Transporter 5 Cylinder Diesel Engine Mechanical

Service
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Service Department. Technical Information

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List of Workshop Manual Repair GroupsList of Workshop Manual
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Repair GroupsList of Workshop Manual Repair Groups
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00 - Technical data
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10 - Removing and installing engine
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13 - Crankshaft group
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15 - Cylinder head, Valve gear

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17 - Lubrication
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19 - Cooling system
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20 - Fuel supply system
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21 - Charging
26 - Exhaust system
Technical information should always be available to the foremen and mechanics, because their careful
and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In
addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course,
be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg 00052705220

5-Cyl. diesel engine, Mech. - Edition 10.2000
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.2 Notes on removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.3 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.4 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.5 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.6 Additional information and work instructions for vehicles with air conditioner . . . . . . . . . . . .12
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.2 Adjusting alternator V-belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
1.3 Removing and installing ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
1.4 Removing and installing ribbed belt tensioning device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
1.5 Removing, installing and tensioning camshaft toothed belt (>01.95) . . . . . . . . . . . . . . . . . .42
1.6 Removing, installing and tensioning camshaft toothed belt (02.95 >) . . . . . . . . . . . . . . . . . .49
1.7 Removing, installing and tensioning G. Volkswage
injection pump toothed belt (engine codes AAB, AJA)
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1.8 Removing, installing db
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AXL, AYC) . . . . . . . . . . . . . . . . . . .a.nt.ee. . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
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2 Removing au and installing sealing flange and flywheel . . . .r a.c . . . . . . . . . . . . . . . . . . . . . . . . .66
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2.1 Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
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2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

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2.3 Removing and installing dual mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

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2.4 Renewing crankshaft oil seal - pulley end - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

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3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

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3.1 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

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3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

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4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

4.1 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
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4.2 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
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15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

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1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

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1.1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

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1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

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1.3 Checking compression pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

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2 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

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2.1 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

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2.2 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
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2.3 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
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2.4 Renewing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
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2.5 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
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2.6 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

2.7 Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
2.8 Replacing swirl chambers (engine codes AAB, AJA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Contents i
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
1.1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
1.2 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141

1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
1.1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
1.2 Parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
1.3 Parts of cooling system - engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
1.4 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
1.5 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
1.6 Removing and installing radiator and fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
1.7 Checking thermo switch and coolant circulation pump or continued coolant circulation pump
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167

1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
1.1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
1.2 Removing and installing fuel tank with its attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
1.3 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . .170
1.4 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
1.5 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
1.6 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
1.7 Servicing accelerator mechanism (engine codes AAB, AJA) . . . . . . . . . . . . . . . . . . . . . . . .174
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1.8 Adjusting accelerator cable . . . s. w. a.g.en. A. G. .. . . . . . g.e.n .AG
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1.9 Servicing cold start accelerator
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1.10 Adjusting CSA operating ris cable . . . . . . . . . . . . . . . . . . . . . . . . . .a.nt.e . . . . . . . . . . . . . . . . . . . .178
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21 - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
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1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179

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1.1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179

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1.2 Removing and installing turbocharger with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . .179

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1.3 Removing and installing air cooling parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188

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1.4 Turbocharger hose/pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193

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1.5 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194

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1.6 Removing and installing exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195

2 Checking charge pressure system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
2.1 Checking charge pressure system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
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2.2 Checking turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199

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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205

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1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205

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1.1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205

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1.2 Removing and installing clamping springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210

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1.3 Tensioning and relieving tension on clamping springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211

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2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214

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2.1 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214

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2.2 Removing and installing parts of exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . .214 op
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2.3 Vacuum hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
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2.4 Checking exhaust gas recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
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ii Contents
00 - Technical data
1 - Technical kdata
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1.2 - Engine number
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Additionally there is a sticker on the upper toothed belt guard with "Engine code" and "Serial number".
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The engine code is also included on the vehicle data plate.
1.3 - Engine data
Codes AAB ACV AJA AHY

Manufactured 09.90 ▸ 08.95 ▸ 04.97 ▸ 06.98 ▸
Capacity ltr. 2.4 2.5 2.4 2.5
Output kW at rpm 57/3700 75/3500 55/3700 111/4000
Torque Nm at rpm 164/1800...2200 250/2300 160/1900...2900 295/1900...3000
Bore ø mm 79.5 81 79.5 81
Stroke mm 95.5 95.5 95.5 95.5
Compression ratio 23:1 20.5/19.51):1 23:1 19.5:1
CN min. 49 49 49 49
Firing order 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3
Catalyst --- x x x
Exhaust gas recirculation --- x --- x
Charging --- x --- x
1.1 - Technical data 1

Codes AAB ACV AJA AHY

Charge air cooling --- x --- x
1) from 05.99 modified compression ratio
Codes AHY AJT AUF AXG

Manufactured 06.98 ▸ 05.98 ▸ 05.99 ▸ 09.00 ▸
Capacity ltr. 2.5 2.5 2.5 2.5
Output kW at rpm 111/4000 65/3600 75/3500 111/4000
Torque Nm at rpm 295/1900...3000 195/1900...2500 250/1900...2300 295/1900...3000
Bore ø mm 81 81 81 81
Stroke mm 95.5 95.5 95.5 95.5
Compression ratio 19.5:1 19:1 19.0:1 19:1
CN at least 49 49 49 49
Firing order 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3
Catalyst x x x x
Exhaust gas recirculation x x x x
Charging x x x x
Charge air cooling --- x x x
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Output kW
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Torque Nm at rpm 250/1900...2300

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Stroke mm 95.5
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Compression ratio 19:1

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CN min. 49
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Firing order 1-2-4-5-3

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Catalyst x
Exhaust gas recirculation x
Charging x
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Charge air cooling x

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2 00 - Technical data
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1.1 - Removing and installing engine
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Special tools, workshop equipment, test and measuring appliances and auxiliary items required
◆ 2024 A Lifting tackle

◆ 3227 Engine stand
◆ 3250 Support
◆ VW 313 Support clamp
◆ VW 540 Engine and gearbox support
◆ V.A.G 1202 A Workshop crane
1.1 - Removing and installing engine 3

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◆ V.A.G 1306 Drip tray

◆ V.A.G 1331 Torque wrench (5...50 Nm)
◆ V.A.G 1383 A Engine/gearbox jack
◆ V.A.G 1921 Spring-type clip pliers
◆ VAS 5085 Step ladder
◆ G 000 100 Grease (vehicles with manual gearbox)
◆ Cable tie
1.2 - Notes on removing

- First check whether a coded radio is fitted. If this is the case obtain the anti-theft coding.
- With ignition switched off disconnect battery earth strap.
- All cable ties which are opened or cut open when removing engine, must be replaced in the same position
when installing engine.
- The engine is removed downwards together with the gearbox.
Vehicles ▸12.95
- Insert left and right support device 3250 to support the upper wishbone:
4 10 - Removing and installing engine

=> Running gear; Repair group 40; Servicing front suspension Servicing front suspension
Continuation for all vehicles
- Removing insulation tray:
=> General body repairs, exterior; Repair group 50; Noise insulation assembly overview Noise insulation as‐
sembly overview
- Remove front exhaust pipe => Page 205 , Removing and installing parts of exhaust system.
- Drain coolant => Page 158 .
- Pull radiator coolant hoses off engine using spring-type clamp pliers V.A.G 1921.
- Pull connectors off thermo-switch and radiator fan.
Engine codes ACV, AUF, AYC
- -> Remove charge air cooler bracket -1-.

- Remove charge air cooler with air hoses
=> Page 188 , Removing and installing parts of charge air cooling system.
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Identification characteristics for Transporters with
ss a long and short front end from January 1996: ra
c
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=> Automatic gearbox 01P - from 01.95; Repair group 37; Removing and installing gearbox; Identification pt
du
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characteristics for Transporters with long and short front end from January 1996 Removing and installing gear‐ y li
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box Identification characteristics for Transporters with long and short front end from January 1996 ility
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- Removing radiator grille:

h re
hole
spec
=> General body repairs, exterior; Repair group 66; Trims Trims
es, in part or in w
t to the co
Vehicles 10.91▸
rrectness of i
- Disconnect power assisted steering coolant pipe from radiator.

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Vehicles with air conditioner

nform
ercia
- Unscrew condenser from radiator.

- Observe additional information and work instructions => Page 12 .
m
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Warning!
o
his
e
The air conditioning system refrigerant circuit must not be opened.

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1.2 - Notes on removing 5

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- Remove lock carrier: oris e nte
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=> General body repairs,
s exterior; Repair
group 50; Removing and installing lock carrier with attachments
ce
le
Removing and installing lock carrier with attachments
un
pt
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- Lift out radiator with fan, air guide and lock carrier.
rm
ab
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- Separate speedometer drive at gearbox.
es, in part or in w
t to the co
Engine codes AAB, AJA
- Disconnect throttle cable at injection pump lever, remove securing clip on support bracket and remove
rrectness of i
throttle cable from injection pump =>Page 174 , servicing accelerator mechanism.
l purpos
- Disconnect CSA cable Page => 177 , servicing cold start accelerator (CSA) cable.
Vehicles with automatic gearbox
nform
mercia
- Remove selector lever cable from gearbox:
a
com
tion in
r
=> Repair group 37; Servicing selector mechanism; Dismantling and assembling selector mechanism Servicing
te o
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selector mechanism Dismantling and assembling selector mechanism
s
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t. rig
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=> Repair group 30; Servicing hydraulic clutch control Servicing hydraulic clutch control
cted agen
Prote AG.
- Remove hose/metal pipe from hydraulic clutch slave cylinder on gearbox:
=> Repair group 30; Hydraulic clutch control. Hydraulic clutch control.
- Disconnect selector mechanism from gearbox.
=> Repair group 34; Servicing gear change mechanism Servicing gear change mechanism
Vehicles with four-wheel-drive
- Remove front propshaft:
=> Repair group 39; Removing and installing propshaft Removing and installing propshaft
- Remove fuel supply and return pipes at injection pump.

- Remove inter-connecting, coolant, vacuum and intake hoses on engine.
- Disconnect all electric wires from engine, gearbox, alternator and starter and move clear.
- Disconnect P.A.S. vane pump hydraulic pipes from engine and drain hydraulic fluid:
=> Running gear; Repair group 48; Servicing power assisted steering. Servicing power assisted steering.
or
=> Running gear from January 1996; Repair group 48; Assembly overview: Vane pump, reservoir, hydraulic
pipes Assembly overview: Vane pump, reservoir, hydraulic pipes
Vehicles ▸12.95
- Disconnect pressure and return hoses from power assisted steering box:

=> Running gear, Repair group 48; Power assisted steering assembly overview.
Vehicles01.96▸
- Unscrew securing tabs of steering box return pipe:
- Remove left-hand drive shaft and disconnect right-hand drive shaft at gearbox:
=> Running gear; Repair group 40; Removing and installing drive shaft Removing and installing drive shaft
or
=> Running gear from January 1996; Repair group 40; Servicing drive shaft Servicing drive shaft
- Remove rear assembly mounting or pendulum support:
=> Repair group 34; Removing and installing gearbox Removing and installing gearbox
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- Lift engine and gearbox lightly using engine/gearbox jack V.A.G 1383 A.
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- -> Remove gearbox mounting centre bolt -arrow- left in engine compartment.
- Remove engine mounting centre bolt, right in engine compartment.
1.2 - Notes on removing 7

Assembly mountings without centre bolt
- -> Unscrew assembly mountings engine side -A- and gearbox side -B-, from above -arrows-.
Note:
To remove securing bolts use ladder VAS 5085.
- Remove engine with gearbox downwards, when doing this guide power assisted steering oil return hose.
Note:
When lowering the assembly must be carefully guided, to prevent damage to the bodywork.
1.3 - Securing engine to assembly stand

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- -> Screw
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eo plate -arrow A-.
- Hook
ss a lifting device into selector lever cable support rbracket
u ac -arrow B- and into lifting eye -arrow A-.
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=> Repair group 37; Removing and installing gearbox Removing and installing gearbox
- Secure torque converter against "falling out" after separating engine from gearbox.
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- Release guide tube for oil dipstick and remove turbocharger to air mass meter connecting pipe.
- -> Attach lifting tackle 2024A with extension 2024 A/1 as follows and lift out from engine/gearbox jack V.A.G
1383 with workshop crane:
Warning!
The hooks and locating pins must be secured with locking pins.
- -> Secure engine to support clamp VW 313 using engine and gearbox bracket VW 540 and supplementary
kit VW 540/1.
1.3 - Securing engine to assembly stand 9

1.4 - Notes on installing
Installation is carried out in the reverse sequence, when doing this note the following:
Warning!
When doing any repair work, especially in the engine compartment, pay attention to the following due to the
cramped conditions:
◆ Route all the various lines (e.g. for fuel, hydraulics, activated charcoal filter system, coolant, refrigerant,
brake fluid and vacuum pipes and hoses) and electrical wiring so that the original positions are restored.
◆ Ensure sufficient clearance to all moving or hot components.
Versions with clutch cable

- Check clutch release bearing for wear, renew if necessary.
- Lightly grease clutch release bearing and input shaft splines with grease G 000 100.
Versions with hydraulic clutch control

- Check clutch release bearing for wear, renew if necessary.
- Lightly grease clutch release bearing, release bearing guide sleeve and input shaft splines with grease G
000 100.
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Continued for all versions Vo lksw
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- Check whether theordowel
ise sleeves for centralising engine/gearbox nte
eo
are in the cylinder block, install if neces‐
sary. aut
h
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- Place intermediate
ss plate on dowel sleeves and secure at several points c on cylinder block with a small amount
ce
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of grease.
nl
pt
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- When installing the assembly, ensure sufficient clearance to drive shafts.

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- Install front exhaust pipe => Page 205 , Removing and installing parts of exhaust system.
erm
ab
- Install drive shafts:

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=> Running gear from January 1996; Repair group 40; Servicing drive shaft Servicing drive shaft
- Installing hydraulic pipes for power steering vane pump:
rrectness of i
=> Running gear; Repair group 48; Servicing P.A.S. Servicing P.A.S.
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or
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- Electrical connections and routing:

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=> Electrical system; Repair group 97

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Assembly mountings with centre bolt
- -> Ensure the lugs of the bonded rubber mounting -arrow- engage in the cut-outs in the mounting bracket.
- Align engine and gearbox mountings stress-free by rocking.
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- Adjusting accelerator
au cable =>Page
174 , Servicing accelerator mechanism.
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- Adjusting CSA operating cable =>Page 178 .
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wit
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=> Repair group 37; Servicing selector mechanism; Dismantling and assembling selector mechanism Servicing
hole
spec
selector mechanism Dismantling and assembling selector mechanism
es, in part or in w
t to the co
rrectness of i
- Installing mechanical clutch control clutch cable or hydraulic clutch control slave cylinder:
l purpos
=> Repair group 30; Servicing hydraulic clutch control Servicing hydraulic clutch control
nf
- Installing hose/metal pipe from hydraulic clutch slave cylinder to gearbox:
ercia
orm
m
atio
=> Repair group 30; Hydraulic clutch control. Hydraulic clutch control.
om
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- Connecting selector mechanism to gearbox.
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=> Repair group 34; Servicing gear change mechanism Servicing gear change mechanism cu
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- Install front propshaft:
c by lksw
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=> Repair group 39; Removing and installing propshaft Removing and installing propshaft
- Filling with coolant => Page 158

- Top up hydraulic oil in reservoir.
- Start engine. Turn steering to full left and right locks. Check fluid level with engine running and wheels in
straight-ahead position.
Fluid level:
Between Max. and Min. marking, if necessary top up hydraulic oil.
1.5 - Tightening torques
Bolted connection Tightening torque

Engine to gearbox M8 25 Nm
M10 60 Nm
M12 80 Nm
Engine mounting centre M10 65 Nm
bolt
Engine mounting nuts M10 55 Nm
Continuation for all vehicles with short front end
- Check headlight adjustment and adjust if necessary:
1.4 - Notes on installing 11

=> Maintenance manual
Continued for all versions
- Carry out a test drive and interrogate fault memory:
=> Repair group 01; Self-diagnosis; Interrogating fault memory Self-diagnosis Interrogating fault memory
1.6 - Additional information and work instructions for vehicles with air conditioner
Warning!
Note:
To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the pipes and hoses are
not stretched, kinked or bent.
To facilitate removing and installing the engine without opening the refrigerant circuit:
- Remove air conditioner compressor and condenser and lay to one side so that the refrigerant pipes/hoses
are not stressed. . Volkswag AG en AG
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13 - Crankshaft group
1 - Dismantling and assembling engine

1.1 - Dismantling and assembling engine
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Notes:
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◆ If during repair work, metal shavings or larger quantities of small metal particles are found in the engine oil
f
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- caused, for example, by partial seizure of the crankshaft and conrod bearings - then, apart from thoroughly
Co
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◆ Defective injectors can cause violent knocking noises in the engine which sound like defective bearings.
p by
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When this occurs, run engine at idling speed and slacken off injector pipe unions one after the other. If
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knocking stops when a union is loosened, this indicates that the injector concerned is defective.
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1.1 - Dismantling and assembling engine 13

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Servicing injectors:
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=> Repair group 23; Servicing fuel injection system; Servicing injectors Servicing fuel injection system Servicing
es, in part or in w
injectors
t to the co
Engine codes ACV, AHY, AJT, AUF, AXG, AXL, AYC

rrectness of i
=> Repair group 23; Diesel direct injection system; Servicing injectors Diesel direct injection system Servicing
injectors
l purpos
I =>Page 15
nform
ercia
II ▸01.95 =>Page 20
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II 02.95 ▸=>Page 23
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III =>Page 26
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14 13 - Crankshaft group
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Part I
1 Dust cap
2 Tensioner
◆ Engine code AHY, AXG
3 40 Nm
4 Bracket
5 Tensioning element for tensioning roller
◆ Engine code AHY, AXG
◆ To remove, the vibration damper must be removed first
6 20 Nm
7 Bracket
8 Seal
◆ Renew if damaged

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9 Tensioning element for tensioning roller
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◆ 02.95 ▸ s aut or
ac
◆ Engine codes AAB, ACV, AJA, AJT, AUF, AXL, AYC
s
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◆ Can only be installed in one position. Holes are off-set

un
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◆ Removing and installing ribbed belt tensioning device

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=>Page 39
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10 20 Nm
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12 40 Nm
spec
13 160 Nm + 1/2 turn (180 °) further

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◆ 02.95 ▸
◆ Renew
◆ Threads and shoulder must be free of oil and grease
rrectne
◆ Counter-hold with T10025 to loosen and tighten

◆ Removing, installing and tensioning camshaft toothed belt=> Page 49
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14 20 Nm + 1/4 turn (90 °) further

◆ 02.95 ▸
15 Vibration damper with ribbed belt pulley
◆ 02.95 ▸
◆ When installing note fixing arrangement
16 Washer
◆ Renew
◆ diamond coated
17 V-belt
◆ For P.A.S. vane pump
◆ ▸01.95
◆ Check tension by thumb pressure
Deflection:
Approx. 5 mm (new and used V-belts)
◆ Adjusting V-belt tension:
=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic pipes Assembly over‐
view: vane pump, reservoir, hydraulic pipes

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18 V-belt
◆ For alternator
◆ ▸01.95
max. deflection:
New ribbed belt approx. 2 mm
Used ribbed belt approx. 5 mm
◆ Checking V-belt tension on vehicles with toothed rack tensioner
=>Page 35
19 20 Nm
◆ ▸01.95
20 460 Nm
◆ ▸01.95
◆ Coat threads and bolt head contact surface with sealing paste AMV 188 001 02
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21 Vibration damper with V-belt pulley

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22 Ribbed belt
spec
◆ 02.95 ▸
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◆ Mark direction of rotation before removing

◆ Check for wear
◆ Removing and installing
rrectne
=> Page 36
23 Spacer bush
s
24 20 Nm
s o
cial p
25 Idler wheel
inform
26 Tensioning lever
mer
atio
27 Tensioning roller securing bolt

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28 Tensioner
i
or
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e
◆ Engine codes AAB, ACV, AJA, AJT, AUF, AXL, AYC

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um
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◆ Check for wear
◆ Do not kink
◆ Removing, installing and tensioning
=> Page 42
4 Camshaft sprocket securing bolt
◆ Observe steel type marking on bolt head:
8.8 = 85 Nm
10.9 = 100 Nm
◆ Counter-hold with 3036 to loosen and tighten
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5 Camshaft sprocket
◆ Drive off camshaft taper using hammer and drift through toothed belt guard openings
◆ Note position when installing toothed belt
=> Page 42 , Removing, installing and tensioning camshaft toothed belt
6 10 Nm
7 Toothed belt guard - rear
8 Coolant pump
◆ With elongated holes
◆ Check for ease of movement
◆ If damaged or leaking renew complete
◆ Loosen slightly and turn with screwdriver to tension toothed belt => Page 42 , Removing and installing
camshaft toothed belt

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9 O-ring
◆ If leaking and damaged renew
10 Crankshaft toothed belt sprocket
11 Idler wheel
◆ Remove using puller 3034 and bolt 3034/1
12 Toothed belt guard - lower part
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1 Toothed belt guard - upper part
AG.
2 Camshaft toothed belt

◆ Mark D.O.R. before removing
◆ Check for wear
◆ Do not kink
◆ Removing, installing and tensioning
=> Page 49
8.8 = 85 Nm
10.9 = 100 Nm

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4 Camshaft sprocket
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◆ Note position when installing toothed belt

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5 Toothed belt guard - rear

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6 20 Nm
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10 10 Nm
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11 Tensioning roller
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13 Toothed belt guard

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Part III ss
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1 Cylinder head cover
pt
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◆ Engine code: AAB, AJA
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◆ For engine codes ACV, AHY, AJT, AUF, AXG, AXL, AYC the cylinder head cover is secured to bearing
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2 Cover cap
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3 10 Nm
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4 Dished washer
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5 Upper sealing washer
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6 10 Nm
m
at
◆ Engine codes ACV, AHY, AJT, AUF, AXG, AXL, AYC

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7 Cylinder head cover gasket

◆ Insert into groove on cylinder head cover
8 Cylinder head bolt

◆ Renew
◆ Note sequence when loosening and tightening
=> Page 99 , Installing cylinder head
9 Toothed belt guard securing bolt
◆ M6 = 10 Nm
◆ M8 = 20 Nm
11 Injection pump sprocket securing bolt AG. Volkswagen
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◆ Engine code AAB. AJA: 100 VolkNm
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◆ Engine codes ACV, AHY, ed AJT, AUF, AXG, AXL, AYC: 160 Nm
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◆ Oil threads and contact
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◆ Counter-hold withs au3036 to loosen and tighten
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12 Injection pump toothed belt

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◆ Removing, installing and tensioning:
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Engine codes AAB, AJA=> Page 60
agen
Prote AG.
13 Injection pump sprocket

◆ Note position when installing toothed belt:
Engine codes AAB, AJA =>Page 60 , Removing, installing and tensioning injection pump toothed belt

AG. Volkswagen AG d
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14 20 Nm Vol
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15 Idler roller rised ara
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◆ Engine codes ACV, AHY, AJT,auAUF,th AXG, AXL, AYC eo
ra
◆ Note installation position =>Page
ss 60 , Removing, installing and tensioning injection c pump toothed belt
ce
le
16 Vacuum pump
un
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d
17 Plunger
itte
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18 O-ring
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◆ Renew
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19 Cylinder head gasket
hole
spec
◆ Renew
es, in part or in w
◆ Note marking
t to the co
=>Page 89
◆ If replaced renew the complete
coolant
rrectness of i
l purpos
nform
mercia
a
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tion in
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20 Cylinder head
◆ Installing => Page 99
coolant
◆ Removing and installing injectors for engine codes AAB, AJA:
=> Repair group 23; Servicing fuel injection system; Removing and installing injectors Servicing fuel injection
system Removing and installing injectors
◆ Removing and installing injectors for engine codes ACV, AHY, AJT, AUF, AXG, AXL, AYC:
=> Repair group 23; Diesel direct system; Removing and installing injectors Diesel direct system Removing
and installing injectors
21 15 Nm
22 Lower sealing cone
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Part IV
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1 Oil filter
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◆ Tighten by hand
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2 25 Nm cop Vo
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3 Oil collector
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Prote AG.
4 Oil cooler

◆ Coat contact area to flange, outside the seal, with AMV 188 100 02
◆ Ensure clearance to adjacent components
◆ See note
=> Page 13
5 O-ring
6 Oil filter bracket
◆ Installation position determined by fitted pin
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7 Sealing ring
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◆ Renew
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8 Sealing plug, 40 Nm
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10 Banjo bolt, 30 Nm
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11 Oil supply pipe
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◆ To turbocharger Prote AG.
13 Cylinder block
◆ Removing and installing sealing flange and flywheel
=> Page 66
◆ Removing and installing crankshaft => Page 77
◆ Dismantling and assembling pistons and conrods
=> Page 80
14 Console
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15 Tensioner
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=> Page 60 , Removing and installing injection pump toothed belt

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16 15 Nm
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17 30 Nm
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18 Injection pump sprocket

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◆ Removing and installing, engine codes ACV, AHY, AJT, AUF, AXG, AXL, AYC Prote AG.
=> Repair group 23; Diesel direct injection system; Removing and installing injection pump Diesel direct injec‐
tion system Removing and installing injection pump

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19 Injection pump sprocket securing bolt
◆ Engine codes AAB, AJA
s
50 Nm
s o
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90 Nm
form
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20 Console securing bolt

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◆ Engine codes AAB, AJA

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◆ Engine codes ACV, AHY, AJT, AUF, AXG, AXL AYC

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21 Engine speed sender (G28) t. Cop py
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◆ Checking:
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=> Repair Group 01; Self-diagnosis; Interrogating fault memory Self-diagnosis Interrogating fault memory
Prote AG.
22 10 Nm
23 Woodruff key
◆ Check for tight fit
5-Cyl. wdiesel
agen
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VolkswagenMech.
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24 Injection pump
◆ Engine codes AAB, AJA, removing and installing
=> Repair group 23; Servicing fuel injection system; Removing and installing injection pump Servicing fuel
injection system Removing and installing injection pump
◆ Removing and installing, engine codes ACV, AHY, AJT, AUF, AXG, AXL, AYC
=> Repair group 23; Diesel direct injection system; Removing and installing injection pump Diesel direct injec‐
tion system Removing and installing injection pump
25 25 Nm
◆ With cone
26 Injector pipes
◆ Tighten to 25 Nm
◆ Remove with ring spanner 3035
◆ Always remove pipework complete
◆ Do not alter shape
27 Sump gasket
◆ Renew
◆ M8, install bolt with hexagon head to gearbox side

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Prote AG.
28 Sump
◆ Clean sealing surface before installing
29 20 Nm
30 10 Nm
◆ Remove and install with socket 3249
◆ With flywheel installed:
Turn flywheel so that cut-outs align with bolts
1.2 - Adjusting alternator V-belt tension
(Only vehicles ▸01.95 with toothed rack tensioner)
Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
◆ -> V.A.G 1410/2 Ring insert

◆ V.A.G 1331 Torque wrench (5 - 50 Nm)
Work sequence
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=> General body repairs; Repair group 50; Removing insulation tray Removing insulation tray
spec
- -> Loosen all securing bolts for tensioning bracket -A- and alternator at least one turn. t to the co
Note:
rrectne
It must be possible to move the alternator easily by hand.

ss o
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- Tension V-belt by turning the tensioning nut -B- with torque wrench
inform
Specification:
mer
New V-belt 8 Nm
atio
m
Used V-belt 4 Nm
o
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- Tighten tensioning nut securing bolt to

i
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30 Nm.
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- Tighten alternator mounting securing bolt to 35 Nm

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and tensioning bracket to cylinder head/lifting eye to 25 Nm.

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1.2 - Adjusting alternator V-belt tension 35

1.3 - Removing and installing ribbed belt
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(Only vehicles 02.95 ▸with tensioning roller)
Engine codes AAB, ACV, AJA, AJT, AUF, AXL, AYC
rrectness of i
Engine codes AHY, AXG => Page 37
l purpos
nform
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◆ -> 3299 Lever

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Note:
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Before removing the ribbed belt mark the direction of rotation. When installing the belt ensure it is correctly
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- Removing insulation tray: by c lksw
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- -> Lift tensioning roller with lever 3299 and remove ribbed belt from the alternator pulley.
- Remove ribbed belt.
Installing ribbed belt
Note:
Before fitting the ribbed belt ensure that all sub-assemblies (alternator, air conditioner compressor, vane pump)
are tight.
- Place ribbed belt on ribbed belt pulley with vibration damper.
- Lift tensioning roller with lever 3299, fit ribbed belt and tension.
-> Belt drive without air conditioner compressor
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-> Belt drive with air conditioner compressor
hole
spec
es, in part or in w
- Start engine and check belt running.
t to the co
Engine code AHY, AXG
rrectness of i
Note:
l purpos
Before removing the ribbed belt mark the direction of rotation. When installing the belt ensure it is correctly
nf
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seated in the pulley.

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Removing ribbed belt

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1.3 - Removing and installing ribbed belt 37

- -> Grasp the ribbed belt on the left and right-hand sides of the P.A.S. vane pump -7- with both hands.
- Slowly pull the ribbed belt in direction of arrow using substantial force and remove it from the P.A.S. vane
pump -7- and then from the other belt pulleys.
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Installing ribbed belt ed b ara
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ss on tensioning roller -1-, then on alternator -2-, idler
a ra
c roller -3-, vibration damper -4-,
idler roller -5- and as far as possible on air conditioner compressor -6-.
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- -> Grasp the ribbed belt -arrows- with both hands and slowly pull it over P.A.S. vane pump.
rm
- Turn engine over by hand in engine direction of rotation and ensure ribbed belt seats correctly in the running
m
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grooves in the belt pulley.

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- Start engine and check belt running.

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1.4 - Removing and installing ribbed belt tensioning device
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(Only for vehicles 02.95 ▸ with tensioning roller)
◆ 3227 Engine stand

◆ Wooden wedge
Removing
- Remove ribbed belt => Page 36 .

=> General body repairs; Repair group 66; Servicing radiator grille Servicing radiator grille
1.4 - Removing and installing ribbed belt tensioning device 39


- Remove charged air cooler with air hoses
=> Page 188 , removing and installing parts of charge air cooling.
Continued for all vehicles

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- Remove left and right-hand securing bolts -2-. d byV
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- Fold lock carrier and radiator out forwards -arrow-. o
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- Disconnect P.A.S. vane pump hydraulic pipes from engine.auth or
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- Unbolt right-hand drive shaft at gearbox:
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- -> Bolt engine stand 3227 onto cylinder block and tighten to approx. 20 Nm.
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- Lift engine and gearbox lightly with engine/gearbox jack V.A.G 1383 A.
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- Remove gearbox mountings: C py
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◆ Engine codes AAB, AJA, AJT
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=> 5-Speed manual gearbox 02B; Repair group 34; Removing and installing gearbox Removing and installing
gearbox
◆ Engine codes ACV, AUF, AXL, AYC
=> 5-Speed manual gearbox 02G; Repair group 34; Removing and installing gearbox Removing and installing
gearbox
- Remove right-hand engine mounting centre bolt(s).
Notes:
◆ When lowering engine ensure that front exhaust pipe does not lie on steering box.
◆ When pushing engine forwards ensure that cables, pipes and hoses are not overstretched.
- -> Lower engine with engine/gearbox jack V.A.G 1383 A as far as possible, push forwards and prevent from
swinging back by securing with wooden wedge -arrow-.
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- -> Remove ribbed V-belt idler roller -arrow 1-.

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- Remove ribbed V-belt tensioning roller -arrow 2-.

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- Remove tensioning device bracket -arrow 3-.

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- Dismantling and assembling tensioning device => Page 15 .

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Installing
spec
es, in part or in w
t to the co
Install ribbed V-belt tensioning device in reverse sequence.
Tightening torques
rrectness of i
Screwed/bolted connection Tightening torque

l purpos
Bracket to cylinder block 70 Nm

nf
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Tensioning roller to tensioning lever 20 Nm

orm
Idler roller to bracket 20 Nm

m
atio
om
Centre engine mounting M10x60 65 Nm

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1.4 - Removing and installing ribbed belt tensioning device 41

1.5 - Removing, installing and tensioning camshaft toothed belt (>01.95)
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Vehicles ▸ 01.95 with elongated holes in coolant pump for tensioning toothed belt
Vehicles 02.95 ▸ with tensioning roller for tensioning toothed belt => Page 49
◆ 2064 Pin
◆ 2065 A Setting bar
◆ 2066 Adapter for dial gauge
◆ 3036 Retainer
◆ T10025 Counter-hold
◆ VW 210 Checking appliance for V-belt and toothed belt
AG. Volkswagen AG d
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Prote AG.
With engine removed:
◆ 3419 Counter-hold
◆ 2068 A TDC setting device
◆ Feeler gauge
◆ Dial gauge (measuring range 0...3 mm)
Removing
Vehicles 09.94▸
1.5 - Removing, installing and tensioning camshaft toothed belt (>01.95) 43

AG. Volkswagen AG d
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- -> Unbolt left and right-hand securing bolts -1-.
ce
e
nl
pt
du
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Note:
erm
ab
Vehicles 09.94▸one securing bolt is located on each left and right-hand side on lock carrier.
ility
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- Fold lock carrier with radiator out forwards -arrow-.
, is n
h re
- Removing alternator V-belt:
hole
spec
es, in part or in w
=> Electrical system; Repair group 27; Removing and installing alternator with V-belt Removing and installing
t to the co
alternator with V-belt
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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op py
- Fold alternator up fully and secure. t. C rig
gh ht
- Removing V-belt for P.A.S. vane pump: yri
p by
co Vo
by lksw
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Prote
=> Running gear; Repair group 48; Assembly overview: Vane pump, reservoir, hydraulic pipes Assembly over‐
AG.
view: Vane pump, reservoir, hydraulic pipes

- Remove cylinder head cover and toothed belt guard for both toothed belts.
- -> Insert counter-hold T10025 and loosen vibration damper/toothed belt pulley by loosening centre bolt.
Note:
With engine removed, the counter-hold 3419 can also be used.
n AG. VolkTransporter
swagen AG
does 1991 ➤
lkswage not
5-Cyl. dieseld by V engine, Mech. - Edition 10.2000
o gu
ara
e nte
oris
- Turn crankshaft to TDC No. 1 cylinder -arrow-. auth eo
ra
ss c
ce
e
-> Engine installed
nl
pt
du
an
itte
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- Marks -arrows- on injection pump sprocket/console -C- and on flywheel/clutch bell housing -A- or drive plate/
erm
ab
clutch bell housing -B-must align.
ility
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Note:
h re
hole
spec
This condition only occurs every 2nd TDC position.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
-> Engine removed

- Set TDC setting device 2068 A to 82 mm -arrow A- the left-hand mark on the scale is the reference point.
- Fit setting device as shown. Turn crankshaft until TDC mark on flywheel/drive plate aligns with edge of
setting device -arrow B- and marks on injection pump sprocket and console also align.
Note:
- -> Lock injection pump sprocket with pin 2064.

- Mark D.O.R. of toothed belt.
- Hold injection pump drive sprocket with counter-hold 3036. Remove securing bolt and take off drive sprocket
with toothed belt.
- Remove vibration damper centre bolt.
- Remove the 4 x M8 crankshaft vibration damper/toothed belt pulley securing bolts.
- Remove vibration damper.
- Relieve toothed belt tension (loosen coolant pump).
- Remove lower toothed belt guard.

- Take off toothed belt.
Installing, tensioning
- Check whether TDC mark on flywheel and reference mark are aligned.
AG. Volkswagen AG d
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ab
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es, in part or in w
t to the co
- -> Lock camshaft with setting bar 2065 A.
- Centralize setting bar as follows:
rrectness of i
Turn camshaft so that one end of setting bar contacts the cylinder head. Using feeler gauge establish the
l purpos
gap at the other end of the setting bar. Place a feeler gauge corresponding to half the gap between setting
bar and cylinder head. Turn camshaft until the setting bar contacts the feeler gauge. Place a 2nd feeler
gauge, of same thickness, at the other end between setting bar and cylinder head.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
- -> Loosen camshaft sprocket securing bolt a 1/2 turn. Release camshaft sprocket from camshaft taper by
tapping with a hammer (using a drift through rear toothed belt guard opening).
- Fit toothed belt for camshaft drive. Note direction of rotation for used belts.
- Fit lower toothed belt guard and also fit M8 securing bolt for coolant pump.
- -> Adjust toothed belt tension by turning coolant pump with test unit VW 210.
Scale value: 12...13
measured between coolant pump and camshaft sprocket.
- Tighten coolant pump securing bolts to
20 Nm.
- Tighten lower toothed belt guard.
- Check if crankshaft is still positioned at TDC No. 1 cylinder, correctVoiflknecessary.
swa AG. gen AG
agen does
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ility
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es, in part or in w
t to the co
- Tighten camshaft sprocket securing bolt using counter-hold 3036.
rrectness of i
Observe steel type marking on bolt head:
8.8 = 85 Nm
l purpos
10.9 = 100 Nm
- -> Take setting bar 2065 A off camshaft.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
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f
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
- -> Insert counter-hold T10025 and tighten crankshaft vibration damper/toothed belt pulley centre bolt to
460 Nm.
Note:
With engine removed the counter-hold 3419 can also be used.
- Tighten the 4 x M8 crankshaft vibration damper/toothed belt pulley securing bolts to
20 Nm.
- Install injection pump drive toothed belt with injection pump drive sprocket. Tighten securing bolt until drive
sprocket can still just be turned by hand. Note direction of rotation for used toothed belts.
- Check toothed belt tension, adjust if necessary
=>Page 55 , Removing, installing and tensioning injection pump toothed belt (engine codes AAB, AJA).
- Remove pin 2064 from injection pump sprocket.

- -> Install adapter for gauge 2066 and gauge (measuring range 0...3 mm) with 2.0 mm preload in place of
sealing plug.
- Check that crankshaft is still on G
TDC No. 1 cylinder and adjust commencement of injection as follows:
. Volkswage
nA n AG d
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Notes: d by V gu
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h
◆ The vehicle smust
aut
be raised and readings made from below to enable
ra
c
the gauge to read whilst turning injection
pump drive sprocket.
s
ce
e
◆ A second mechanic is required to observe the flywheel/clutch bell housing markings when checking the
nl
pt
du
an
commencement of injection whilst the crankshaft is turned back and forth.
itte
y li
erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
- -> Turn injection pump drive sprocket against engine direction of rotation -direction of arrow A- using counter-
om
ion
hold 3036 until the gauge needle does not move any more.
c
in t
or
- Set gauge to "0" .

his
ate
- Turn injection pump drive sprocket in engine direction of rotation -direction of arrow B- using counter-hold
do
priv
3036 until the gauge reads:

um
for
en
1.00 ±0.02 mm lift (commencement of injection).

ng
t.
yi Co
- Hold injection pump drive sprocket in this position with counter-hold 3036 and pre-tighten to
. Cop py
50 Nm.
t rig
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pyri by
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by
Note:
cted agen
Prote AG.
The commencement of injection must be checked again by turning crankshaft back via vibration damper to
gauge reading "0" and forward to TDC. The reading will deviate due to toothed belt step.
- The commencement of injection is to be reset a second time taking deviation into account.
Example:
- First value 1.00 mm

Checked value 0.93 mm
= Deviation 0.07 mm
Value for second adjustment 1.07 mm
- Hold injection pump drive sprocket with counter-hold 3036, after second adjustment and tighten to
100 Nm.
- Install cylinder head cover and toothed belt guard.
- Install P.A.S. vane pump V-belt and adjust => Page 17 , item 17 .
- Install alternator V-belt and adjust => Page 35 .
- Install insulation tray.
- Install radiator with lock carrier.
1.6 - Removing, installing and tensioning camshaft toothed belt (02.95 >)
lkswage es n
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ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.
Vehicles 02.95 ▸ with tensioning roller for tensioning toothed belt
◆ 2065 A Setting bar

◆ 3036 Retainer
◆ T10025 Counter-hold
◆ 3355 Ring spanner
With engine removed:
◆ 3419 Counter-hold

◆ Feeler gauge
1.6 - Removing, installing and tensioning camshaft toothed belt (02.95 >) 49
Removing
- Remove ribbed belt => Page 36 .
- -> Remove charged air cooler bracket -1-.

- Remove left and right-hand securing bolts -2-.
AG. Volkswagen AG d
- Fold lock carrier and radiator out forwards -arrow-. ksw
agen oes
not
- Remove both toothed belt guards and cylinder head cover.
by
Vol
gu
a
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
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itte
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erm
ab
ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
- -> Insert counter-hold T10025 and loosen vibration damper/toothed belt pulley by loosening centre bolt.
l purpos
Note: nf
ercia
With engine removed, the counter-hold 3419 can also be used.

orm
m
- Turn crankshaft to TDC No. 1 cylinder -arrow-.

atio
om
n in
or c
Engine installed:
thi
te
sd
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f
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t.
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Cop py
t. rig
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Prote AG.
-> Engine codes AAB, AJA, AJT, ACV, AUF, AYC
AG. Volkswagen AG d
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ility
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es, in part or in w
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-> Engine codes ACV syncro, AHY, AXG, AXL
rrectness of i
l purpos
Note:
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
-> Engine removed

- Set TDC setting device 2068 A to 82 mm -arrow A- the left-hand mark on the scale is the reference point.
Note:
- Remove injection pump toothed belt:
◆ Engine codes AAB, AJA => Page 55 .

=> Page 60 .
- Remove vibration damper centre bolt.

- Loosen the 4 x M8 crankshaft vibration damper/toothed belt pulley securing bolts and remove 2 opposing
bolts.
- Loosen the 2 remaining bolts until the vibration damper can be released from crankshaft toothed belt pulley
by a light hammer blow on the bolt heads.
- Remove vibration damper.
- Remove lower toothed belt guard.
- Relieve toothed belt tension with ring spanner 3355.
- Take off toothed belt.
- Remove injection pump drive sprocket.

lkswage es n
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byV ua
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a ac
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ab
ility
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, is n
- -> Lock camshaft with setting bar 2065 A.
h re
- Centralize setting bar as follows:
hole
spec
Turn camshaft so that one end of setting bar contacts the cylinder head. Using feeler gauge establish the
es, in part or in w
gap at the other end of the setting bar. Place a feeler gauge corresponding to half the gap between setting
t to the co
bar and cylinder head. Turn camshaft until the setting bar contacts the feeler gauge. Place a 2nd feeler
gauge, of same thickness, at the other end between setting bar and cylinder head.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
- -> Loosen camshaft sprocket securing bolt a 1/2 turn. Release camshaft sprocket from camshaft taper by
by lksw
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Prote
tapping with a hammer (using a drift through rear toothed belt guard opening).
AG.
- -> Install tensioning roller -1- so that the retaining lug locates on the retaining pin -2- on the lower part of the
toothed belt guard.
- Fit toothed belt for camshaft drive. For used belts note direction of rotation.
- Tighten tensioning roller securing bolt hand tight.
AG. Volkswagen AG d
agen oes
olksw not
yV gu
- -> To tension
ed b the toothed belt turn the tensioning ara roller clockwise with ring spanner 3355 -direction of arrow-,
nte
is
untilththe
o right edge of indicator -A- aligns with right
r e oedge of indicator -B-.
au ra
ss c
Note:
ce
le
un
pt
The right edge of indicator -A- must not be rotated past the right edge of indicator -B-, otherwise the tensioning
an
d
itte
y li
roller can be damaged.

erm
ab
ility
If it does happen that it is turned too far, the tensioning roller must be fully released and then retensioned. You
ot p
must not turn the eccentric back by purely the amount it has been turned too far.
wit
is n
h re
ole,
- Tighten tensioning roller securing bolt to

spec
20 Nm.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi
- Check if crankshaft is still on TDC No. 1 cylinder, correct if necessary.
Co
op py
- Tighten camshaft sprocket securing bolt using counter-hold 3036.
t. C rig
gh ht
Observe steel type marking on bolt head:
yri
p by
o Vo
by c
8.8 = 85 Nm
lksw
cted agen
10.9 = 100 Nm
Prote AG.
- -> Remove setting bar 2065A from camshaft.
- Install lower toothed belt guard.
- Fit vibration damper with new centre bolt.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
e
nl
pt
du
an
itte
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- -> Insert counter-hold T10025 and tighten vibration damper/crankshaft toothed belt sprocket centre bolt to
erm
ab
160 Nm and turn 180° (1/2 turn) further (turning further can be completed in several stages).
ility
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Note:
h re
hole
spec
With engine removed the counter-hold 3419 can also be used.
es, in part or in w
t to the co
- Tighten the 4 x M8 crankshaft vibration damper/toothed belt pulley securing bolts to 20 Nm and turn
90° (1/4 turn)
rrectness of i
further (turning further can be completed in several stages).
- Turn crankshaft two rotations in engine D.O.R. until crankshaft is set to TDC No. 1 cylinder again.
l purpos
nf
ercia
orm
m
atio
om
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
- -> Again check the position of the tensioning roller indicator. If the right edges of indicator -A- and -B- do
not align, the tensioning procedure must be repeated.
- Install injection pump toothed belt:

=> Page 60 .
- Install both toothed belt guards and cylinder head cover.

- Install ribbed belt => Page 36 .
1.7 - Removing, installing and tensioning injection pump toothed belt (engine codes AAB,
AJA)
AG. Volkswagen AG d
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pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
◆ 2064 Pin
nf
ercia

or
◆ 3036 Retainer
m
m
atio
◆ VW 210 Checking appliance for V-belt and toothed belt

om
n in
or c
thi
te
sd
iva
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rp
cu

o
m
f
en
ng

t.
yi Co
op
◆ Dial gauge (measuring range 0...3 mm) C py
t. rig
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Vo
o
Removing
c by lksw
cted agen
Prote AG.
- Remove insulation tray:
AJA) 55
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un
pt
an
d
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erm
Vehicles 09.94▸
ab
ility
ot p
wit
- Remove radiator grille:
is n
h re
ole,
spec
t to the co
- -> Remove left and right-hand securing bolts -1-.
rrectne
Note:
ss o
cial p
f
Vehicles 09.94▸there is 1 securing bolt on each left and right-hand side of lock carrier.
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
- Remove injection pump toothed belt guard.

- Turn crankshaft in engine direction of rotation to TDC No. 1 cylinder:
-> Engine installed
-> Engine removed

- Set TDC setting device 2068 A to 82 mm -arrow A-, the left scale mark is the reference point.
setting device -arrow B-geand
n AGmarks
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geninjection
AG d pump sprocket and console also align.
wa oes
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Note: ed b ara
nte
ris
This conditionthoonly occurs every 2nd TDC position. eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
- -> Lock injection pump sprocket with pin 2064.

ss

o
cial p
inform
with toothed belt.

mer
atio
m
o
n
c
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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by c lksw
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Prote AG.
AJA) 57
lkswage es n
Transporter d1991 by
Vo ➤ ot g
ua
ran
5-Cyl. diesel horise
engine, Mech. - Edition 10.2000 tee
ut or
a a
- Install injection pump drive toothed belt with injection pump drivec sprocket.
ss
Tighten securing bolt until the
ce
le
drive sprocket can still just be turned by hand. For used toothed belts note direction of rotation.
un
pt
- -> Check toothed belt tension with test unit VW 210.
an
d
itte
y li
Scale value: 12...13
erm
ab
ility
ot p
If scale value is not achieved:
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
- -> Adjust toothed belt tension to scale value after loosening securing bolts -arrows- and moving console
t
sd
va
(with injection pump).

i
o
pr
cum
r
fo
en
ng
If scale value is achieved:

t.
yi Co
op py
- Remove pin 2064 from injection pump sprocket. t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- -> Install adapter for gauge 2066 and gauge (measuring range 0...3 mm) with 2.0 mm preload in place of
sealing plug.
- Check that crankshaft is still on TDC No. 1 cylinder and adjust commencement of injection as follows:
Notes:
◆ The vehicle must be raised and readings made from below to enable the gauge to read whilst turning injection
pump drive sprocket.
◆ A second mechanic is required to observe the flywheel/clutch bell housing markings when checking the
commencement of injection whilst turning crankshaft back and forth.
- -> Turn injection pump drive sprocket against engine direction of rotation -direction of arrow A- using counter-
hold 3036 until the gauge needle does not move any more.
- Set gauge to "0".
- Turn injection pump drive sprocket in engine direction of rotation -direction of arrow B- using counter-hold
3036 until the gauge reads:
Engine code AAB
Engine code AJA
- Hold injection pump drive sprocket in this position with counter-hold 3036 and pre-tighten to
50 Nm.
Note:
The commencement of injection must be checked again by turning crankshaft back via vibration damper to
gauge reading "0" and forward to TDC. The value will deviate due to toothed belt step.
- The commencement of injection is to be reset a second time taking deviation into account.
Example:
- First value 1.00 mm

Checked value 0.93 mm
= Deviation 0.07 mm lkswage es n
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Value for second adjustment 1.07 mmsed b ua
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- Hold injection pump drive sprocket, after second
ss
au
adjustment with counter-hold 3036 and tighten
r a to
c
100 Nm.
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- Install toothed belt guard for injection pump.
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AJA) 59
1.8 - Removing, installing and tensioning injection pump toothed belt (engine codes ACV,
AHY, AJT, AUF, AXG, AXL, AYC)
AG. Volkswagen AG d
agen oes
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◆ 3036 Retainer
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◆ Dial gauge (measuring range 0...3 mm) C py
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Removing
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AG. Volkswagen AG d
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Engine codes ACV, AUF, AYCVolksw not
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- -> Remove charge air cooler -1-.
l purpos

- Remove left and right-hand securing bolts -2-.
nf
ercia
orm
m
atio
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Engine codes AHY, AXG, AXL

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- Disconnect charge air cooler/intake pipe connecting pipe.
thi
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- Unscrew coolant pipe securing bolt from starter.
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- Remove injection pump toothed belt guard. C py
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- Turn crankshaft in engine direction of rotation to TDC No. 1 cylinder: gh ht
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Prote AG.
Engine installed:
-> Engine codes ACV, AJT, AUF, AYC
AHY, AJT, AUF, AXG, AXL, AYC) 61

-> Engine codes ACV syncro, AHY, AXG, AXL
Note:
AG. Volkswagen AG d
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nf
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-> Engine removed
rm
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- Set TDC setting device 2068 A to 82 mm -arrow A-, the left scale mark is the reference point.
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Cop py
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with toothed belt.
- Remove toothed belt tensioning roller.
- -> Fit adapter 3313 instead of sealing plug.
AG. Volkswagen AG d
agen Transporter not 1991 ➤
oes
olksw
V
5-Cyl. diesel d by engine, Mech. - Edition g10.2000
ua
ran
rise tee
ho
- Insert dial gauge (measuring range 0...3.0 mm) auinto
t
adapter with approx. 2.0 mm pretension. or
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ss
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nl
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t to the co
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- -> Check if markings on injection pump sprocket and injection pump align -arrow-.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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Prote AG.
- -> Remove blocking bolt -2- on injection pump.

- Remove intermediate plate -1-.
- Set dial gauge to "0".
- To check that the injection pump high pressure pistons are at BDC turn injection pump sprocket slowly with
counter hold 3036 against engine direction of rotation (clockwise). The dial gauge indicator must remain on
"0"; otherwise, set dial gauge to "0" after achieving BDC.
- Turn injection pump sprocket with counter hold 3036 slowly in engine direction of rotation (anti-clockwise)
until the dial gauge indicator displays 0.55 mm lift.
- Tighten the blocking bolt to 30 Nm.
- Place tooth belt on injection pump sprocket.
- Observe direction of rotation with used toothed belt.
- Fit injection pump sprocket into toothed belt and secure sprocket to the camshaft so that it can still turn.
- -> Checking idler roller installation position:

- Turn idler roller until the indicator aligns with the cylinder head flange contour -arrow-.
- Tighten securing nut -2- to 20 Nm.

- -> Install tensioning roller -1- so that the tensioning roller cap sits within the cut-outs on the console -arrow
B-.
- Tighten securing bolt and tight.
- To tension toothed belt turn tensioning roller anti-clockwise until both indicators align -arrow A-.
- Tighten securing bolt to 15 Nm.
- Tighten injection pump drive pulley securing nut to 160 Nm. Use counter hold 3036.
Note:
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Ensure when tightening the securing bolt that no torque is transferred to the blocked commencement of injection
pump shaft.
l purpos
- -> Remove injection pump locking bolt -2-.
nf
ercia
- Fit intermediate plate -1- and tighten blocking bolt to 12 Nm.
or
- Remove dial gauge and fit injection pump sealing plug.
m
m
atio
- Turn crankshaft two rotations in engine D.O.R. until crankshaft is set to TDC No. 1 cylinder again.
om
n in
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Cop py
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pyri by
Vo
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by
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Prote AG.
- -> Check the position of the indicator -arrow A-. The indicators must align. If the indicators do not align but
the front indicator is within the metal backing plate of the rear indicator, the setting is OK.
Note:
If the front indicator is outside the metal backing plate of the rear indicator the tensioning procedure must be
repeated.
- Install toothed belt guard.
Engine code AHY, AXG, AXL
- Install charge air cooler/intake pipe connecting pipe

- Tighten coolant pipe securing bolt on starter.
Continuation for all vehicles AG. Volkswagen AG d

agen oes
olksw not
- Dynamically check commencement of injection andedadjust by
V
if necessary: gu
ara
ris nte
ho eo
=> Repair group 23; Servicing Diesel direct injection
aut system; Dynamically checking commencement r aof injection
s c
and adjusting Servicing Diesel direct injection system
s Dynamically checking commencement of injection and
ce
e
nl
adjusting
pt
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mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
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Cop py
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Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V
Transporter 1991 ➤ ed b y gu
ara
is nte
5-Cyl. diesel engine,thor Mech. - Edition 10.2000 eo
au ra
s c
2 - Removing and installing sealing flange and flywheel
s
ce
le
un
pt
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d
itte
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2.1 - Removing and installing sealing flange and flywheel
erm
ab
ility
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t to the co
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mer
atio
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te
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fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note:
For repairs to the clutch:
◆ Engine codes AAB, AJA, AJT
=> 5-Speed manual gearbox 02B; Repair group 30; Servicing clutch Servicing clutch
◆ Engine codes ACV, AHY, AUF, AXG, AXL, AYC
=> 5-Speed manual gearbox 02G; Repair group 30; Servicing clutch Servicing clutch
1 Oil seal
◆ Note differing versions
◆ Sealing flange with PTFE oil seal without inner coil spring
◆ Renewing => Page 74
AG. Volkswagen AG d
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nform
mercia
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com
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2 Gasket
on in
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◆ Renew
te o
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3 Securing plate
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◆ Renew
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4 10 Nm
C py
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5 Suction pipe p by
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6 Gasket cted agen
Prote AG.
◆ Renew
2.1 - Removing and installing sealing flange and flywheel 67

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7 Sealing flange with oil seal

◆ Must be located on dowel sleeves
nform
ercia
◆ Note differing versions

◆ Only renew complete
m
at
◆ Lightly oil sealing lip of oil seal

om
ion
◆ Sealing flange with PTFE oil seal

c
in t
or
◆ Identification: no inner coil spring

his
ate

do
priv
◆ Do not additionally oil or grease the oil seal sealing lip

um
for
◆ Before installing, remove oil remains from crankshaft journal with a clean cloth
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◆ Use protective sleeve supplied when installing Cop py
◆ Remove protective sleeve first after sealing flange has been slid onto crankshaft journal
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Cop py
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8 Flywheel
◆ To remove and install flywheel counter-hold with 3067
◆ Removing and installing drive plate (for vehicles with automatic gearbox)
=> Page 71
◆ Removing and installing dual mass flywheel =>Page 73
9 60 Nm + 1/4 turn (90 °) further
◆ Renew
10 Cylinder block
◆ Removing and installing crankshaft => Page 77
=> Page 80
2.1 - Removing and installing sealing flange and flywheel 69

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11 Oil pump coupling ring t to the co

◆ With four drive lugs
◆ Break open to pull off
rrectne
◆ Heat new coupling ring to max. 200 °C before fitting

12 Gasket
ss
◆ Renew
o
cial p
13 Oil pump
inform
mer
◆ When installing note coupling ring -item 11 - on crankshaft

atio

om

n
c
i
or
◆ Dismantling and assembling => Page 123 , Removing and installing parts of lubrication system
thi
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14 20 Nm
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Prote AG.
2.2 - Removing and installing drive plate
◆ -> VW 558 Counter-hold tool

◆ Hexagon bolt M8x45 and two M10 hexagon nuts
◆ Depth gauge
Loosening and tightening drive plate
AG. Volkswagen AG d
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- -> Secure counter-hold tool VW 558 to the drive plate with a hexagon bolt M8x45. Place two M10 hexagon
l purpos
nuts between counter-hold tool and drive plate.
Position of counter-hold tool:

nform
ercia
A - To loosen
m
B - To tighten
a
com
tion in
r
te o
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2.2 - Removing and installing drive plate
agen
Prote AG.
Installing drive plate
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
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pt
du
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spec
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t to the co
- -> Locate drive plate and packing plate with recesses -1-.
rrectness of i
- Fit new bolts -3- and tighten to
30 Nm.
l purpos
nf
ercia
orm
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atio
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Vo
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Prote AG.
- -> Check dimension -a- at three points and calculate average.

Specification: 10.7...12.3 mm
If the specification is not attained:
- -> Remove drive plate again and fit shim -2-. Again tighten bolts -3- to
30 Nm.
- Tighten bolts -3- to 60 Nm and turn
90° (1/4 turn)
further (the additional 1/4 turn can be done in several stages).
AG. Volkswagen AG d
agen oes
ksw
2.3 - Removing by V and installing dual mass
ol not
guflywheel
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◆ -> 3067 Counter-hold

form
mer

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2.2 - Removing and installing drive plate 73

Removing AG. Volkswagen AG d
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nf
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atio
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- -> Turn secondary flywheel mass -B- of dual mass flywheel until the heads of the securing bolts can be seen
n in
or c
in the holes of secondary flywheel mass.
thi
te
sd
- Carefully loosen one securing bolt -1- and unscrew until it sits in the hole of secondary flywheel mass and
iva
o
r
prevents it from turning.

rp
cu
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- Loosen remaining dual mass flywheel securing bolts -2- diagonally and remove.
f
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t.
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- Remove dual mass flywheel.
Co
Cop py
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Installing py by
co Vo
by lksw
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Prote AG.
- Fit dual mass flywheel to crankshaft.
- Align primary flywheel mass -A- and secondary flywheel mass -B- bolt holes.
- Insert new securing bolts and tighten by hand.
- Tighten securing bolts to 60 Nm and then
90° (1/4 turn)
further (turning further can be done in several stages).
2.4 - Renewing crankshaft oil seal - pulley end -
◆ -> 3203 Oil seal extractor
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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nl
pt
du
an
itte
◆ -> 2080 A Fitting sleeve
y li
erm
ab
ility
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es, in part or in w
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rrectness of i
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nform
mercia
at
om
io
◆ -> Assembly device T10117
n
c
in t
r
(for PTFE oil seal)

o
his
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do
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Removing
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- Remove camshaft toothed belt: t. Cop py
rig
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◆ Vehicles ▸01.95 => Page 42 , Removing, installing and tensioning camshaft toothed belt.
cop Vo
by lksw
◆ Vehicles 02.95 ▸=> Page 49 , Removing, installing and tensioning camshaft toothed belt. cted agen
Prote AG.
- Unscrew inner part of the oil seal extractor 3203 two turns (approx. 3 mm) out of the outer part and lock with
knurled screw.
- -> Lubricate threaded head of oil seal extractor, place it in position and exerting firm pressure screw it as
far as possible into oil seal.
- Loosen knurled screw and turn inner part against crankshaft until the oil seal is pulled out.
Installing
Installing PTFE oil seal
2.4 - Renewing crankshaft oil seal - pulley end - 75

=> Page 76 .
- Lightly oil sealing lip of oil seal.

- Slide oil seal over guide sleeve from 2080 A.
- -> Press oil seal in onto stop with press sleeve from 2080 A and centre bolt from vibration damper.
- Install toothed belt and tension:
AG. Volkswagen AG d
◆ Vehicles 02.95 ▸=> Page 49lks,wRemoving,
agen installing and
oes tensioning camshaft toothed belt.
no o t gu
yV
db ara
Installing PTFE oil sealhorise nte
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t
au ra
c
ss
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Note:
nl
pt
du
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The oil seal sealing lip must not be additionally oiled or greased.
erm
ab
ility
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nf
ercia
orm
m
atio
om
n in
- Before installing, remove oil remains from crankshaft journal with a clean cloth.
or c
- -> Fit guide sleeve T10117/1 onto crankshaft journal.

thi
te
sd
a
- Slide oil seal over guide sleeve onto crankshaft journal.

iv
o
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Cop py
t. rig
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Prote AG.
- -> Press oil seal in onto stop with press sleeve from T10117 and centre bolt from vibration damper.
- Install toothed belt and tension:
◆ Vehicles 02.95 ▸=> Page 49 , Removing, installing and tensioning camshaft toothed belt.
3 - Removing and installing crankshaft

3.1 - Removing and installing crankshaft
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1 Oil pump coupling ring

rrectness of i
◆ Break open to pull off

l purpos

2 Bearing shell 1, 2, 3, 5 and 6
nform
ercia
◆ For bearing caps without oil groove

◆ For cylinder block with oil groove
m
◆ Do not interchange used bearing shells (mark)

com
tion in
3 Bearing cap
r
te o
thi
◆ Bearing cap 1: Pulley end

s
iva
do
◆ Bearing cap 4 with recesses for thrust washers

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Prote AG.
2.4 - Renewing crankshaft oil seal - pulley end -
◆ Bearing shell retaining lugs (cylinder block/bearing cap) must be on the same side
AG. Volkswagen AG d
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pt
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t. rig
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Prote AG.
4 65 Nm
5 Crankshaft
◆ Axial clearance new: 0.07...0.18 mm
Wear limit: 0.25 mm
◆ Check radial clearance with Plastigage
New: 0.016...0.075 mm
Wear limit: 0.16 mm
◆ Do not rotate the crankshaft when checking the radial clearance
◆ Crankshaft dimensions
=> Page 79
6 Sender wheel
◆ For engine speed sender (G28)
7 25 Nm
◆ Renew
8 Thrust washer
◆ For bearing cap 4
◆ Note fixing arrangement
AG. Volkswagen AG d
agen oes
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rm
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mercia
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com
tion in
r
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9 Bearing shell 4
◆ For bearing cap without oil groove
◆ For cylinder block with oil groove
10 Thrust washer
◆ For cylinder block, bearing 4
11 Cylinder block
=> Page 80
3.2 - Crankshaft dimensions
(in mm)
Honing Main journal Conrod

dimension -ø journal-ø
Basic -0.022 -0.022
dimension 58.00 47.80
-0.042 -0.042
3.1 - Removing and installing crankshaft 79

Honing Main journal Conrod

dimension -ø journal-ø
1st undersize -0.022 -0.022
57.75 47.55
-0.042 -0.042
2nd undersize -0.022 -0.022
57.50 47.30
-0.042 -0.042
3rd undersize -0.022 -0.022
57.25 47.05
-0.042 -0.042
4 - Dismantling and assembling pistons and conrods

4.1 - Dismantling and assembling pistons and conrods
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1 Piston ring
◆ Offset gaps by 120 °
◆ Remove and install with piston ring pliers
◆ "TOP" faces towards piston crown
◆ Checking ring gap=> Fig. 1
◆ Checking ring to groove clearance
=> Fig. 2
2 Circlip
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3 Piston
◆ Engine codes ACV, AHY, AJT, AUF, AXG, AXL, AYC with combustion chamber
◆ Mark installation position and cylinder number
◆ Piston/cylinder installation position and allocation for engine codes ACV, AHY, AJT, AUF, AXG, AXL,
AYC => Fig. 4
◆ Arrow on piston crown points to pulley end
◆ Install using piston ring clamp
◆ Cracks on piston skirt, renew piston
◆ With cut-out for oil jet
◆ Checking piston projection at TDC
=>Page 87
4.1 - Dismantling and assembling pistons and conrods 81

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◆ Only renew as a set

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◆ Mark cylinder number -A-

◆ Installation position:
Marking -B- faces towards pulley end
rrectness of i
5 Oil spray jet

◆ For piston cooling
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6 10 Nm
◆ Install with AMV 188 100 02
nform
ercia
7 Conrod bolt, 30 Nm + 1/4 turn (90 °) further

m
◆ Renew
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◆ Oil threads and contact surface

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◆ To measure radial clearance use old bolts

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8 Conrod bearing cap

◆ Mark cylinder number -A-
◆ Installation position:
Marking -B- faces towards pulley end
9 Bearing shell
◆ Note installation position
◆ Do not interchange used bearing shells
◆ Ensure retaining lugs fit tightly in recesses
◆ Axial clearance
Wear limit: 0.40 mm
◆ Check radial clearance with Plastigage:
Wear limit: 0.08 mm
Do not rotate crankshaft when checking radial clearance

AG. Volkswagen AG d
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10 Cylinder block
◆ Checking cylinder bores
=>Fig. 3
◆ Piston and cylinder dimensions
=>Page 89
11 Fitted pin
◆ The fitted pin must seat securely in the conrod, not in the bearing cap
12 Piston pin
◆ If difficult to remove, heat piston to 60 °C
◆ Remove and install with drift VW 222a
-> Fig. 1 Checking piston ring gap

◆ Feeler gauge
Test sequence gen AG

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does
- Push ring squarely from above down to approx.
o l swamm from bottom end
k15 of ncylinder.
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Piston ring New uth Wear
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limit or
Dimensions in mm ss
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1st compression ring 0.20...0.40 1.2

nl
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AAB, AJA 0.25...0.45 1.0
itte
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ACV, AHY, AJT, AUF, AXG,
erm
ab
AXL, AYC
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2nd compression ring 0.20...0.40 0.6
h re
AAB, AJA 0.20...0.40 1.0
hole
spec
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AXL, AYC
t to the co
Oil scraper ring 0.25...0.50 1.2
AAB, AJA 0.25...0.50 1.0
rrectness of i
AXL, AYC
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Prote AG.

-> Fig. 2 Checking ring to groove clearance
◆ Feeler gauge
Test sequence
Clean groove before check.
Piston ring New Wear limit

Dimensions in mm
1st compression ring 0.09...0.12 0.25
AAB, AJA 0.07...0.11 0.25
AXL, AYC
2nd compression ring 0.05...0.08 0.25
Oil scraper ring 0.03...0.06 0.15
AG. Volkswagen AG d
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-> Fig. 3 Checking cylinder bores

rrectness of i
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nform
ercia
◆ Internal dial gauge 50...100 mm

m
at
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Test sequence
on
c
in t
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- Take measurements at 3 positions in both lateral -A- and longitudinal -B- directions. Deviation from nominal
at
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dimension:
p
cum
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Engine code Deviation from nominal di‐
Co
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Dimensions in mm mension
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AAB, AJA 0.10
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ACV, AHY, AJT, AUF, 0.08
Prote AG.
AXG, AXL, AYC
Note:
Measuring the cylinder bores must not be done when the cylinder block is mounted on a repair stand with
adapter bracket VW 540, as incorrect measurements would then be possible.
-> Fig.4 Piston installation position and piston/cylinder allocation
Engine codes: ACV, AHY, AJT, AUF, AXG, AXL, AYC
Piston in cylinders 1 and 2:
Larger inlet valve chamber towards flywheel -arrows-
Piston in cylinders 3, 4 and 5:
Larger inlet valve chamber towards belt pulley side -arrows-.
Note:
wage
New piston allocation to cylinders is yshown
Volks by a coloured marking on
es n
ot gpiston crown.
ua
d b ran
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◆ Piston for cylinder 1 and 2:utho
or
marked 1/2 ss
a ac
◆ Piston for cylinder 3, 4 and 5:
ce
e
nl
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marked 3/4/5
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4.2 - Checking piston projection at TDC

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◆ -> VW 382/7 Measuring bridge
t. rig
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◆ -> VW 385/17 End measuring plate

◆ Dial gauge
Test sequence
-> Piston projection at TDC must be measured when installing new pistons or a short engine. Depending upon
piston projection, install the corresponding cylinder head gasket according to following table:
Engine codes: AAB, AJA
Piston projection Identification AG. Volkswagen AG d

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Piston projection Identification

om
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Holes/notches
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Up to ... 0.96 mm 1
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Piston projection Identification

Holes/notches
0.97 mm ... 1.01 mm 2
Above ... 1.01 mm 3
-> Cylinder head gasket identification
◆ Part No. = Arrow A

◆ Holes/notches = Arrow B
Note:
If differing figures are obtained when measuring piston projection, the highest figure should be taken when
selecting the gasket.
4.3 - Piston and cylinder dimensions

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Engine codes: AAB, AJA byV ua
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Honing Piston-ø Cylinder
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Basic dimension mm 79.48 79.51
an
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1st oversize mm 79.73 79.76
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Honing Piston-ø Cylinder bore-ø
dimension
Basic dimension mm 80.96 81.01
rrectness of i
1st oversize mm 81.21 81.26
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4.2 - Checking piston projection at TDC 89

15 - Cylinder head, Valve gear
1 - Removing and installing cylinder head

1.1 - Removing and installing cylinder head
AG. Volkswagen AG d
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Checking compression pressures
=> Page 101
Notes:
◆ When installing an exchange cylinder head with fitted camshaft, the contact surfaces between bucket tappet
and cam must be oiled after installation.
◆ The plastic protectors fitted to protect the open valves must only be removed immediately before fitting the
cylinder head.
90 15 - Cylinder head, Valve gear

◆ When replacing the cylinder head the complete coolant must be renewed.
AG. Volkswagen AG d
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1 Cylinder head cover

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◆ For engine codes ACV, AHY, AJT, AUF, AXG, AXL, AYC the cylinder head cover is secured to bearing
cap with hexagon bolts
rrectness of i
2 Cover cap
l purpos
3 10 Nm
nf
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or
4 Dished washer
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5 Upper sealing washer

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◆ Engine codes ACV, AHY, AJT, AUF, AXG, AXL, AYC C py
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1.1 - Removing and installing cylinder head 91

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7 Cylinder head cover gasket t to the co
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◆ Insert into groove on cylinder head cover

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8 Cylinder head bolt

◆ Renew
nform
ercia
◆ Note sequence when loosening and tightening

=> Page 99 , Installing cylinder head
m
at
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9 Toothed belt guard securing bolt

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◆ M6 = 10 Nm
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◆ M8 = 20 Nm
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11 Injection pump drive sprocket securing bolt

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◆ Engine code AAB. AJA: 100 Nm C py
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◆ Engine codes ACV, AHY, AJT, AUF, AXG, AXL, AYC: 160 Nm
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◆ Oil threads and contact surface
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◆ Use counter-hold 3036 to loosen and tighten
agen
Prote AG.

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12 Injection pump toothed belt

◆ Check for wear
◆ Do not kink
Engine codes AAB, AJA=> Page 60
13 Injection pump drive sprocket
Engine codes AAB, AJA =>Page 60 , Removing, installing and tensioning injection pump toothed belt

AG. Volkswagen AG d
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14 20 Nm
for
en
ng
t.
15 Idler roller
yi Co
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◆ Note installation position =>Page 60 , Removing, installing and tensioning injection pump toothed belt p by
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by c lksw
16 Vacuum pump cted agen
Prote AG.
17 Plunger
18 O-ring
◆ Renew
19 Cylinder head gasket
◆ Renew
◆ Note marking
=>Fig. 2
coolant

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20 Cylinder head
um
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fo
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◆ Check for distortion => Fig. 1

t.
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op
◆ Installing => Page 99 C py
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◆ If replaced renew the complete gh ht
yri by
coolant cop Vo
by lksw
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Prote AG.
=> Repair group 23; Diesel direct injection system; Removing and installing injectors Diesel direct injection
21 Rear toothed belt guard

◆ 02.95 ▸
◆ ▸01.95 =>Page 21 , item 7

AG. Volkswagen AG d
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c
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22 Camshaft sprocket
p by
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Prote AG.
Vehicles ▸01.95
8.8 = 85 Nm
10.9 = 100 Nm
◆ Use counter-hold 3036 to loosen and tighten

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◆ Check for wear
◆ Do not kink
Vehicles ▸ 01.95
=> Page 49
26 15 Nm

AG. Volkswagen AG d
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-> Fig. 1 Checking cylinder head for distortion
wit
, is n
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hole
spec
es, in part or in w
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◆ Knife edge straight edge
◆ Feeler gauge
rrectness of i
Max. permissible distortion: 0.2 mm
l purpos
Note:
nform
ercia
Reworking diesel cylinder heads is not permissible.

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ion
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-> Fig.2 Cylinder head gasket identification
◆ Part No. = Arrow A

◆ Holes/notches = Arrow B
Note:
Different thicknesses of cylinder head gasket are fitted depending on the piston projection. When replacing the
cylinder head gasket, install a new gasket with the same identification.

1.2 - Removing and installing cylinder head
AG. Volkswagen AG d
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ion
c
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or
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do
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.
◆ 3070 Fitting tool with guide pins
◆ V.A.G 1332 (40...200 Nm) Torque wrench
Removing

- -> Maintain sequence when loosening and tightening cylinder head bolts.
Installing
Notes:
Warning!
cramped conditions:
◆ Always renew cylinder head bolts.

◆ In cases of repair carefully remove gasket remains from cylinder head and cylinder block. Ensure that no
long grooves or scratches are created. When using abrasive paper do not use a grade less than 100.
◆ Carefully remove emery and abrasive remains.
◆ Remove new cylinder head gasket from packaging, just before installation.
◆ Handle gasket extremely carefully. Damaging the silicone layer or the indented area will lead to leaks.
◆ Vehicles ▸01.95 with soft material cylinder head gasket. In cases of repair install a new metal cylinder head
gasket.
◆ Replace swirl chambers before installing metal cylinder head gasket on vehicles with engine code AAB =>
Page 121 .
AG. Volkswagen AG d
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- Turn crankshaft to TDCVmarking
olks
w
before fitting cylinder
es n
ohead.
t
- Turn crankshaft against
d by engine direction of rotation untilguno
ara piston is at TDC.
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- Place cylinder head gasket on.

- -> To centralize, screw guide pins from 3070 into the outer threaded holes on the intake side.
- Fit cylinder head, screw in 10 remaining cylinder head bolts and tighten hand tight.
nf
ercia
- Remove guide pins with removal tool from 3070 and install cylinder head bolts.
orm
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Prote AG.
- -> Tighten cylinder head in four stages in sequence shown as follows:

- 1. Tighten initially with torque wrench:
Stage I = 40 Nm
Stage II = 60 Nm
- 2. Turn further with normal spanner:

Stage III = 1/4 turn (90 °)
Stage IV = 1/4 turn (90 °)
Notes:
◆ Loosening cylinder head: Reverse sequence.

◆ Pulling-down cylinder head after repairs is not necessary.
- After tightening the cylinder head turn camshaft so that the cams for No. 1 cylinder point evenly upwards.
Turn crankshaft, in engine D.O.R., To TDC before fitting toothed belt.
1.3 - Checking compression pressures
AG. Volkswagen AG d
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◆ V.A.G 1381 Compression tester
yi Co
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◆ V.A.G 1763 Compression tester t. C rig
gh ht
◆ 3035 Ring spanner yri
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◆ 3220 Joint spanner by c lksw
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Prote AG.

olkswagen AG
en AG. V
Transporter 1991 ➤ ksw
ag does
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Vol
5-Cyl. diesel engine, Mech. - Edition 10.2000ed by gu
ara
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◆ V.A.G 1332 Torque wrench (40...200 Nm) au ra
c
ss
ce
le
Test conditions
un
pt
an
d
itte
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erm
• Engine oil temperature min. 30 °C.
ab
ility
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Test sequence
is n
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spec
t to the co
- Pull electrical wire off engine stop device on injection pump, insulate and lay to side.
- Remove injection pipes with slotted ring spanner 3035.
- Unscrew all injectors and take out heat shields.
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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sd
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- -> Screw in adapter V.A.G 1323/2A in place of the injectors.
agen
Prote AG.
Insert old heat shield between adapter and cylinder head.
- Screw compression pressure recorder V.A.G 1381 or V.A.G 1763 into the adapter by hand.
Note:
Using the compression tester => Operating instructions.
- Operate starter until tester shows no further pressure increase.
Compression pressure:
New: 34 bar
Wear limit: 26 bar
Permissible difference between all cylinders: 5 bar

Note:
Always renew heat shield seals between cylinder head and injectors.
-> Installation position of heat shield:

Arrow points towards cylinder head.
◆ Tightening torques:
Injector pipes = 25 Nm
Injectors = 70 Nm
- Pull connector off fuel cut-off valve/commencement of injection valve on injection pump.
- Separate connector to quantity adjuster on injection pump.
- Remove all glow plugs using socket spanner 3220.
AG. Volkswagen AG d
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- -> Screw in adapter V.A.G 1381/12 in place of the glow plugs.

nl
pt
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an
- Check compressions with compression tester V.A.G 1381 or V.A.G 1763.
itte
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Note: ility
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Using the compression tester => Operating instructions.
hole
spec
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- Operate starter until tester shows no further pressure increase.

t to the co
Compression pressure:
rrectness of i
New: 25...31 bar

l purpos
Wear limit: 24 bar
Permissible difference between all cylinders: 5 bar

nform
mercia
- Install glow plugs with socket and jointed extension 3220

at
om
io
Tightening torque: 15 Nm.

n
c
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- Interrogate fault memory:

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Note:
Co
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Faults will have been stored because the connector to injection pump has been separated. Therefore inter‐
op Vo
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rogate and erase fault memory. cted agen
Prote AG.
1.3 - Checking compression pressures 103

2 - Servicing valve gear

2.1 - Servicing valve gear
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Prote AG.
Note:
Cylinder heads with cracks between the valve seats may be used without reducing engine life, provided the
cracks are small and not more than 0.5 mm wide.
1 20 Nm
2 15 Nm
4 Bearing cap
◆ Installation position => Fig. 2
◆ Installation sequence
=> Page 119 , removing and installing camshaft
◆ To install, seal separating surfaces of bearing caps 1 and 4 with AMV

174 004 01
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5 Camshaft
t to the co
◆ Checking axial clearance => Fig. 1

=> Page 119
rrectness of i
◆ Checking radial clearance with plastigage

Wear limit: 0.11 mm
l purpos
◆ Run-out: max. 0.01 mm

◆ Identification and valve timing
nform
ercia
=> Fig. 4
6 Bucket tappet
m
a
com
tio
◆ Do not interchange
n in
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◆ With hydraulic valve clearance compensation

te o
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◆ Checking => Page 120

s
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◆ Store with cam lobe contact surface downwards

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◆ Before installing check camshaft axial clearance => Fig. 1

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◆ Oil contact surface
Co
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Prote AG.
2.1 - Servicing valve gear 105

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7 Cotters
on in
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8 Upper valve spring plate

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9 Valve spring
do
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◆ Removing and installing:

fo
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Cylinder head
n
t.
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removed: With valve spring compressor 2037 Cop py
t. rig
installed: => Page 117 , Renewing valve stem seals gh ht
pyri by
Vo
10 Inner valve spring
co lksw
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◆ Engine code AAB ▸11.94
AG.
◆ Removing and installing:

Cylinder head
removed: With valve spring compressor 2037
installed: => Page 117 , Renewing valve stem seals

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11 Lower valve spring plate py by
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◆ Remove and install with puller 3047A cted agen
Prote AG.
12 Valve stem seal
◆ Renewing=> Page 117
13 Valve guide
14 Service part - valve guide
◆ Service version with collar
15 Oil seal
◆ To remove and install, remove bearing cap
◆ Removing, installing and tensioning injection pump toothed belt:
Engine codes AAB, AJA =>Page 60

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16 Injector
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nf
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m
=> Repair group 23; Servicing Diesel direct injection system; Removing and installing injectors Servicing Diesel
atio
m
direct injection system Removing and installing injectors

o
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17 Heat insulation seal

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◆ Installation position => Fig. 5

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mer
atio
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18 Glow plug
n
c
i
or
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◆ Removing, installing and checking glow plug for engine codes AAB, AJA:
iv
o
pr
cum
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fo
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=> Diesel injection and glow plug system (2.4 ltr. engine); Repair group 28; Checking glow plug system Check‐
t.
yi Co
ing glow plug system Cop py
t. rig
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◆ Removing, installing and checking glow plug for engine codes ACV, AHY, AJT, AUF, AXG, AXL, AYC:
co Vo
by lksw
cted agen
Prote AG.
=> Diesel direct injection and glow plug system; Repair group 28; Checking glow plug system Checking glow
plug system
19 Cylinder head
◆ See note
=> Page 104
◆ Reworking valve seats
=> Page 113
20 Valves
◆ Valve dimensions => Fig. 3

AG. Volkswagen AG d
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21 Swirl chamber
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hole

spec
es, in part or in w
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22 Oil seal
◆ To remove and install, remove bearing cap
rrectness of i
◆ Removing, installing and tensioning camshaft toothed belt:

l purpos
▸01.95 => Page 49

nf
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-> Fig. 1 Checking camshaft axial clearance
Special tools, testers, measuring instruments and auxiliary items required
◆ VW 387 Universal dial gauge bracket

◆ Dial gauge AG. Volkswagen AG d
agen oes
olksw not
V
Wear limit: max. 0.15 mm ed by gu
ara
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Check with bucket tappets removed and
aut with first and last bearing caps fitted. ra
ss c
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un
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an
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ab
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mer
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c
i
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t.
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Cop py
t. rig
gh ht
pyri by
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by c lksw
cted agen
Prote AG.
-> Fig. 2 Fitting position of camshaft bearing caps
Note offset. Before installing camshaft fit bearing caps and determine fitting position.

-> Fig. 3 Valve dimensions
Note:
Valves must not be reworked. Only lapping-in is permitted.
Dimension Inlet valve Exhaust valve

øa mm 36.00 31.00
øb mm 7.97 7.95
c mm 95.00 95.00
α <° 45 45
n AG. Volkswagen A
Engine codes: ACV, AHY,
olks
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age AUF, AXG, AXL,
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Dimension tho Inlet
r valve Exhaust valve eo
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øa mm ss 36.00 31.50 c
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øb mm 7.97 7.95
un
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c mm 96.85 96.85
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α <° 45 45 ab
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nform
mercia
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te o
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-> Fig.4 Camshaft identification, valve timing

do
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Identification C py
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◆ Cam base diameter: a = 38 mm ø
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◆ Identification via numbers and letters stamped between inlet and exhaust cams:
agen
Prote AG.
Engine codes AAB, AJA ACV, AHY, AJT,

AUF, AXG,
AXL, AYC
No. 1 cylinder -arrow W WZO
A-
No. 2 cylinder -arrow - 046
B-
Between No. 4 and 5 074B -
cylinder -arrow C-

Valve timing at 1 mm valve lift
Engine codes AAB, AJA ACV, AHY, AJT,

AUF, AXG, AXL,
AYC
Inlet opens after TDC 6.0 ° 8.0 °
Inlet closes after BDC 20.0 ° 28.0 °
Exhaust opens BBDC 25.5 ° 37.0 °
Exhaust closes 6.5 ° 10.0 °
BTDC
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-> Fig.5 Installation position of heat insulation seal
hole
spec
es, in part or in w
t to the co
Direction of arrow to cylinder head
rrectness of i
l purpos
2.2 - Reworking valve seats
nform
mercia
a
com
ti
on in
r
te o
thi
◆ Depth gauge
s
iva
do
◆ Valve seat refacing tool

r
rp
cum
fo
en
ng
t.
Notes:
yi Co
Cop py
t. rig
gh ht
yri
◆ When repairing engines with leaking valves, it is not always sufficient to reface or renew valve seats and
p by
o Vo
by c
valves. It is also necessary to check the valve guides for wear. This is particularly important on high mileage
lksw
cted agen
Prote
engines.
AG.
◆ The valve seats should only be reworked just enough to produce a perfect seating pattern. The maximum
permissible reworking dimension must be calculated before work is carried out. If the reworking dimension
is exceeded, the function of the hydraulic tappets can no longer be guaranteed and therefore the cylinder
head should be renewed.
Calculating max. permissible reworking dimension
- Insert valve and press firmly against seat.
Note:
If the valve is to be renewed as part of a repair, use a new valve for the calculation.

- -> Measure distance -a- between end of valve stem and upper edge of cylinder head.
- Calculate max. permissible reworking dimension from measured distance -a- and minimum dimension.
Minimum dimension:
Inlet valve 35.8 mm
Exhaust valve 36.1 mm
Measured distance minus minimum dimension

= max. permissible reworking dimension.
Example:
- Measured distance 36.5 mm

Minimum dimension 35.8 mm
= max. perm. rework dimension 0.7 mm agen
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Cop py
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py by
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-> Reworking valve seats by c lksw
cted agen
Prote AG.
Dimen. In. valve seats Ex. valve seats

øa mm 37.201) 33.201)
øb mm 34.80 30.40

Dimen. In. valve seats Ex. valve seats

c mm 2.70 2.05
45° Valve seat angle
15° Correction angle
en AG. V
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2.3 - Checking valve guides

un
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an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
◆ VW 387 Universal dial gauge bracket
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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◆ Dial gauge
en
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t.
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Cop py
Test sequence
t. rig
gh ht
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Vo
co lksw
by
- -> Insert new valve into guide until end of valve stem is flush with end of guide. Due to the slight difference
cted agen
Prote AG.
in stem dimensions, ensure that only an inlet valve is used in the inlet guide and an exhaust valve in the
exhaust guide.
Valve rock: max. 1.3 mm
2.4 - Renewing valve guides
◆ -> 10-206 Drift
2.2 - Reworking valve seats 115

AG. Volkswagen AG d
agen oes
Transporter 1991 ➤ Vol
ksw not
gu
by
5-Cyl. diesel engine, Mech. ri-se Edition 10.2000
d ara
nte
o th eo
s au ra
c
s
ce
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un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
◆ -> 10-215 Hand reamer and cutting fluid
Removing
nform
mercia
- Clean and check cylinder head. Cylinder heads in which the valve seats can no longer be reworked, or
a
com
tio
cylinder heads which have already been machined to the minimum dimension, should not have the valve
n in
r
guides replaced.
te o
thi
- Press out worn valve guides with drift 10-206 from the camshaft side (valve guides with shoulder - repair
s
iva
do
version - from the combustion chamber side).
r
rp
cum
fo
en
ng
t.
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Installing
Co
Cop py
t. rig
gh ht
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- Coat new guides with oil and press in with drift 10-206 from the camshaft side (cylinder head cold) until
p by
co Vo
by lksw
shoulder makes contact. Prote
cted AG.
agen
Note:
When the shoulder on guide makes contact, the pressure must not exceed 1.0 t otherwise shoulder may break
off.
- Ream guides out with hand reamer 10-215 using plenty of cutting fluid.
- Rework valve seats => Page 113 .

2.5 - Renewing valve stem seals
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◆ 2036 Assembly appliance

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◆ 3047A Puller
hole
spec
◆ 10-204 Fitting tool

es, in part or in w
◆ VW 541/1A Valve lever

t to the co
◆ VW 541/5 Thrust piece

rrectness of i
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nform
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a
com
tion in
r
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Cop py
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Prote AG.
2.5 - Renewing valve stem seals 117

olksw
- Edition 10.2000
AG. V agen AG
agen does
Removing olksw not
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un
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
(with cylinder head fitted)
nform
ercia
- Remove camshaft => Page 119 .

- Remove bucket tappets (do not interchange) and store with the contact surface downwards.
m
a
com
t
- Set piston of respective cylinder to top dead centre (TDC).
ion in
- -> Fit assembly tool 2036 and adjust mountings to height of studs.
r
te o
thi
- Remove valve springs with valve lever VW 541/1A and press piece.
s
iva
do
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fo
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t.
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gh ht
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Prote AG.
Note:
The valves are supported by the piston crown.
- -> Pull off valve stem seals with puller 3047A.

lkswage es n
o ot g
byV ua
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Transporter
or 1991 ➤
u
ss
a
5-Cyl. diesel engine, Mech.ac- Edition 10.2000
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
Installing
mer
atio
m
- -> To prevent damage to the new valve stem seals, place plastic sleeve -A- on valve shaft.
o
n
c
i
or
n
- Oil valve stem seal -B-, place it in the tool 10-204 and push carefully onto the valve guide.
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
2.6 - Removing and installing camshaft

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
Special tools, testers, measuring instruments and auxiliary items required cted agen
Prote AG.
Removing
- Remove camshaft toothed belt:
- Removing injection pump toothed belt:
◆ Engine codes AAB, AJA => Page 55 , Removing, installing and tensioning injection pump toothed belt.
◆ Engine codes ACV, AHY, AJT, AUF, AXG, AXL, AYC => Page 60 , Removing, installing and tensioning
injection pump toothed belt.
- Remove vacuum pump with plunger => Page 94 , items 16 and 17 .

- First remove bearing caps 1 and 3. Then loosen bearing caps 2 and 4 alternately and diagonally.
Installing
Notes:
◆ When installing the camshaft No. 1 cylinder cams must point upwards.
2.5 - Renewing valve stem seals 119

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Transporter yV
o1991 ➤
lks ot g
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5-Cyl. rdiesel
ise
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tee
tho
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du
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ab
ility
ot p
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
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en
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Cop py
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Prote AG.
◆ -> When installing the bearing cap note offset, before installing camshaft fit bearing caps and determine
fitting position.
◆ Seal separating surfaces of bearing caps 1 and 4 using AMV 174 004 01.
- Oil camshaft running surfaces.

- Tighten bearing caps 2 and 4 alternately and
diagonally to
20 Nm.
- Install bearing caps 1 and 3 and also tighten to
20 Nm.
- Install camshaft toothed belt and tension:
- Install injection pump toothed belt and tension:
◆ Engine codes AAB, AJA => Page 55 , Removing, installing and tensioning injection pump toothed belt.
◆ Engine codes ACV, AHY, AJT, AUF, AXG, AXL, AYC => Page 60 , Removing, installing and tensioning
injection pump toothed belt.
Note:
When new tappets have been installed the engine must not be started for about 30 minutes. Hydraulic com‐
pensation elements must settle (otherwise valves will strike pistons).
2.7 - Checking hydraulic bucket tappets
◆ Feeler gauge

◆ Wood or plastic wedge
Notes:
◆ Renew defective tappet complete (cannot be adjusted or repaired).
◆ Irregular valve noises when starting engine are normal.
Test sequence
- Start engine and run until the radiator fan has switched on once.
- Increase engine speed to about 2500 rpm for 2 minutes.
en AG. V
olkswagen AG
ag does
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If the hydraulic tappets are still noisy, locateeddefective tappets as
by follows: gu
ara
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- Remove cylinder head cover. utho eo
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a
- Rotate crankshaft clockwise, untilsscam of the bucket tappet tobe checked is pointing upwards. c
ce
le
- Determine play between cam and bucket tappet.

un
pt
- If the play is in excess of 0.1 mm, renew bucket tappet. If the play is less than 0.1 mm or no play, proceed
an
d
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with check as follows:
rm
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tion in
- -> Press tappet down with a wooden or plastic wedge. If free travel in excess of 1 mm is felt before tappet
r
te o
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After installing new tappets the engine must not be started for approx. 30 minutes. Hydraulic compensation
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Prote AG.
2.8 - Replacing swirl chambers (engine codes AAB, AJA)

◆ -> VW 382/7 Measuring bridge
◆ Dial gauge
2.7 - Checking hydraulic bucket tappets 121

◆ Drift
◆ Synthetic head hammer
◆ -> VW 385/17 End measuring plate AG. Volkswagen AG d

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Work sequence orise nte
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• Cylinder head removed ss c
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nl
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- Remove injectors:
itte
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=> Repair group 23; Servicing fuel injection; Removing and installing injectors. Servicing fuel injection Removing
ot p
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and installing injectors.
, is n
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spec
- Remove glow plugs with ring spanner 3035.
es, in part or in w
- Drive swirl chamber out using a suitable drift through injector opening.
t to the co
- Clean off combustion residue from swirl chamber contact surfaces in cylinder head.
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
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- Fit new swirl chamber in position, installation position is determined by guide lug and groove.
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- Drive swirl chamber in using a synthetic head hammer.
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- -> Measure the swirl chamber projection. Prote AG.
Specification: max. 0.05 mm
If the specification is exceeded:
- Replace cylinder head.

17 - Lubrication
1 - Removing and installing parts of the lubrication system

1.1 - Removing and installing parts of the lubrication system
Notes:
◆ If large quantities of metal particles or other deposits (caused, for example, by partial seizure of the crank‐
shaft or conrod bearings) are found in the engine oil when performing repairs, clean the oil passages
thoroughly and renew the oil cooler in order to prevent further damage from occurring later.
◆ The oil level must not be above the max. mark - danger of damage to catalyst!
Checking oil pressure => Page 138

AG. Volkswagen AG d
Oil system capacity1): agen oes
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Without oil filter 5.0 ltrs. horis nte
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With oil filter 5.5 ltrs. s aut ra
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1) Up-to-date figures:
pt
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=> "Emission and idling test" binder
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Engine oil specification: Vehicles without long-life service
h re
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spec
Naturally aspirated Diesel (engine codes AAB, AJA):
es, in part or in w
Only use engine oil conforming to VW standard 500 00, 501 01, 502 00, 505 00 or 505 01 or multi-grade oil to
t to the co
ACEA B3/B4.
Turbo Diesel (engine codes ACV, AJT, AHY, AUF):
rrectness of i
Only use engine oil conforming to VW standard 505 00 or 505 01.
l purpos
Engine oil specification: Vehicles05.99 ▸with long-life service

nform
ercia
Only use engine oil conforming to VW standard 506 00 or 506 01.

m
at
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io
Note:
n
c
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or
his
ate
Engine oils conforming to VW standard 500 00 or 501 01 can be used furthermore. The oil must then be changed
do
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every 12 months or every 15,000 km and the service interval display must be programmed correspondingly.
p
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Procedure:
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Cop py
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1.1 - Removing and installing parts of the lubrication system 123

AG. Volkswagen AG d
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I =>Page 125
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II =>Page 131
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124 17 - Lubrication
AG. Volkswagen AG d
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Part I
1 160 Nm + 1/2 turn (180 °) further

◆ 02.95 ▸
◆ Renew
◆ Threads and shoulder must be free of oil and grease
2 20 Nm + 1/4 turn (90 °) further
◆ 02.95 ▸
3 Ribbed belt
◆ 02.95 ▸
◆ Mark direction of rotation before removing
◆ Check for wear
◆ Remove and install with lever 3299 => Page 36

AG. Volkswagen AG d
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4 Vibration damper with ribbed V-belt pulley rised b ara
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◆ 02.95 ▸ aut
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◆ When installing note fixing arrangement ss c
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Vehicles ▸ 01.95
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=> Page 49
t to the co

◆ Observe steel type markings on bolt head:
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8.8 = 85 Nm
10.9 = 100 Nm
l purpos
◆ To loosen and tighten use counter-hold 3036

nform
mercia
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om
ion
c
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ate
do
priv
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for
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t.
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Cop py
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Prote AG.
AG. Volkswagen AG d
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8 Camshaft sprocket ss
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nl

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Vehicles ▸01.95
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9 10 Nm
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◆ ▸01.95
spec
◆ 02.95 ▸=>Page 24 , item 5

es, in part or in w
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11 20 Nm
12 Oil pump
rrectness of i
◆ When installing note coupling ring on crankshaft

=> Page 136 , item 38
l purpos

nf
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13 End plate
l purpos
14 Oil pump
◆ Identification mark "Δ" points in direction of end plate
nform
ercia
15 Pressure relief valve, 40 Nm

m
at
◆ Opening pressure: 5.3...6.3 bar

om
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16 Seal
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18 Tensioner
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◆ 02.95 ▸ C py
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19 Idler wheel
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◆ Remove with puller 3034 and bolt 3034/1
AG.

◆ ▸01.95
AG. Volkswagen AG d
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Prote AG.
21 Vibration damper with V-belt pulley

◆ ▸01.95
22 460 Nm
◆ ▸01.95
◆ Coat threads and bolt head contact surfaces with sealing paste AMV 188 001 02
23 V-belt
◆ For alternator
◆ ▸01.95
max. deflection:
new V-belt approx. 2 mm
used V-belt approx. 5 mm
◆ Checking V-belt tension on vehicles with toothed rack tensioner
=>Page 35

AG. Volkswagen AG d
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24 V-belt
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◆ For P.A.S vane pump

is n
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◆ ▸01.95
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spec

deflection:
t to the co
approx. 5 mm (new and used V-belt)

◆ Adjusting V-belt tension:
rrectne
ss o
cial p
25 Washer
f inform
◆ Renew
mer
◆ diamond coated
atio
om
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c
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Prote AG.
AG. Volkswagen AG d
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V gu
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or eo
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un
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an
d
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rm
ab
pe
ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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s
iva
do
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cum
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en
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t.
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Cop py
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by c lksw
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Prote AG.
Part II
1 Oil filter
◆ Loosen with strap wrench
◆ Tighten by hand
◆ Note instructions on filter when installing
2 25 Nm
3 Oil collector
4 Oil cooler
◆ Coat contact area to flange, outside the seal, with AMV 188 100 02
◆ Ensure clearance to adjacent components
◆ See note
=> Page 123
5 O-ring
6 Oil filter bracket
◆ Installation position determined by dowel pin

AG. Volkswagen AG d
agen oes
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V gu
d by ara
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aut ra
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un
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7 Sealing ring
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◆ Renew
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spec
es, in part or in w
9 Sealing plug, 20 Nm t to the co

11 Oil supply pipe
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◆ To exhaust turbocharger
l purpos
13 Cap
nform
ercia
14 Gasket
m
a
com
ti
on in
r
15 Dipstick
te o
thi
s
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◆ The oil level must not be above the max. mark!

do
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16 Oil filler tube uth o
or
a ac
◆ Engine code: ss AAB, AJA
ce
le
◆ Engine codes ACV, AHY, AJT, AUF, AXG, AXL, AYC with crankcase breather valve
un
pt
an
d
17 10 Nm
itte
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ab
18 0.9 bar oil pressure switch (F1), 25 Nm

ility
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◆ Only on vehicles with two oil pressure switches

wit
is n
◆ If sealing ring is leaking nip open and replace.

h re
ole,

spec
19 Oil pressure retention valve

t to the co
20 Adapter, 50 Nm
rrectness o
cial p
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mer
atio
om
n
c
i
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t.
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Cop py
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133
cted agen
Prote AG.
1.1 - Removing and installing parts of the lubrication system
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21 0.3 bar oil pressure switch (F22), 25 Nm

spec
es, in part or in w
◆ Only on vehicles with two oil pressure switches

t to the co
◆ On vehicles with one oil pressure switch:

0.7 bar (F1)
rrectness of i

22 Oil spray jet
l purpos
◆ For piston cooling

23 10 Nm
nform
ercia
◆ Install with AMV 188 100 02

m
at
om
24 Sump gasket
ion
c
in t
◆ Series production: Silicone sealant

or
his
e
◆ Case of repair: Gasket

at
do
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◆ Renew
p
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or
25 Suction pipe
f
en
ng
t.
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◆ Clean strainer if soiled t. Cop py
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ility
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hole
spec
es, in part or in w
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26 Sump
◆ Clean sealing surface before installing
nform
ercia
27 20 Nm
m
a
com

ion in
r
28 Oil seal
te o
thi
s
iva
do
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rp
29 Oil level/temperature sender (G266)

um
fo
en
ng
◆ Check
t.
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Cop py
t. rig
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=> Current flow diagrams, Electrical fault finding and Fitting locations binder
yri
p by
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Prote
30 Retaining clip
AG.
31 10 Nm
32 10 Nm
◆ Remove and install with socket 3249
◆ With flywheel installed:
Turn flywheel so that cut-outs align with bolts

AG. Volkswagen AG d
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pt
du
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ab
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nf
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33 Spreader clip
o
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or c
34 Sump cover
thi
te
sd
a
35 Oil drain plug, 50 Nm

iv
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36 Securing plate
o
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◆ Renew
. C rig
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rig
37 Gasket
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◆ Renew
agen
Prote AG.
38 Coupling ring
◆ For oil pump
39 Guide tube
◆ For dipstick
◆ Engine codes ACV, AJT, AHY, AUF, AXG, AXL, AYC with connection for oil return pipe
AG. Volkswagen AG d
agen oes
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40 20 Nm
rrectness of i
41 40 Nm
l purpos
42 Oil return pipe

◆ To exhaust turbocharger
nform
mercia
a
com
tion in
r
te o
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do
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1.2 - Checking oil pressure and oil pressure switch
AG. Volkswagen AG d
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t to the co
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◆ V.A.G 1342 Oil pressure tester
◆ V.A.G 1527 B Diode test lamp inform
mer
◆ V.A.G 1594 A Adapter set

atio
om
n
c
i
or
Note:
thi
te
Functional check and servicing the optical and acoustic oil pressure warning:
sd
iva
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cum
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t.
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Cop py
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rig ht
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Prote AG.
=> Current flow diagrams, Electrical fault finding and Fitting locations
On vehicles with 2 oil pressure switches
Test sequence
- Remove noise insulation tray:
sembly overview
- -> Remove 0.3 bar oil pressure switch (F22) and screw into the tester.
- Screw tester V.A.G 1342 into position for oil pressure switchn in
AGcylinder
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es, in part or in w
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- Connect brown wire -3- of tester to earth (-).
- -> Connect diode test lamp V.A.G 1527 with aux. cables from V.A.G 1594 to battery positive (+) and 0.3 bar
l purpos
oil pressure switch (F22) -A-. LED must light up.

- Start engine and increase speed slowly.
At
nf
ercia
o
0.15...0.45 bar
rm
the LED must go out, otherwise renew 0.3 bar oil pressure switch.
m
atio
m
- Connect diode test lamp to 0.9 bar oil pressure switch (F1) -B-.
o
n in
c
At
or
thi
e
0.75...1.05 bar
t
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iva
The LED must light up, otherwise renew oil pressure switch.
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- Increase engine speed further.
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At 2000 rpm and an oil temperature of 80 °C the oil pressure should be at least 2.0 bar.
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At higher engine speed the oil pressure must not exceed yri
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Prote AG.
- Renew oil pressure relief valve (=> Page 133 , item 19 ).
On vehicles with 1 oil pressure switch

Test sequence
- Remove noise insulation tray:
sembly overview
1.2 - Checking oil pressure and oil pressure switch 139

- -> Remove oil pressure switch (F1) and screw into tester.
- Screw tester V.A.G 1342 into position for oil pressure switch in cylinder head.
- Connect brown wire of tester to earth (-).
- Connect diode test lamp V.A.G 1527 B using auxiliary cables from V.A.G 1594 A to battery positive (+) and
oil pressure switch.
LED must not light up.
- Start engine and increase speed slowly.
At
0.55...0.85 bar
the LED must light up, otherwise renew oil pressure switch.
- Increase engine speed further.
At 2000 rpm and an oil temperature of 80 °C the oil pressure should be at least 2.0 bar.
At higher engine speed the oil pressure must not exceed

7.0 bar.
- Renew oil pressure relief valve (=> Page 133 , item 19 ).
AG. Volkswagen AG d
agen oes
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V gu
d by ara
ise nte
or eo
h
aut ra
ss c
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e
nl
pt
du
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ab
ility
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es, in part or in w
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mercia
at
om
ion
c
in t
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ate
do
priv
cum
for
en
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t.
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19 - Cooling system
1 - Removing and installing parts of cooling system

AG. Volkswagen AG d
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1.1 - Removing and installing parts of cooling system ol not
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Warning!
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cramped conditions:
erm
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Notes:
rrectne
◆ When the engine is warm the cooling system is under pressure. If necessary release pressure before com‐
mencing repair work.
◆ Hoses are secured with spring-type clips. In cases of repair only use spring-type clips.
ss o
◆ V.A.G 1921 pliers are recommended when installing spring-type clips.
cial p
f inform
mer
Perform cooling system leakage check with cooling system tester V.A.G 1274 and adapter 1274/3.
atio
om
n
c
Parts of cooling system body side =>Page 142 .
i
or
n thi
te
sd
va
Parts of cooling system engine side =>Page 150 .

i
o
pr
cum
r
fo
en
ng
Coolant hose connection diagram =>Page 154 .

t.
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Cop py
t. rig
gh
Draining and filling with coolant=> Page 158 .
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pyri by
Vo
co lksw
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Prote
Coolant mixture ratios => Page 158 , draining and filling with coolant.
AG.
Checking thermo switch and coolant circulation pump or continued coolant circulation pump =>Page 164 .
1.1 - Removing and installing parts of cooling system 141

1.2 - Parts of cooling system, body side
AG. Volkswagen AG d
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olksw not
V gu
d by ara
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or eo
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aut ra
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un
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d
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rm
ab
pe
ility
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, is n
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spec
es, in part or in w
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nform
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a
com
tion in
r
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iva
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cum
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Vehicles ▸12.95
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ng
t.
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Cop py
t. rig
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Vehicles 01.96 ▸=>Page 146
p by
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by c lksw
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Prote AG.
1 10 Nm
2 Lock carrier
3 Radiator grille
4 Air ducting
◆ Secured at radiator:
Vertically 4 screws, horizontally 4 rivets or 4 screws -arrows-
5 Securing rubber
6 Radiator
=>Page 161
◆ After replacing renew entire coolant
7 Seal
142 19 - Cooling system

◆ Renew
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
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ce
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nl
pt
du
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ab
ility
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es, in part or in w
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nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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8 Radiator fan thermo switch (F18),

n
t.
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35 Nm Cop py
t. rig
gh
◆ Switching temperatures:
ht
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Vo
1st speed
o
by c lksw
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on: 84...89 °C Prote AG.
off: 76...83 °C
2nd speed
on: 90...95 °C
off: 82...89 °C
9 Radiator cowling
◆ With electric fan and adjustable shut-off ring (only vehicles with optional equipment)
10 Cable clip
11 Adjusting device
◆ Only vehicles with optional equipment
◆ Checking:
Engine cold (coolant temperature below 25 °C) shut-off ring item - 13 - closed
12 Radiator fan
1.2 - Parts of cooling system, body side 143

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Cop py
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Prote AG.
13 Shut-off ring
14 Cover
15 Expansion tank
16 To cylinder head
◆ Coolant hose connection diagram =>Page 154
17 To coolant pipe
18 To heat exchanger
19 Junction piece
20 Coolant breather hose
◆ To top of radiator

AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
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au ra
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nl
pt
du
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ility
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21 Cap
l purpos
◆ Check with cooling system tester V.A.G 1274 and adapter V.A.G 1274/4
◆ Test pressure 1.3...1.5 bar nf
ercia
o
22 Lower coolant hose
rm
m
atio

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n in
c
23 Rubber washer
or
thi
e
24 Pin
t
sd
iva
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rp
25 Upper coolant hose

cu
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f
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ng

t.
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op
26 Spreader clip C py
t. rig
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27 Bracket pyri by
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by
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Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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nl
pt
du
an
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erm
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ility
ot p
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spec
es, in part or in w
t to the co
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l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
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t.
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Cop py
t. rig
Vehicles01.96 ▸ opyri
gh by
Vo
ht
c by lksw
cted
1 10 Nm
agen
Prote AG.
2 Charge air cooler
◆ Screwed to radiator on vehicles with engine codes AHY, AXG, AXL
4 Upper coolant hose
5 Radiator
=>Page 161
◆ After replacing renew entire coolant
6 Lock carrier

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
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erm
ab
ility
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hole
spec
es, in part or in w
t to the co
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l purpos
7 Radiator fan thermo switch (F18),

35 Nm
◆ Switching temperatures:
nf
ercia
o
1st speed
rm
m
atio
on: 84...89 °C
om
off: 76...83 °C
n in
or c
2nd speed
thi
te
sd
on: 90...95 °C
iva
o
r
off: 82...89 °C
rp
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f
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8 Connector
ng
t.
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op
◆ Black, 3 pin C py
t. rig
◆ For radiator fan thermo switch
gh ht
pyri by
Vo
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9 Adjusting device by c lksw
cted agen
Prote
◆ Checking:
AG.
Engine cold (coolant temperature below 25 °C) shut-off ring item - 13 - closed
10 Right radiator fan (V35)
=>Page 161

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
11 2 pin connector
◆ Black
◆ For right radiator fan (V35)
12 2 pin connector
◆ Black
◆ For left radiator fan (V7)
13 Shut-off ring
14 Cable/line guide
15 Left radiator fan (V7)
=>Page 161

lkswage es n
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16 Lower coolant hose

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ab

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17 Expansion tank
wit
, is n
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18 To cylinder head
hole
spec

es, in part or in w
t to the co
19 To coolant pipe
20 Junction piece
rrectness of i
22 Cap
l purpos
◆ Check with cooling system tester V.A.G 1274 and adapter V.A.G 1274/4
◆ Test pressure 1.3...1.5 bar
nf
ercia
23 Air intake ducting

orm
24 Securing rubber
m
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t.
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Cop py
t. rig
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Vo
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by
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Prote AG.

1.3 - Parts of cooling system - engine side
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
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fo
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t.
yi Co
Cop py
t.
rig
gh ht
pyri by
◆ ▸01.95
o Vo
by c lksw
cted agen
2 20 Nm
Prote AG.

8.8 = 85 Nm
10.9 = 100 Nm
5 Camshaft sprocket
Vehicles ▸01.95

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
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spec
es, in part or in w

t to the co
◆ ▸01.95
◆ 02.95 ▸ =>Page 24 , item 5
rrectness of i
7 Coolant pump
l purpos
◆ Renew complete if damaged or leaking

◆ ▸01.95 with elongated holes:
nf
ercia
To tension the toothed belt, loosen slightly and turn using a screwdriver => Page 42 , Removing, installing
orm
and tensioning camshaft toothed belt

m
atio
m
8 O-ring
o
n in
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thi
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sd
a
9 Retaining clip
iv
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◆ Check seated securely

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f
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
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Prote AG.
1.3 - Parts of cooling system - engine side 151

AG. Volkswagen AG d
5-Cyl. diesel engine, Mech. - Edition 10.2000 lksw
agen oes
not
Vo gu
d by ara
ise nte
or eo
h
aut ra
ss c
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e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
10 Coolant circulation thermo-switch (F51) or thermo-switch for coolant circulation run-on (F95)
◆ Checking coolant circulation thermo switch or continued coolant circulation thermo-switch =>Page
164
11 Connection
12 10 Nm
13 Coolant thermostat
◆ Checking: heat-up thermostat in water
◆ Opening commences approx. 87 °C
◆ Ends approx. 102 °C
◆ Opening lift min. 7 mm

AG. Volkswagen AG d
agen oes
olksw not
d by
V gu
ara Transporter 1991 ➤
e nte
thoris 5-Cyl. diesel engine, e or
Mech. - Edition 10.2000
s au ac
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
14 Coolant temperature sender (G62)

◆ With temperature gauge sender (G2)
◆ Engine codes AAB, AJA:
◆ Checking:
◆ Engine codes ACV, AJT, AHY, AUF, AXG, AXL, AYC:

◆ Checking:

◆ Check for wear
◆ Do not kink
Vehicles ▸ 01.95
=> Page 49
1.3 - Parts of cooling system - engine side 153

1.4 - Coolant hose connection diagram
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
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wit
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spec
es, in part or in w
Vehicles with engine codes AHY, AXG, AXL=>Page 156

t to the co
1 Expansion tank
2 Radiator
rrectness of i
◆ a = top
l purpos
◆ b = bottom
3 Coolant circulation pump (V50) or continued coolant circulation pump (V51)
nf
ercia
◆ Checking =>Page 164

orm
m
4 Drain screw, 10 Nm
atio
om
n in
c
or
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6 Coolant pump
t
sd
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7 Cylinder block
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8 Oil cooler
en
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t.
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9 Cylinder head C py
t. rig
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Vo
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by c lksw
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Prote AG.

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, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
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10 Solenoid valve yri
p by
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by lksw
◆ Only vehicles with optional equipment Prote
cted AG.
agen
11 Additional heater
12 Control valve
13 Heating system heat exchanger
14 Additional heat exchanger
1.4 - Coolant hose connection diagram 155

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spec
t to the co
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cial p
f inform
mer
atio
om
n
c
Vehicles with engine codes AHY, AXG, AXL

i
or
n thi
te
sd
va
1 Expansion tank
i
o
pr
cum
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fo
2 Radiator
en
ng
t.
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◆ a = top
Co
Cop py
◆ b = bottom
t. rig
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3 Continued coolant circulation pump (V51) cop Vo
by lksw
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◆ Checking =>Page 164 Prote AG.
4 Drain screw, 10 Nm
6 Coolant pump
7 Cylinder block
8 Oil cooler
9 Cylinder head

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
horis Transportereo 1991 ➤
ut
ss a 5-Cyl. diesel engine, Mech. - Edition
ra
c 10.2000
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
10 Additional heater
11 Solenoid valve
12 Heating system heat exchanger
13 Additional heat exchanger
1.4 - Coolant hose connection diagram 157

1.5 - Draining and filling coolant
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Prote AG.

Not illustrated:
◆ Anti-freeze tester
◆ VAS 6096 Cooling system charging
Draining
- Remove cap from coolant expansion tank.

=> General body repairs, exterior; Repair group 50; Removing and installing lock carrier with attachments
Removing and installing lock carrier with attachments

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- -> Drain coolant:
erm
ab
ility
- Either via drain plug -1- and coolant hose -2-,
ot p
- or via thermostat connection -3-.
wit
is n
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ole,
Note:
spec
t to the co
Observe disposal regulations!
- Insert drain plug and tighten to 10 Nm.
rrectne
Filling
ss o
cial p
f
Notes:
inform
mer
◆ Only use coolant additive G 12 in accordance with TL VW 774 F.
atio
m
Distinguishing feature: coloured violet

o
n
c
i
or
n thi
te
◆ G 12 and coolant additives marked "In accordance with TL VW 774 F" prevent frost and corrosion damage,
sd
iva
o
r
scaling and also raise boiling point of coolant. For this reason the system must be filled all year round with
p
cum
r
fo
frost and corrosion protection additives. en

ng
t.
◆ G 12 violet (in accordance with TL VW 774 F) can be mixed with the previous coolant additives G 11 and
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◆ Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly in
yri
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countries with tropical climates.
c by lksw
cted agen
◆ Protection against frost must be assured to about -25 °C (in arctic climatic countries to about -35 °C).
Prote AG.
◆ 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 %.
◆ If for climatic reasons a greater frost protection is required, the amount of G 12 can be increased, but only
up to 60 % (frost protection to about -40 °C), as otherwise frost protection is reduced again and cooling
effectiveness is also reduced.
◆ If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.
Recommended mixture ratios:
Frost protection Anti-freeze G 122) Water2)

to amount1)
-25 °C 40 % 3.6 ltr. 5.4 ltr.
-35 °C 50 % 4.5 ltr. 4.5 ltr.
1) The amount of anti-freeze must not exceed 60 %; frost protection and cooling effect will decrease if
amount of anti-freeze is too high.
2) The quantity of coolant can vary depending upon the vehicle equipment.
With cooling system charging unit VAS 6096:
- Screw adapter from V.A.G 1274 suitable for this vehicle onto expansion tank.
- Fill coolant circuit using cooling system charging unit VAS 6096.
1.5 - Draining and filling coolant 159

=> Operating instructions for cooling system charging unit VAS 6096
Without cooling system charging unit VAS 6096:
- Open bleed screw in coolant hose to heat exchanger.

- Press down top radiator hose.
- Close bleed screw.
- -> Slowly fill with coolant up to max. mark on expansion tank (filling time approx. 5 minutes).
- Start engine and run at approx. 1500 rpm for max. 2 minutes and at the same time fill with coolant up to
over-flow hole on expansion tank.
- Fit expansion tank cap.
- Run engine until radiator fan cuts-in.
- Check coolant level and replenish as necessary. When the engine is at normal operating temperature, the
coolant level must be on the max. mark, when the engine is cold, between the min. and max. marks.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1.6 - Removing and installing radiator and fan
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
ercia

m
at
◆ Anti-freeze tester
om
ion
c
in t
or
Removing
his
ate
do
priv

um
for
en
ng
t.
yi Co
op
=> General body repairs, exterior; Repair group 50; Body front Body front C py
t. rig
gh ht
pyri by
Vo
- Drain coolant => Page 158
co lksw
by
cted agen
- Pull coolant hoses off radiator using hose clip pliers V.A.G 1921. Prote AG.
1.6 - Removing and installing radiator and fan 161

lkswage es n
o ot g
byV ua
d ran
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tho
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a ac
ss
- Pull connectors off thermo-switch and radiator fan.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
- Remove charge air cooler with air hoses
h re
hole
=> Page 188 , Removing and installing parts of charge air cooling system.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Vehicles 10.91▸
nform
ercia
- Disconnect power assisted steering hydraulic pipe from radiator.

m
a
com
tion in
Vehicles with air conditioner
r
te o
thi
s
iva
do
- Observe additional information and removal work => Page 163 .
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- -> Remove retaining clamp -1- from refrigerant pipes.

- Remove securing screws -2- on left and right of condenser.
- Lift condenser out of brackets and place on cross member.
- Unclip radiator/charge air cooler securing rubber from lock carrier.

- Remove lock carrier:
=> General body repairs, exterior; Repair group 50; Removing and installing lock carrier with its attachments
Removing and installing lock carrier with its attachments

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
- -> Pull both hoses off charge air cooler -3- with spring-type clip pliers V.A.G 1921.
ot p
- Lift out radiator with charge air cooler, fan and air guide.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
- Lift out radiator with fan and air guide.
Installing
rrectness of i
l purpos
Installation is carried out in the reverse order, when doing this note the following:
- Filling with coolant => Page 158
nform
ercia
- Electrical connections and routing:

m
at
om
io
=> Electrical system; Repair group 97
n
c
in t
or
his
te
- Check headlight adjustment and adjust if necessary:

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Additional information and removal work on vehicles with air conditioner ht. rig
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Prote AG.
Warning!
Note:
To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the pipes and hoses are
not stretched, kinked or bent.
- Unbolt condenser and secure to body so that refrigerant pipes/hoses are not stressed.
1.6 - Removing and installing radiator and fan 163

AG. Volkswagen AG d
agen oes
olksw not
V gu
Transporter 1991 ➤ d by ara
ise nte
r
ut
ho eo
ra
s a c
s
1.7 - Checking thermo switch and coolant circulation pump or continued coolant circulation
ce
le
un
pt
pump
an
d
itte
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rm
ab
pe
ility
ot
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
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t.
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t. rig
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pyri by
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by c lksw
cted agen
Prote AG.
◆ V.A.G 1526 Hand multimeter

◆ V.A.G 1527 B Diode test lamp
◆ V.A.G 1594 A Adapter set
◆ Current flow diagram
Test sequence

AG. Volkswagen AG d Transporter 1991 ➤
agen oes
5-Cyl.
Volksw diesel engine, Mech. not - Edition 10.2000
g
y ua
db ran
rise tee
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s au ac
s
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le
un
pt
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ility
ot
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hole
spec
es, in part or in w
t to the co
rrectness of i
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sembly overview
nform
ercia
- -> Pull 2-pin connector -2- off thermo-switch for coolant circulation run-on (F95) -1-.
- Bridge contacts 1 and 2 of connector -2- using auxiliary cables from V.A.G 1594 A.
m
a
com
ti
Coolant circulation pump must start.
on in
r
te o
thi
When coolant circulation pump does not run:
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Prote AG.
- -> Pull 2-pin connector off coolant circulation pump (V50) or continued coolant circulation pump (V51) -1-
and connect diode test lamp V.A.G 1527 with aux. cables from V.A.G 1594 to disconnected connector.
The LED must flash or light up
LED flashes or lights up (voltage supply OK.):
- Renew coolant circulation pump (V51) or continued coolant circulation pump (V51).
If LED does not light up or flash:
- Locate and rectify open circuit using current flow diagram:
1.7 - Checking thermo switch and coolant circulation pump or continued coolant circulation
pump 165
Checking thermo switch resistance
- -> Connect hand multimeter V.A.G 1526 or multimeter V.A.G 1715 using cables from V.A.G 1594 to thermo-
switch -B- connector contacts -1- and -4- to measure resistance.
Specifications:
below approx. 103 °C = ∞ ω
above approx.: 104 °C = 0 ω
If the specifications are not attained:
- Renew coolant circulation thermo-switch (F51) or continued coolant circulation thermo-switch (F95) with
coolant temperature gauge sender (G2)).
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20 - Fuel supply system
1 - Removing and installing parts of fuel supply system

1.1 - Removing and installing parts of fuel supply system
Removing and installing fuel filter:
◆ Engine code AAB, AJA
=> Repair group 23; Servicing fuel injection system; Removing and installing fuel filter. Servicing fuel injection
system Removing and installing fuel filter.
=> Repair group 23; Servicing diesel direct injection system; Servicing fuel filter Servicing diesel direct injection
system Servicing fuel filter
Checking fuel system for leaks:

AG. Volkswagen AG d
agen oes
◆ Engine code AAB, AJAVolksw not
gu
y
db ara
ise nte
=> Repair group 23; thoServicing
r
fuel injection system. Servicing fuele o injection system.
s au ra
c
s
Servicing accelerator mechanism:
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e
nl
pt
du
an
itte
y li

erm
ab

ility
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, is n
=> Repair group 23; Servicing diesel direct injection system; Servicing accelerator mechanism Servicing diesel
h re
hole
direct injection system Servicing accelerator mechanism

spec
es, in part or in w
t to the co
Servicing cold start accelerator operating cable (engine codes AAB, AJA) =>Page 177 .
Observe safety precautions=> Page 170 .

rrectness of i
Observe rules for cleanliness => Page 171 .

l purpos
Notes:
nform
mercia
Warning!
at
om
io
n
c
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r
cramped conditions:
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te
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◆ Hose connections are secured with either screw-type or spring-type clips. cted agen
Prote AG.
◆ Always replace clamp-type clips with screw or spring-type clips.
◆ Fuel hoses in engine compartment must only be secured with spring-type clips. The use of clamp or screw-
type clips is not permissible.
1.1 - Removing and installing parts of fuel supply system 167

olkswagen AG
wag en AG. V
Transporter 1991 ➤ olks
does
not
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se
d b ara
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ri
ho eo
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1.2 - Removing and installing fuel tank with itsssattachments
a ra
c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1 Union nut
◆ Remove and install with spanner 3217
2 Fuel gauge sender (G)
=> Page 171
3 Sealing ring
◆ Coat with fuel when installing
4 Fuel tank
◆ Support with engine and gearbox jack V.A.G 1383 A when removing
=> Page 173
168 20 - Fuel supply system

AG. Volkswagen AG d
agen oes
olksw not
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5 25 Nm auth
ra
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6 Securing strap s
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un
pt
◆ Note differing length

an
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itte
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7 Bracket
erm
ab
◆ For securing straps

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8 Vent pipe
is n
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ole,
◆ Filling vent
spec
9 Cap
t to the co
◆ Renew seal if damaged

10 Retaining ring
11 Rubber cup
rrectne
12 10 Nm
13 Vent pipe
ss o
◆ Operating vent
cial p
f inform
mer
atio
om
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169
agen
Prote AG.
1.2 - Removing and installing fuel tank with its attachments
AG. Volkswagen AG d
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olksw not
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un
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ility
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hole
spec
es, in part or in w
t to the co
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14 Screw-type clip
l purpos
15 Supply pipe
◆ Black
nform
ercia
16 Return pipe
◆ Blue
m
a
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tion in
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1.3 - Safety precautions when working on the fuel supply system

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When removing and installing the fuel gauge sender on a full or partly filled fuel tank the following must be
t. C rig
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observed: p by
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Prote AG.
◆ Before commencing work, switch on exhaust extraction system and place an extraction hose close to the
sender opening in the fuel tank to extract escaping fuel fumes.
If no exhaust extraction system is available, a radial fan (as long as motor is not in air flow) with a displace‐
ment greater than 15 m3/h can be used.
◆ Prevent skin contact with fuel! Wear fuel-resistant gloves!

1.4 - Rules for cleanliness
When working on the fuel supply/injection system, pay careful attention to the following "5 rules":
◆ Thoroughly clean all unions and the adjacent areas before disconnecting.
◆ Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!
◆ Carefully cover opened components or seal, if the repair cannot be carried out immediately.
◆ Only install clean components:
Only unpack replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in tool boxes etc.).
◆ When the system is open:
Do not work with compressed air if this can be avoided.
Do not move vehicle unless absolutely necessary.
◆ Also ensure that no diesel fuel runs onto the coolant hoses. Hoses coming in contact with fuel must be
cleaned immediately. Damaged hoses must be replaced.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
1.5 - Removing and installing fuel gauge senderoris d ara
e nte
h eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
◆ -> 3217 Union nut spanner
atio
om
n
c
Removing
i
or
n thi
te
sd
va
- Lift carpet above the hand brake lever.

i
o
pr
cum
r
- Remove cover plate.

fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.
- Pull connector and supply and return pipes off fuel gauge sender.
- -> Remove union nut with spanner 3217.
- Take out fuel gauge sender.
1.4 - Rules for cleanliness 171

Installing
Installing the fuel gauge sender is carried out in the reverse order.
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olksw not
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ara
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- -> Note installation
aut
h position: eo
ra
ss c
ce
le
Marking on the sender -1- must align with marking on the fuel tank -2-.
un
pt
an
d
itte
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rm
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pe
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
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te o
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iva
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Cop py
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rig ht
py by
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Prote AG.

1.6 - Removing and installing fuel tank
AG. Volkswagen AG d
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olksw not
V gu
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erm
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ility
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es, in part or in w
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nform
ercia
m
at
om
◆ 3217 Spanner for union nut

on
c

in t
or
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at
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or
Removing
f
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t.
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Observe safety precautions=> Page 170 . t. C rig
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pyri by
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by c
lksw
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Prote AG.
Note:
If necessary the anti-theft coding for the radio must be obtained first.
- Drain fuel tank, clean fuel filler neck and surrounding area.
- Remove clamping ring and rubber cup from filler neck and remove securing bolt.
- Remove tensioning strap. When doing this support fuel tank with engine/gearbox jack V.A.G 1383 A.
1.6 - Removing and installing fuel tank 173

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
Transporter 1991 ➤ ut
ho eo
ra
a
5-Cyl. diesel engine, Mech. -s Edition 10.2000
s c
ce
le
un
pt
- Lower using engine/gearbox jack V.A.G 1383 A only sufficiently to allow supply and return pipes and fuel
an
d
itte
y li
gauge sender connector to be pulled off.
rm
ab
pe
ility
Notes:
ot
wit
, is n
h re
hole
On vehicles with additional heater, pull off fuel pipes between supply and return pipes.
spec
es, in part or in w
t to the co
- Lower fuel tank.
Installing
rrectness of i
Install in reverse order but note following:
l purpos
◆ Route breather hose kink free.
nform
ercia
◆ Secure fuel hoses with screw-type clamps.

◆ Do not interchange supply and return pipes (return pipe -blue-).
m
a
com
tion in
r
te o
thi
s
iva
1.7 - Servicing accelerator mechanism (engine codes AAB, AJA)
do
r
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cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
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by c lksw
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Prote AG.
Engine codes ACV, AHY, AJT, AUF, AXG, AXL, AYC

=> Repair group 23; Servicing diesel direct injection system; Servicing accelerator mechanism Servicing diesel
direct injection system Servicing accelerator mechanism
1 Retainer
2 Accelerator cable
◆ Adjust by moving position of securing clip (retainer) on outer cable grooves
=> Page 176 , adjusting accelerator cable
3 Securing clip
4 Rubber bush
5 Accelerator pedal
AG. Volkswagen AG d
agen oes
olksw not
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ara
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ris nte
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nl
pt
du
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ility
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spec
es, in part or in w
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nf
ercia
orm
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Cop py
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rig ht
py by
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by lksw
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Prote AG.
6 Bush
7 Accelerator pedal carrier
8 Securing clip
9 Load change damper
1.7 - Servicing accelerator mechanism (engine codes AAB, AJA) 175

1.8 - Adjusting accelerator cable
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byV ua
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ss
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pt
an
d
Work sequence
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erm
ab
ility
ot p
Vehicles 09.94▸
wit
is n
h re
ole,
spec
t to the co
rrectne
ss
Note:
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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t. rig
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pyri by
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co lksw
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cted agen
Prote AG.
Vehicles 09.94▸Qty. 1 securing bolt located on each left and right-hand side in lock carrier.
- Fold lock carrier and radiator out forwards -arrow-.

- -> When adjusting accelerator pedal full throttle position, adjust accelerator cable by moving position of
securing clip (retainer) -arrow- on outer cable grooves so that the injection pump lever lies stress free on
stop.

1.9 - Servicing cold start accelerator (CSA) operating cable (engine codes AAB, AJA)
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
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tion in
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te o
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Cop py
t. rig
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pyri by
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by
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Prote AG.
1 Locking screw
2 Pivot pin
3 Pull cable
4 Securing clip
5 Washer
6 CSA operating cable
◆ Adjusting Page 178
7 Cable tie
◆ In engine compartment
8 Nut
9 Release lever
1.9 - Servicing cold start accelerator (CSA) operating cable (engine codes AAB, AJA)
177
1.10 - Adjusting CSA operating cable
Work sequence
Vehicles 09.94▸
Note:
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
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tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
Vehicles 09.94▸Qty. 1 securing bolt located on each left and right-hand side in lock carrier.
es, in part or in w
t to the co
- Fold lock carrier and radiator out forwards -arrow-.

- -> Slide washer -1- on operating cable and secure cable with securing clip -2-.
- Set operating lever in 0 position -direction of arrow-.
rrectness of i
Pull inner cable taut and secure in pin -3- with locking screw.
l purpos
nf
ercia
orm
m
atio
om
n in
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c by lksw
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Prote AG.
lkswage es n Transporter 1991 ➤
o ot g
by V5-Cyl. diesel engine, Mech. u-a Edition 10.2000
d ran
ir se tee
ho
21 - Charging
ut or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
1 - Charge air system with turbocharger
is n
h re
ole,
spec
1.1 - Charge air system with turbocharger
t to the co
rrectne
1.2 - Removing and installing turbocharger with attachments
ss o
cial p
f inform
Warning!
mer
atio
om
cramped conditions:
n
c
i
or
n
thi
te
sd
iva
o
pr
c
um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Observe rules for cleanliness => Page 194 . cop Vo
by lksw
cted agen
Prote AG.
Engine codes ACV, AJT, AUF, AYC =>Page 180
Engine codes AHY, AXG, AXL =>Page 185
Notes:
◆ All hose connections are secured with clips.

◆ Charge air system must be free of leaks.
◆ Renew self-locking nuts.
◆ Before screwing on oil supply pipe fill turbocharger at connection with engine oil.
◆ After installing turbocharger run engine for approx. 1 minute at idling speed, do not rev engine. This ensures
that the turbocharger is adequately lubricated.
1.1 - Charge air system with turbocharger 179

AG. Volkswagen AG d
agen oes
olksw not
byV gu
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ed
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aut ra
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ce
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un
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rm
ab
pe
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Engine codes ACV, AJT, AUF, AYC
1 Gasket
◆ Renew
2 25 Nm
3 Connecting pipe
◆ When installing, just nip all bolts (parts must be just free to move), then tighten stress free
4 15 Nm
5 To exhaust gas recirculation valve
◆ => Page 215 , item 1
6 Heat shield
◆ For intake pipe
180 21 - Charging
AG. Volkswagen AG d
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ility
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, is n
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hole
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es, in part or in w
t to the co
rrectness of i
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7 Gasket
nform
ercia
◆ Renew
m
a
com
8 Exhaust manifold
ion in
9 Vacuum hose
r
te o
thi
◆ rot
s
iva
do
r
rp
10 Vacuum hose
um
fo
en
g
◆ Black
n
t.
yi Co
op
11 From crankcase breather valve
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12 10 Nm py by
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by lksw
13 Connecting pipe cted agen
Prote AG.
◆ Between exhaust turbocharger and air mass meter connecting hose
◆ Secured to intake pipe along with dipstick guide tube
1.2 - Removing and installing turbocharger with attachments 181

lkswage es n
Transporter 1991 ➤ byV
o ot g
ua
ed ran
5-Cyl. diesel engine, Mech. hor - Edition 10.2000
is tee
ut or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
15 Seal
◆ Renew
16 O-ring
17 Retainer
◆ For exhaust gas recirculation valve (N18) and charge pressure limitation solenoid valve (N75)
18 Charge pressure limitation solenoid valve (N75)
◆ Checking control:
=> Repair group 23; Servicing Diesel direct injection system; Checking charge pressure control Servicing Diesel
direct injection system Checking charge pressure control
19 Connector
◆ 2-pin
◆ For charge pressure limitation solenoid valve (N75)
20 40 Nm
182 21 - Charging
AG. Volkswagen AG d
agen oes
olksw not
V gu
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nl
pt
du
an
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erm
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ility
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
21 Oil return pipe

m
at
◆ To connection on dipstick guide tube

om
ion
=> Page 136 , item 39

c
in t
or
his
22 30 Nm
ate
do
riv
p
cum
or
24 Oil supply pipe

f
en
ng
t.
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◆ Before installing, fill turbocharger with engine oil via oil supply pipe connection t. Cop py
◆ From oil filter bracket
rig
gh ht
yri by
=> Page 132 , item 11 op Vo
by c lksw
cted
25 45 Nm
agen
Prote AG.
◆ Renew
◆ Coat threads and bolt head contact surface with grease G 000 500
26 Exhaust turbocharger
=> Page 195
◆ Checking charge pressure
=> Page 199 , Checking exhaust turbocharger

AG. Volkswagen AG d
agen oes
olksw not
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tho eo
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
27 To front exhaust pipe

m
◆ => Page 209 , item 9

a
com
tion in
28 Pipe elbow
r
te o
thi
29 Nut or hexagon socket head bolt,

s
iva
do
25 Nm
r
rp
cum
fo
30 Cap nut, 15 Nm
en
ng
t.
yi Co
31 Control pipe t. Cop py
rig
◆ Blue
gh ht
pyri by
Vo
o
32 Charge pressure regulating valve
c by lksw
cted agen
Prote AG.
◆ Integral part of turbocharger cannot be replaced
33 Air hose
34 To charge air cooler or intake pipe
184 21 - Charging
lkswage es n
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nl
Engine codes AHY, AXG, AXL pt

du
an
itte
y li
erm
1 Seal ab
ility
ot p
2 25 Nm
wit
, is n
3 15 Nm
h re
hole
spec
4 To intake pipe
es, in part or in w
5 Connecting pipe
t to the co
6 Heat shield
rrectness of i
◆ For intake pipe

7 Gasket
l purpos
◆ Renew
nform
ercia
8 Exhaust manifold
m
at
om
ion
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in t
or
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ate
do
priv
cum
for
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
5-Cyl. diesel engine, Mech. - Edition
ksw
agen 10.2000 oes
n ol ot g
yV ua
edb ran
ris tee
tho or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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f
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
9 Control pipe
◆ Connecting diagram for turbocharger hose/pipe connections => Page 193
10 Exhaust turbocharger
=> Page 195
11 Air hose
12 From air cleaner
13 Oil return pipe
◆ To connection on dipstick guide tube
=> Page 136 , item 39
14 30 Nm
16 Seal
◆ Renew
186 21 - Charging
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
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ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
17 45 Nm
rrectness of i
◆ Renew
◆ Coat threads and bolt head contact surface with grease G 000 500
l purpos
18 Oil supply pipe

◆ Before installing, fill turbocharger with engine oil via oil supply pipe connection
nf
ercia
◆ From oil filter bracket

rm
=> Page 132 , item 11

m
atio
om
19 Cap nut, 15 Nm
n in
or c
20 Front exhaust pipe

thi
te
sd
iva
21 To charge air cooler

o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1.3 - Removing and installing air cooling parts
AG. Volkswagen AG d
agen oes
olksw not
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au ra
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nl
pt
du
an
itte
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
ercia
Engine codes AHY, AXG, AXL => Page 191

m
at
om
io
Notes:
n
c
in t
or
his
e
◆ All hose connections secured by clips.

at
do
riv

p
cum
for
en
ng
t.
1 Charge air cooler
yi Co
Cop py
t. rig
2 Air hose pyri
gh by
ht

co Vo
by lksw
cted agen
3 From exhaust turbocharger
Prote AG.
◆ => Page 183 , item 26

4 10 Nm
5 Retainer
◆ For charge air cooler
6 Bonded rubber mounting
188 21 - Charging
lkswage es n
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byV ua
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nl
pt
du
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itte
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ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
7 O-ring
rrectness of i
l purpos
8 Retaining clip
nf
ercia
9 Sender
orm
◆ ▸04.99 for intake manifold temperature (G72)

m
atio
m
◆ 05.99 ▸for intake manifold pressure (G71) with intake manifold temperature sender (G72)
o
n in
c
◆ Checking:
or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
10 Connector
yi Co
op py
◆ ▸04.99 2-pin
t. C rig
gh ht
yri
◆ For intake manifold temperature sender (G72) p by
co Vo
◆ 05.99 ▸4-pin
by lksw
cted agen
Prote
◆ For intake manifold pressure sender (G71) with intake manifold temperature sender (G72)
AG.
1.3 - Removing and installing air cooling parts 189

lkswage es n
o ot g
byV ua
d ran
ir se tee
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u or
a ac
ss
11 To Diesel direct injection system control unit (J248)
ce
le
un
pt
◆ ▸04.99
an
d
itte
y li
12 Pressure hose
erm
ab
ility
ot p
◆ Black
wit
is n
13 To exhaust gas recirculation valve

h re
ole,
◆ => Page 215 , item 1

spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
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fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
190 21 - Charging
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
Notes:
◆ All hose connections secured by clips.

1 10 Nm
2 From exhaust turbocharger
3 Connecting hose
4 To intake pipe
5 O-ring
6 Retaining clip
7 Sender
◆ ▸04.99 for intake manifold temperature (G72)
◆ 05.99 ▸for intake manifold pressure (G71) with intake manifold temperature sender (G72)
◆ Checking:
1.3 - Removing and installing air cooling parts 191

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
8 Connector
◆ ▸04.99 2-pin
◆ For intake manifold temperature sender (G72)
◆ 05.99 ▸4-pin
◆ For intake manifold pressure sender (G71) with intake manifold temperature sender (G72)
9 To Diesel direct injection system control unit (J248)
◆ ▸04.99
◆ Connecting diagram for turbocharger hose/pipe connections => Page 193
10 Pressure hose
◆ Black
11 Connecting pipe
12 Lock carrier
13 Charge air cooler
◆ Removing and installing => Page 161 , Removing and installing radiator and fan
14 Securing rubber
192 21 - Charging
1.4 - Turbocharger hose/pipe connections
AG. Volkswagen AG d
agen oes
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byV gu
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ed
ris nte
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aut ra
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ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
=> Illustration on Page 180
1 Vacuum reservoir
2 Breather pipe
◆ To air cleaner
3 Air cleaner
4 Charge pressure control solenoid
valve (N75)
5 Non-return valve
◆ White connection to charge pressure control solenoid valve item 4 and to vacuum reservoir
6 Exhaust gas recirculation valve (N18)
1.4 - Turbocharger hose/pipe connections 193

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
7 Intake manifold flap change-over valve

te o
thi
s
iva
◆ Vehicles09.00 ▸only
do
r
rp
c
8 Brake servo
um
fo
en
ng
9 Vacuum connection
t.
yi Co
op py
◆ For brake servo t. C rig
gh ht
yri
10 Diesel direct injection system control unit (J248)
p by
co Vo
by lksw
cted
◆ 05.99 ▸without connection to charge air cooling connecting pipe
agen
Prote AG.
12 Vacuum pump
13 Intake connecting flange
◆ With exhaust gas recirculation valve and intake manifold flap
15 Air cleaner
1.5 - Rules for cleanliness
When working on the exhaust gas turbocharger, pay careful attention to the following "5 rules":
194 21 - Charging
◆ Thoroughly clean all unions and the adjacent areas before disconnecting.
◆ Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!
◆ Carefully cover opened components or seal, if the repair cannot be carried out immediately.
◆ Only install clean components: AG. Volkswagen AG d
Only unpack replacement parts immediately prior to installation. agen oes
olksw not
Do not use parts that have been stored loose (e.g. ed in
by Vtool boxes etc.). gu
ara
◆ When the system is open: oris nte
eo
th
Do not work with compressed air if this cans be
au avoided. ra
c
Do not move vehicle unless absolutely necessary.
s
ce
le
un
pt
an
d
itte
y li
rm
ab
1.6 - Removing and installing exhaust turbocharger
pe
ility
ot
wit
, is n
h re
hole
spec
Engine codes AHY, AXG, AXL =>Page 197
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
Co
Cop py
ht. rig
◆ -> V.A.G 1331 Torque wrench (5...50 Nm) rig ht
py by
◆ Grease G 000 500 co Vo
by lksw
cted agen
Prote AG.
Removing
Note:
If necessary the anti-theft coding for the radio must be obtained first.
=> General body repairs, exterior; Repair group 50; Noise insulation assembly overview. Noise insulation as‐
sembly overview.
- Remove front exhaust pipe => Page 205 , Removing and installing parts of exhaust system.
1.5 - Rules for cleanliness 195

- -> Remove charge air cooler bracket -1-. n AG. Volkswagen AG do
- Remove left and right hand securing bolts lkswage
-2-. es n
Vo ot g
- Fold lock carrier and radiator out forwards
ed
by -arrow-. ua
ran
- Remove charge air cooler with air thor hoses
is tee
=> Page 188 , Removing and s auinstalling parts of charge air cooling system. or
ac
- Pull off control pipe on charge pressure control valve (blue).
s
ce
le
- Pull off vacuum hoses on connecting pipe (black), exhaust turbocharger (red) and exhaust gas recirculation
un
pt
an
d
valve (black). itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
- Remove connecting hose between connecting pipe and air mass meter.
o
n
c
- -> Remove breather hose -1- between crankcase breather valve and connecting pipe.
i
or
n thi
- Remove connecting pipe -2-.
te
sd
a
- Remove connecting pipe between exhaust gas recirculation valve and exhaust manifold => Page 215 ,
iv
o
pr
c
Removing and installing parts of exhaust gas recirculation system.
um
r
fo
en
ng
- Remove intake pipe with heat shield and exhaust gas recirculation valve.
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- -> Remove oil supply pipe -1- and oil return pipe -2- on turbocharger.
- -> Remove pipe elbow -1-.

- Remove securing bolts and securing nuts between exhaust manifold and turbocharger.
- Lift turbocharger -2- out, upwards.
196 21 - Charging
Installing
- Coat threads and contact surfaces of nuts and bolts which are used between exhaust manifold and turbo‐
charger with grease G 000 500 and tighten to AG. Volkswagen AG d
agen
45 Nm. olksw
oes
not
- Fit pipe elbow to turbocharger and tighten to byV gu
ara
ed
25 Nm. thoris nte
eo
- Install oil return pipe with new seal and tighten to s au ra
c
30 Nm. s
ce
e
- Fill the turbocharger with engine oil via the oil supply connection.
nl
pt
du
an
- Install oil supply pipe with new seal and tighten cap nut to
itte
y li
25 Nm.
erm
ab
ility
ot p
wit
- Fit intake pipe with heat shield and new seal (coating or seal bead points to intake pipe) and tighten to
, is n
h re
25 Nm.
hole
spec
- Install connecting pipe between exhaust gas recirculation valve and exhaust manifold => Page 215 , Re‐
es, in part or in w
moving and installing parts of exhaust gas recirculation system.
t to the co
Note:
rrectness of i
When installing, just nip all bolts (parts must be just free to move), then tighten stress free.
l purpos
- Fit control hose (blue) to exhaust gas recirculation valve and secure with a hose clamp.
- Fit vacuum hose (red) to turbocharger and secure with hose clamp.
nf
ercia
- After installing the turbocharger, run engine for approx. 1 minute at idling speed, do not rev. up immediately.
or
This ensures the turbocharger is properly lubricated.
m
m
atio
om
n in
c

or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
◆ -> T10026 Ring spanner
◆ -> V.A.G 1331 Torque wrench (5...50 Nm)
1.6 - Removing and installing exhaust turbocharger 197

◆ Grease G 000 500
Removing
sembly overview
- Loosen connecting hoses between air cleaner/turbocharger and turbocharger/charge air cooler on turbo‐
charger.
- Disconnect front exhaust pipe on turbocharger
- Remove oil filter. wage
e
olks s no
yV t gu
edb ara
ris nte
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
- -> Unscrew oil return pipe -arrow- on oil dip stick guide tube.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
- -> Unscrew captive nut of oil supply pipe -1- and the three securing nuts -2- between exhaust manifold and
turbocharger.
- -> Unscrew 4th securing nut -arrow- with ring spanner T10026.
- Lift turbocharger out upwards.
- Guide oil return pipe/hose when doing this.
198 21 - Charging
Installing
- Coat threads and contact surfaces of nuts between exhaust manifold and turbocharger with grease G 000
500 and tighten to 45 Nm.
- Tighten oil return pipe to 40 Nm.
- Fill the turbocharger with engine oil via the oil supply connection.
- Install oil supply pipe with new seal and tighten cap nut to
25 Nm.
- Tighten front exhaust pipe to 25 Nm.
- After installing the turbocharger, run engine for approx. 1 minute at idling speed, do not rev. up immediately.
This ensures the turbocharger is properly lubricated.
2 - Checking charge pressure system

2.1 - Checking charge pressure system
Note:
The check described below only applies to vehicles ▸ 04.99 with intake manifold pressure sender in control
unit.
On vehicles 05.99 ▸ without intake manifold pressure sender in control unit the charge pressure can only be
checked with fault reader V.A.G 1551 (V.A.G 1552).
=> Repair group 23; Diesel direct injection system; Checking charge pressure control Diesel direct injection
system Checking charge pressure control
2.2 - Checking turbocharger AG. Volkswagen AG d

agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Engine codes ACV, AJT, AUF

l purpos
Engine code AHY =>Page 201

nf
ercia
rm
m
atio
m
◆ -> V.A.G 1397 A Turbocharger tester

o
n in
or c
◆ V.A.G 1397 A/1 Connecting hose with T-piece

thi
te
sd
iva
o
r
rp
cu
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m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.6 - Removing and installing exhaust turbocharger 199

AG. Volkswagen AG d
agen oes
Check conditions Volksw not
gu
by ara
d
ise nte
Turbocharger and wastegatethor constitute one unit. A defective turbochargereo becomes an item for exchange, as
repairs with workshopss equipment
au
are not possible. ra
c
ce
le
un
Prerequisites for the perfect functioning of the turbocharger and attainment of prescribed boost pressure are:
pt
an
d
itte
y li
rm
ab
• No fault in fault memory:
pe
ility
ot
wit
, is n
h re
hole
spec
• Final control diagnosis performed:
es, in part or in w
t to the co
=> Repair group 01; Self-diagnosis; final control diagnosis Self-diagnosis final control diagnosis
• No leaks on intake and exhaust systems.
rrectness of i
• Control pipe (blue) between charge pressure control valve and charge pressure limitation solenoid valve
l purpos
(N75) and pressure pipe (black) between charge air cooler and Diesel direct injection system control unit
(J248) is not blocked, loose or leaking.
• No faults in engine and fuel injection system, e.g. commencement of injection, injectors and compression
nform
ercia
pressure.
• Engine oil temperature min. 80 °C.
m
a
com
tion in
r
Test sequence
te o
thi
s
iva
do
r
- The charge pressure is measured under full load, whilst driving or on a rolling road. Test duration per meas‐
rp
cum
fo
urement max. 10 seconds.

en
ng
t.
- Pull connector off solenoid valve for charge pressure control (N75).
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- -> Pull off pressure pipe (black) between charge air cooler and Diesel direct injection system control unit
(J248) at charge air cooler.
- Connect T-piece to charge air cooler and pressure hose.
- Use connecting hose V.A.G 1397 A/1 to connect T-piece to turbocharger tester V.A.G 1397 A (connection
II).
- Select measuring range ll.
Notes:
◆ To operate turbocharger tester see operating instructions.
◆ The hoses and pipes must be connected so that there is no possibility of leaks.
◆ If boost pressure is measured whilst driving, it is necessary for safety reasons, for a second person to operate
the turbocharger tester.
◆ Ensure that the V.A.G 1397 A/1 connecting hose is not trapped between bonnet and body.
- Measure charge pressure at full throttle:

On a rolling road:
In 3rd gear at
2500...3000 rpm.
Whilst driving:
In 2nd gear
at full throttle acceleration whilst observing
200 21 - Charging
rev counter.
Note:
The brake pedal must not be operated whilst taking measurements. The control unit will thus reduce the fuel
quantity which will lead to incorrect measurements.
- Press the memory button "M" on turbocharger tester at 2500...3000 rpm and read off values.
Specification: (Relative pressure)
0.60...0.80 bar
If the specifications are not achieved:
- Renew turbocharger => Page 195 , Removing and installing turbocharger.

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
- If the charge pressure is too high and if the control pipe to charge pressure control valve is not blocked,
loose or leaking, then also replace turbocharger as the charge pressure control valve is defective.
rrectness of i
Engine code AHY

l purpos
nform
ercia
m
at
◆ -> V.A.G 1397 A Turbocharger tester

om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
◆ -> V.A.G 1390 Vacuum pump

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3
Check conditions
• No fault stored in fault memory
• No leaks on intake and exhaust systems.

• No faults in engine and fuel injection system, e.g. commencement of injection, injectors and compression
pressure.
2.2 - Checking turbocharger 201

• Engine oil temperature min. 80 °C
Test sequence
Observe following if test and measuring instruments are required during a test drive:
◆ Test and measuring instruments must be secured to rear seat and operated by a 2nd person from this
location.
If test and measuring instruments are operated from front passenger's seat and the vehicle is involved in
an accident, there is a possibility that theVoperson sitting in this seat may receive serious injuries when the
. lkswagen AG
airbag is triggered. swa gen AG does
olk not
yV gu
db a
- The charge pressure ois ris measured
e with the turbocharger testerraV.A.G
nte 1397/A and the fault reader V.A.G
1551 during a test adrive.
ut
h eo
ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
- -> Pull off connecting hose running between intake manifold and diesel direct injection system control unit
nform
(J248) and using T-piece connect in turbocharger tester V.A.G 1397 A.
ercia
- Select measuring range l.

m
a
com
tion in
Notes:
r
te o
thi
s
iva
◆ To operate turbocharger tester see operating instructions.

do
r
rp
◆ The hoses must be connected so that there is no possibility of leaks.

um
fo
en
g
◆ Ensure that the pressure hose is not trapped between the bonnet and the body.
n
t.
yi Co
Cop py
ht. rig
- Connect fault reader V.A.G 1551 (V.A.G 1552) and select engine electronics control unit with the "Address
rig ht
py by
word" 01. When doing this the engine must be running at idling speed. co Vo
by lksw
cted agen
Prote AG.
=> Repair group 01; Self-diagnosis; Connecting fault reader V.A.G 1551 and selecting engine electronics con‐
trol unit Self-diagnosis Connecting fault reader V.A.G 1551 and selecting engine electronics control unit
-> Indicated on display:

Rapid data transfer HELP
Select function XXX
- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.

Read measured value block HELP
Input display group number XXX
- Press keys 0, 1 and 1 for display group 11 and confirm entry by pressing Q.
- measured value block 11
Read "
840 rpm 938 mbar 978 mbar 92 %

- Accelerate vehicle in 3rd gear from about 1500 rpm using full throttle.
- Press PRINT key on V.A.G 1551 at approx. 3000 rpm and simultaneously the memory key on V.A.G 1397/
A..
202 21 - Charging
Specification on V.A.G 1397/A: 1.750...2.080 bar
-> Specification on V.A.G 1551: 1750...2080 mbar (in display zone 3)

Read measured value block 11
3090 rpm 1866 mbar 1917 mbar
62 %
Note:
The charge pressure is determined with the turbocharger tester V.A.G 1397/A. The fault reader V.A.G 1551
serves as a check that the charge pressure is being recorded in the control unit.
If the specification is not obtained:
- Carry out final control diagnosis and activate the charge pressure control solenoid valve:
=> Repair group 01; Self-diagnosis; Final control diagnosis Self-diagnosis Final control diagnosis

Final control diagnosis
Charge pressure control solenoid valve -
N75
The solenoid valve must function and the charge pressure control pressure unit rod must move to and fro (at
least 3...4 times, as long as there is vacuum in vacuum reservoir).
- If the rod moves and the charge pressure specifications are not obtained, renew turbocharger.
AG. Volkswagen AG d
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ole,
spec
t to the co
rrectne
If rod does not move because solenoid valve is not working:

ss o
- Check solenoid valve for charge pressure control (N75):

cial p
f inform
mer
=> Repair group 23; Diesel direct injection system; Checking charge pressure control Diesel direct injection
atio
m
system Checking charge pressure control

o
n
c
i
or
n thi
e
- Check vacuum hoses => Page 193

t
sd
iva
o
pr
cum
r
If the rod does not move but the solenoid operates:

fo
en
ng
t.
yi Co
op
- -> Connect vacuum pump V.A.G 1390 to charge pressure regulating valve and check rod for ease of move‐
C py
t. rig
gh
ment.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.2 - Checking turbocharger 203

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gen AG d
Transporter 1991 ➤ olks
wa oes
not
yV gu
5-Cyl. diesel engine,
isedMech.
b - Edition 10.2000 ara
n r tee
ho
ut or
- If the rod does not move
ss
aeasily, replace exhaust turbocharger. ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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orm
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Cop py
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Vo
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by c lksw
cted agen
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204 21 - Charging
26 - Exhaust system lksw

agen
AG. Volkswagen AG d
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1 - Removing and installing parts of exhaust system
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ab
1.1 - Removing and installing parts of exhaust system
ility
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Notes:
hole
spec
◆ After working on the exhaust system ensure that the system is not under stress, and that it has sufficient
es, in part or in w
clearance from the bodywork. If necessary, loosen double and single clamps and align silencer and exhaust
t to the co
pipe so that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded.
rrectness of i
Exhaust system, engine code AAB => Page 206 .
l purpos
Front exhaust pipe and catalyst with attachments, engine codes ACV, AJA, AJT, AHY, AUF, AXG, AXL, AYC
=> Page 207 .
nf
ercia
Silencer with mountings, engine codes ACV, AJA, AJT, AHY, AUF, AXG, AXL, AYC => Page 212 .
orm
Silencer with mountings for vehicles with four-wheel drive => Page 213 .
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.1 - Removing and installing parts of exhaust system 205

AG. Volkswagen AG d
agen oes
o lksw not
V gu
d by ara
e nte
Transporter 1991 ➤ tho ris
eo
u
ss a Mech. - Edition 10.2000 ra
c
ce
e
nl
Exhaust system, engine code AAB
pt
du
an
itte
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erm
ab
Note:
ility
ot p
Align the exhaust system longitudinally so that the dimensions -a- and -b- are maintained.
wit
, is n
h re
1 25 Nm
hole
spec
2 Gasket
es, in part or in w
t to the co
◆ Renew
3 Exhaust manifold
4 Ring
rrectness of i
l purpos
◆ Lever off with screwdriver

5 Clamping spring
nform
ercia
◆ Remove and install with tensioning wedges 3140A => Page 210
◆ Tensioning or relieving tension
m
at
om
=> Page 211
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

7 Clamp
8 40 Nm
9 Front silencer
206 26 - Exhaust system

AG. Volksw Mech.
agen - Edition 10.2000
n AG do
wage es n
10 Mounting Volks ot g
by ua
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11 Retainer oris tee
th or
12 Retaining ring au ac
ss
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nl
pt
du
13 Centre silencer
an
itte
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14 End pipe
erm
ab
ility
ot p
15 Dimension -b- = min. 10 mm
wit
, is n
16 Dimension -a- = 50 ±5 mm
h re
hole
spec
17 5 Nm
es, in part or in w
18 Heat shield
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Front exhaust pipe and catalyst with attachments, engine codes ACV, AJA, AJT, AHY, AUF, AXG, AXL, AYC
Notes:
◆ Removing and installing exhaust manifold, engine codes ACV, AJT, AHY, AUF, AXG, AXL, AYC =>Page
179 , Removing and installing turbocharger with attachments.

◆ Align exhaust system longitudinally so that dimensions -a- and -b- are ensured.

◆ Engine codes AHY, AXG, AXL
2 Gasket
◆ Renew
3 Mounting
◆ Engine code AHY, AXG, AXL
lkswage es n
o ot g
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d ran
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nl
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itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
4 Clamping spring
l purpos
◆ Remove and install with tensioning wedges 3140A => Page 210
◆ Tensioning or relieving tension
=> Page 211
nf
ercia
5 Pipe elbow
rm
m
atio
◆ Engine codes ACV, AJT, AUF, AYC

om
◆ Between turbocharger and front exhaust pipe

n in
or c
=>Page 184 , item 28

thi
te
sd
a
6 Ring
iv
o
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rp
cu
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m
f
en
ng
◆ Lever off with screwdriver

t.
yi Co
op py
7 25 Nm t. C rig
gh ht
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8 Exhaust manifold
p by
co Vo
by lksw
cted agen
Prote AG.

◆ Engine code AJA
AG. Volkswagen AG d
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ab
ility
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t to the co
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cial p
f inform
mer
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c
i
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fo
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◆ Engine codes ACV,AJA,AJT, AUF, AYC
C py
t. rig
gh ht
yri
10 Dimension -b- = min. 10 mm p by
o Vo
by c lksw
11 Mounting cted agen
Prote AG.
12 Catalyst
13 To centre silencer
14 5 Nm
16 Heat shield
17 Support bracket
◆ For damper rubber
18 Damper rubber
◆ For front exhaust pipe item 9

1.2 - Removing and installing clamping springs
◆ -> 3140 A Tensioning wedges
Removing
• Exhaust system cold
Engine code AAB
- Separate exhaust system between front exhaust pipe and front silencer. In some cases it is necessary to
release the exhaust system from its hangers.
Engine codes ACV, AJA, AJT, AUF, AYC

AG. Volkswagen n AG do
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au ac
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nl
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ab
ility
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spec
es, in part or in w
t to the co
- Separate exhaust system between front exhaust pipe and catalyst.

rrectness of i

l purpos
- -> Open clamping spring by pressing sideways on exhaust pipe until short tensioning wedge 3140 A/2 can
nf
ercia
pushed in onto stops.

orm
m
atio
Note:
om
n in
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thi
Opening clamping springs:

te
sd
iva
o
r
rp
cu
◆ Grip front exhaust pipe with pipe wrench and push exhaust system to side in relevant direction.
o
m
f
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t.
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op
Installing C py
ht. rig
rig ht
py by
o Vo
Install in reverse order but note following: by c lksw
cted agen
Prote AG.
- Finally, check seating of tensioning springs in cut-outs.

1.3 - Tensioning and relieving tension on clamping springs
◆ -> 3140 A Tensioning wedges

◆ Synthetic head hammer
If a removed clamping spring is to be relieved or a new clamping spring requires tensioning then perform this
function in a vice as follows:
wage
Relieving tensioning yV
olks es n
ot g
d b ua
ran
ir se te
- Place clamping spring with tensioningth wedge 3140 A/2 on a vice, opened approx.e15
o
or mm, so that the striking
au
side of the tensioning wedge isssbetween the vice jaws. ac
- Carefully drive tensioning wedge out between the gap in the vice jaws using a synthetic head hammer.
ce
le
un
pt
an
d
itte
Tensioning
y li
erm
ab
ility
ot p
- Place clamping spring on a vice opened approx. 15 mm.
wit
is n
- Drive long tensioning wedge through tensioning spring, between vice jaws, onto stop using a synthetic head
h re
ole,
hammer.
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
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pr
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fo
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Note:
Co
Cop py
t. rig
gh ht
yri by
On vehicles where the clamping spring with fitted longer tensioning wedge still cannot be fitted then the ten‐
cop Vo
by lksw
sioning spring is to be fitted onto a shorter tensioning spring as follows: cted agen
Prote AG.
- -> Additionally drive shorter tensioning wedge next to longer tensioning wedge into clamping spring onto
stop.
- Hold clamping spring over the opened vice gap so that only the shorter tensioning wedge striking side lies
on a vice jaw.
1.3 - Tensioning and relieving tension on clamping springs 211

- Carefully drive out longer tensioning wedge through gap between vice jaws using a synthetic hammer.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c ce
e
nl
pt
du
an
itte
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Silencer with mountings, engine codes ACV, AJA, AJT, AHY, AUF, AXG, AXL, AYC
erm
ab
ility
ot p
1 Central silencer
wit
, is n
h re
2 Retaining ring
hole
spec
es, in part or in w
t to the co
3 Bracket
4 25 Nm
5 To catalyst
rrectness of i
6 Clamp
l purpos
7 40 Nm
8 Mounting
nform
ercia
m
at

om
ion
10 Rear silencer
c
in t
or
his
e
at
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Silencer with mountings for vehicles with four-wheel drive
1 Central silencer
2 Retaining ring
3 Bracket
4 25 Nm
5 To catalyst
6 Clamp
7 40 Nm
9 Rear silencer
10 Mounting
1.3 - Tensioning and relieving tension on clamping springs 213

2 - Exhaust gas recirculation system

2.1 - Exhaust gas recirculation system
AG. Volkswagen AG d
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olksw not
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Notes: orise nte
eo
th
au ra
c
◆ The control of the exhaust gas recirculation system is undertaken by diesel direct injection system control
ss
ce
le
unit (J248) via EGR valve (N18) (electric) to exhaust gas recirculation valve (mechanical).
un
pt
◆ Checking exhaust gas recirculation valve (N18).
an
d
itte
y li
erm
ab
ility
=> Repair group 01; Self-diagnosis; Final control diagnosis Self-diagnosis Final control diagnosis
ot p
wit
is n
h re
◆ The cone-shaped plunger in the mechanical exhaust gas recirculation valve ensures that various cross
ole,
sectional openings are possible at different plunger lifts.
spec
◆ Pulsed control makes every conceivable valve position possible.
t to the co
rrectne
2.2 - Removing and installing parts of exhaust gas recirculation system
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
rised
nte Transporter 1991 ➤
o eo
aut
h
5-Cyl. diesel engine, Mech. ra - Edition 10.2000
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
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1 Exhaust gas recirculation valve
hole
spec
es, in part or in w
t to the co
2 15 Nm
3 Vacuum control element
◆ For intake manifold flap 09.00 ▸
rrectness of i
4 Bracket
l purpos

nform
ercia
6 Gasket
◆ Renew
m
a
com
tio
7 Intake manifold
n in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
8 Vacuum hose
◆ From air cleaner upper part or filter
2.2 - Removing and installing parts of exhaust gas recirculation system 215
◆ Checking control
=> Repair Group 01; Self-diagnosis; Final control diagnosis Self-diagnosis Final control diagnosis
10 Connector
◆ 2-pin
◆ For exhaust gas recirculation valve (N18)
11 10 Nm
12 Vacuum hose
◆ To non-return valve between vacuum pump and brake servo
AG. Volkswagen AG d
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spec
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nform
mercia
a
com
tion in
r
te o
thi
s
iva
13 Retainer
do
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rp
cum
◆ For exhaust gas recirculation valve (N18) and charge pressure limitation solenoid valve (N75)
fo
en
ng
t.
yi
14 Exhaust manifold
Co
Cop py
15 25 Nm ht. rig
rig ht
py by
16 Connecting pipe
co Vo
by lksw
cted agen
Prote AG.
17 Air hose
18 From charge air cooler or turbocharger

AG. Volkswagen AG d
agen oes
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by Vol
gu
ara
d
rise 5-Cyl. diesel engine, nMech.
te - Edition 10.2000
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
m
atio
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n in
or c
thi
te
sd
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cu
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f
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Engine code AHY ▸ 0900
Engine codes
AHY 09.00 ▸, AXG, AXL => Page 219
1 Seal
◆ Renew
◆ Checking activation
3 To exhaust gas recirculation valve (N18)

◆ Vacuum hose connection diagram => Page 221
4 15 Nm
5 From charge air cooler
◆ => Page 191 , item 4
6 Connecting hose
AG. Volkswagen AG d
agen oes
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byV gu
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aut ra
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un
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ab
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wit
is n
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ole,
spec
t to the co
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cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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cum
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fo
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ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
7 Intake manifold
8 25 Nm
9 Exhaust manifold
10 Connecting pipe

AG. Volkswagen AG d
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olksw not
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d b ara
rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
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sd
iva
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Engine codes
t.
yi Co
AHY 09.00 ▸, AXG, AXL Cop py
t. rig
gh ht
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1 From charge air cooler cop Vo
by lksw
cted agen
◆ => Page 191 , item 4 Prote AG.
2 Connecting hose
3 To exhaust gas recirculation valve (N18)
◆ Vacuum hose connection diagram => Page 221
4 Vacuum control element

◆ For intake manifold flap
◆ Checking activation
AG. Volkswagen AG d
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olksw not
V gu
d by ara
ise nte
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aut ra
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le
un
pt
an
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itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
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cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

◆ To remove, unbolt coolant expansion tank and place to one side
7 O-ring
◆ Renew
8 Intake manifold
9 Exhaust manifold
10 25 Nm
11 Gasket
◆ Renew
12 Connecting pipe
13 15 Nm
14 10 Nm

2.3 - Vacuum hose connection diagram
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
m
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om
n in
or c
thi
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sd
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t.
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Cop py
t. rig
Engine codes ACV, AJT, AUF, AYC => Illustration on Page 215 gh ht
pyri by
Vo
co lksw
by
cted agen
1 Vacuum reservoir Prote AG.
2 Breather pipe
◆ To air cleaner
3 Air cleaner
4 Charge pressure control solenoid
valve (N75)
5 Non-return valve
◆ White connection to charge pressure control solenoid valve item 4 and to vacuum reservoir
2.3 - Vacuum hose connection diagram 221

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
7 Intake manifold flap change-over valve

◆ Vehicles09.00 ▸ only
8 Brake servo
9 Vacuum connection
◆ For brake servo
10 Diesel direct injection system control unit (J248)
◆ 05.99 ▸without connection to charge air cooling connecting pipe
12 Vacuum pump
15 Air cleaner

2.4 - Checking exhaust gas recirculation valve

◆ -> V.A.G 1390 Hand vacuum pump AG. Volkswagen AG d
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Note:
No charge air cooler is fitted with engine code AJT. The components of the exhaust gas recirculation system ss o
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inform
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Test sequence
atio
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Engine codes ACV, AUF

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- Remove lower bracket for charge air cooler.

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- Remove air hose between exhaust gas recirculation valve and charge air cooler at exhaust gas recirculation
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valve using hose clip pliers V.A.G 1921.

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2.4 - Checking exhaust gas recirculation valve 223

Engine code AJT
- Remove air hose between exhaust gas recirculation valve connecting pipe and exhaust turbocharger using
spring-type clip pliers V.A.G 1921.
olks
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V
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- -> Pull vacuum hori hose off exhaust gas recirculation valve.
s tee
- Connect handaut vacuum pump V.A.G 1390 to valve. or
ac
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- -> Operate pump.
nf
ercia
The membrane rod must move towards

orm
vacuum connection.
m
atio
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- Pull hand vacuum pump hose of exhaust gas recirculation valve.

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c
The valve must clearly be heard to close (membrane rod moves

or
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towards intake manifold).

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Engine code AHY ▸ 09.00

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- Pull vacuum hose off (mechanical) exhaust gas recirculation valve.
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- Remove exhaust gas recirculation valve =>Page 217 , item 2 .
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- Connect hand vacuum pump V.A.G 1390 to valve.

- -> Operate pump.
Membrane must move in direction of vacuum connection.
- Pull hand vacuum pump hose off exhaust gas recirculation valve.
The valve must clearly be heard to close (membrane moves
downwards).
Engine code AHY 09.00 ▸, AXG, AXL
- Remove engine cover.

- Remove connecting hose between charge air pipe and intake connecting flange.

- Pull vacuum hose off (mechanical) exhaust gas recirculation valve.

- Connect hand vacuum pump V.A.G 1390 to valve.
- -> Operate pump and observe membrane rod.
Note:
Observe movement of membrane rod either using a mirror or by touch.
The membrane rod must move in direction of arrow.
- Pull hand vacuum pump hose off exhaust gas recirculation valve.
The membrane rod must move back against the direction of arrow to its original position.
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2.4 - Checking exhaust gas recirculation valve 225

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Service

5-Cyl. diesel engine, Mech.

Service Department. Technical Information

5-Cyl. diesel engine, Mech.

10 - Removing and installing engine

15 - Cylinder head, Valve gear

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Copyright © 2010 Volkswagen AG, Wolfsburg 00052705220

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

2.3 Removing and installing dual mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

2.4 Renewing crankshaft oil seal - pulley end - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

3.1 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

4.2 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

1.1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

1.3 Checking compression pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

2 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

2.1 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

2.6 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167

1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179

1.1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179

1.2 Removing and installing turbocharger with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . .179

1.3 Removing and installing air cooling parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188

1.4 Turbocharger hose/pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193

1.5 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194

1.6 Removing and installing exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195

2.2 Checking turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205

1.1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205

1.2 Removing and installing clamping springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210

1.3 Tensioning and relieving tension on clamping springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211

2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214

2.1 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214

The engine code is also included on the vehicle data plate.

1.3 - Engine data

Codes AAB ACV AJA AHY

1.1 - Technical data 1

Codes AAB ACV AJA AHY

1) from 05.99 modified compression ratio

Codes AHY AJT AUF AXG

Torque Nm at rpm 250/1900...2300

Compression ratio 19:1

Firing order 1-2-4-5-3

Charge air cooling x

◆ 2024 A Lifting tackle

1.1 - Removing and installing engine 3

◆ V.A.G 1306 Drip tray

1.2 - Notes on removing

4 10 - Removing and installing engine