Perform cooling system leakage test using VAG

1274 cooling system tester and 1274/9 adapter.
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19-2
Cooling system components (on body)
1 - Radiator
After replacing, completely replace coolant
With ATF cooler on vehicles with automatic
transmission
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2 - Securing clip
3 - Securing rubber
4 - O-ring
Replace if damaged
5 - Lower coolant hose
Secured to radiator with retaining clip
Make sure hose is securely seated
Coolant hose connection diagram page
19-9
6 - Securing clip
To secure temperature switch in coolant
hose
19-3
7 - O-ring
Replace if damaged
8 - Coolant Fan Control (FC) thermal switch -
F18-
35 Nm (26 ft lb)
For electric coolant fan
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Switching temperatures, stage 1:
On: 92-97 C (198-207 F)
Off: 84-91 C (183-196 F)
Switching temperatures, stage 2:
On: 99-105 C (210-221 F)
Off: 91-98 C (196-208 F)
9 - Locking bolt
10 - 10 Nm (7 ft lb)
11 - Fan ring
Clipped into air ducting and secured with
locking 9 bolt
12 - 2-pin harness connector
13 - Coolant fan -V7-
Checking page 19-26
14 - Rubber washer
15 - Coolant drain plug

10 Nm (7 ft lb)
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19-4
16 - Upper coolant hose

19-9
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19-5
Cooling system components (on engine)
1 - Connection
For thermostat
2 - O-ring
Always replace
3 - Coolant thermostat
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Note installation position page 19-23
Checking:
Heat thermostat in water
Opening begins at approx. 86 C (187 F)
Min. opening: 7 mm (0.28 in.)
4 - Bleeder screw
20 Nm (15 ft lb)
5 - Bolt
25 Nm (18 ft lb)
6 - Retaining clip
Make sure clip is seated securely
19-6
7 - Engine Coolant Temperature (ECT) sensor

-G62-
For Engine Control Module (ECM)
If necessary, release pressure in cooling
system before removing
Checking Repair Manual, 2.8 Liter V6
5V Fuel Injection & Ignition, Repair Group
01
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8 - Rear coolant line
19-9
9 - Lifting eye
10 - 10 Nm (7 ft lb)
11 - Coolant line
19-9
12 - Front coolant hose
19-9
13 - Sealing cap
Check using VAG1274 cooling system
tester with VAG1274/8 adapter
Test pressure: 1.4-1.6 bar (20-23 psi)
19-7
14 - O-ring
Replace if damaged
15 - Expansion tank
Check using VAG1274 cooling system
tester with VAG1274/9 adapter
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19-9
17 - Coolant line
19-9
18 - Rear toothed belt guard
19 - Gasket
Always replace
20 - Coolant pump
Check for ease of movement
Completely replace if damaged or leaking
19-8
21 - Lower coolant line

19-9
22 - Oil cooler
23 - Belt pulley
For viscous fan
24 - Fan wheel for viscous fan
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25 - Viscous fan coupling
Note left-hand thread
Tightening torque only valid when using
3312 open end spanner.
Tighten to 40 Nm (30 ft lb)
26 - Bracket
For viscous fan
27 - From bottom of radiator
19-9
19-9
Coolant hose connection diagram
1 - Lower coolant hose

From radiator to engine
2 - Cylinder head/cylinder block
3 - Intake manifold
4 - Coolant line
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From heat exchanger to engine block
5 - Heater core
6 - Coolant hose
To heat exchanger
7 - Rear coolant line
8 - Expansion tank
19-10
9 - Oil cooler
10 - Coolant line
From expansion tank to lower coolant pipe
12 - Radiator
13 - Coolant pump
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14 - Lower coolant line
15 - Connection
For thermostat
19-11
Cooling system, draining and refilling
Draining
WARNING!

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slowly.
- Open coolant expansion tank cap.
- Remove noise insulation panel.

- Place VAG1306 drip tray underneath engine.
- With bumper removed, open coolant drain plug (arrow) on lower left of
radiator by turning it counterclockwise. If necessary, attach accessory
hose to connection.
- With bumper installed, pull off retaining clamp for lower right radiator
hose (from radiator to engine) and disconnect radiator hose from

radiator.
CAUTION!
Follow disposal regulations for coolant.
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19-12
- Drain engine coolant at drain plug (arrow).
Filling
Notes:
Only use coolant additive G12 (according to TL VW 7745 D). G12 is
red in color.
Do not mix G12 with any other coolant additive!
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If the fluid in expansion tank is brown, G12 has been mixed with other
coolant. In this case, the coolant must flushed and replaced.
"G12" and coolant additives marked in accordance with "TL VW 774
D" prevent frost and corrosion damage, scaling and also raise the
boiling point of the coolant. Therefore, the cooling system must be
filled year round with frost and corrosion protection additives.
A higher boiling point improves engine reliability under heavy load
particularly in countries with tropical climates.
Frost protection additives protect against frost to about -25 C (about -
35 C in arctic climates).
The coolant concentration must not be reduced by adding water even
in warmer seasons and in warmer countries. The anti-freeze ratio
must be at least 40%.
19-13
Note (continued from page Page 19-12 ):
If for climatic reasons greater frost protection is

required, the amount of G 12 can be increased,
but only up to 60% (frost protection to about -
40 C), otherwise frost protection and cooling
effectiveness will be reduced.
If the radiator, heat exchanger, cylinder head or
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cylinder head gasket is replaced, completely
replace the engine coolant.
Test coolant frost protection using T10007 special tool.
Recommended mixture ratios:
Frost protection Anti-freeze G 121) Water 1)

to amount
-25 C (-13 F) 40 % 2.5 l (2.7 3.5 l (3.7
qt.) qt.)
-35 C (-31 F) 50 %
3.0 l (3.2 3.0 l (3.2
qt.) qt.)
1)The quantity of coolant can vary depending upon the equipment

installed in the vehicle.
19-14
- Replace coolant drain plug O-ring and install

coolant drain plug into engine.
Tightening torque: 20 Nm (15 ft lb).
- Install lower right coolant hose and secure with

retaining clip.
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- Secure coolant drain valve to radiator.
- Screw VAG1274/9 onto expansion tank and insert VAG1274/10 into

adapter.
- Loosen clamp on coolant hose on heater core and pull back hose until
bleeder hole in coolant hose (arrow) is no longer sealed by connection.
- Top off coolant until it flows out from bleeder hole in coolant hose.
- Push coolant hose onto connection and tighten.
19-15
- Loosen bleeder screw on lower coolant line (arrow) under expansion

tank (if necessary, unbolt expansion tank).
- Top off coolant until it flows out from bleeder screw.
- Close bleeder screw and tighten to 20 Nm (15 ft lb).
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- Loosen bleeder screw on front coolant line (arrow) between power
steering pump and left-side of cylinder head.
- Top off coolant until it flows out from bleeder hole in coolant line.
- Close bleeder screw and tighten to 20 Nm (15 ft lb).
- Top up coolant to MAX mark.
- Install coolant expansion tank cap.
- Set heater controls to maximum heat position.
- Start engine and let run at idle for approx. 10 minutes.
19-16
- Raise engine speed to approx. 2000 rpm for

approx. 5 minutes.
- Allow engine to idle until lower coolant hose on

radiator is hot.
- Check coolant level and top-off if necessary.

When engine is at normal operating
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temperature, coolant level must be on MAX
mark. When engine is cold, coolant level must
be between MIN and MAX marks.
WARNING!

slowly.
19-17
Radiator, removing and installing
Removing
Repair Manual, Body Exterior, Repair Group
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63
- Drain coolant at drain plug (arrow) page 19-11 .
- Disconnect coolant hoses at radiator, unhinge clamp from connection

flange (arrow).
- Disconnect connector from temperature switch at bottom-left of
radiator.
- Remove ATF lines from radiator.
Repair Manual, 5 Spd. Automatic Transmission 01V, Repair Group 37
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19-18
All models
- Unbolt power steering hydraulic oil cooling line (arrows).
Vehicles with air conditioning
CAUTION!
DO NOT open the air conditioning refrigerant circuit.
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Disconnect A/C refrigerant lines at brackets and support points
only.
Avoid damage from bending. Refrigerant lines kink easily.
- Unbolt air guides at radiator -4- on left and right-sides.

- Unbolt retaining bolts -1- and -2- from condenser.
- Disconnect harness connector -3- at A/C pressure switch -F129-.
- Pull condenser upward out of retaining bracket, swing to side and hang
at right-front wheel using wire loop.
19-19
All models
- Release both radiator retaining bolts, pull up and remove (arrows).

- Tilt radiator toward front, lift up and remove.
Installing
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- Fill up coolant page 19-11 .
- Check ATF level.
Repair Manual, 5 Spd. Automatic Transmission 01V, Repair Group 37
Tightening torques

Condenser to radiator 10 Nm (7 ft lb)
Coolant line to radiator 10 Nm (7 ft lb)
19-20
Coolant pump, removing and installing
Notes:
Cover the toothed belt with a cloth to protect it

from coolant before removing the coolant pump.
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Removing

63
- Move lock carrier into service position.

50
- Drain coolant page 19-11 .
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19-21
- Remove the following components before removing coolant pump:

1 - Toothed belt tensioner roller
2 - Idler roller
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- Remove coolant pump mounting bolts -1- and remove coolant pump -
2-.
19-22
Installing

following:
- Remove any remaining sealant from sealing

surfaces of coolant pump and cylinder block.
- Clean sealing surfaces so they are completely
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free of any oil or grease.
- Install new gasket on water pump flange.
- Install coolant pump -2- into cylinder block and tighten all 9 mounting
bolts (arrow -2-) to 10 Nm (7 ft lb).
- Install rear toothed belt guard on water pump housing (arrow -1-).
- Install and tension toothed belt page 13-12 .
- Install toothed belt guard.
- Install ribbed belt page 13-8 .
- Fill cooling system with coolant page 19-11 .
19-23
Thermostat, removing and installing
Notes:
Cover the toothed belt with a cloth to protect it

from coolant before removing thermostat.
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Removing

63
Lock carrier in service position

50
- Remove connection mounting bolts -1- and remove connection -2-.

- Remove thermostat -4-.
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19-24
Installing

following:
Bleeder valve for thermostat (arrow) must be at the top.

- Install thermostat -4- into engine block.
- Moisten new O-ring -3- with coolant.
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- Install connection -2- for thermostat and tighten bolt -1- to 10 Nm (7 ft
lb).
- Install and tension toothed belt page 13-12 .
- Install ribbed belt page 13-8 .
- Fill cooling system with coolant page 19-11 .
19-25
Viscous fan, removing and installing
Removing
- Counterhold pulley for viscous fan using 3212 spanner wrench and
remove viscous fan using 3312 open-end spanner (left thread).
- Carefully lift out viscous fan.
Installing
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Tightening torque for viscous fan Nm

1331 torque wrench and 3312 open-end spanner 37 Nm (27 ft lb)
1331 torque wrench without 3312 open-end spanner 70 Nm (52 ft lb)
19-26
Coolant fan, checking
Test requirements
Fuse No. 34 OK
Coolant Fan Control (FC) thermal switch -F18- OK
Test procedure
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- Disconnect 3-pin harness connector from coolant Fan Control (FC)
thermal switch -F18- at bottom left of radiator.
- Switch ignition on.
- Bridge terminal -1- and terminal -2- of harness connector using

auxiliary cables from VW1594 connector test kit.
Coolant fan -V7- must run on 1st speed.
19-27
- Bridge terminal -1- and terminal -3- of harness connector using

auxiliary cables from VW1594 connector test kit.
Coolant fan -V7- must run on 2nd speed.
If 1st or 2nd fan speed does not run:
- Locate and repair open circuit using wiring diagram:
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Electrical Wiring Diagrams, Troubleshooting & Component Locations
If no open circuit can be found:
- Replace coolant fan -V7-.
19-28
Cooling system, pressure test
Engine at operating temperature
WARNING!

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slowly.
- Open cap on coolant expansion tank.
- Using VAG1274/8 adapter attach VAG1274 cooling system tester to

coolant expansion tank.
- Use tester hand pump to create a pressure of approx. 1.0 bar (14.5
psi).
- If pressure falls, check for leaks and repair.
19-29
Pressure relief valve in cap, checking
- Attach sealing cap to tester using VAG1274/9

adapter.
- Install hand pump and pump.

- Pressure relief valve must open at pressure between 1.4-1.6 bar (20.3-
23.2 psi).
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19-30
After-run coolant pump
1 - Coolant reservoir
Perform coolant system leak test using
VAG1274 cooling system tester and
VAG1274/9 adapter.
2 - Lower coolant pipe
3 - 25 Nm
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4 - 25 Nm
5 - Bracket for after-run coolant pump
19-31
6 - Spring clamp
7 - Coolant hose
8 - Spring clamp
9 - Electrical after-run coolant pump
Checking page 19-32
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10 - 10 Nm
11 - Spring clamp
12 - Coolant hose
13 - Spring clamp
14 - Connection
For thermostat
15 - Oil cooler
16 - Oil filter
19-32
After-run coolant pump, checking
Note:
Control modules with an after-run time of 15

seconds after engine is turned off were installed
since start of production. As a running change
in m.y. 1999, control modules with an after-run
time of 3 minutes were installed.
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The coolant after-run pump also continues to
run after the engine is started again before the
15 second or 3 minute cycle is completed.
The coolant after-run pump and the after-run

fan are controlled via the same control module.
After switching off the engine, the after-run pump

always runs for 15 seconds or 3 minutes after the
engine has been switched off. If during this time
the switch-on temperature of 102 C (coolant
temperature) is reached at the thermostat of the
second fan stage, the after-run pump continues
to run and the coolant fan continues to run in the
after-run stage until the switch-off temperature of
91 C of the coolant at thermostat has been
reached. The maximum running time of the after-
run pump is 10 minutes.
19-33
The control module for the after-run pump and coolant fan is installed
below the longmember (left side)
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The thermostat is installed in the coolant return hose.
19-34
After-run coolant pump, removing and

installing
- Remove noise insulation panel.
Note:
The electrical coolant pump is located on the right side behind the
generator.
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- Disconnect connection -1-.

- Disconnect both hoses -3- and -4- from pump.
- Unbolt pump from bracket -2-.
Exhaust system components, removing and installing Page 1 of 12
26-1
Exhaust system components,

WARNING!

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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.
Notes:
Always replace gaskets and self-locking nuts.
After exhaust system repairs, make sure

exhaust system is not under stress and that it
has sufficient clearance from the bodywork. If
necessary, loosen double clamps and align
muffler and and exhaust pipe so that sufficient
clearance is maintained to the bodywork and
the support rings are evenly loaded.
The flexpipe in left and right exhaust pipes must

not be bent more than 10 , otherwise it may be
damaged.
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26-2
Exhaust manifold, front exhaust pipe and

Three Way Catalytic Converter (TWC) with
attachments
1 - Spacer sleeve
2 - Bolt
3 - Washers
4 - Bracket
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5 - Spacer bushing
6 - Rubber bushing
7 - 25 Nm (18 ft lb)
8 - Spring
9 - Bolt
25 Nm (18 ft lb)
10 - To center muffler
26-3
11 - Left-front exhaust pipe with Three Way

Catalytic Converter (TWC)
The flexpipe in left and right exhaust pipes
must not be bent more than 10 , otherwise
it may be damaged
12 - Heated Oxygen Sensor (HO2S) 2 -G108-
50 Nm (37 ft lb)
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Only grease threads using "G5" ("G5" must
not get into slots on body of sensor)
Checking DTC memory Repair Manual,
2.8 Liter V6 5V Fuel Injection & Ignition,
Repair Group 01
Checking components and heating function
Repair Manual, 2.8 Liter V6 5V Fuel
Injection & Ignition, Repair Group 24
CAUTION!
Part numbers are listed here for reference only.

Always check with your Parts department for
the latest information.
26-4
13 - 4-pin harness connectors

Black
Mounted to bulkhead
For Heated Oxygen Sensors (HO2S) and
for heating function
14 - 25 Nm (18 ft lb)
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15 - Cover cap
10 Nm (7 ft lb)
16 - Connection
17 - Upper heat shield
18 - Lower heat shield
19 - Left-side exhaust manifold
20 - Gaskets
Always replace
21 - Right-side exhaust manifold
26-5
22 - Heated Oxygen Sensor (HO2S) -G39-

50 Nm (37 ft lb)
Only grease threads with "G5" ("G5" must
not get into slots on body of sensor)
Checking DTC memory Repair Manual,
2.8 Liter V6 5V Fuel Injection & Ignition,
Repair Group 01
cardiagn.com
Checking components and heating
function Repair Manual, 2.8 Liter V6 5V
Fuel Injection & Ignition, Repair Group 24
CAUTION!
Part numbers are listed here for reference only.

Always check with your Parts department for
the latest information.
23 - Right-front exhaust pipe with Three Way

Catalytic Converter (TWC)
The flexpipe in left and right exhaust pipes
must not be bent more than 10 , otherwise
it may be damaged
26-6
Mufflers with mounts
Vehicles with all-wheel drive
Vehicles with front-wheel-drive page 26-9 .
1 - 40 Nm (30 ft lb)
2 - From Three Way Catalytic Converter
(TWC)
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3 - Carriage bolts
4 - Double clamp
5 - 25 Nm (18 ft lb)
6 - Mounts
With retaining ring
7 - Center muffler
8 - Double clamp (for repair)
26-7
9 - Separating points
At factory, center and rear mufflers are
installed as single component.
Replacement center and rear mufflers are
supplied separately, with double clamp for
connecting joint
Cutting through at separating point Fig.
1
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10 - Right-rear muffler
11 - Mounts
12 - Brackets
13 - Left-rear muffler
26-8
Fig. 1 Separating point between front and rear mufflers
Cutting
- Using VAG1523 body saw, cut through connecting pipe between

center muffler and rear muffler at groove.
Distance -a-: approx. 244 mm (9-1/2 in.).
cardiagn.com
26-9
Vehicles with front wheel drive
1 - 40 Nm (30 ft lb)
2 - From Three Way Catalytic Converter
(TWC)
3 - Carriage bolts
4 - Double clamps
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5 - 25 Nm (18 ft lb)
6 - Mounts
With retaining ring
7 - Center muffler
8 - Bracket
9 - Mount
10 - Rear muffler
11 - Double clamp (for repair)
26-10
12 - Separating point
At factory, center and rear mufflers are
installed as single component.
Replacement center and rear mufflers are
supplied separately, with double clamp for
connecting joint
Cutting through at separating point Fig.
1
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13 - To front mufflers
26-11
Fig. 1 Separating point between front and rear mufflers
Cutting
- Using VAG1523 body saw, cut through connecting pipe between

center muffler and rear muffler at groove.
Distance -a-: approx. 182 mm (7 in.).
cardiagn.com
Secondary Air Injection (AIR) system Page 1 of 10
26-12
Secondary Air Injection (AIR)

system
Check Diagnostic Trouble Code (DTC)
memory.
Repair Manual, 2.8 Liter V6 5V Fuel Injection
cardiagn.com
& Ignition, Repair Group 01
Initiate output Diagnostic Test Mode (DTM).

Initiate "Basic Setting" (scan tool function 04).

Check Secondary Air Injection (AIR) valve.
Notes:
The secondary air injection system injects air

behind the exhaust valves during a cold start.
Cold start means engine coolant temperature
between 8-65 C (46-149 F). The amount of
air injected is temperature dependent.
The need for secondary air is triggered by the

Motronic Engine Control Module (ECM) -J220-
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via the Secondary Air Injection (AIR) Injection
pump relay -J299- to the Secondary Air
Injection (AIR) solenoid valve -N112- and the
two combination valves.
When "Basic Setting" (scan tool function 04) is

initiated, a diagnosis for the secondary air
injection system can be carried out. The
diagnostics consists of a flow test and a leak
test.
26-13
Flow test
During the flow test, the oxygen sensor control is

switched off (engine runs rich at that time). At the
same time the secondary air injection pump is
switched on, injecting fresh air into the exhaust
manifold which increases the oxygen content in
the exhaust gas. The oxygen sensor now
measures a lean mixture. To pass the diagnostic
test, the oxygen sensor must measure a lean
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mixture for a certain time. Passing the test
means that the secondary air injection system
delivers enough air and the secondary air
injection system is OK.
Leak test
Flow test must check out OK
Engine at operating temperature
The secondary air injection pump is switched on

during idle. Since the combination valves are not
triggered by the secondary air injection solenoid
valve, they remain closed. When the secondary
air injection pump is switched on, the oxygen
sensor system is monitored by the ECM. If the
system does not leak, fresh air cannot enter the
exhaust manifold. If the system is leaking, the
oxygen sensor signal will respond to the leaner
mixture (caused by the secondary air getting into
the exhaust manifold) and cause a noticeable
enrichment. This enrichment is recognized by the

ECM.
cardiagn.com
26-14
Secondary Air Injection (AIR) system,

overview
1 - Motronic Engine Control Module (ECM) -

J220-
2 - Air cleaner
Connection for intake air of Secondary Air
Injection (AIR) pump
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3 - Secondary Air Injection (AIR) pump motor
-V101-
4 - Connection
Between air cleaner and secondary air
injection pump
Removing page 26-16
5 - Vacuum line
Control line between Secondary Air
Injection (AIR) solenoid valve -N112- and
combination valves
6 - Connection tube
From secondary air injection pump to
combination valves
26-15
7 - Combination valves
Located at rear of left and right cylinder
heads
8 - Engine
9 - Right exhaust manifold
10 - Left exhaust manifold
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11 - Secondary Air Injection (AIR) solenoid
valve -N112-
12 - Vacuum reservoir
Located in left-front wheelhousing
26-16
Secondary Air Injection (AIR) system

components, removing and installing
Component locations page 26-14 .
Fuel injection and ignition components.
cardiagn.com
Note:
Always replace gaskets and seals.
A - Combination valve, left
- Remove engine coolant expansion tank from

bracket.
- Disconnect vacuum line -1-.

- Disconnect connection tube -2- from combination valve.
- Remove bolts -3- for combination valve from cylinder head and remove
valve.
26-17
B - Combination valve, right
intake air elbow (three -arrows- on right).
- Remove intake air elbow from throttle body connector.
- Disconnect harness connector for Evaporative Emission (EVAP)
canister purge regulator valve (left arrow) and pull valve out of bracket.
- Disconnect harness connector at Mass Air Flow (MAF) sensor.
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- Turn connector tube for Secondary Air Injection (AIR) pump 1/4-turn
(45 ) to right and pull forward off air cleaner.
- Remove air cleaner housing.
26-18
- Remove vacuum line -1-.

- Disconnect connection tube -2- from combination valve.
- Remove bolts -3- for combination valve from cylinder head and if
necessary, remove bracket -4- from cylinder head.
Bolt -3- tightening torque: 10 Nm (7 ft lb).
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Bracket -4- tightening torque: 20 Nm (15 ft lb).
- Remove combination valve.
C - Secondary Air Injection (AIR) pump motor

- Move lock carrier into service position.
26-19
- Remove air duct to generator at front of air shroud.

- Disconnect connection at connector tube to Secondary Air Injection
(AIR) pump combination valves (left arrows), pull down to remove and
cut tie wraps.
- Remove three bolts on Secondary Air Injection (AIR) pump (lower right
arrows) but do not remove nuts.
- Remove pump toward rear from bracket.
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- Remove connection line on Secondary Air Injection (AIR) pump to air
cleaner.
- Turn connector tube for Secondary Air Injection (AIR) pump 45 to

right and disconnect.
- Remove air Secondary Air Injection (AIR) pump.
Installing
Installation is the reverse of removal.

2.8 V6 5V (Aha & Atq)

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Technical data Page 1 of 3

The engine code is also listed on the vehicle data label.

Identifying engine with modified oil pump (engine code AHA)

Engine code AHA ATQ

HP @ RPM 190/6000 193/6000

Ft lb @ RPM 207/3200 207/3200

Engine code AHA ATQ

Engine, disassembling and

Special tools and equipment

3369 support tool

- Remove front bumper.

Repair Manual, Body Exterior, Repair Group 63

- Remove 3 quick-release screws on front of noise

- After installing lock carrier, check wiring for

Repair Manual, Body Exterior, Repair Group 63

Cylinder block, crankshaft and

4 - Connecting rod bearings

Replacing page 13-18

Ribbed belt, removing and installing

Lock carrier in service position page 13-1

Before removing ribbed belt, note direction of

- Remove engine cover (arrows).

- Remove noise insulation panel (arrows).

Observe previously marked direction of rotation of belt and that it is

Observe previously marked direction of rotation of belt and that it is

D1 - without air conditioning

Tightening torque for viscous fan Tightening

Vibration damper, removing and

Lock carrier in service position page 13-1

Ribbed belt, removing and installing page 13-

- Remove vibration damper.

- When installing, make sure notches (arrows) in vibration damper are

Toothed belt, removing and installing

- Remove engine cover.

Ribbed belt, removing and installing page 13-8 .

- Unclip toothed belt guard on both sides and remove.

- Turn crankshaft at central bolt of toothed belt gear in direction of

DO NOT turn crankshaft while checking for TDC mark. Personal

- Install 3242 crankshaft holder into sealing plug opening.

Before removing ribbed belt, note direction of rotation with chalk or

- Insert pin and release tension.

- Remove vibration damper page 13-11 .

- Remove idler wheel for ribbed belt (arrows).

- Remove both camshaft sprockets using T40001 special tool.

The camshaft sprockets should be loose enough on the cone to be

Component Tightening torque

1) Always replace the center bolt.

2) Two turns of 90 are permissible.

Crankshaft seal, replacing

Toothed belt side

Lock carrier in service position page 13-1

Ribbed belt, removing and installing page 13-

- Remove sealing plug from left-side of cylinder

- Turn crankshaft to TDC for cylinder 3. The TDC

- Install 3242 crankshaft holder in bore to secure crankshaft.

- Remove crankshaft/toothed belt gear.

- Unscrew inner part of 3203 seal puller two turns

- Place 3202/1 guide sleeve on crankshaft pin.