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Service
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
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26 - Exhaust system
28 - Glow plug system
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Technical information should always be available to the foremen and mechanics, because their
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg D4B804089DC

3-Zyl. Dieselmotor - Edition 05.2014
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . a.g.en. A. G. ..V.o.lk.sw. a.g.e.n A
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1.2 Engine data . . . . . . . . . . . . . .y V. o.lk.s. . . . . . . . . . . . . . . . . . . .n.ot.g.u . . . . . . . . . . . . . . . . . . . . 1
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10 - Removing and installing engine
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1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1.3 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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1.4 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1.5 Additional information and assembly work for vehicles with air conditioner . . . . . . . . . . . . 12
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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1.2 Assembly overview - crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2 Sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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2.1 Assembly overview - sealing flange and flywheel, engine codes AMF, BAY, BNM, BNV . . 20
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2.2 Assembly overview - sealing flange and flywheel, engine codes BMS, BWB . . . . . . . . . . 22
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2.3 Renewing crankshaft oil seal - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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2.4 Removing and installing sealing flange - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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2.5 Renewing crankshaft sealing flange - flywheel end, engine codes BMS, BWB . . . . . . . . . . 27
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2.6 Removing and installing engine speed sender G28 , engine codes BMS, BWB . . . . . . . . 35
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3 Balancer shaft and retaining frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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3.1 Assembly overview - balancer shaft and retaining frame . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.2 Removing and installing balancer shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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4 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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4.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2 Separating new conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.3 Checking pistons, piston rings and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.4 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.5 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.2 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.2 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.3 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.4 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.5 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.6 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Contents i
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.1 Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.2 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.1 Assembly overview - parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.2 Assembly overview - oil filter bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.3 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.4 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.1 Assembly overview - parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.2 Assembly overview - parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . 98
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1.3 Coolant hose schematic diagram . . . . . . . . . . . . . . . . k. s.w.ag. e.n.A.G. . . . . . . e.n.A.G. d.o.es. . . . . . . . 99
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1.4 Draining and filling coolant . . . . . . . . . . . . . . . . . .d b. y.V. . . . . . . . . . . . . . . . . . . . . . . . t. g.u.ar. . . 101
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1.5 Removing and installing radiator . . . . . . . . . t.ho.ris. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . n.te.e o105
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1.6 Removing and installing coolant pump . . s.s .a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 ra
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1.7 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
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1.8 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
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1.9 Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
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20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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1.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.3 Assembly overview - fuel tank with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.4 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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1.5 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
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1.6 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

1.7 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
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1.8 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

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1.9 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
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1.10 Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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1.11 Checking tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
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1.12 Removing and installing tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
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21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
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1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
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1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
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1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.3 Installing hose connections with connector couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

1.4 Hose connections with spring band ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.5 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.6 Removing and installing turbocharger, engine codes BMS, BWB . . . . . . . . . . . . . . . . . . . . 140
1.7 Assembly overview - parts of charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
1.8 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

1 Repairing diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.3 Assembly overview - intake manifold with intake manifold flap . . . . . . . . . . . . . . . . . . . . . . 148
1.4 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.5 Assembly overview - unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
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1.6 Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

1.7 Adjusting non-contact gap of unit injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.8 Removing and installing O-rings for unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.2 Removing and installing anti-theft engine control unit , engine codes AMF, BAY, BNM,
BNV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.3 Removing and installing anti-theft engine control unit , engine codes BMS, BWB . . . . . . 161
2.4 Reading and clearing engine control unit
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2.5 Adapting functions and components olksw . . . . . . . . . . . . . . . n. o.t . . . . . . . . . . . . . . . . . . . . . . . . . 163
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26 - Exhaust system . . . .au.tho. . . . . . . . . . . . . . . . . . . . . . . . . . . . e.e o.r a. . . . . . . . . . . . . . . 165
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1 Exhaust system s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
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1.1 Assembly overview - front exhaust pipe with catalytic converter and silencer . . . . . . . . . . 165
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1.2 Assembly overview - front exhaust pipe with particulate filter . . . . . . . . . . . . . . . . . . . . . . 167
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1.3 Assembly overview - silencer, vehicles with particulate filter . . . . . . . . . . . . . . . . . . . . . . . . 168
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1.4 Removing and installing front exhaust pipe with particulate filter . . . . . . . . . . . . . . . . . . . . 169
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1.5 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
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2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
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2.1 Assembly overview - parts of exhaust gas recirculation system, engine code AMF . . . . . . 173
2.2 Assembly overview - parts of exhaust gas recirculation system, engine codes BAY, BNM,
BNV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
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2.3 Assembly overview - parts of exhaust gas recirculation system, engine codes BMS, BWB
........................................................................ 175
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2.4 Assembly overview - exhaust gas recirculation cooler, engine codes BMS, BWB . . . . . . 176
2.5 Removing and installing exhaust gas recirculation cooler, engine codes BMS, BWB . . . . 177
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2.6 Vacuum hose assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

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28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
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1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

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1.1 Removing, installing and checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

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1.2 Characteristics of ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

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1.3 Removing, installing and checking ceramic glow pin plugs . . . . . . . . . . . . . . . . . . . . . . . . 181
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Contents iii
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iv Contents
AG. Volkswagen AG d Polo Classic 2007 ➤
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1 Technical data
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(VRL006704; Edition 05.2014)
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Engine number ⇒ page 1
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Engine data ⇒ page 1
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1.1 Engine number
rrectness of i
The engine number (“code letters” and “serial number”) can be
found at the joint between engine and gearbox.
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Additionally there is a sticker on the toothed belt guard with “en‐

gine code” and “serial number”.
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The engine code is also included on the vehicle data sticker.
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1.2 Engine data

Edition 12.2011 Version 10
Engine code AMF BAY BNM BNV
Manufactured 11.01 ► 11.01 ► 03.05 ► 03.05 ►
Capacity l 1.4 1.4 1.4 1.4
Output kW at rpm 55/4000 55/4000 51/4000 58/4000
Torque Nm at rpm 195/2200 195/2200 155/2200 195/2200
Bore ∅ mm 79.5 79.5 79.5 79.5
Stroke mm 95.5 95.5 95.5 95.5
Compression ratio 19.5 19.5 19.5 19.5
Fuel according to DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590
Firing order 1-2-3 1-2-3 1-2-3 1-2-3
Catalytic converter yes yes yes yes
Diesel particulate filter no no no no
Exhaust gas recirculation yes yes yes yes
Turbocharging/supercharging yes yes yes yes
Charge air cooling yes yes yes yes
Engine code BMS BWB

Manufactured 01.06 ► 06.06 ►
Capacity l 1.4 1.4
Output kW at rpm 59/4000 51/4000
1. Technical data 1
Engine code BMS BWB

Torque NmAGat. Vrpm
olkswagen AG 195/2200 155/2200
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Fuel according to DIN EN 590 DIN EN 590
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Firing order 1-2-3 1-2-3
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Catalytic converter yes
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Diesel particulate filter yes yes
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Exhaust gas recirculation yes yes
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Turbocharging/supercharging yes yes
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Charge air cooling yes yes
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2 Rep. gr.00 - Technical data

10 – Removing and installing engine

1 Removing and installing engine
Removing engine ⇒ page 3 .
Securing engine to assembly stand ⇒ page 9 .
Notes on installing ⇒ page 10 .
Assembly mountings ⇒ page 11
Additional information and assembly work for vehicles with air
conditioner ⇒ page 12 .
1.1 Removing engine
Special tools and workshop

equipment required
♦ Lifting tackle - VAS 2024A-
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♦ Engine bracket - T10012- AG. Volkswagen AG d
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♦ Support clamp - VW 313- by Vo gu
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♦ Engine and gearbox sup‐ uthor eo
port - VW 540- or engine
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and gearbox support - VAS
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♦ Workshop hoist - V.A.G
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1202 A- or workshop crane
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- VAS 6100-
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♦ Drip tray - V.A.G 1306- or spec

drip tray - VAS 6208-
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1. Removing and installing engine 3

♦ Torque wrench - V.A.G

1331-
1332-
♦ Engine and gearbox jack -
V.A.G 1383/A-
♦ Spring-type clip pliers -
VAS 5024-
♦ Stepladder - VAS 5085-
♦ Support bracket - 10-222A-
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♦ Engine support - T40076- (vehicles with no air conditioner)

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Not illustrated:
♦ Container for removed parts - V.A.G 1698-

♦ Engine bung set - VAS 6122-
♦ Grease - G 000 100-
♦ Cable ties
4 Rep. gr.10 - Removing and installing engine

Modifying engine bracket - T10012-

– If not already modified, drill an additional hole -a- at the height
of the existing holes, according the dimensions provided.
Procedure
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♦ Before or carrying out further work, disconnect battery
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♦ In vehicles with engine codes AMF, BAY, BNM and BNV the
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♦ In vehicles with engine codes BMS and BWB the engine is
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When doing any repair work, especially in the engine compart‐
satelettronica
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ment, pay attention to the following due to the cramped condi‐
tions:
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♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
nform
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fluid and vacuum) and electrical wiring in their original po‐

sitions.
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♦ Ensure that there is sufficient clearance to all moving or

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– Disconnect battery ⇒ Electrical system; Rep. gr. 27 .

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– Remove engine cover panel ⇒ Maintenance ; Booklet 15.1 .
– Remove air filter housing together with intake hoses
⇒ page 152 .
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 .
– Remove engine control unit - J623- ⇒ page 159 .
– Release engine wiring harness from body and lay it on engine.
– Unbolt earth strap from longitudinal member.
– Disconnect starter and alternator ⇒ Electrical system; Rep.
gr. 27 .
– Remove noise insulation tray ⇒ General body repairs, exteri‐
or; Rep. gr. 50 .
– Drain coolant ⇒ page 101 .

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WARNING au ac
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♦ The fuel and the fuel lines in the fuel system can become
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very hot (danger of scalding)!
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♦ The fuel system is also under pressure! Before opening
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♦ Wear eye and hand protection when performing any type
es, in part or in w
of repair work on the fuel system!
t to the co
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– Pull fuel supply and return lines as well as coolant line off ex‐
pansion tank on cylinder head.
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– Unscrew connecting pipe between charge air cooler and tur‐

bocharger.
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– Remove connecting pipe between charge air cooler and intake
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– Remove poly V-belt ⇒ page 16 .
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– Pull off radiator coolant hoses from engine using hose clip pli‐
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ers - V.A.G 1921- or spring-type clip pliers - VAS 5024A- .
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– Pull off/disconnect all electrical connections as necessary . Cop py
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– Pull radiator coolant hoses off engine using spring-type clip
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pliers - VAS 5024- .
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– Separate all connecting, coolant, vacuum and intake hoses

from engine.
Vehicles with engine codes AMF, BAY, BNM, BNV
– Unscrew cable support bracket securing bolt and locate clutch

release lever in position using locking pin - T10060 A-
-arrow-.
– Unscrew upper securing bolts of engine/gearbox unit.
– Remove coolant expansion tank.
– Unbolt starter and pull it back as far as possible to allow the
gearbox support - 3147- to be fitted.
– Fit support bracket - 10 - 222 A- as shown and take up weight

of engine and gearbox in installation position.

– Remove engine carrier -1- and engine console -2-.

– Remove right drive shaft ⇒ Rep. gr. 40 .
– Unbolt front exhaust pipe from turbocharger, loosen double
clamp and slide exhaust pipe back ⇒ page 165 .
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– Remove cover plate behind drive shaft flange.
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– Disconnect selector mechanism from gearbox ⇒ 5-speed
spec
manual gearbox 02R; Rep. gr. 34 .
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– Remove clutch slave cylinder and move it aside (the hydraulic
system must not be opened) ⇒ 5-speed manual gearbox 02R;
Rep. gr. 30 .
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Note
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Clutch pedal must not be depressed.
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– Remove pendulum support ⇒ page 11 .

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– Unscrew steering from subframe.

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– Remove subframe, the hydraulic steering circuit need not be

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opened for this ⇒ Running gear, axles, steering; Rep. gr. 40 .

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Secure steering box to body of vehicle so that hydraulic lines are
not stressed.
– Remove securing bolts -1- and remove cover -2- from cylinder
block for right drive shaft.
– Disconnect both drive shafts at gearbox ⇒ Running gear,
axles, steering; Rep. gr. 40 .
– Remove front exhaust pipe together with diesel particulate fil‐
ter ⇒ page 169 .
Vehicles with air conditioner
– Observe additional information and installation work
⇒ page 12 .

AG. Volkswagen AG d
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3-Zyl. Dieselmotored-byEdition 05.2014 gu
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– Insert engine bracket
ss
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- T10012- in engine and gearbox jack - ra
c
V.A.G 1383/A- .
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– Bolt mounting pin -1- with one washer and mounting pin -2- d
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with two washers A13 X 24 X 2.5 to engine bracket -arrows-
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– Secure engine bracket - T10012- on cylinder block using se‐
h re
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curing nut -3- and securing bolt for ancillary bracket.
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Note
rrectne
Fit two washers A 10.5 X 21 X 2 between engine bracket and
ancillary bracket so that the engine bracket rests flat against an‐
cillary bracket.
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Vehicles with no air conditioner

– Insert engine bracket - T40076- in engine and gearbox jack -
V.A.G 1383/A- .
– Secure engine support - T40076- with nut -1- and one bolt
-2- (M10 x 30 mm). Use a nut -3- (M12) as spacer to cylinder
block.
– Unscrew lower securing bolts of engine/gearbox unit. agen
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– Lift engine and gearbox lightly using engine and gearbox ed jack
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– Unhook spindle of engine support bracket - 10 - 222
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Use stepladder - VAS 5085- for unhooking the spindle.
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– Press engine off gearbox, carefully lower engine using engine
t to the co
satelettronica
and gearbox jack - V.A.G 1383 A- and remove engine down‐
wards.
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– Raise engine and gearbox slightly using engine and gearbox
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– Unbolt assembly mountings on engine side and gearbox side

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To remove securing bolts, use stepladder - VAS 5085- .
– Carefully lower engine with gearbox.
Note
When lowering, the engine must be carefully guided to prevent

damage to the bodywork.
1.2 Securing engine to assembly stand

When working on the engine, secure it with engine and gearbox
support - VW 540- to support clamp - VW 313- of the assembly
stand or to engine and gearbox support - VAS 6095- .
Procedure
– Unbolt gearbox.

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Polo Classic 2007 hori➤
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3-Zyl. Dieselmotor
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Continuation for all engine codes
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– Attach lifting tackle - 2024 A- as shown and raise engine out
ab
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of engine and gearbox jack - V.A.G 1202 A- using workshop
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crane - VAS 6100- or workshop crane - V.A.G 1383 A- .
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Belt pulley end: 4th hole in hook rail at position 1
spec
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Flywheel end: 2nd hole in hook rail at position 8
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WARNING
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Use locking pins -arrows- to secure hooks and locating pins.
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♦ The positions marked 1…4 on the bar must face towards the
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♦ The holes in the hook rails are counted up from the hook.
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– Using engine and gearbox support -VW 540- , secure engine yri
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1.3 Notes on installing

Installation is carried out in the reverse order. When installing,
note the following:
– Check clutch release bearing for wear and renew if necessary.
– Lightly grease clutch release bearing, release bearing guide
sleeve and splines on input shaft with G 000 100.
– Check whether dowel sleeves for centring engine/gearbox
have been fitted in cylinder block, insert if necessary.
– Align engine the mountings stress-free by rocking, if neces‐
sary loosen the engine mountings on the body.
Note
Specified torques for assembly mountings ⇒ page 11 .
– Electrical connections and routing ⇒ Rep. gr. 97


– Remove locking pin - T10060 A- -arrow- and reinstall securing
bolt.
– Install front exhaust pipe ⇒ page 165 .
– Install front exhaust pipe with particulate filter ⇒ page 169 .
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
40 .
– Install subframe ⇒ Running gear, axles, steering; Rep. gr.
40 .
Continuation for all engine codes
– Install drive shafts ⇒ Rep. gr. 40 .
– Install poly V-belt ⇒ page 16 .
– Install hydraulic clutch slave cylinder ⇒ 5-speed manual gear‐
box 02R; Rep. gr. 30 .
– Install selector mechanism and adjust cables if necessary ⇒
satelettronica
5-speed manual gearbox 02R; Rep. gr. 34 .
– Install connecting pipes
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– Replenish
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– Install noise insulation ⇒ Rep. gr. 50 .
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– Carry out road test and read all event memories

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⇒ page 162 .
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Specified torques
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Threaded connection Specified torque

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Bolts, nuts M6 10 Nm
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M8 20 Nm
M10 45 Nm
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M12 60 Nm
s
Deviations
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Front exhaust pipe to turbocharger 25 Nm

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1.4 Assembly mountings

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Engine assembly mountings

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Gearbox assembly mounting
-A- 1) 50 Nm + 90° (1/4 turn) further

-B- 1) 40 Nm + 90° (1/4 turn) further
1) Renew.
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Pendulum support
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Position bolts -A- in elongated holes of pendulum support so that
the clearance between the gearbox and mountings is at its max‐
imum.
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-A- 1) 30 Nm + 90° (1/4 turn) further

-B- 1) 40 Nm + 90° (1/4 turn) further
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1.5 Additional information and assembly
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♦ To remove the engine, the air conditioner refrigerant circuit
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♦ To prevent damage to condenser or to refrigerant lines/hoses,

ensure that the lines and hoses are not stretched, kinked or
bent.
– Extract refrigerant from air conditioner refrigerant circuit and

open air conditioner refrigerant circuit ⇒ Rep. gr. 87 .
Note
The air conditioner compressor can remain installed.

13 – Crankshaft group
1 Dismantling and assembling engine
Note
If large quantities of swarf or metal particles (caused, for example,

by partial seizure of the crankshaft or conrod bearings) are found
in the engine oil when performing repairs, clean the oil passages
thoroughly and renew the engine oil cooler in order to prevent
subsequent damage.
⇒ “1.1 Assembly overview - toothed belt drive”, page 13

⇒ “1.2 Assembly overview - crankcase”, page 15
⇒ “1.3 Removing and installing poly V-belt”, page 16
1.1 Assembly overview - toothed belt drive
satelettronica
1 - Toothed belt guard upper
part
2 - Toothed belt
❑ Mark direction of rota‐
tion before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing, installing
and tensioning
⇒ page 56 . AG. Volkswagen AG d
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3 - 20 Nm + turn (45°) ise
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4 - Tensioning roller aut ra
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5 - 100 Nm
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6 - 25 Nm
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7 - Camshaft pulley
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8 - Hub
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❑ With sender wheel

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❑ Use counterhold tool -

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T10051- to loosen and

tighten.
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❑ To remove, use puller -

T10052- .
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❑ Removing and installing

⇒ page 80 .
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9 - 10 Nm
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10 - Rear toothed belt guard

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11 - Sealing grommet
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12 - Toothed belt tensioner

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1. Dismantling and assembling engine 13

13 - Idler roller
14 - Coolant pump
❑ Removing and installing ⇒ page 106 .
15 - Crankshaft toothed belt pulley
16 - 120 Nm + 90° further
❑ Renew.
❑ Use counterhold tool - 3415- to loosen and tighten.
❑ Do not additionally oil or grease thread and shoulder.
❑ Turning further can be done in several stages.
17 - 15 Nm
18 - 20 Nm
19 - Toothed belt guard lower part
20 - Belt pulley and vibration damper
❑ Can only be installed in one position. Holes are offset.
21 - 10 Nm + 90° further
satelettronica
22 - Toothed belt guard centre part
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14 Rep. gr.13 - Crankshaft group

1.2 Assembly overview - crankcase
1 - 45 Nm
2 - Engine bracket
3 - Cylinder block
sealing flange and fly‐
wheel ⇒ page 20 .
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 46 .
4 - Union, 40 Nm
❑ For oil return line from
turbocharger.
❑ Renew.
5 - Spacer sleeve
6 - Rubber bush
satelettronica
7 - Bracket
❑ For connectors of Hall
sender - G40- for cam‐
shaft position and of en‐
gine speed sender -
G28- .
8 - 10 Nm
9 - Gasket
❑ Renew.
10 - Oil filter bracket
❑ Dismantling and assem‐ n AG. Volkswagen AG do
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14 - Engine speed sender - G28-

❑ Only vehicles with engine codes AMF, BAY, BNM, BNV.
rrectness of i
❑ Vehicles with engine codes BMS, BWB ⇒ Item 9 (page 22) .

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15 - Connection
❑ For thermostat.
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16 - 15 Nm
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17 - Thermostat
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19 - Bracket for ancillaries C py
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❑ Note dowel sleeve between ancillary bracket and cylinder block.
20 - Tensioning element
❑ For poly V-belt.
21 - 25 Nm
22 - Oil sump
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant - D 176 404 A2- ⇒ page 92 .
❑ Remove gearbox to remove sump ⇒ Rep. gr. 34 .
23 - 15 Nm
❑ To remove rear bolts to gearbox, gearbox must be removed ⇒ Rep. gr. 34 .
24 - Cover
❑ With sealing tape.
❑ Clean strainer if soiled.
25 - Retaining frame
❑ Before installing, check that the dowel sleeves for centring oil pump on cylinder block are fitted and the
O-ring is fitted in the retaining frame
satelettronica
26 - 40 Nm
27 - Protective cap
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Belt drive with tensioning roller ⇒ page 16
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Belt drive without tensioning roller ⇒ page 18
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♦ Locking pin - T10060 A-

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♦ 16 mm open-end spanner - T 10241-
Removing poly V-belt

– Remove noise insulation ⇒ Rep. gr. 50 .
– Remove connecting pipe between intake connecting pipe and
charge air cooler and remove air mass meter.
– Mark direction of rotation of poly V-belt.
– Swing tensioning element -in direction of arrow- to relieve ten‐
satelettronica
sion on poly V-belt.
16 mm open-end spanner - T 10241- is particularly well suited to
relieve tension.
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– Lock tensioning element using locking pin - T10060 A- .

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– Remove poly V-belt.

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Installing poly V-belt

– Install in reverse order.
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♦ Ensure, before installing poly V-belt, that all ancillaries (alter‐

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♦ For vehicles with air conditioning, fit poly V-belt over air con‐
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After completing repairs always:
– Start engine and check that belt runs properly.

Belt drive without air conditioner compressor
Belt drive with air conditioner compressor
satelettronica
1.3.2 Belt drive without tensioning roller
♦ Tensioning lever - 3297-
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♦ Torque wrench - V.A.G 1331-

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Removing t. Cop py
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– Mark direction of rotation of poly V-belt. pyri by
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– Loosen alternator securing bolts.

– Insert tensioning lever - 3297- and secure it with locking pin.
– Swivel alternator downwards and remove poly V-belt.
Installing
– Press down alternator to stop at least 3 times using tensioning
lever - 3297- to ensure ease of movement.
Note
When installing poly V-belt, check markings for direction of rota‐

tion and ensure proper seating of belt in belt pulleys.
– Swivel alternator downwards and fit poly V-belt onto belt pul‐
leys.
– Crank engine several times with alternator still loosened (ap‐
prox. 10 rotations). To do this, briefly operate starter.
Note
satelettronica
When tightening the alternator securing bolts do not apply force
to alternator or touch the poly V-belt. gen AG
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2 Sealing flange and flywheel

⇒ “2.1 Assembly overview - sealing flange and flywheel, engine
codes AMF, BAY, BNM, BNV”, page 20
⇒ “2.2 Assembly overview - sealing flange and flywheel, engine
codes BMS, BWB”, page 22
⇒ “2.3 Renewing crankshaft oil seal - pulley end”, page 23
⇒ “2.4 Removing and installing sealing flange - pulley end”, page
24 wage
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⇒ “2.5 Renewing crankshaft
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⇒ “2.6 Removing
ss and installing engine speed sender G28 , engine
codes BMS, BWB”, page 35
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2.1 Assembly overview - sealing flange and
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Note
Repairing clutch ⇒ Rep. gr. 30 ; Repairing clutch .

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1 - Seal
❑ Do not additionally oil or
grease the oil seal seal‐
ing lip.
❑ Before installing, re‐
move oil residue from
crankshaft journal using
a clean cloth.
❑ Renewing crankshaft oil
seal, belt pulley end
⇒ page 23 .
2 - Sealing flange
❑ Must seat on dowel
sleeves.
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⇒ page 43 .
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4 - Flywheel
❑ When removing and in‐
stalling flywheel, lock
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with counterhold -
3386- .
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8 - Sealing flange with oil seal ht. Cop py
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❑ Renew complete only. rig ht
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❑ Do not additionally oil or grease the oil seal sealing lip.
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❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
❑ Use support sleeve supplied when installing.
❑ Only remove supporting sleeve after sealing flange has been slid onto crankshaft journal.
2. Sealing flange and flywheel 21

2.2 Assembly overview - sealing flange and flywheel, engine codes BMS, BWB
1 - Seal AG. Volkswagen AG d

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⇒ page 23 .
hole
spec
2 - Sealing flange
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sleeves.
❑ Install with silicone seal‐
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ant - D 176 404 A2-
⇒ page 24 .
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⇒ page 24 .
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3 - Cylinder block
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rods ⇒ page 46 . . Cop py
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4 - Flywheel py by
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❑ When removing and in‐ cted agen
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stalling flywheel, lock
with counterhold -
3386- .
5 - 60 Nm + 90° further
❑ Renew.
6 - Intermediate plate
❑ Must seat on dowel sleeves.
❑ Do not damage or bend when assembling.
7 - 15 Nm
8 - Sealing flange with oil seal
❑ Renew complete with oil seal and sender wheel only.
❑ To remove, first remove sump ⇒ page 92 .
9 - Engine speed sender - G28-
❑ Loosen and tighten using commercially available ball-ended hexagon key socket
❑ Specified torque: 5 Nm

2.3 Renewing crankshaft oil seal - pulley end

equipment required
♦ Oil seal extractor - 3203-
♦ Counterhold tool - 3415-
♦ Assembly tool - T10053-
1331- (5...50 Nm)
1332- (40...200 Nm)
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2.3.1 Removing
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– Remove toothed belt ⇒ page 56 .
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– Remove crankshaft toothed belt pulley. To do this, lock tooth‐
cop Vo
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ed belt pulley using counterhold - 3415- .
agen
Prote AG.
– To guide seal extractor, screw centre bolt into crankshaft to

stop by hand.
– Screw inner part of oil seal extractor - 3203- two turns (approx.
3 mm) out of outer part and lock using knurled screw.

– Lubricate threaded head of oil seal extractor, place it in posi‐

tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
2.3.2 Installing
Note
The oil seal sealing lip must not be additionally oiled or greased.
– Remove oil residue from crankshaft journal using clean cloth.
satelettronica
– Fit guide sleeve - T10053/1- onto crankshaft journal.
– Slide oil seal over guide sleeve onto crankshaft journal.
AG. Volkswagen AG d
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– Using pressure sleeve from press sleeve - T10053- , press in

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seal to stop with centre bolt.

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– Install and tension toothed belt ⇒ page 56 .

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2.4 Removing and installing sealing flange - pulley end

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Special tools and workshopen AG. Volkswagen AG

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Not illustrated:
♦ Hand drill with plastic brush
♦ Silicone sealant - D 176 404 A2-
♦ Eye protection
♦ Flat scraper
2.4.1 Removing

– Remove crankshaft toothed belt pulley. To do this, lock tooth‐

ed belt pulley using counterhold - 3415- .
– Drain engine oil.
– Remove sump ⇒ page 92 .
– Unbolt front sealing flange.
– Remove sealing flange; if necessary, loosen using light blows
with a rubber headed hammer.
olkswagen AG
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– Remove sealant residue from cylinder
olks
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– Cover seal with a cleanriscloth.
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– Remove residual sealant on sealing flange using a rotating
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– Clean sealing surfaces. They must be free of oil and grease.
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2.4.2 Installing
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Note
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♦ Observe expiry date of sealing compound.

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♦ The sealing flange must be installed within 5 minutes of ap‐

fo
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plying the silicone sealant.

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rig ht
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– Cut off tube nozzle at forward marking (∅ of nozzle approx. 3

mm).
– Apply silicone sealing compound, as shown, to clean sealing
flange sealing surface. Sealant bead must be:
♦ The sealant bead should be -arrows-: 2…3 mm thick
Note
♦ Sealant bead should not be thicker because otherwise excess

sealant can enter sump and plug up strainer in retaining frame
cover, as well as drip onto crankshaft oil seal.
♦ Before applying sealant bead, cover sealing ring with a clean
cloth.
– Fit sealing flange immediately

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- T10053/1- .
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– Tighten sealing flange securing bolts diagonally and alternate‐
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– Remove excess sealant.
spec
es, in part or in w
– Install sump ⇒ page 92 .

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Note
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Sealing compound must dry for approx. 30 minutes after instal‐

lation. Only then fill with engine oil.
nf
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Installing toothed belt and adjusting valve timing ⇒ page 56 .

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2.5 Renewing crankshaft sealing flange - flywheel end, engine codes BMS,
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equipment required
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♦ Torque wrench - ot p
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V.A.G 1331-
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♦ Socket - V.A.G 1332/11-
spec
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♦ Assembly tool - T10134-
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♦ Vernier gauge
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♦ Three hexagon bolts - M6 x
35 mm-
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♦ Two hexagon bolts - M7 x

35 mm-
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2.5.1 Pressing out sealing flange with sender

wheel
Note
♦ For the sake of clarity, the work is performed with the engine
removed.
♦ The procedure is identical whether the engine is installed or
removed.
– Remove flywheel.
– Remove intermediate plate.
– Set engine to TDC No. 1 cylinder ⇒ page 56

lkswage es n
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– Remove engine speed esender db
yV - G28- -arrow- using a com‐t guara
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– Unscrew sealingssflange securing bolts. c
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– Screw three M 6 x 35 mm bolts into threaded holes of sealing
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flange -arrows-.
s
– Screw bolts alternately (max. 1/2 turn (180 °) for each bolt) into
s o
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sealing flange and press sealing flange together with sender
inform
wheel off crankshaft.
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2.5.2 Pressing in sealing flange with sender
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wheel
Note
♦ The sealing flange with a PTFE seal is equipped with a sealing

lip support ring. This support ring serves as a fitting sleeve and
must not be removed prior to installation.
♦ Sealing flange and sender wheel must not be separated or
turned after removal from packaging.
♦ The sender wheel is held in its installation position on the as‐
sembly device - T10134- by a locating pin.
♦ Sealing flange and oil seal form one unit and must only be
renewed together with the sender wheel.
♦ The assembly device - T10134- is held in its position relative
to the crankshaft by a guide pin inserted into a hole in the
crankshaft.
Assembly tool - T10134-

A - Clamping surface
B - Hexagon nut
C - Assembly housing
D - Locating pin
E - Hexagon socket head bolt
F - Guide pin for diesel engines (black knob)
G - Guide pin for petrol engines (red knob)

AG. Volkswagen AG d
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2.5.3 A - Assembling seal with sender wheel
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– Screw in hexagon nut -B- to just before clamping surface -A-
wit
is n
of threaded spindle.
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
– Clamp assembly device - T10134- in a vice on clamping sur‐
i
or
n thi
e
face -A- of threaded spindle.

t
sd
iva
o
pr
c
– Press assembly housing -C- downwards so that it lies on hex‐
um
r
fo
agon nut -B- -arrow-.
en
ng
t.
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Cop py
t. rig
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Note
op Vo
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Prote AG.
Inner part of assembly tool and assembly housing must be at
same height.
– Remove securing clip -arrow- from new sealing flange.
Note
The sender wheel must not be taken out of the sealing flange or
twisted.
– Locating hole -A- on sender wheel -C- must align with marking
-B- on sealing flange.
– Place sealing flange with front side downwards on a clean flat
surface.

AG. Volkswagen AG d
agen oes 3-Zyl. Dieselmotor - Edition 05.2014
olksw not
V gu
by ara
ed
– Push sealing rlip
is support ring -A- downwards in directionnteof ar‐
tho eo
row until sita lies on flat surface.
u ra
c
s
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
– Upper edge of sender wheel and front edge of sealing flange
l purpos
must align -arrows-.
nform
mercia
at
om
ion
c
in t
or
his
ate
satelettronica
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
– Place sealing flange with front side on assembly tool - T10134- Prote AG.
so that locating pin -B- can be inserted in sender wheel hole
-A-.
Note
Ensure sealing flange lies flat on assembly tool.
– Push sealing flange and support ring for sealing lip -B- against
surface of assembly tool - T10134- whilst tightening the three
knurled screws -A- so that locating pin cannot slide out of
sender wheel hole.
Note
When installing sealing flange, ensure that sender wheel remains

fixed in assembly device.
2.5.4 B - Attaching assembling tool - T10134-

with sealing flange on crankshaft flange
• Crankshaft flange must be free of oil and grease.
• Engine positioned at TDC No. 1 cylinder.

– Screw hexagon nut -B- to end of threaded spindle.

– Press threaded spindle of assembly tool - T10134- in direction
of arrow, until hexagon nut -B- lies against assembly housing
-A-.
– Align flat side of assembly housing on sump side of crankcase
sealing surface.
– Secure assembly tool - T10134- to crankshaft flange using

hexagon socket head bolts -A-.
Note
Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
prox. 5 full turns).
satelettronica
– To guide sealing flange, screw two M 7 × 35 mm bolts -A- into
cylinder block.
AG. Volkswagen AG d
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olksw not
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2.5.5 C - Bolting assembly tool - T10134- onto

ce
le
un
pt
an
d
crankshaft flange
itte
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rm
ab
pe
ility
– Push assembly housing -C- by hand in direction of arrow until

ot
wit
sealing lip support ring -B- contacts crankshaft flange -A-.

, is n
h re
hole
– Push guide pin for diesel engines (black knob) -D- into hole in
spec
crankshaft. This ensures that the sender wheel reaches its fi‐
es, in part or in w
t to the co
nal installation position.

rrectness of i
Note
l purpos
The guide pin for petrol engines (red knob) -F- must not be inser‐
ted in threaded hole of crankshaft.
nform
ercia
– Hand-tighten both hexagon socket head bolts of assembly

m
a
com
ti
tool.
on in
r
te o
thi
– Screw hexagon nut -E- onto threaded spindle by hand until it

s
iva
lies on assembly housing -C-.

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fo
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32
co Vo
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Rep. gr.13 - Crankshaft group
agen
Prote AG.
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yV
olks ot g Polo Classic 2007 ➤
b ua
ir se
d 3-Zyl. Dieselmotor
ran
tee - Edition 05.2014
utho or
a ac
2.5.6 D - Pressing sender wheel onto crank‐ ss
ce
e
nl
shaft flange using assembly tool -
pt
du
an
itte
y li
T10134-
erm
ab
ility
ot p
– Tighten hexagon nut of assembly tool - T10134- to 35 Nm us‐
wit
, is n
ing torque wrench - V.A.G 1331- and tool insert, 24 mm - V.A.G
h re
hole
1332/11- .
spec
es, in part or in w
t to the co
Note
rrectness of i
After hexagon nut is tightened to 35 Nm, a small air gap must still
be present between cylinder block and sealing flange.
l purpos
nf
ercia
orm
m
atio
om
n in
c
2.5.7 E - Checking sender wheel installation

or
thi
te
sd
a
position on crankshaft
iv
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o
satelettronica
f
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ng
– Screw hexagon nut -E- to end of threaded spindle.

t.
yi Co
op py
– Remove the two bolts -A- from cylinder block.
t. C rig
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pyri by
Vo
– Screw the three knurled screws -B- out of sealing flange.
co lksw
by
cted agen
Prote AG.
– Remove assembly tool - T10134- .
– Remove sealing lip support ring.
– The sender wheel is in the correct installation position on the

crankshaft if a gap -a- = 0.5 mm exists between crankshaft
flange -A- and sender wheel -B-.
– Set vernier gauge on crankshaft flange.

– Measure distance -a- between crankshaft flange and sender
wheel.
If distance -a- is too small:
– Re-press sender wheel ⇒ page 34 .
If distance -a- is attained:
– Tighten new securing bolts for sealing flange to 15 Nm using
alternate and diagonal sequence.

– Install engine speed sender - G28- -arrow- and tighten secur‐

ing bolt to 5 Nm.
– Install intermediate plate.
– Install flywheel using new bolts. Tighten securing bolts to
60 Nm + 1/4 turn (90°).
2.5.8 F - Re-pressing sender wheel

– Secure assembly tool - T10134- to crankshaft flange using
hexagon socket head bolts -A-.
– Hand tighten both hexagon socket head bolts.
– Push assembly tool - T10134- by hand to sealing flange.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
– Screw hexagon nut -E- onto ed threaded
by spindle by hand until it ara
nte
is
lies on assembly housing hor -C-. eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Tighten hexagon nut of assembly tool - T10134- to 40 Nm us‐

ing torque wrench - V.A.G 1331- and tool insert, 24 mm - V.A.G
l purpos
1332/11- .
– Check installation position of sender wheel on crankshaft
nf
ercia
again ⇒ page 33 .
orm
m
atio
If dimension -a- is too small again:

om
n in
or c
– Tighten hexagon nut for assembly tool - T10134- to 45 Nm.

thi
te
sd
iva
– Check installation position of sender wheel on crankshaft

o
r
rp
cu
again ⇒ page 33 .
o
m
f
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t.
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Cop py
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Vo
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Prote AG.

AG. Volkswagen AG d Polo Classic 2007 ➤
olksw not
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ris nte
2.6 Removing and installing engine speed
aut
ho eo
ra
sender - G28- , engine codes BMS,
ss c
ce
le
un
BWB
pt
an
d
itte
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erm
ab
Removing
ility
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wit
is n
h re
or; Rep. gr. 50 .
ole,
spec
– Clamp off coolant hoses at engine oil cooler using hose clip
t to the co
and pull off hoses.
– Remove oil filter bracket ⇒ page 91 .
rrectne
– Loosen securing bolt through the hole in crankcase -arrow-
and pull out engine speed sender - G28- .
ss
Installing
o
cial p
f in
Installation is performed in the reverse order, observing the fol‐
form
mer
lowing: specified torque for engine speed sender - G28- securing
atio
m
bolt: 5 Nm.
o
n
c
i
or
n thi
te
sd
va
satelettronica
i
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pr
cum
r
fo
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t.
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Cop py
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Prote AG.

3 Balancer shaft and retaining frame

⇒ “3.1 Assembly overview - balancer shaft and retaining frame”,
page 36
⇒ “3.2 Removing and installing balancer shaft”, page 38
3.1 Assembly overview - balancer shaft and retaining frame
Note
All bearing and running surfaces must be oiled before assembly.
1 - Chain
❑ Observe installation po‐
sition ⇒ page 38 , Re‐
moving and installing
balancer shaft
2 - 100 Nm + 90° further
satelettronica
❑ Renew.
❑ Turning further can be
done in several stages.
❑ Use counterhold - lkswage es n
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T10061- to loosen and d byV ua
ran
tighten ir se tee
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3 - Balance weight ss
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❑ Fitting possible in one

nl
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position only.
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4 - Chain sprocket
ility
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❑ For balancer shaft.
, is n
❑ Fitting possible in one h re

hole
spec
position only.
es, in part or in w
t to the co
5 - Dowel sleeve
6 - 20 Nm + 90° further
rrectness of i
❑ Renew.
l purpos
7 - Chain sprocket
❑ For oil pump.
nf
ercia
❑ Fitting possible in one

orm
position only.
m
atio
om
n in
c
8 - Cover
or
thi
e

t
sd
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t.
9 - 5 Nm
yi Co
Cop py
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10 - O-ring
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pyri by
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co
❑ Renew.
by lksw
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Prote AG.
❑ Check for secure seating.
❑ Lightly coat with oil before installing.
11 - 20 Nm
12 - Oil pump
❑ With 11.5 bar pressure relief valve.
❑ Before installing, ensure that both dowel sleeves for centring are installed.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
horis nte
eo Polo Classic 2007 ➤
aut ra 3-Zyl. Dieselmotor - Edition 05.2014
ss c
ce
le
un
pt
13 - Balancer shaft
an
d
itte
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erm
ab
ility
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wit
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spec
t to the co
15 - O-ring
❑ Renew.
rrectne
❑ Check for secure seating in retaining frame.
s
16 - Cylinder block
s o
cial p
f i
17 - Chain sprocket/guide roller
nform
mer
18 - 20 Nm
atio
om
n
c
19 - Chain tensioner with tensioning plate
i
or
n thi
e
❑ To remove, lock with locking pin - T10060 A-

t
sd
iva
o
pr
c
um
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fo
en
ng
t.
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20 - 8 Nm + 90° further
Co
op
satelettronica
C py
.
❑ Renew.
ht rig
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Prote AG.
3. Balancer shaft and retaining frame 37

3.2 Removing and installing

en AG. V
olkswagen AGbalancer shaft
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Special tools andoris workshop nte
eo
equipment required
au
th
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♦ Locking pin - T10060 A-
ce
le
un
pt
an
d
♦ Socket, multi-point bit XZN

itte
y li
erm
14 - T10061-
ab
ility
ot p
wit
is n
1331- (5...50 Nm)
h re
ole,
spec
1332- (40...200 Nm)
t to the co
rrectness o
cial p
f inform
mer
satelettronica
atio
om
n
c
i
or
n thi
te
sd
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Prote AG.
Not illustrated
♦ 24/27 mm spanner
Removing
– Remove sealing flange at belt pulley end ⇒ page 23 .
– Unscrew securing bolts of cover.
– Unclip cover from retaining frame.

AG. Volkswagen AG d
agen oes
olksw not
V
d by gu
ara Polo Classic 2007 ➤
ise nte
thor 3-Zyl. Dieselmotor
e or - Edition 05.2014
s au ac
s
– Lock chain tensioner with locking pin - T10060 A- -arrow-.
ce
e
nl
pt
du
an
– Unbolt chain sprocket/idler roller -1- from retaining frame.
itte
y li
erm
ab
– Unscrew chain tensioner securing bolts -2- and remove chain
ility
ot p
tensioner.
wit
, is n
h re
– Remove chain from chain sprockets and place chain onto a hole
spec
clean surface.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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f
en
ng
satelettronica
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
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d b ara
rise nte
Polo Classic 2007 ➤ autho eo
ra
3-Zyl. Dieselmotor - Edition 05.2014 ss c
ce
e
nl
pt
du
an
– Lock balancer shaft using a 24/27 mm spanner -1-, as shown.
itte
y li
erm
ab
ility
ot p
wit
Note
, is n
h re
hole
spec
The spanner must be centred relative to the balance weight of the
es, in part or in w
balancer shaft and aligned at right angles relative to the balancer
t to the co
shaft itself.
– Loosen securing bolt -2- for balance weight.
rrectness of i
l purpos
Note
nf
ercia
o
Only loosen balance weight securing bolt -2-, do not unscrew
rm
m
atio
completely.
om
n in
or c
thi
– Unbolt retaining frame -3- from cylinder block and remove re‐
te
sd
iva
taining frame with balancer shaft.
o
r
rp
cu
o
m
f
– Place retaining frame on a clean surface.
en
ng
t.
yi Co
op
– Unscrew balance weight securing bolt.
C py
t.
satelettronica
rig
gh ht
yri by
– Remove balance weight and chain sprocket from balancer
cop Vo
by lksw
cted
shaft.
agen
Prote AG.
– Turn balancer shaft so that it can be removed from its mount‐

ings.
Installing
– Oil contact surfaces of mountings.
– Insert balancer shaft into mountings.
– Fit balance weight and chain sprocket onto balancer shaft.
Note
Chain sprocket and balance weight can only be installed in one

position.
– Tighten new securing bolt for balance weight and chain

sprocket hand-tight.
– Bolt retaining frame to cylinder block by hand so there is no
clearance.
Note
♦ When installing the retaining frame, ensure that the dowel

sleeve is fitted in the cylinder block and the O-ring is fitted in
the retaining frame.
♦ Align the retaining frame so that the belt pulley end is flush
with the outer edge of the cylinder block.
– Bolt retaining frame with balancer shaft to cylinder block and

tighten bolts to specified torque of 20 Nm.
– Check that the belt pulley end of the retaining frame is aligned
flush with the outer edge of the cylinder block

– Lock balancer shaft using a 24/27 mm spanner -1-, as shown.
Note
The spanner must be cantered relative to the balance weight of

the balancer shaft and aligned at right angles relative to the bal‐
ancer shaft itself.
– Tighten balance weight securing bolt -2- to specified torque of

100 Nm + 1/4 turn (90°) further.
Note
The securing bolt is a stretch bolt and must always be renewed.

AG. Volkswagen AG d
agen oes
olksw not
– Install chain tensioner and tighten bolts to specified torque
d by V of gu
ara
8 Nm + 1/4 turn (90°) further. ise nte
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aut ra
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un
Note
satelettronica
pt
an
d
itte
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rm
ab
The chain tensioner securing bolts are stretch bolts and must al‐
pe
ility
ways be renewed.
ot
wit
, is n
h re
hole
– Clean chain with a lint-free cloth.
spec
es, in part or in w
t to the co
– Check that marking on crankshaft chain sprocket -arrow- is
positioned at top.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi
– Fit chain onto crankshaft chain sprocket, oil pump chain
Co
op py
sprocket and balancer shaft chain sprocket. The markings on
. C rig
ht ht
rig
crankshaft chain sprocket and balancer shaft chain sprocket py by
co Vo
must be aligned with the colour markings on the chain links
by lksw
cted agen
Prote
-arrows- as shown in illustration.
AG.
Note
In addition to the colour markings the chain links are marked with
a crease.
– Fit idler roller chain sprocket to the chain, bolt idler roller chain
sprocket to retaining frame and tighten bolt to specified torque
of 20 Nm.
– Remove locking pin - T10060 A- from chain tensioner.

– Check whether markings on crankshaft chain sprocket and

balancer shaft chain sprocket are still aligned correctly with
colour markings on chain links -arrows-.
Note
In addition to the colour markings the chain links are marked with
a crease.
– Install sealing flange at belt pulley end ⇒ page 23 .

– Install balancer shaft cover and tighten bolts to specified tor‐
que of 5 Nm.
Note
olkswagen AG
en AG. V
♦ Before installing cover, oil O-ring for oil pump
olks and shaft on
wag does
not
inside of cover. ed byV gu
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♦ Ensure proper seating of sealingauttape on cover.
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ra
ss c
♦ When installing, make sure that cover engages in retaining
satelettronica
ce
le
un
frame.
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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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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pr
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fo
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ng
t.
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Cop py
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by lksw
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Prote AG.

4 Crankshaft
⇒ “4.1 Assembly overview - crankshaft”, page 43
⇒ “4.2 Crankshaft dimensions”, page 44
4.1 Assembly overview - crankshaft
Note
♦ Before removing crankshaft, make provision for a suitable surface for storing crankshaft to ensure that
sender wheel ⇒ Item 5 (page 43) is not damaged or lies against any other item.
♦ All bearing and running surfaces must be oiled before assembly.
1 - Bearing shells 1, 2 and 4

❑ For bearing cap without
oil groove.
❑ For cylinder block with
oil groove.
satelettronica
❑ Do not interchange
used bearing shells
(mark).
2 - 65 Nm + 90° further
❑ Renew.
❑ To measure radial clear‐
ance, tighten to 65 Nm n AG. Volkswagen AG do
but not further. olkswage es n
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3 - Bearing cap ris
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❑ Bearing cap au 1: belt pul‐
t ra
c
ley end. ss
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nl
pt
❑ Bearing shell retaining

du
an
itte
lugs in cylinder block

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erm
ab
and bearing caps must

ility
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align.
wit
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4 - Bearing shell 3
hole
spec
❑ For bearing cap without

es, in part or in w
oil groove.
t to the co
❑ For cylinder block with

oil groove.
rrectness of i
5 - Sender wheel
l purpos
❑ For engine speed send‐

er - G28- .
nf
ercia
❑ Only engine codes

or
AMF, BAY, BNM, BNV.

m
m
atio
m
o
n in
or c
❑ Always renew sender

thi
te
wheel if securing bolts

sd
iva
o
r
have been unscrewed.

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ng

t.
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op py
6 - 10 Nm + 90° further
t. C rig
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❑ Renew. cop Vo
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❑ Only engine codes AMF, BAY, BNM, BNV. Prote AG.
7 - Dowel pin
❑ Check projection from crankshaft ⇒ page 44
4. Crankshaft 43
❑ Only engine codes AMF, BAY, BNM, BNV.
8 - Crankshaft
❑ Before removing, see notes ⇒ page 43 .
❑ Axial clearance new: 0.07…0.17 mm, wear limit: 0.37 mm.
❑ Check radial clearance using Plastigage new: 0.03…0.08 mm, wear limit: 0.17 mm.
❑ Do not rotate crankshaft when checking radial clearance.
❑ Crankshaft dimensions ⇒ page 44 .
9 - Thrust washer
❑ For cylinder block, bearing 3.
Checking dowel pin projection out of crankshaft

lkswage es n
o ot g
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d ran
ir se tee
tho
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ss
ce
e
nl
pt
du
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itte
satelettronica
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Depth gauge
rrectness of i
Test procedure
l purpos
– Use depth gauge to check fitted pin projection -a- with sender
wheel -1- removed.
nf
ercia
1 - Sender wheel
orm
m
atio
2 - Securing bolt
om
n in
or c
3 - Projection of dowel pin -3- out of crankshaft a = 2.5…3.0 mm
thi
te
sd
iva
Removing and installing sender wheel

o
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cu
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f
– Renew sender wheel -2- each time bolts -1- are loosened.
en
ng
t.
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Specified torque: 10 Nm + 90° (1/4 turn) t. Cop py
rig
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pyri by
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co lksw
by
Note cted agen
Prote AG.
The second time the bolts are tightened, the contact points in the
sender wheel for the countersunk head bolts are deformed so far
that the bolt heads seat on the crankshaft -3-, -arrows- and the
sender wheel is loose under the bolts.
4.2 Crankshaft dimensions

(Dimensions in mm)
Honing dimension Main journal ∅ Conrod journal ∅
-0.022 -0.022
Basic dimension 54.00 47.80
-0.042 -0.042
-0.022 -0.022
Stage I 53.75 47.55

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agen oes
Honing dimension y Volksw Main journal n∅ot g Conrod journal ∅
db ua
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ris
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-0.042 tee -0.042
utho or
ss
a -0.022 ac -0.022
ce
Stage II 53.50 47.30
e
nl
pt
du
an
-0.042 -0.042
itte
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ab
-0.022 -0.022
ility
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Stage III 53.25 47.05
wit
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-0.042 -0.042
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
m
atio
om
n in
satelettronica
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4. Crankshaft 45
5 Pistons and conrods

⇒ “5.1 Assembly overview - pistons and conrods”, page 46
⇒ “5.3 Checking pistons, piston rings and cylinder bores”,
page 48
⇒ “5.4 Checking piston projection at TDC”, page 50
⇒ “5.5 Piston and cylinder dimensions”, page 51
5.1 Assembly overview - pistons and conrods
Note
All bearing and running surfaces must be oiled before assembly.
1 - Circlip
❑ Renew.
2 - Piston ring
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❑ Offset gaps by 120°.
❑ Use piston ring pliers to
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⇒ page 48 .
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❑ Checking ring-to-groove
clearance ⇒ page 49 .
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3 - Piston ring
❑ compression ring
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❑ Offset gaps by 120°.

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❑ Checking ring-to-groove clearance ⇒ page 49 .
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4 - Piston ring
❑ Oil scraper ring
❑ Offset gaps by 120° relative to lower compression ring.
❑ Use piston ring pliers to remove and install.

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❑ Installation position: marking
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❑ First tighten evenly to 5 Nm.
❑ Use old bolt for measuring radial clearance.
rrectness of i
6 - Conrod bearing cap
❑ The conrod bearing cap only fits in one position and only on the appropriate conrod due to the breaking
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procedure (cracking) separating the cap from the conrod.

❑ Mark cylinder allocation in colour -A-.
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❑ Installation position: Marking -B- faces towards pulley end.

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7 - Bearing shells
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❑ Axial clearance, wear limit: 0.37 mm

❑ Check radial clearance with Plastigage: Wear limit: 0.08 mm, do not rotate crankshaft when checking
radial clearance
8 - Bolt with pressure relief valve
❑ Insert without sealant.
❑ Specified torque: 25 Nm.
9 - Oil spray jet (for cooling of pistons)
10 - Conrod
❑ Renew as set only.
❑ Mark cylinder allocation in colour -B-.
❑ Installation position: markings -A- towards belt pulley end
11 - Circlip
❑ Renew.
12 - Piston pin
❑ If difficult to remove, heat piston to approx. 60 °C.
❑ Remove and install using drift - VW 222 A- .
13 - Piston
❑ With combustion chamber.
❑ Mark installation position and cylinder number.
❑ Installation position and allocation of piston to cylinder ⇒ page 50 .
❑ Arrow on piston crown points to belt pulley end.
❑ Install using piston ring clamp.
❑ If piston skirt is cracked, renew piston.
❑ Checking piston projection at TDC ⇒ page 50 .
5. Pistons and conrods 47

3-Zyl. Dieselmotor - Edition
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– Mark cylinder allocation
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– Lightly clamp the conrods in a vice using aluminium vice
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clamps, as shown in illustration.
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♦ To prevent damage to the conrods, only clamp conrods in
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lightly.
♦ Clamp conrods in below the dashed line.
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– Unscrew the two bolts -arrows- approx. 5 turns.
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– Using a plastic hammer, carefully knock against conrod bear‐

ing cap -arrow- until it is loose.
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5.3 Checking pistons, piston rings and cyl‐

inder bores
Checking piston ring gap

♦ Feeler gauge (commercially available).
– Insert ring at right angles from above and push down into cyl‐
inder approx. 15 mm from bottom end of cylinder.
Piston ring Ring gap
New Wear limit
1st compression ring mm 0.25…0.40 1.0
2nd compression ring mm 0.20…0.40 1.0
Oil scraper ring mm 0.25…0.50 1.0

Checking ring-to-groove clearance

♦ Feeler gauge (commercially available).
Clean annular groove before check.
Piston ring Clearance
New Wear limit
1st compression ring mm 0.06…0.09 0.25
satelettronica
2nd compression ring mm 0.05…0.08 0.25
Oil scraper ring mm 0.03…0.06 0.15
Checking cylinder bores
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– Take measurements at 3 positions in both lateral direction

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-A- and longitudinal direction -B-.

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Deviation from nominal dimension max. 0.10 mm

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Note
Cylinder bores must not be measured when cylinder block is wage

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Piston installation position and allocation of piston tosscylinder
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Piston in cylinders 1 and 2:
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Larger inlet valve recess -arrows- towards flywheel.
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Larger inlet valve recess -arrow- towards belt pulley end.
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♦ New piston allocation to cylinders is shown by a coloured
marking on piston crown.
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♦ Piston for cylinders 1 and 2: marked 1/2
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♦ Piston in cylinder 3: marked 3
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5.4 Checking piston projection at TDC

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♦ Measuring tool - VW 382/7-
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♦ Universal measuring tool - VW 385/17-

Test procedure
Piston projection at TDC must be measured when installing new
pistons or a short engine. Install the appropriate cylinder head
gasket depending upon piston nprojection,
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Turn engine clockwise to measure piston projection at TDC.
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Piston projection Identification
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Holes/notches
0.91 mm … 1.00 mm 1
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1.01 mm … 1.10 mm 2
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1.11 mm … 1.20 mm 3
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5.4.1 Cylinder head gasket identification
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♦ If different values are determined during the projection meas‐
urement, use the largest dimension for selecting the gasket.
♦ Different thicknesses of cylinder head gasket are fitted de‐
pending on the piston projection. When renewing gasket,
install new gasket with same identification.
5.5 Piston and cylinder dimensions

Honing dimen‐ Piston ∅ Cylinder bore ∅
sion
Basic dimension mm 79.47 79.51
Stage I mm 79.97 80.01

15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Assembly overview - cylinder head”, page 52
⇒ “1.2 Removing, installing and tensioning toothed belt”,
page 56
⇒ “1.3 Removing and installing cylinder head”, page 66
⇒ “1.4 Checking compression”, page 70
1.1 Assembly overview - cylinder head
Note
♦ When installing an exchange cylinder head with fitted camshaft, the contact surfaces between the bucket
tappets and the cam must be oiled before installing the cylinder head cover.
♦ All bearing and running surfaces must be oiled before assembly.
satelettronica
♦ The plastic protectors fitted to protect the open valves must be removed only immediately before the cylinder
head is fitted.
♦ If the cylinder head is replaced, all the coolant in the system must also be renewed.
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52 Rep. gr.15 - Cylinder head, valve gear

1 - Toothed belt guard upper

part
2 - Toothed belt
❑ Mark direction of rota‐
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⇒ page 56 .
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3 - 10 Nm
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5 - 100 Nm
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6 - Camshaft pulley
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7 - Hub
❑ With sender wheel
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❑ Use counterhold tool -
satelettronica
T10051- to loosen and
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tighten.
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❑ To remove, use puller -
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⇒ page 80 , removing
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and installing camshaft.

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8 - Rear toothed belt guard
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❑ For camshaft position.
❑ To remove, unbutton
sealing grommet
⇒ Item 9 (page 53) from rear toothed belt guard.
11 - Cylinder head bolt
❑ Renew.
❑ Note sequence when loosening and tightening ⇒ page 66 , Removing and installing cylinder head.
❑ Before installing, place washers in cylinder head ⇒ Item 4 (page 73) .
12 - Pin, 10 Nm
❑ For engine cover
13 - Cylinder head cover
❑ With oil filler neck and pressure control valve for crankcase breather system.
❑ Thoroughly clean sealant groove and securing bolts before fitting a new gasket.
❑ If cylinder head cover is damaged, always renew oil filler neck.
❑ Before fitting, thoroughly clean sealing surface of cylinder head with clean cloth.
14 - To turbocharger.
15 - 10 Nm
❑ First hand tighten all bolts
❑ Then, first tighten both upper bolts and then tighten the remaining bolts to specified torque in diagonal
sequence working from inside to outside using socket Torx T30 - T10347- .
1. Cylinder head 53
16 - Pressure regulating valve

❑ For crankcase ventilation.
17 - Oil filler neck
❑ Renew.
18 - Cap
❑ Renew seal if damaged.
19 - Seal
20 - Bracket
❑ With fuel lines.
21 - Gasket for cylinder head cover
❑ Thoroughly clean sealant groove and securing bolts before fitting a new gasket.
❑ Seal transitions with -AMV 174 004 01- before fitting.
22 - 20 Nm
23 - Lifting eye
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24 - Unit injector
25 - Central connector
❑ For unit injector
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27 - Tandem pump ir se tee
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❑ Check ⇒ page 126 .

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28 - Supply hose
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❑ From fuel filter ⇒ Item 2 (page 120) .
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❑ White or with white marking.
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❑ Secure with spring-type clips.
29 - Return hose
❑ To fuel filter ⇒ Item 2 (page 120) . rrectne
❑ Blue or with blue marking.
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❑ Secure with spring-type clips.

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30 - Gasket
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❑ Renew.
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31 - Bracket
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32 - Hexagon cone nut

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33 - Cylinder head
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❑ After replacing, renew entire coolant.
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34 - Cylinder head gasket

❑ Renew.
❑ Note marking ⇒ page 51 .
❑ After replacing, renew entire coolant.

35 - Glow plug
❑ 15 Nm
36 - Tensioning roller
37 - 20 Nm + turn (45°)
Checking cylinder head for distortion

Max. permissible distortion: 0.1 mm.
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1. Cylinder head 55
1.2 Removing, installing and tensioning

toothed belt
Vehicles with friction-damped belt tensioning system
⇒ page 56 .
Vehicles with hydraulic belt tensioning system ⇒ page 60 .
1.2.1 Vehicles with friction-damped belt tensioning system

equipment required
♦ Diesel injection pump lock‐
ing pin - 3359-
♦ 2-hole pin wrench - 3387-
♦ Crankshaft stop - T10050-
♦ Locking pin - T10115-
1331- (5...50 Nm)
satelettronica
1332- (40…200 Nm)
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♦ Support bracket - 10 - 222 A- with rack - 10 - 222 A /1-

Removing
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Adjustment work on toothed belts must be performed ir se
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– Remove engine cover.
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– Remove locking pin - T10060 A- from tensioning element.
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– Remove upper toothed belt guard. cop Vo
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– Remove connecting pipe between turbocharger and charge
air cooler.
– Carefully cover or seal open ends.
– Remove belt pulley with vibration damper.
– Remove centre toothed belt guard.
– Remove lower toothed belt guard.
– Turn crankshaft to TDC No. 1 cylinder.
1. Cylinder head 57
Note
Turn the crankshaft until the mark on the crankshaft toothed belt
pulley is on the top and the arrow on the rear toothed belt guard
aligns with the lug on the hub sender wheel -arrows-.
– Lock hub using diesel injection pump locking pin - 3359- . To

do this, slide locking pin through the free elongated hole on
left into hole in cylinder head.
– Lock crankshaft toothed belt pulley with crankshaft stop -
T10050- . To do this, slide crankshaft stop - T10050- from face
side of toothed belt pulley into teeth.
Note
The marks on the crankshaft pulley and the crankshaft stop -

T10050- must be aligned. At the same time, the pin of the crank‐
shaft stop - T10050- must engage in the drilling in the sealing
flange.
satelettronica
– Mark direction of rotation of toothed belt.
– Loosen tensioning roller securing nut.
– Loosen securing bolts -1- of camshaft pulley until the camshaft

pulley can be moved within the elongated holes.
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– Turn pin wrench - 3387- anti-clockwise (opposite direction of

es, in part or in w
arrow) until toothed belt tensioning roller can be locked with

t to the co
locking pin - T10115- .

– Now turn pin wrench - 3387- to stop in -direction of arrow- and
rrectness of i
remove toothed belt first from coolant pump toothed belt pulley
and then from the remaining pulleys.
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Note
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or
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engines, as the indicator position on the tensioning element varies

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– Turn camshaft pulley anti-clockwise -in direction of arrow- in

elongated holes until stop is reached.
– Fit toothed belt to crankshaft toothed belt pulley, tensioning
roller and camshaft pulley.
Note
Ensure that tensioning roller seats correctly in rear toothed belt

guard -arrow-.
– Now turn tensioning roller to stop in direction of arrow using

pin wrench - 3387- and fit toothed belt onto coolant pump
satelettronica
toothed belt pulley.
– Release tension on tensioning roller by turning it against di‐
rection of arrow using pin wrench - 3387- and remove locking
pin from tensioning roller.
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– Hold tensioning roller in this position and tighten
tho tensioning or
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– Tighten securing bolts of camshaft belt pulley to 25 Nm.
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– Remove locking pin for diesel injection pump - 3359- and
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crankshaft stop - T10050- .
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– Turn crankshaft two rotations in engine direction of rotation
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and set again to TDC no. 1 cylinder.
spec
es, in part or in w
Note t to the co
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♦ When doing this, the pin of the crankshaft stop - T10050- must
engage in the sealing flange from the rotational movement.
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♦ If the crankshaft is turned past TDC No. 1 cylinder and the

crankshaft stop - T10050- was unable to engage in the sealing
nf
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flange, turn the crankshaft back 1/4 turn to set it to TDC No. 1
rm
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cylinder by again turning in direction of engine rotation. Cor‐

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– Pull crankshaft stop - T10050- pin out of hole in sealing flange

and turn crankshaft until hub can be locked with locking pin.
1. Cylinder head 59
– Loosen securing bolts -1- of camshaft pulley.
– Turn crankshaft slightly against engine direction of rotation

until the pin of the crankshaft stop - T10050- is positioned just
before the hole in the sealing flange -arrow-.
– Now turn crankshaft in engine direction of rotation until pin of
crankshaft stop - T10050- engages in sealing flange from ro‐
tational movement.
– Tighten securing bolts of camshaft belt pulley to 25 Nm.
satelettronica
until crankshaft is set to TDC No. 1 cylinder again. agen
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rrectness of i
– Repeat check.
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– Install lower toothed belt guard and pulley vibration damper.

– Install centre toothed belt guard.
nform
ercia
– Install lower part of toothed belt guard.

m
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– Install engine carrier and engine console. Specified torque

on in
⇒ page 11 .
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– Install connecting pipes between charge air cooler and turbo‐

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charger and between charge air cooler and intake connecting
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1.2.2 Vehicles with hydraulic belt tensioning system


equipment required
♦ Diesel injection pump lock‐
ing pin - 3359-
♦ 2-hole pin wrench - 3387-
♦ Crankshaft stop - T10050-
♦ Locking pin - T10115-
1331- (5...50 Nm)
1332- (40…200 Nm)
satelettronica
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1. Cylinder head 61
♦ Locking plate - T10008-

♦ Support bracket - 10 - 222 A- with rack - 10 - 222 A /1-
Removing
Note

engines, as the indicator position on the
agtensioning
en AG. V
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connection.
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– Remove locking pin - T10060 A- from tensioning element.

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– Remove upper toothed belt guard.

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– Remove noise insulation ⇒ Rep. gr. 50 . ht. rig
rig ht
py by
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– Remove connecting pipe between turbocharger and charge
by c lksw
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air cooler.
Prote AG.
– Carefully cover or seal open ends.

– Remove belt pulley with vibration damper.
– Remove centre toothed belt guard.
– Remove lower toothed belt guard.
– Turn crankshaft to TDC No. 1 cylinder.

Note
Turn the crankshaft until the mark on the crankshaft toothed belt
pulley is on the top and the arrow on the rear toothed belt guard
aligns with the lug on the hub sender wheel -arrows-.
– Lock hub using diesel injection pump locking pin - 3359- . To

do this, slide locking pin through the free elongated hole on
left into hole in cylinder head.
– Lock crankshaft toothed belt pulley with crankshaft stop -
T10050- . To do this, slide crankshaft stop - T10050- from face
side of toothed belt pulley into teeth.
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The marks on the crankshaft
utho pulley and the crankshaft stop - eo
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T10050- must be aligned.
ss a At the same time, the pin of the crank‐ c
shaft stop - T10050- must engage in the drilling in the sealing
ce
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un
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flange.
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– Mark direction of rotation of toothed belt.
pe
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– Insert a hexagon key into the hexagon hole onto limit stop and
hole
spec
push the tensioning roller anti-clockwise -arrow- until the
es, in part or in w
toothed belt tensioner can be fixed with the locking plate -
t to the co
T10008- .
rrectness of i
Note
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If the hexagon key is not inserted deeply enough there is a risk of

it slipping out.
nform
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– Loosen tensioning roller securing nut.

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– Unscrew and remove securing bolts -1- of toothed belt ten‐

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– Remove toothed belt.

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Installing
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Note

engines, as the indicator position on the tensioning element varies
1. Cylinder head 63
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– Loosen securing bolts -1- of camshaft pulley until the camshaft
an
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pulley can be moved within the elongated holes.
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– Turn camshaft pulley anti-clockwise -in direction of arrow- in
ot p
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elongated holes until stop is reached.
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– Now carefully turn eccentric clockwise using pin wrench -
form
mer
3387- until eccentric lug lies directly before limit stop -B-.
atio
m
– First fit toothed belt onto camshaft pulley, tensioning roller,

o
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n
crankshaft toothed belt pulley and finally onto coolant pump
thi
te
toothed belt pulley.
sd
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– Install toothed belt tensioner.

fo
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– Turn eccentric anti-clockwise using pin wrench - 3387- (lug of op
satelettronica
C py
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eccentric moves in direction of limit stop -A-), until the locking
rig
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plate - T10008- is not under tension and can be pulled out. op Vo
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– Release force of tensioning element in clockwise direction (lug
AG.
of eccentric moves towards stop -B-) until dimension -a- has

been attained. Specification dimension -a-: 4 ± 1 mm.
Note
♦ Dimension -a- reduces when the tensioning roller securing nut

is tightened. Therefore adjust generously using ∅ 4 mm drill
bit.
♦ Measurement -a- may be reduced to 1 mm if engine is at op‐
erating temperature.
– Hold tensioning roller in this position and tighten tensioning

roller securing nut as follows: 20 Nm + 45° (1/8 turn) further.

– Tighten securing bolts -1- of camshaft pulley to 25 Nm.

and set again to TDC no. 1 cylinder.
Note
permissible.
– Once the crankshaft stop - T10050- has engaged, check

whether dimension -a- has been attained and whether the hub
satelettronica
can be fixed in place using diesel injection pump locking pin -
3359- .
If dimension -a- is not attained:

– Tension the tensioning roller again. To do this, hold tensioning
roller with pin wrench - 3387- , loosen securing nut and release
force of tensioning device until dimension -a- is attained. Spec‐
ification dimension -a-: 4 ± 1 mm.
olkswagen AG
en AG. V
– Retighten securing nut to 20 Nm + 45° (1/8 turnolkfurther).
swa
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If the hub cannot be locked:

wit
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– Pull crankshaft stop - T10050- pin out of hole in sealing flange

hole
spec
and turn crankshaft until hub can be locked with diesel injec‐
es, in part or in w
tion pump locking pin - 3359- .

t to the co
– Loosen securing bolts -1- for camshaft toothed belt pulley.

rrectness of i
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1. Cylinder head 65
– Turn crankshaft slightly against engine direction of rotation

until the pin of the crankshaft stop - T10050- is positioned just
before the hole in the sealing flange -arrow-.
– Now turn crankshaft in engine direction of rotation until pin of
crankshaft stop - T10050- engages in sealing flange from ro‐
tational movement.
– Tighten securing bolts -1- of camshaft pulley to 25 Nm.

until crankshaft is set to TDC No. 1 cylinder again.
Note
satelettronica
permissible.
– Repeat check.
– Install lower toothed beltwaguard
gen AGand pulley
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damper.
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– Install centre toothed
ed
by belt guard. ara
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or
– Install lower
au part of toothed belt guard.
th eo
ra
ss c
– Install engine carrier and engine console. Specified torque
ce
e
nl
pt
⇒ page 11 .
du
an
itte
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erm
ab
ility
ot p
– Install connecting pipes between charge air cooler and turbo‐

wit
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charger and between charge air cooler and intake connecting

h re
hole
flange.
spec
es, in part or in w

t to the co
1.3 Removing and installing cylinder head

rrectness of i
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for
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cted agen
Prote AG.
Rep. gr.15 - Cylinder head, valve gear

equipment required
♦ Support bracket - 10 - 222
A-
♦ Bracket - T10014-
♦ Drip tray - V.A.G 1306- or
drip tray for workshop hoist
- VAS 6208-
1331- (5...50 Nm)
1332- (40...200 Nm)
♦ Hand vacuum pump with
accessories - V.A.G 1390-
AG. Volkswagen AG d
agen oes
olksw not
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satelettronica
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♦ Water drainage container - 1390/1-

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1.3.1 Removing
– Remove air filter with air intake hoses ⇒ page 152 .
– Remove battery ⇒ Electrical system; Rep. gr. 27 .
– Remove unions ⇒ Item 2 (page 98) .
1. Cylinder head 67
– Pull off or disconnect all other electrical connections as nec‐

essary from cylinder head and lay to side.
– Separate all connection, coolant, vacuum and intake hoses
from cylinder head.
– Remove front exhaust pipe together with catalytic converter
⇒ page 165 .
ter ⇒ page 169 . en AG. V
olkswagen AG
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– Disconnect fuel supply and return linesutas
ho well as coolant line eo
on cylinder head. ss
a ra
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– Before removing cylinder head extract fuel from tandem pump

un
pt
an
d
using hand vacuum pump with accessories - V.A.G 1390- and

itte
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bleeder container - V.A.G 1390/1- ⇒ page 130 , Removing
rm
ab
pe
and installing tandem pump.
ility
ot
wit
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h re
hole
spec
es, in part or in w
t to the co
Note
Before removing toothed belt from camshaft pulley, lock toothed
rrectness of i
belt tensioner in place ⇒ page 56 .
l purpos
– Remove toothed belt tensioning roller.

– Remove hub from taper of camshaft ⇒ page 80 .
nform
mercia
– Unscrew rear toothed belt guard.
a
com
tion in
– Remove charge air pipe for charge air cooler/intake pipe
r
te o
⇒ page 142 . thi

s
iva
do
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rp
– Remove oil return line from turbocharger ⇒ page 135 .

um
fo
en
ng
t.
– Remove oil supply line ⇒ page 135 .
yi Co
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t. rig
– Remove connecting pipe from exhaust gas recirculation cooler
gh ht
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⇒ page 173 .
cop Vo
by lksw
cted agen
Prote AG.
– Remove cylinder head cover ⇒ Item 13 (page 53) .
Note
Both lifting eyes are located on the cylinder head, so for removing
the cylinder head an additional bracket must be secured to the
cylinder block to support the engine.


– Carefully lift up engine slightly via spindle -A-.
– Screw bracket - T10014- in threaded hole in cylinder block in

area of coolant pump. Specified torque: 20 Nm.
– Lift engine slightly using spindle -B-
AG.until
Volksspindle
wagen A -A- is relieved.
G do gen
es n swa
– Remove spindle -A-. by Volk ot g
ua
ed ran
s
– Before removingthocylinder head extract fuel from tandem pump
ri tee
or
using hand vacuum
ss
au
pump with accessories - V.A.G 1390- and ac
bleeder container - V.A.G 1390/1- ⇒ page 130 , Removing
satelettronica
ce
le
and installing tandem pump.

un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
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hole
– Maintain sequence when loosening and tightening cylinder
spec
head bolts.
es, in part or in w
t to the co
Note
rrectness of i
The cylinder head must be guided carefully to prevent damage.

l purpos
nform
mercia
a
com
tion in
r
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1.3.2 Installing
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Note
rig
gh ht
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by
cted
♦ Always renew cylinder head bolts.
agen
Prote AG.
♦ In cases of repair carefully remove gasket remains from cyl‐

inder head and cylinder block. Ensure that no long scores or
scratches are made on the surfaces. When using abrasive
paper do not use a grade less than 100.
♦ Carefully remove emery and abrasive remains.
♦ Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
♦ Handle gasket very carefully. Damage to the silicone coating
or the indented area will lead to leaks.
– Turn crankshaft to TDC marking before fitting cylinder head.

– Turn crankshaft against engine direction of rotation until all
pistons are about the same distance below TDC.
1. Cylinder head 69
– Position cylinder head gasket.

– Fit cylinder head and hand-tighten all cylinder head bolts (Qty.
8).
– 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 rigid spanner:
Stage III = 1/4 turn (90°) Stage IV = 1/4 turn (90°)
Note
After repair work it is not necessary to retighten the cylinder head

bolts.
– After tightening cylinder head, turn camshaft so that cams for
satelettronica
No. 1 cylinder point equally upwards. Before fitting toothed
belt, turn crankshaft in engine direction of rotation
⇒ page 56 , removing, installing and tightening toothed belt.
– After installing cylinder head prime fuel on tandem pump using
hand vacuum pump with accessories - V.A.G 1390- and bleed‐
er container - 1390/1- ⇒ page 130 , Removing and installing
tandem pump.
– Carry out a road test and read event memory ⇒ page 162
Reading and clearing event memory of engine control unit.
1.4 Checking compression
AG. Volkswagen AG d
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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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fo
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Cop py
ht. rig
rig ht
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70
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Rep. gr.15 - Cylinder head, valve gear Prote AG.

equipment required
♦ Jointed wrench 10 mm -
3220-
1331- (5...50 Nm)
♦ Compression tester - V.A.G
1763-
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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Test prerequisite
ole,
spec
• Engine oil temperature min. 30 °C.

t to the co
Test procedure
– Pull off central connector for unit injectors.
rrectne
Note
ss o
cial p
f in
Always observe the notes on removing and installing the ceramic

form
mer
glow plugs ⇒ page 181 .

atio
om
n
c
– Remove all glow plugs or ceramic glow plugs using U/J ex‐
or
n thi
e
tension and socket, 10 mm - 3220- .

t
sd
iva
o
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cum
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fo
en
ng
t.
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Cop py
ht. rig
rig ht
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Prote AG.
1. Cylinder head 71
olkswagen AG
Polo Classic 2007 ➤ wage
n AG. V does
olks not
3-Zyl. Dieselmotor - Edition
db
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ris
ho eo
– Screw in adapter - V.A.G
au 1381/12- in place
t of the glow plugs. ra
c
ss
– Check compression using compression tester - V.A.G 1763- .
ce
le
un
pt
an
d
itte
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rm
ab
Note
pe
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ot
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Using compression tester ⇒ operating instructions .
h re
hole
spec
es, in part or in w
– Operate starter until tester shows no further pressure in‐
t to the co
crease.
Compression pressures:
rrectness of i
New: 25…31 bar, wear limit: 19 bar
l purpos
Maximum permissible difference between all cylinders: 5 bar
nform
ercia
Note
m
a
com
tion in
Always observe the notes on removing and installing the ceramic
r
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thi
glow plugs ⇒ page 181 .
s
iva
do
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rp
satelettronica
um
fo
– Install glow plugs or ceramic glow plugs, using U/J extension
en
ng
t.
yi
and socket, 10 mm - 3220- and tighten to specified torque of
Co
Cop py
15 Nm.
t. rig
gh ht
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Vo
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– Read event memory ⇒ page 162 ; Reading and deleting en‐
c by lksw
cted agen
gine control unit event memory. Prote AG.
Note
Disconnecting the central connector for unit injectors causes

faults to be stored. Therefore, read event memory and delete if
necessary.

2 Valve gear
⇒ “2.1 Assembly overview - valve gear”, page 73
⇒ “2.2 Reworking valve seats”, page 76
⇒ “2.3 Checking valve guides”, page 78
⇒ “2.4 Renewing valve stem seals”, page 78
⇒ “2.5 Removing and installing camshaft”, page 80
⇒ “2.6 Removing and installing camshaft oil seal”, page 84
2.1 Assembly
wage
n AG.overview
Volkswagen AG- valve gear
doe
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Vol t gu
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uNote
tho eo
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ss
♦ Cylinder heads with cracks between the valve seats may be
ce
le
un
pt
used without reducing engine life, provided the cracks are
an
d
itte
y li
small and not more than 0.5 mm wide.
rm
ab
pe
ility
♦ All bearing and running surfaces must be oiled before assem‐
ot
satelettronica
wit
, is n
bly.
h re
hole
spec
es, in part or in w
1 - 20 Nm + 90° further t to the co
❑ Renew.
❑ Note sequence when
rrectness of i
loosening and tighten‐

l purpos
ing ⇒ page 80 , Re‐

moving and installing
camshaft.
nform
ercia
2 - Rocker arm shaft

m
a
com
tio
3 - Cylinder head bolt

n in
r
te o
thi
❑ Renew.
s
iva
do
❑ Note sequence when

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loosening and tighten‐

en
ng
t.
ing ⇒ page 66 , Remov‐
yi Co
op
ing and installing cylin‐
C py
t. rig
gh
der head.
ht
pyri by
Vo
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by
❑ Before installing, insert
Prote
cted AG.
agen
washers
⇒ Item 4 (page 73) in
cylinder head.
4 - Washer
❑ For cylinder head bolts.
5 - Bucket tappet
❑ Do not interchange.
❑ With hydraulic valve
clearance compensa‐
tion.
❑ Set down with contact
surface facing down‐
wards.
❑ Before installing, check
camshaft axial clear‐
ance ⇒ page 75 .
❑ Oil contact surface.
2. Valve gear 73
AG. Volkswagen AG d
agen oes
ksw not
Polo Classic 2007 ➤ by V ol
gu
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d
3-Zyl. Dieselmotoro-risEdition
e 05.2014 nte
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th
au ra
❑ Before removing,s re‐
s c
move camshaft bearing caps
ce
e
nl
pt
du
an
itte
6 - Cotters
y li
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ab
ility
7 - Valve spring plate
ot p
wit
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8 - Outer valve spring
h re
hole
spec
❑ Removing and installing: with cylinder head removed: fitted with valve spring compressor - 2037- :
es, in part or in w
⇒ page 78 , renewing valve stem seals
t to the co
9 - Inner valve spring
❑ Removing and installing: with cylinder head removed: fitted with valve spring compressor - 2037- :
rrectness of i
⇒ page 78 , renewing valve stem seals
l purpos
❑ Insert in cylinder head before installing bearing caps

10 - Valve stem seal
nform
ercia
❑ Renew. ⇒ page 78 .
m
at
11 - Valve guide
om
ion
c
in t
or
his
ate
do
riv
12 - Unit injector
p
cum
or

f
en
satelettronica
ng
t.
yi Co
op
13 - Cylinder head C py
t. rig
gh ht
❑ See note ⇒ page 73 . yri
p by
co Vo
by lksw
❑ Reworking valve seats ⇒ page 76 . cted agen
Prote AG.
14 - Seal
❑ Do not additionally oil or grease the oil seal sealing lip.
❑ Before installing, remove residual oil from camshaft journal using a clean cloth.
❑ To install, mask off groove on camshaft taper (e.g. using Sellotape)
15 - Valves
❑ Valve dimensions ⇒ page 76
16 - Bearing shell
❑ Do not interchange used bearing shells (mark).
❑ Ensure that retaining lugs are correctly seated in bearing caps and cylinder head
17 - Camshaft
❑ Check axial clearance ⇒ page 75
❑ Check radial clearance with Plastigage, wear limit: 0.11 mm.
❑ Runout: max. 0.01 mm.
❑ Identification and valve timing ⇒ page 76 .
18 - Bearing cap
❑ Installation sequence ⇒ page 80 , removing and installing camshaft
❑ Bearing cap 4 is marked as bearing cap 5.
❑ To install, seal parting surfaces of bearing caps 1 and 4 with sealant - AMV 174 004 01- ⇒ page 75 .
19 - 8 Nm + 90° further
❑ Renew.

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Checking camshaft axial
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♦ Universal dial gauge bracket - VW 387-
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♦ Dial gauge
Perform measurement with bucket tappets removed and bearing
caps fitted.
Wear limit: max. 0.15 mm
Sealing parting surfaces of bearing caps 1 and 4 with sealant -
AMV 174 004 01-

♦ Sealant - AMV 174 004 01-
Apply sealant - AMV 174 004 01- thinly and evenly to surfaces
-1-.
2. Valve gear 75
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Valves must not be reworked. Only lapping-in is permitted.
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Dimension Inlet valve ercia
Exhaust valve
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∅b mm 6.980 6.956
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♦ Identification by stamped numbers and letters on face of no.
3 cylinder exhaust cam.
Cylinder 3 -arrow- = 858 C
Valve timing at 1 mm valve lift
Inlet opens ATDC 15.8°
Inlet closes ABDC 25.3°
Exhaust opens BBDC 28.2°
Exhaust closes BTDC 18.7°
2.2 Reworking valve seats

♦ Depth gauge
♦ Valve seat refacing tool
Note
♦ When repairing engines with leaking valves, it is not sufficient

to rework or renew valve seats and valves. There is also a
requirement to check the valve guides for wear. This is par‐
ticularly important on high mileage engines.
♦ Valve seats are only to be reworked to the extent required to
yield a proper surface appearance. Before beginning to rework
valve seats, calculate the maximum permissible reworking di‐
mensions. If the reworking dimension is exceeded, the hy‐
draulic valve clearance compensation can no longer be
guaranteed and the cylinder head must be renewed.
The max. permissible reworking dimension is calculated as fol‐

lows:
– 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 maximum permissible reworking dimension from
measured distance -a- and minimum dimension.
Minimum dimension: inlet valve 43.4 mm, exhaust valve 43.2 mm
Measured distance minus minimum dimension = max. permissi‐
ble reworking dimension. AG. Volkswagen
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Measured distance -a- 44.1 mm
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Minimum dimension 43.4 mm
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Max. permissible reworking dimension 0.7 mm
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Reworking inlet valve seat
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Note
The 30° lower valve seat chamfer is necessary to ensure that the
inlet channel flow characteristics are maintained.
Reworking exhaust valve seat
a = ∅ 31.4 mm
b = 2.7 mm
2. Valve gear 77
45° = Valve seat angle
2.3 Checking valve guides

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♦ Dial gauge
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Test procedure
– Insert new valve into guide. The end of the valve stem must
nform
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be flush with the guide. On account of differing stem diame‐

ters, only use inlet valve in inlet guide and exhaust valve in
m
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– Determine rock. Wear limit: max. 1.3 mm

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– Cylinder head must be renewed if rock exceeds wear limit.

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2.4 Renewing valve stem seals


equipment required
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♦ Valve assembly device - ag
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♦ Puller - 3047
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Removing
(With cylinder head installed)
– Remove camshaft ⇒ page 80 .
– Remove bucket tappets and place them with the contact sur‐
face downwards. When doing this, ensure that the tappets are
not interchanged.
– Set piston of respective cylinder to top dead centre (TDC).
– Fit valve assembly tool - 2036- and adjust mountings to height
of studs.
– Remove valve springs using valve lever - VW 541/1 A- and
thrust piece for VW 541 / 1 A and 2037 - VW 541/5- .
Note
The valves are supported by the piston crown.
2. Valve gear 79
– Pull off valve stem seals using puller - 3047 A- .

Installing
– Place the plastic sleeve -A- supplied on the respective valve

stem. This will prevent the new valve stem seal -B- being
damaged.
– Place new valve stem seal in fitting tool - 3129- .
– Oil valve stem seal sealing lip and press carefully onto the
valve guide.
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2.5 Removing and installing camshaft
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equipment required
♦ Counterhold tool - T10051-
♦ Puller - T10052-
1331- (5...50 Nm)
1332- (40...200 Nm)
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♦ Sealant - AMV 174 004 01-

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– Remove securing bolts for camshaft toothed belt pulley -1-. cted agen
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– Pull camshaft toothed belt pulley off hub.
2. Valve gear 81
– Loosen hub securing bolt -1-.

– To do this, use counterhold - T10051- .
– Loosen hub securing bolt about 2 turns.
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– Fit puller - T10052- and align it with holes in hub.

– Screw securing bolts -1- into hub.
– Apply tension to hub by evenly tightening puller central bolt
-2- until hub releases from taper of camshaft.
Note
When doing this, hold puller with 30 mm spanner.
– Remove hub from taper of camshaft.

– Remove cylinder head cover.
– Remove rocker arm shaft.
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First loosen the outer and then both inner securing
ss bolts, using c
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– Remove tandem pump ⇒ page 130 .
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4 alternately and diagonally.
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Note
Bearing cap 4 is marked as bearing cap 5.
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Installing
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Note
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♦ When camshaft is installed, No. 1 cylinder cams must point

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♦ When installing the camshaft, ensure proper seating of retain‐

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– Oil running surfaces of shell bearings.

– Tighten bearing caps 2 and 3 alternately and diagonally to 8
Nm + 1/4 turn (90°) further (renew).
– Install bearing caps 1 and 4 and also tighten to 8 Nm + 1/4 turn
(90°) (renew).
Note
♦ Bearing cap 4 is marked as bearing cap 5.

♦ Sealing parting surfaces of bearing caps 1 and 4 with sealant
- AMV 174 004 01- ⇒ page 75 .
♦ Bearing cap 4 must be flush with outer edge of cylinder head,
otherwise leaks can occur at the tandem pump.
2. Valve gear 83
– Install camshaft oil seal ⇒ page 84 .

– Install rocker arm shaft and tighten securing bolts, first the in‐
ner and then the outer, diagonally and evenly by hand so there
is no clearance to mounting. Specified torque: 20 Nm + 1/4 agen
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– Fit hub onto camshaft. hor eo
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– Push camshaft toothed belt pulley onto hub.
nf
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The toothed segment -arrow- of the camshaft belt pulley must be

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Prote AG.
– Lock hub using diesel injection pump locking pin - 3359- .

– Install tandem pump ⇒ page 130 .
Note
When new bucket tappets have been installed the engine must
not be started for about 30 minutes. Hydraulic compensation el‐
ements must settle (otherwise valves will strike pistons).
2.6 Removing and installing camshaft oil seal

agen
AG. Volkswagen AG d
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Special tools and workshop tho eo
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equipment required ss c
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pt
♦ Fitting tool - 10 - 203-
du
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♦ Oil seal extractor - 3240-
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1332- (40...200 Nm)
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nf
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Not illustrated
♦ Bolt M12×65
Removing
– Remove camshaft toothed belt pulley and hub ⇒ page 80 ,
Removing and installing camshaft.
– Screw inner part of oil seal extractor - 3240- two turns (approx.
3 mm) out of outer part and lock using knurled screw.
2. Valve gear 85
– Lubricate threaded head of oil seal extractor, place it in posi‐

tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against camshaft
until oil seal is pulled out.
Installing
Note
The oil seal sealing lip must not be additionally oiled or greased.
– Remove oil residue from camshaft journal using a clean cloth.

– Tape over groove in taper of camshaft (e.g. with Sellotape).
– Fit oil seal carefully on camshaft.
– Press in oil seal with press piece of fitting tool - 10 - 203- and
bolt M12×65 onto stop.
satelettronica
AG. Volkswagen AG d
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17 – Lubrication
1 Engine oil
⇒ Maintenance ; Booklet 15.1
⇒ “1.1 Oil capacities”, page 87
⇒ “1.2 Checking engine oil level”, page 87
1.1 Oil capacities

Vehicles with engine codes BAY, BNM, BNV:
With oil filter, 3.8 l
Vehicles with engine code AMF:
Engine codes BMS, BWB:
satelettronica
Without oil filter 3.9 l
1.2 Checking engine oil level n AG. Volkswagen AG do

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2 - Min. mark
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c - Oil level in area from min. mark up to hatched field: Must be
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1. Engine oil 87
2 Parts of lubrication system
Note
♦ If large quantities of swarf or metal particles (caused, for ex‐

ample, by partial seizure of the crankshaft or conrod bearings)
are found in the engine oil when performing repairs, clean the
oil passages thoroughly and renew the engine oil cooler in or‐
der to prevent subsequent damage.
♦ The oil level must not be above the max. mark - danger of
damage to catalytic converter!
♦ All bearing and running surfaces must be oiled before assem‐
bly.
⇒ “2.1 Assembly overview - parts of lubrication system”,

page 88
⇒ “2.2 Assembly overview - oil filter bracket”, page 91
⇒ “2.3 Removing and installing oil sump”, page 92 AG. Volkswagen AG d
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⇒ “2.4 Checking oil pressure and oil pressure switch”, d byV gu
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88 Rep. gr.17 - Lubrication

1 - 15 Nm
2 - Sealing flange
❑ With seal.
sleeves.
⇒ page 24 .
❑ Install with silicone seal‐
ant - D 176 404 A2-
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a clean cloth.
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seal - belt pulley end
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⇒ page 23 .
hole
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3 - Cylinder block
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4 - Gasket
❑ Renew.
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❑ With oil cooler.

nf
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bling ⇒ page 91 .
orm
❑ Checking oil cooler for
m
atio
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leaks ⇒ page 111

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6 - 15 Nm + 90° further
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7 - Oil dipstick
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❑ The oil level must not be above the max. mark!
❑ Checking oil level ⇒ page 87 .
8 - Piston fitting tool
❑ Pull out to extract oil.
9 - 5 Nm
10 - Guide tube
11 - 10 Nm
12 - O-ring
❑ Renew.
❑ Lightly coat with oil before installing.
13 - Cover
2. Parts of lubrication system 89

14 - 20 Nm
15 - Oil pump
❑ With 11.5 bar pressure relief valve.
❑ Before installing, ensure that both dowel sleeves for centring are installed.
16 - Dowel sleeve
17 - 25 Nm
❑ Insert without sealant.
19 - Oil spray jet
❑ For piston cooling.
❑ Observe installation position: Screw oil spray jet in anti-clockwise direction to stop into cylinder block and
tighten oil spray jet in this position.
20 - O-ring
❑ Renew.
satelettronica
21 - Oil sump
❑ Clean sealing surface before fitting. n AG. Volkswagen AG do
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❑ Remove gearbox to remove ris sump ⇒ Rep. gr. 34 .
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22 - Bracket ss
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23 - 15 Nm
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❑ To remove rear bolts to gearbox, gearbox must be removed ⇒ Rep. gr. 34 .

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24 - Seal
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❑ Renew.
spec
25 - Oil drain plug, 30 Nm

t to the co
26 - Chain sprocket
❑ For oil pump.
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❑ Fitting possible in one position only.

ss
27 - 20 Nm + 90° further
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❑ Renew.
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28 - Chain
atio
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❑ Observe installation position ⇒ page 38 , Removing and installing balancer shaft

n
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29 - Chain sprocket
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❑ For balancer shaft.

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❑ Turning further can be done in several stages.
AG.
❑ Use counterhold - T10061- to loosen and tighten

31 - Balance weight

32 - 20 Nm
33 - Chain sprocket/guide roller
34 - 8 Nm + 90° further
❑ Renew.
35 - Chain tensioner with tensioning plate
❑ To remove, lock with locking pin - T10060 A-
36 - O-ring
❑ Renew.
37 - Oil level and oil temperature sender - G266-
❑ Check ⇒ Vehicle diagnostic tester.
❑ To remove with engine installed, engine bracket must be removed ⇒ page 56 .
2.2 Assembly overview - oil filter bracket
satelettronica
1 - Gasket
❑ Renew.
2 - 15 Nm + 90° further
❑ Renew. lkswage es n
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❑ First fit upper left and ir se
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4 - Seal
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5 - Union, 25 Nm spec
es, in part or in w
❑ For oil supply line to tur‐

t to the co
bocharger.
6 - Oil supply line, 22 Nm
rrectness of i
❑ To turbocharger.
l purpos
7 - 0.7 oil pressure switch -

F1- .
nform
ercia
❑ If seal is leaking, nip

open and renew.
m
a
com
tio
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8 - Cap, 25 Nm
s
iva
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9 - O-ring
um
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❑ Renew.
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Cop py
.
10 - Oil filter element
t rig
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pyri by
Vo
co
11 - Plug, 10 Nm
by lksw
cted agen
Prote AG.
12 - Gasket
❑ Renew.
❑ Fit into lugs on oil cooler.
13 - Engine oil cooler
❑ See note ⇒ page 88 .

❑ Checking oil cooler for leaks ⇒ page 111
14 - Gasket
❑ Renew.
15 - Plug, 25 Nm
2.3 Removing and installing oil sump

♦ Hand drill with plastic brush
♦ Silicone sealant - D 176 404 A2-
♦ Flat scraper
Removing agen
AG. Volkswagen AG d
oes
olksw not
V gu
– Remove noise insulation
ed by ⇒ Rep. gr. 50 . ara
nte
ris
o eo
– Drain engine
aut oil.
h
ra
ss c
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nl
pt
du
satelettronica
an
Note
itte
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ab
Before removing sump, check whether the flywheel is provided ility
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with recesses for loosening the sump bolts. To do this, crank en‐ wit
, is n
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gine at crankshaft.
hole
spec
es, in part or in w
Vehicles without recesses in flywheel

t to the co
– Remove gearbox ⇒ Rep. gr. 34 .

rrectness of i
Continuation for all vehicles

l purpos
– Remove sump.
– Loosen sump with light blows of a rubber headed hammer if
nform
ercia
necessary.
m
– Remove sealant residue from cylinder block with a flat scraper.

at
om
ion
c
in t
– Remove sealant residues on sump with a rotating brush, e.g.

or
his
e
an electric drill with plastic brush attachment (wear eye pro‐

at
do
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tection).
p
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– Clean sealing surfaces. They must be free of oil and grease.

n
t.
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Installing
t. C rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
Note
♦ Note the expiry date of the Silicone sealant - D 176 404 A2- .
♦ Install sump within 5 minutes of applying silicone sealant - D
176 404 A2- .

– Cut off tube nozzle at forward marking (∅ of nozzle approx. 3

mm).
– Apply silicone sealant - D 176 404 A2- , as shown, to clean
sump sealing surface. Sealant bead must be:
♦ 2 … 3 mm thick.
♦ Run bead along inner side of bolt holes -arrows-.
Note
The sealant bead must not be thicker, otherwise excess sealing

compound will enter the oil sump and may block the oil suction
AG. Volkswagen AG d
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– Apply silicone sealantau-t D 176 404 A2- to clean sealing surface
h or
ac
of sump as shown inssillustration. (The figure shows the position
ce
of the sealant bead on the cylinder block).
le
un
pt
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– Install sump immediately and tighten all sump bolts lightly.
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satelettronica
wit
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Note
h re
ole,
spec
The sump must be flush with cylinder block.
t to the co
– Tighten oil sump bolts to 15 Nm.
rrectne
– Install gearbox ⇒ Rep. gr. 34 .
– Tighten bolts securing sump to gearbox to 45 Nm.
ss o
cial p
Note f inform
mer
atio
m
Let sealing compound dry for approx. 30 minutes after installing

o
n
c
i
or
oil sump. Only then fill with engine oil.

thi
te
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Further assembly is basically the reverse of the dismantling se‐

um
r
fo
quence.
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t.
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Cop py
t. rig
gh
2.4 Checking oil pressure and oil pressure switch
ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.


equipment required
AG. Volkswagen AG d
agen oes
♦ Oil pressure tester - V.A.G olksw not
y V gu
1342- ise
d b ara
nte
or eo
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♦ Voltage tester - V.A.G s aut ra
c
1527B- s
ce
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nl
pt
du
♦ Auxiliary measuring set -
an
itte
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V.A.G 1594 A- or auxiliary
erm
ab
measuring set - V.A.G
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1594C-
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nform
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satelettronica
m
at
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c
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or
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ate
do
priv
cum
for
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Functional check and repair of optical and acoustic oil pressure

warning: ⇒ Current flow diagrams, Guided fault finding with VAS
5051 .

Test procedure
– Remove oil pressure switch - F1- and screw into tester.
– Screw oil pressure tester - V.A.G 1342- into oil filter bracket in
place of oil pressure switch.
– Connect brown wire of oil pressure tester - V.A.G 1342- to
earth (-).
– Connect voltage tester - V.A.G 1527B- to battery positive (+)
and oil pressure switch using cables from auxiliary measuring
set - V.A.G 1594 A- or auxiliary measuring set - V.A.G 1594C- .
. Volkswagen AG
gen AG
– Start engine and increase speed Vol
slowly.
ksw
a At 0.55 … 0.85 dbar
oes
not
the LED must light up, otherwise
ed by renew oil pressure switch. gu
ara
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or
– Increase engine speedautfurther.
h At 2,000 rpm and an oil tem‐ eo
ra
perature of 80°C the soil pressure should be at least 2.0 bar.
s c
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le
un
pt
At higher engine speed, oil pressure must not exceed 5.8 bar.
an
d
itte
Renew oil filter bracket if necessary.
y li
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pe
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wit
, is n
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satelettronica
spec
es, in part or in w
t to the co
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nform
mercia
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s
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Cop py
t. rig
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by c lksw
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Prote AG.

19 – Cooling
1 Removing and installing parts of cool‐
ing system
AG. Volkswagen AG d
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♦ When the engine is warm, the cooling system is under pres‐
s a c
s
sure. If necessary, release pressure before beginning repair
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work.
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♦ Hoses are secured with spring-type clips. In case of repair,
ab
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only use spring-type clips.
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♦ Spring-type clip pliers - VAS 5024A- or hose clip pliers - V.A.G
h re
hole
1921- are recommended for installation of spring-type clips.
spec
es, in part or in w
t to the co
⇒ “1.1 Assembly overview - parts of cooling system, body side”,
page 96
satelettronica
rrectness of i
⇒ “1.2 Assembly overview - parts of cooling system, engine side”,
page 98
l purpos
⇒ “1.3 Coolant hose schematic diagram”, page 99
nform
ercia
⇒ “1.4 Draining and filling coolant”, page 101

m
at
⇒ “1.5 Removing and installing radiator”, page 105
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⇒ “1.7 Removing and installing thermostat”, page 108
or
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ate
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⇒ “1.4 Draining and filling coolant”, page 101

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⇒ “1.7 Removing and installing thermostat”, page 108

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⇒ “1.8 Checking cooling system for leaks”, page 109
C py
t. rig
gh ht
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⇒ “1.9 Checking engine oil cooler for leaks”, page 111
op Vo
by c lksw
cted agen
Prote AG.
1.1 Assembly overview - parts of cooling system, body side
96 Rep. gr.19 - Cooling

AG. Volkswagen AG d
agen oes
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by Vol
gu
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rise 3-Zyl. Dieselmotor
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ho eo
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1 - Radiator
ce
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pt
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⇒ page 105 .
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❑ After replacing, renew
ility
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entire coolant.
wit
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2 - O-ring
hole
spec
es, in part or in w
t to the co
3 - Upper coolant hose
❑ Coolant hose schematic
rrectness of i
diagram ⇒ page 99 .
l purpos
4 - Cap
❑ Check using cooling
system tester - V.A.G
nform
ercia
1274- and adapter for

m
cooling system tester -
at
om
io
V.A.G 1274/9- .
n
c
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or
❑ Test pressure 1.4…1.6
his
ate
bar.
do
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cum
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5 - Connector
f
en
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t.
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op
6 - 5 Nm
C py
t. rig
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7 - Expansion tank cop Vo
by lksw
cted agen
❑ Test cooling system for Prote AG.
leaks using cooling sys‐
tem tester - V.A.G 1274-
and adapter for cooling
system tester - V.A.G
1274/8- .
8 - Cowling
9 - 5 Nm
10 - Fan ring
11 - 10 Nm
12 - Radiator fan
13 - Bracket
❑ For fan connector.
14 - Lower coolant hose
❑ Coolant hose schematic diagram ⇒ page 99 .
15 - Radiator fan thermal switch - F18- , 35 Nm
❑ For electric fan.
❑ Switching temperatures:
• 1. Stage on: 92…97 °C, off: 84…91 °C
• 2. Stage on: 99…105 °C, off: 91…98 °C
16 - Radiator lower mounting

❑ Black
17 - 5 Nm
18 - Radiator upper mounting
❑ White
1. Removing and installing parts of cooling system 97

1.2 Assembly overview - parts of cooling system, engine side
1 - Coolant hose
❑ To heat exchanger
2 - Connection
3 - 10 Nm
4 - Coolant hose
❑ From heat exchanger
5 - 25 Nm
6 - Coolant hose
❑ To bottom of expansion
tank
satelettronica
7 - Bracket
8 - Coolant pipe
diagram ⇒ page 99 . agen
AG. Volkswagen AG d
oes
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9 - O-ring ed by
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❑ Renew. ut
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10 - Coolant hose s
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nl
pt
❑ To top of expansion tank

du
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itte
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11 - Coolant hose
h re
hole
❑ To top of radiator
spec
es, in part or in w

t to the co
12 - Coolant hose
rrectness of i
❑ From bottom of radiator.

l purpos
❑ Coolant hose schematic diagram ⇒ page 99 .

13 - Connection
nform
ercia
❑ For thermostat.
m
at
om
14 - 15 Nm
ion
c
in t
or
15 - Thermostat
his
ate
do
riv

p
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or
❑ Observe installation position ⇒ page 108 , removing and installing thermostat.

f
en
ng
t.
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❑ Checking: heat thermostat in water. t. Cop py
rig
gh
❑ Opening begins at approx. 85 °C.
ht
pyri by
Vo
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❑ Ends at approx. 105 °C. Prote
cted AG.
agen
❑ Opening lift at least 7 mm.

16 - Coolant pump
❑ Check for ease of movement.

17 - O-ring
❑ Renew.
18 - Retaining clip
AG. Volkswagen n AG do
ks sender - G62- wage es
19 - Coolant temperatureVol
not
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d by ar
❑ With coolant
orise temperature display sender - G2- . ante
e th or
s au ac
s
ce
e
nl
pt
1.3 Coolant hose schematic diagram
du
an
itte
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⇒ “1.3.1 Engine code AMF”, page 99
ility
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wit
⇒ “1.3.2 Engine codes BAY, BNM, BNV, BWB”, page 100
, is n
h re
hole
⇒ “1.3.3 Engine code BMS”, page 101
spec
es, in part or in w
t to the co
1.3.1 Engine code AMF
rrectness of i
1 - Intake manifold
satelettronica
l purpos
2 - Expansion tank
3 - Heat exchanger for heater
nform
ercia
unit
m
4 - Coolant pipe at
om
ion
c
in t

or
his
ate
do
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6 - Upper coolant hose

p
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for
7 - Radiator
en
ng
t.
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op
8 - Lower coolant hose
C py
t. rig
gh ht
yri by
9 - Coolant pump and thermo‐ cop Vo
by lksw
cted
stat
agen
Prote AG.
10 - Cylinder block/cylinder
head

1.3.2 Engine codes BAY, BNM, BNV, BWB
1 - Expansion tank
2 - Intake manifold
head
unit
5 - Radiator
❑ For exhaust gas recircu‐
lation.
6 - Radiator
7 - Oil cooler
8 - Coolant pump and thermo‐
stat n AG. Volkswagen AG do
lkswage es n
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byV ua
satelettronica
d ran
ir se tee
tho
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nl
pt
du
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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
rrectness of i
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nform
mercia
at
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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.

1.3.3 Engine code BMS
1 - Expansion tank
2 - Intake manifold
head
unit
5 - Radiator
lation.
6 - Radiator
8 - Coolant pump and thermo‐
stat
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
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a ac
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pt
du
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itte
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ab
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spec
es, in part or in w
1.4 Draining and filling coolant t to the co

rrectness of i
⇒ “1.4.1 Draining”, page 102

l purpos
⇒ “1.4.2 Filling”, page 103

nf
ercia
orm
m
atio
om
n in
or c
thi
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f
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t.
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Cop py
t. rig
gh ht
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Vo
co lksw
by
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Prote AG.


equipment required
♦ Refractometer - T10007-
VAS 5024-
♦ Cooling system charge unit
- VAS 6096-
♦ Adapter for cooling system gen AG
. Volkswagen AG
does
tester - V.A.G 1274/8- Volkswa not
g by ua
ed ran
oris tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
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ab
pe
ility
ot
wit
, is n
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satelettronica
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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fo
en
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t.
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Cop py
1.4.1 Draining
ht. rig
rig ht
py by
co Vo
by lksw
– Open filler cap on coolant expansion tank. cted agen
Prote AG.
WARNING
Hot steam may escape when expansion tank is opened. Place

cloth over cap and open with caution.

– To drain coolant from radiator, open drain plug -arrow-.
– To drain coolant from engine, also detach coolant hoses from

engine oil cooler -arrows-.
Note
Observe environmental regulations for disposal.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
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nl
pt
du
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itte
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ab
ility
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spec
es, in part or in w
1.4.2 Filling t to the co
Caution
rrectness of i
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For mixing only tap water must be used. Well water does not
have the required quality to ensure the coolant's function.
nform
mercia
at
om
ion
c
in t
or
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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.

Note
♦ In vehicles as of model year 2008, only G 12 plus-plus ac‐

cording to TL VW 774 G may be used as coolant additive.
♦ For vehicles up to and including model year 2007 coolant ad‐
ditive G 12 plus according to TL VW 774 F and G 12 plus-plus
according to TL VW 774 G can be used.
♦ The coolant additive G 12 plus-plus can be mixed with the
previous coolant additive G 12 plus. Identification: both are
coloured purple.
♦ Coolant additives marked “according to TL VW 774 G” or “ac‐
cording to TL VW 774 F” prevent frost and corrosion damage,
scaling and also raise boiling point of coolant. Therefore, the
cooling system must be filled all year round with coolant ad‐
ditive and corrosion protection additive.
♦ Because of its higher boiling point, the coolant improves en‐
gine reliability under heavy loads, particularly in countries with
tropical climates.
♦ Frost protection is required down to about -25°C (in countries
satelettronica
with arctic climates: down to about -35°C).
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The
coolant additive concentration must be at least 40%.
♦ If for climatic reasons greater frost protection is required, the
amount of coolant additive can be increased, but only up to 60
% (frost protection to about -40 °C). Otherwise frost protection
and cooling effectiveness are reduced again.
♦ The refractometer -T10007- is recommended for determining
the current anti-freeze concentration.
♦ If radiator, heat exchanger, cylinder head
en AG. V
olkswaor
gencylinder
AG head
gasket is renewed, do not
olksreuse old coolant.
wag does
not
yV gu
db ara
ise nte
Recommended mixture
tho
r
ratios: eo
s au ra
c
s
Frost protection to Anti-freeze quantity G 12 plus 1) Water
ce
e
nl
pt
G 12 plus-plus1)G 12
du
an
itte
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erm
-25 °C 40 % 2.0 l 3.0 l

ab
ility
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-35 °C 50 % 2.5 l 2.5 l

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The quantity of coolant can vary depending upon vehicle equipment.

hole
spec
es, in part or in w
t to the co
– Close coolant drain plug.

– Connect coolant hoses to oil cooler.
rrectness of i

l purpos
With cooling system charge unit - VAS 6096- :

nform
ercia
– Screw a suitable adapter from cooling system tester - V.A.G

1274- onto expansion tank.
m
at
om
ion
c
– Fill coolant circuit using cooling system charge unit - VAS

in t
or
6096- ⇒ Operating manual for cooling system charge unit -

his
ate
VAS 6096- .
do
priv
cum
for
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.

Without cooling system charge unit - VAS 6096- :

– Fill with coolant up to max. mark on expansion tank.
– Fit expansion tank cap.
– Turn off heater controls.
– Start engine and maintain an engine speed of about 2,000 rpm
for about 3 minutes.
– Run engine until radiator fan cuts in.
– Check coolant level and top-up if necessary. When the engine
is at normal operating temperature, the coolant level must be
at the max. mark; when the engine is cold, between the min.
and max. marks. agen
AG. Volkswagen AG d
o w es n
olks ot g
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1.5 Removing and installing radiator ed ran
ris tee
tho or
au ac
ss
ce
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nl
pt
du
an
equipment required
itte
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erm
ab
ility
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satelettronica
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
VAS 5024-
- VAS 6096-
rrectness of i
♦ Adapter for cooling system
l purpos
tester - V.A.G 1274/8-

♦ Torque wrench -
nform
ercia
V.A.G 1331-
m
at
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ion
c
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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.
Removing
– Remove front bumper ⇒ Rep. gr. 63
– Bring lock carrier into service position ⇒ Rep. gr. 50 .

– Pull coolant hoses off radiator.

– Pull connectors off thermal switch and radiator fan.
– Remove radiator securing bolts and remove radiator with fan
downwards.
Vehicles with air conditioning system:
– Observe additional information and installation work
⇒ page 106 .
Installing
note the following:
– Replenish coolant ⇒ page 101 .
Additional information and assembly work for vehicles with air
conditioner
WARNING
The air conditioner refrigerant circuit must not be opened.
satelettronica
Note
To prevent damage to condenser or to refrigerant lines/hoses,

ensure that the lines and hoses are not stretched, kinked or bent.
– Remove retaining clamp(s) for refrigerant lines.

AG. Volkswagen AG d
agen
– Unbolt condenser from radiator and secure to lock carrier. Volksw
oes
not
by gu
d ara
1.6 Removing and installing coolant pump ise nte
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by c lksw
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Prote AG.

AG. Volkswagen AG d
agen oes
lksw not
Special tools andby V workshop
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equipmentrisrequired
ed
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♦ Refractometer
ss a - T10007- ra
c
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VAS 5024-
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spec
- VAS 6096-
t to the co
♦ Torque wrench -
rrectne
V.A.G 1331-
ss o
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f inform
mer
atio
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satelettronica
thi
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sd
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cum
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
Removing
Note
Always renew seals and gaskets.


– Remove coolant pump securing bolts -1- and carefully remove

coolant pump -2-.
Installing
note the following:
– Moisten new O-ring -3- with coolant.
– Insert coolant pump -2- into cylinder block and tighten securing
bolts -1-. Specified torque: 15 Nm
Note
The coolant pump plug faces downwards.

lkswage es n
o ot g
– Install and tension toothed belt ⇒ page 56 . d byV ua
ran
ir se tee
o
– Install poly V-belt ⇒ page 16 . auth or
ac
ss
ce
e
nl
pt
du
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1.7 Removing and installing thermostat
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VAS 5024-
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- VAS 6096-
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V.A.G 1331-
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– Remove alternator ⇒ Rep. gr. 27
spec
– Pull coolant hose off connection.
t to the co
– Unscrew securing bolts -1- of connecting flange -2- and re‐
move connecting flange -2- with thermostat -4-.
rrectne
– Turn thermostat -4- 1/4 turn (90°) to left and remove from con‐
nection -2-.
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Installing
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note the following:
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– Moisten new O-ring -3- with coolant.
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– Insert thermostat -4- in union -2- and turn 1/4 turn (90°) to right.
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The brace on the thermostat must be almost vertical.
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– Fit connection -2- with thermostat -4- into cylinder block.
– Tighten securing bolts -1-. Specified torque: 15 Nm

1.8 Checking cooling system for leaks


equipment required
♦ Cooling system tester -
V.A.G 1274-
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Test prerequisite
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• Engine at operating temperature.

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Test sequence:
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cloth over cap and open with caution. opyri
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– Open cap on coolant expansion tank.

– Attach cooling system tester - V.A.G 1274- with cooling sys‐

tem tester adapter - V.A.G 1274/8- to expansion tank.
– Use hand pump on tester to create a pressure of about 1.0 bar.
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– Find leaks and isrectify.
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Checking pressure
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– Attach cooling system tester - V.A.G 1274- with cooling sys‐
hole
tem tester adapter - V.A.G 1274/9- to cap.
spec
es, in part or in w
t to the co
– Use hand pump on cooling system tester to create a pressure
of max. 1.6 bar.
The pressure relief valve must not open.
rrectness of i
If the pressure relief valve opens prematurely:
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– Renew sealing cap.
nf
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– Increase pressure to over 1.6 bar.
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The pressure relief valve must open.
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If the pressure relief valve does not open:

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– Renew sealing cap.

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1.9 Checking engine oil cooler for leaks
Co
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AG. Volkswagen AG d
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Special tools and workshop ris tee
equipment required tho or
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♦ Hose clips up to 25 mm Ø -
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3094-
ility
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♦ Cooling system tester -
wit
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V.A.G 1274-
hole
spec
es, in part or in w
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VAS 5024 A-
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Not illustrated
♦ Expansion tank - 1K0 121 407 A bzw. 6Q0 121 407 A bzw.
1J0 121 407 B-
♦ Plug - 191 211 343-
♦ Cap - 1J0 121 324-
♦ Coolant hose - 251 265 056-

Prerequisites:
• Engine cold
Test procedure
– Remove noise insulation.
– Clamp supply line and return line off engine oil cooler using
hose clips to ∅ 25 mm - VAS 3094- .
– Loosen hose clips -arrows- using spring-type clip pliers - VAS
5024- .
Note
Collect escaping coolant with drip tray - V.A.G 1306- or drip tray
- VAS 6208- .
– Pull coolant hoses off oil cooler.
– Slide cover -5- onto rear connection of oil cooler -4-.

– Secure sealing plug -2- to breather connection of expansion
satelettronica
tank -1-.
– Secure coolant hose -3- to engine oil cooler and expansion
tank.
AG. Volkswagen A
– Fill expansion tank
olks
wup
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“Max” marking.
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– Attach cooling
ris
ed system tester - V.A.G 1274- with cooling
ara
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tem tester
utho adapter - V.A.G 1274/8- to expansion tank. eo
r
sa ac
– Use shand pump on tester to create a pressure of about 1.6 bar.
ce
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un
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– Watch pressure drop on pressure gauge. A pressure drop

an
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within 10 minutes is not permitted.

rm
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If pressure drops:
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– Renew engine oil cooler ⇒ page 91 .

hole
spec

es, in part or in w
t to the co
note the following:

– Check coolant level, replenish coolant if necessary
⇒ page 101 .
rrectness of i
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20 – Fuel supply system

AG. Volkswagen AG d
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1 Removing and installing parts of fuel
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♦ Hose connections are secured with either spring-type or
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clamp-type clips.
, is n
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hole
♦ Always renew clamp-type clips with spring-type clips.
spec
es, in part or in w
♦ Spring-type clip pliers - VAS 5024A- or hose clip pliers - V.A.G
t to the co
1921- are recommended for installation of spring-type clips.
rrectness of i
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114 Rep. gr.20 - Fuel supply system

⇒ “1.1 Safety precautions when working on fuel supply system”,

page 115
⇒ “1.2 Rules for cleanliness”, page 115
⇒ “1.3 Assembly overview - fuel tank with attachments”,
page 116
⇒ “1.4 Removing and installing fuel tank”, page 118
⇒ “1.5 Assembly overview - fuel filter”, page 119
⇒ “1.6 Removing and installing fuel cooler”, page 122
⇒ “1.7 Removing and installing fuel delivery unit”, page 122
⇒ “1.8 Removing and installing fuel gauge sender G ”,
page 124
⇒ “1.9 Checking fuel pump”, page 124
⇒ “1.10 Assembly overview - accelerator mechanism”,
page 125
⇒ “1.11 Checking tandem pump”, page 126
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⇒ “1.12 Removing and installing
by
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olk pump”, page 130 ot g
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1.1 Safety precautions when working on
tee
tho or
au ac
fuel supply system
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WARNING
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tions:
spec
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐ t to the co
sitions.
rrectne

s
hot components.
s o
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carefully loosen connection to release the pressure!

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When removing and installing fuel gauge sender - G- or fuel pump
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(fuel delivery unit) from a full or partly full fuel tank, observe the Prote AG.
following:
♦ Even before work commences, the extraction hose of an ac‐
tivated fume extraction system has to be placed in the vicinity
of the assembly opening of the fuel tank to extract any escap‐
ing fumes. If no exhaust gas extraction system is available, a
radial fan with a displacement greater than 15 m3/h can be
used providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
1.2 Rules for cleanliness

When working on the fuel supply and injection system, pay careful
attention to the following “six rules” for cleanliness:
1. Removing and installing parts of fuel supply system 115

♦ Thoroughly clean all unions and surrounding areas before dis‐

connecting.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ When system is open: do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
1.3 Assembly overview - fuel tank with attachments

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1 - Cap ho
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2 - 1.5 Nm ss c
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3 - Tank flap unit
pt
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⇒ Rep. gr. 55 .
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4 - Gravity/overflow valve
h re
ole,
❑ To remove, release
spec
locking lug and unclip
t to the co
valve upwards out of fill‐
er neck.
❑ Check valve for
rrectne
through-flow; valve ver‐
tical: open, valve tilted
45°: closed.
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5 - Earth connection
inform
mer
❑ Check for secure seat‐

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6 - 10 Nm
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7 - Breather line
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❑ Clipped onto top of fuel

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8 - 25 Nm
AG.
9 - Fuel tank
❑ When removing, sup‐
port using engine and
gearbox jack - V.A.G
1383 A- .
⇒ page 118 .
10 - Securing strap
11 - Fuel delivery unit
❑ Note installation position of flange on fuel tank ⇒ page 117 .

❑ Checking fuel pump ⇒ page 124 .
❑ With fuel gauge sender - G- .
❑ Removing and installing fuel gauge sender - G- ⇒ page 124 .
12 - Seal
❑ Moisten with fuel when installing
13 - Union nut
❑ Remove and install using union nut tool - 3217- .
14 - Supply line
❑ To fuel filter ⇒ Item 2 (page 120) or ⇒ Item 3 (page 121)
❑ Clipped onto fuel tank.
❑ Black
❑ To pull off flange, press release button on connecting piece.
15 - Return line
❑ From fuel cooler ⇒ page 122 or from regulating valve ⇒ Item 2 (page 121) .
satelettronica
❑ Clipped onto fuel tank.
❑ To pull off flange, press release button on connecting piece.
16 - Breather valve
❑ To remove valve unclip sideways out of support.
❑ Remove cap before installing.
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❑ Renew if damaged. ised b ara
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Installation position of fuel delivery unit

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Marking on flange must align with marking on fuel tank -arrows-.

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

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

spec
es, in part or in w
t to the co
Note
rrectness of i
After installing fuel delivery unit flange, check that supply, return
and breather lines are still clipped onto fuel tank.
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mercia
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Checking breather valve

Lever in rest position: closed.
Lever pushed -in direction of arrow-: open.
Note
Before installing breather valve remove fuel tank cap.
1.4 Removing and installing fuel tank

♦ Torque wrench - V.A.G 1331- (5...50 Nm)
satelettronica
AG. Volkswagen AG d
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♦ Engine and gearbox jack - V.A.G 1383 A-
ility
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spec
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Removing
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– Note safety precautions before beginning work ⇒ page 115 .

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Observe rules for cleanliness ⇒ page 115 .

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Before carrying out further work, disconnect battery earth strap.
Prote AG.
Check whether a coded radio is fitted. Obtain anti-theft coding first

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

– Fold rear bench seat forwards.
– Remove cover plate and pull connector off flange.
– Drain fuel tank.

– Remove rear axle ⇒ Rep. gr. 42 .

– Remove rear right wheel housing liner ⇒ Rep. gr. 66 .
– Disconnect fuel supply line and fuel return line at front right of
fuel tank.
Note
To do this, press down buttons on hose couplings -arrows-.
– Remove rear silencer.

– Remove left heat shield.
– Remove bolts from filler neck -arrows-.

– Support fuel tank using engine and gearbox jack - V.A.G 1383
A- .
satelettronica
– Unscrew securing bolts of fuel tank -arrows-.
– Remove filler neck from rubber cup of tank flap unit and lower
fuel tank.
Installing
AG. Volkswagen AG d
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Install in reverse order. In the process,y Vnote
olks the following:
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♦ Install breather and fuel hoses orisfree of kinks. nte
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♦ Ensure that fuel hose connections
ss are tight. c
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pt
♦ Do not interchange supply line and return line (return line blue
du
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or with blue marking, supply line black).

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ility
♦ Clip supply and return lines onto fuel tank.

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spec
Note
es, in part or in w
t to the co
After installing fuel tank, check that the supply, return and breath‐
er lines are still clipped onto the fuel tank.
rrectness of i
1.5 Assembly overview - fuel filter

l purpos
⇒ “1.5.1 Engine codes AMF, BAY, BNM”, page 119

nf
ercia
or
⇒ “1.5.2 Engine codes BMS, BNV, BWB”, page 121

m
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atio
om
1.5.1 Engine codes AMF, BAY, BNM

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119
Prote AG.
1. Removing and installing parts of fuel supply system
1 - Return line
❑ To fuel cooler
⇒ page 122
❑ Blue or with blue mark‐
ing.
ing.
2 - Supply line
❑ From fuel tank
⇒ Item 9 (page 116) .
❑ White or with white
marking.
ing.
3 - Retaining clip
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❑ Installation position: ar‐ ise
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row points towards fuel uthor eo
tank a ra
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❑ When changing filter,
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remove retaining clip
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and take control valve
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off complete with fuel
ility
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❑ Below +15 °C: passage
hole
to filter open.
spec
es, in part or in w
❑ Over +31 °C: passage
t to the co
to filter closed.
5 - O-ring
rrectness of i
❑ Renew.
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6 - Return line
❑ From tandem pump nform
ercia
⇒ Item 29 (page 54)

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7 - Fuel line
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8 - Fuel temperature sender - G81-

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9 - Non-return valve Cop py
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❑ Installation position: arrow points towards tandem pump
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10 - Supply line
agen
Prote AG.
❑ To tandem pump ⇒ Item 28 (page 54) .

❑ White or with white marking.
11 - Fuel filter
❑ Fill with diesel before installing.
❑ Direction of flow is marked with arrows.
❑ Do not interchange connections.
12 - Gasket

13 - Water drain screw

❑ To bleed remove regulating valve securing clip and remove regulating valve complete with connected
fuel lines.
❑ Loosen and allow approx. 100 cm3 fluid to drain
1.5.2 Engine codes BMS, BNV, BWB
1 - Fuel filter
❑ Fill with diesel before in‐ n AG. Volkswagen AG do
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❑ Direction of flow is ir se
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marked with arrows. tho tee
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❑ Do not interchange con‐ ss
nections.
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❑ Observe change inter‐
ility
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2 - Regulating valve
hole
spec
❑ Below +15 °C: passage
es, in part or in w
to filter open.
t to the co
❑ Over +30 °C: passage
to filter closed.
rrectness of i
3 - Supply line
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❑ From fuel tank

⇒ Item 14 (page 117) .
nform
ercia
❑ White or with white

marking.
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ate
4 - Return line
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❑ To fuel tank
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⇒ Item 15 (page 117) .
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5 - Return line
Prote AG.
❑ From tandem pump.

❑ Blue marking
ing.
6 - Supply line
❑ To tandem pump.
7 - Fuel temperature sender - G81-
8 - Gasket
❑ Renew.
9 - From tandem pump.
10 - Return line
❑ With connection for fuel temperature sender - G81-
11 - Retaining clip

12 - 25 Nm
13 - Bracket
14 - Filter mounting
1.6 Removing and installing fuel cooler
Note
Not all vehicles are equipped with a fuel cooler.

♦ Torque wrench - V.A.G 1331- (5...50 Nm)
AG. Volkswagen AG d
agen
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Removing
wit
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spec
es, in part or in w
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Note
rrectness of i
The fuel cooler is located in the return line to fuel tank. It is located
on the vehicle underbody.
l purpos
– Remove cover -A-.
nform
ercia
– Separate fuel lines at fuel cooler.

m
a
com
ti
– Remove securing nuts -arrows-.
on in
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Installing
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Install in reverse order. In the process, note the following:

cum
fo
en
ng
t.
♦ Tighten fuel cooler securing nuts to 15 Nm.
yi Co
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Prote AG.
1.7 Removing and installing fuel delivery

unit

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♦ Union nut tool - 3217- olks ot g
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es, in part or in w
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ion
c
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or
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ate
do
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co
Removing
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Prote AG.
Observe safety precautions ⇒ page 115 .
– First check whether a coded radio is fitted. If so, obtain anti-
theft coding.
– With the ignition switched off, disconnect battery earth strap.
– Remove cover from fuel delivery unit.
– Pull 4-pin connector as well as supply and return pipes off
flange.
Note
Press buttons on hose couplings to do this.
WARNING

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

– Pull fuel delivery unit and seal out of the opening in fuel tank.
Note
If delivery unit is to be renewed, drain old delivery unit before dis‐

posal.
Installing
– Installing the fuel delivery unit is carried out in reverse order
of removal.
Note AG. Volkswagen AG d

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♦ Do not bend fuel gauge sender - G- edwhen installing.
b gu
ara
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ris
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♦ Insert seal for flange or fuel delivery
aut
h
unit dry into opening of ra
fuel tank. ss c
ce
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nl
satelettronica
pt
♦ Moisten seal with fuel only when installing flange or fuel de‐
du
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itte
livery unit.
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erm
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♦ Ensure that fuel hose connections are tight.
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♦ After installing fuel delivery unit, check that the supply, return
h re
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and breather lines are still clipped onto the fuel tank.
spec
es, in part or in w
♦ Note installation position of fuel delivery unit flange: mark on
t to the co
flange must align with mark on fuel tank -arrows-.
rrectness of i
1.8 Removing and installing fuel gauge
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sender - G- nf
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Removing
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– Remove fuel delivery unit ⇒ page 122 .

atio
om
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– Release connector lugs on lines -3- and -4- and pull off.
or
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– Raise retaining tabs -1- and -2- using a screwdriver and pull
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fuel gauge sender - G- off downwards -arrows-.

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Installing
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– Insert fuel gauge sender - G- into guides on fuel delivery unit
rig ht
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and press upwards until it engages.
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Prote AG.
1.9 Checking fuel pump

♦ Hand multimeter - V.A.G 1526C- or multimeter - V.A.G 1715-
♦ Auxiliary measuring set - V.A.G 1594 A- or auxiliary measuring
set - V.A.G 1594C-
♦ Voltage tester - V.A.G 1527B-
Test prerequisites
• Fuses must be OK.

• The battery voltage must be at least 11.5 V.

• All electrical consumers, e.g. lights and rear window heating,
must be switched off.
Checking function and voltage supply
– Remove cover under rear seat.
– Briefly operate starter. Fuel pump must be heard to run.
– Switch off ignition.
If the fuel pump does not start:
– Pull 4-pin connector off fuel delivery unit flange.
– Connect voltage tester - V.A.G 1527B- to outer contacts of
connector using auxiliary leads from auxiliary measuring set -
V.A.G 1594 A- or auxiliary measuring set - V.A.G 1594C- .
– Switch on ignition; LED must light up for approx. 2 seconds.
If LED does not light up
– Check activation of fuel pump relay and wiring for an open or
satelettronica
short circuit usingagguided
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If LED lights
ho
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– Remove
ss fuel delivery unit ⇒ page 122 .
ce
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– Check that electrical wiring between flange and fuel pump is

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connected and has continuity.

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If no open circuit can be found:

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– Renew fuel delivery unit ⇒ page 122 .

h re
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spec
Checking current draw of fuel pump

t to the co
– Pull 4-pin connector off fuel delivery unit flange.
– Set multimeter to measuring range 20 A and connect in series

rrectne
between contacts -1- of connector and fuel pump using auxil‐

iary cables from auxiliary measuring set - V.A.G 1594 A- or
s
auxiliary measuring set - V.A.G 1594C- .

s o
cial p
f inform
mer
Note
atio
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n
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The current pick-up clamp of multimeter - V.A.G 1715- can also

or
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be attached to an auxiliary cable between contacts -1- of con‐

t
sd
va
nector and fuel pump.

i
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– Connect contacts -4- of connector and fuel pump using an
Co
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auxiliary cable from auxiliary measuring set - V.A.G 1594 A-
t. rig
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or auxiliary measuring set - V.A.G 1594C- .
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– Start engine and run at idling speed.
Prote AG.
– Measure current draw of fuel pump. Specification: max. 7.5

Amperes.
– If the measured value is not within specifications:
– Renew fuel delivery unit ⇒ page 122 .
1.10 Assembly overview - accelerator mechanism

1 - Bearing bracket
⇒ Rep. gr. 46 .
2 - Connector
❑ Black, 6-pin.
3 - Accelerator position sender
- G79-
❑ Not adjustable.
❑ The accelerator position
sender - G79- transmits
the driver's input to the
engine control unit
❑ Remove footwell cover
to remove accelerator
position sender - G79-
4 - 10 Nm
AG. Volkswagen AG d
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1.11 Checking tandem pump

nf
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⇒ “1.11.1 Checking delivery pressure”, page 126 m
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⇒ “1.11.2 Checking for internal leaks”, page 129

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1.11.1 Checking delivery pressure

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♦ Tandem pump tester - VAS 5187- C py
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♦ Torque wrench - V.A.G 1331- (5...50 Nm) en AG. Volkswagen AG

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♦ Vehicle diagnosis, testing and information system - VAS
5051B-
rrectness of i
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Test prerequisites
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• Coolant temperature must be at least 85 °C. cted agen
Prote AG.
• Unit injectors OK.

• Fuel filter and fuel lines must not be blocked.
• The non-return valve in the fuel supply hose must be OK.
• Intact fuel delivery unit
Procedure
WARNING

– Remove screw plug -arrow-.
– Connect tandem pump tester - VAS 5187- as shown.

– Connect vehicle diagnosis, testing and information system -
VAS 5051B- and select operating mode “vehicle self-diagno‐
sis”. Then select engine electronics control unit with the
Address word “01”.
– Press diagnosis function “08-Read measured value block”.
satelettronica
– Enter display group “2” using number block (key pad) and
confirm entry with Q button.
– Read off engine idling speed in display zone 1.
– Increase engine speed to 1500 rpm. AG. Volkswagen AG d
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– Observe pressure indicated on pressure gauge. Specification:
d by
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min. 3.5 bar. orise nte
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– Press ← button. ss a c
ce
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– Select “06-End output” function.
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If the specification is not attained:
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wit
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– Using a hose clip, clamp-off return line between fuel filter and
hole
spec
tandem pump.
es, in part or in w
– Increase engine speed to 1500 rpm. t to the co
– Observe pressure indicated on pressure gauge.

rrectness of i
Specification: min. 3.5 bar

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If specification is now obtained:

Pressure loss at unit injectors.
nform
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– Renew unit injector O-rings.

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If the specification is not attained:

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– Renew tandem pump ⇒ page 130 , Removing and installing

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tandem pump.
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After removing pressure gauge, tighten plug to 25 Nm. Always Prote
cted agen
renew seal.
AG.

1.11.2 Checking for internal leaks
Note
The tandem pump must be checked for internal leaks between

fuel side and oil side after reinstalling a used tandem pump, e.g.
after renewing or repairing a cylinder head and/or when installing
a "short" engine. When leaking it is possible for the fuel to mix
with the oil which may cause the engine to fail.

♦ Tester - V.A.G 1687-
satelettronica
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Procedure auth or
ac
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– Pull fuel supply hose (white marking) ⇒ Item 28 (page 54) and
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nl
pt
fuel return hose (blue marking) ⇒ Item 29 (page 54) off tandem
du
an
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pump.
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– Seal fuel return union on tandem pump with a plug. Secure
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sealing plug with a spring-type clip.
, is n
h re
hole
Prepare test unit - V.A.G 1687- as follows:

spec
es, in part or in w
– Unscrew pressure regulating valve -2- and close valves -3- t to the co
and -4-.
– Connect test connection -5- to fuel supply union of tandem
rrectness of i
pump using a commercially available compressed air connec‐

tion and a section of fuel hose. Use a spring-type clip to secure.
l purpos
nf
ercia
Note
orm
m
atio
m
To turn the pressure regulating valve -2- the knob must be pulled
o
n in
c
upwards.
or
thi
te
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t.
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t. rig
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– Connect compressed air hose -1- (compressedhoairris source) to nte
eo
charge air system tester - V.A.G 1687- . s aut ra
c
s
ce
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nl
pt
du
an
Note
itte
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If there is water in the sight glass, drain at water drain screw -6-.
wit
, is n
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– Open valve -3-.
spec
– Adjust pressure to 1.0 bar with pressure regulating valve -2-. es, in part or in w
t to the co
Caution
rrectness of i
The maximum test pressure is 1.3 bar and this must not be
l purpos
exceeded.
nf
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– Open valve -4- and wait until the test circuit is filled. If neces‐
m
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m
sary readjust pressure to 1.0 bar.

o
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– Close valve -3- to retain pressure and observe the pressure
thi
te
sd
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drop over a period of 1 minute.
satelettronica
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If the pressure does not drop the tandem pump can be reused, if
f
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the pressure drops the tandem pump must be renewed.
Co
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1.12 Removing and installing tandem pump
cop Vo
by lksw
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Prote AG.


equipment required
1331- (5...50 Nm)
♦ Hand vacuum pump with
accessories - V.A.G 1390-
♦ Water drainage container -
1390/1-
VAS 5024A-
satelettronica
AG. Volkswagen AG d
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pt
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Removing
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ility
– Pull supply hose -1- (white marking) and return hose -2- (blue
ot p
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marking) off fuel filter.

, is n
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hole
– Connect hand vacuum pump with accessories - V.A.G 1390-

spec
and bleeder container - 1390/1- to return hose.

es, in part or in w
t to the co
– Operate hand vacuum pump with accessories - V.A.G 1390-

until no more fuel comes out of return hose. Be careful that no
fuel is sucked into hand vacuum pump with accessories -
rrectness of i
V.A.G 1390- .
l purpos
nf
ercia
orm
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Prote AG.

– Pull vacuum line -1- from brake servo off tandem pump -4-.
– Pull supply hose -2- (white marking) off tandem pump -4-.
– Remove securing bolts -arrows-.
– Remove tandem pump -4- from cylinder head.
– Pull tandem pump -4- slightly upwards, pull off return hose
-3- (blue marking) and remove tandem pump -4-.
Installing
note the following:
Note
satelettronica
♦ Ensure that tandem pump coupling seats properly in cam‐
shaft.
♦ Always replace tandem pump seals.
– Connect return hose -3- (blue marking) to return connection of

tandem pump.
– Install tandem pump and tighten upper securing bolts to
20 Nm.
– Tighten lower securing bolts to 10 Nm.
– Connect supply hose -2- (white marking) to supply connection AG. Volkswagen AG d
and vacuum line -1- from brake servo to tandem pump agen
w-4-. oes
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– Attach supply hose -1- (white marking) to fuel
tho filter.
r eo
s au ra
c
– Connect hand vacuum pump with accessoriess - V.A.G 1390-
ce
e
and bleeder container - 1390/1- to return hose -2- (blue mark‐

nl
pt
du
an
ing) of fuel filter.

itte
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– Operate hand vacuum pump with accessories - V.A.G 1390-

ility
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until fuel comes out of return hose. Be careful that no fuel is

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sucked into hand vacuum pump with accessories - V.A.G

h re
1390- .
hole
spec
es, in part or in w
– Connect return hose -2- (blue marking) to fuel filter.

t to the co
rrectness of i
l purpos
nf
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atio
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Cop py
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rig ht
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132
Prote AG.
Rep. gr.20 - Fuel supply system
21 – Turbocharging/supercharging
age G do n AG. Volkswagen A
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1 Charge air system with turbocharger
th or
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Note
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♦ All hose connections are secured.
wit
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♦ Charge air system must be free of leaks.
hole
spec
es, in part or in w
♦ Renew self-locking nuts.
t to the co
♦ Before screwing on oil supply line, fill turbocharger at connec‐
tion with engine oil.
rrectness of i
♦ After installing turbocharger, run engine for about 1 minute at
idling speed to ensure that oil is supplied to turbocharger.
l purpos
⇒ “1.1 Safety precautions”, page 133
nform
ercia

m
at
satelettronica
om
ion
⇒ “1.3 Installing hose connections with connector couplings”,
c
in t
or
page 134
his
ate
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⇒ “1.4 Hose connections with spring band ring”, page 135

p
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for
en
ng
⇒ “1.5 Assembly overview - turbocharger”, page 135

t.
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⇒ “1.6 Removing and installing turbocharger, engine codes BMS,
rig
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BWB”, page 140 op Vo
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⇒ “1.7 Assembly overview - parts of charge air cooling”,
AG.
page 142
⇒ “1.8 Checking charge air system for leaks”, page 144
1.1 Safety precautions
WARNING

tions:
sitions.
hot components.
Note the following if testers and measuring instruments have to

be used during a road test:
♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person from this location.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
1. Charge air system with turbocharger 133


When working on the turbocharger, pay careful attention to the
following rules for cleanliness:
connecting.
lint-free cloths.
tool boxes etc.).
♦ Existing transport and protective packaging and sealing caps
must only be removed immediately prior to installation.
♦ When making repairs, remove oil from connection and hose
ends.
satelettronica
can be avoided. Do not move vehicle unless
n AGabsolutely
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AG do
essary. wage es n
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1.3 Installing hose connections with con‐ tho
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nector couplings ss au ra
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Caution y li
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The seal in the plug-in connector can be damaged if the se‐
ot
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curing clip is in the locked position when fitting the connector.

h re
This can cause leakage. Observe installation instructions.

hole
spec
es, in part or in w
t to the co
Removing
– Release plug-in connector by pulling out retaining clip
rrectness of i
-arrow-. Separate hose/pipe without tools.

l purpos
Installing
– If renewed, place seal in groove of charge air hose. Ensure
nform
ercia
the seal is correctly seated in the groove.

m
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– Lubricate sealing surface and seal with oil.

ion in
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– Bring retaining clip to release position -1-.

thi
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– Push charge air hose into coupling to stop.

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134 Rep. gr.21 - Turbocharging/supercharging

– Bring securing clip to locking position -2- and then push charge
air hose again.
– Check if connector coupling seats correctly and is properly
engaged by pulling hose.
1.4 Hose connections with spring band ring
satelettronica
Note
There is a danger of a “hose detaching” whilst driving after re‐

moving and reinstalling swa
gcharge
en AG. V pressure lines
olkswagen AG
doeswith spring-type
clips. For this reason,
y Volk spring band rings are used
not which can be
gu
opened if a rdefect
ised b item requires the charge pressure ara
nline
tee
has to
be disconnected.
tho In cases of repair, destroy the spring band
o ring
au
using asssuitable tool and renew it with a replacement part from
ra
c ⇒
ETKA (electronic parts catalogue) .
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nl
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ility
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1.5 Assembly overview - turbocharger

h re
hole
spec
es, in part or in w
t to the co
Caution
When a mechanical fault is found on the turbocharger, e.g. a

rrectness of i
destroyed compressor impeller, it is not only sufficient to renew

the turbocharger. To prevent this from causing further damage,
l purpos
perform the following repairs:

♦ Check air filter housing, air filter element and intake hoses
nform
ercia
for soiling.
m
at
♦ Check complete charged air routing and charge air cooler

om
ion
for foreign objects.

c
in t
or
his
te
If foreign objects are found in the charge air system, the charg‐
a
do
riv
ed air routing must be cleaned and the charge air cooler must
p
cum
or
be renewed, if necessary.
f
en
ng
t.
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Cop py
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rig ht
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Prote AG.

⇒ “1.2 Rules for cleanliness”, page 134 AG. Volkswagen AG d

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⇒ “1.1 Safety precautions”, page 133 d by ara
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⇒ “1.5.1 Engine code AMF”, page 136 aut ra
c
ss
⇒ “1.5.2 Engine codes BAY, BNM, BNV”, page 138
ce
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pt
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⇒ “1.5.3 Engine codes BMS, BWB”, page 139
y li
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1 - Exhaust manifold
es, in part or in w
t to the co
2 - 30 Nm
❑ Renew.
rrectness of i
❑ Coat threads and bolt
head seating surface
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with high-temperature
paste - G 052 112 A3- .
nform
ercia
3 - Intake manifold
m
at
4 - From charge air cooler
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satelettronica
n
c
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5 - Gasket
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❑ Renew.
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❑ Coating (beading) to‐

f
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wards intake manifold

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6 - 25 Nm
rig
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7 - Gasket
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Prote AG.
❑ Note installation posi‐
tion.
8 - Bracket
❑ For heat shield
9 - Washer
10 - Heat shield
❑ Engage in bracket
11 - 10 Nm
12 - Circlip
13 - Vacuum unit
❑ For charge pressure
control valve
❑ Integral part of turbocharger and cannot be replaced.
14 - Operating rod
15 - 10 Nm
❑ Insert with locking fluid - D 000 600 A2- .
16 - Bracket
17 - From air filter.
18 - Banjo bolt, 15 Nm
19 - Seal
❑ Renew.

20 - Hose
❑ To charge pressure control solenoid valve - N75- .
21 - Oil return line, 30 Nm
❑ To cylinder block.
22 - 15 Nm
23 - Gasket
❑ Renew.
24 - Front exhaust pipe
25 - 25 Nm
❑ Renew.
26 - Turbocharger
❑ To remove, remove connecting pipe between air mass meter and turbocharger, connecting pipe between
charge air cooler and intake manifold and right drive shaft cover.
27 - Connection
28 - Oil supply line
❑ From oil filter bracket ⇒ Item 6 (page 91) .
satelettronica
❑ Before installing oil supply line, ensure that it is not blocked.
❑ Before installing, fill turbocharger with engine oil through oil supply line connection.
29 - Bracket
AG. Volkswagen AG d
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1.5.2 Engine codes BAY, BNM, BNV
❑ With exhaust turbo‐
charger
❑ Only renew complete
❑ To remove, remove
connecting pipe be‐
tween air mass meter
and turbocharger, con‐
necting pipe between
charge air cooler and in‐
take manifold, intake
connecting pipe with ex‐
haust gas recirculation
valve, intake manifold
flap motor and right
drive shaft cover.
2 - Intake manifold
AG. Volkswagen AG d
3 - From charge air cooler agen oes
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4 - Gasket rised ara
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❑ Renew. aut
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❑ Coating (beading) to‐
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wards intake manifold

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5 - 25 Nm
erm
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6 - Gasket
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spec
es, in part or in w

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8 - Bracket
❑ For heat shield
rrectness of i
9 - Washer
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10 - 25 Nm
nf
ercia
11 - Heat shield
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❑ Engage in bracket ⇒ Item 8 (page 136)

om
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13 - Seal
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❑ Renew.
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14 - Hose C py
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❑ To charge pressure control solenoid valve - N75- . p by
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15 - Oil return line, 30 Nm Prote AG.
❑ To cylinder block.
16 - 15 Nm
17 - Gasket
❑ Renew.
19 - 25 Nm
❑ Renew.

20 - Connection
❑ Coat threads and bolt head seating surface with high-temperature paste - G 052 112 A3- .
21 - Oil supply line
❑ From oil filter bracket ⇒ Item 6 (page 91) .
❑ Before installing oil supply line, ensure that it is not blocked.
❑ Before installing, fill turbocharger with engine oil through oil supply line connection.
1.5.3 Engine codes BMS, BWB
1 - 9 Nm
2 - Heat shield agen
AG. Volkswagen AG d
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3 - Vacuum hose d by V gu
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4 - Oil supply line autho eo
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❑ From oil filter bracket s
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⇒ Item 6 (page 91) .

un
pt
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❑ Before installing oil sup‐
y li
satelettronica
rm
ab
ply line, ensure that it is
pe
ility
not blocked.
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wit
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❑ Before installing, fill tur‐
h re
hole
bocharger with engine
spec
oil through oil supply line
es, in part or in w
t to the co
connection.
5 - Union nut, 22 Nm
rrectness of i
6 - Union, 30 Nm
l purpos
❑ Renew.
❑ Coat threads and bolt
head seating surface nform
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m
paste - G 052 112 A3- .

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7 - Seal
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❑ Renew.
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8 - Turbocharger
fo
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❑ Can only be renewed
Co
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❑ Removing and installing cop Vo
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⇒ page 140 .
cted agen
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9 - Gasket
❑ Renew.
tion.
10 - To particulate filter
11 - Clamp, 7 Nm
❑ For turbocharger/particulate filter
❑ Can only be renewed together with turbocharger
13 - 25 Nm
❑ Renew.

14 - 25 Nm
15 - Gasket
❑ Renew. n AG. Volkswagen AG do
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16 - Connecting pipeed by V ua
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❑ For exhaust uth gas recirculation.
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❑ Assembly ss overview - exhaust gas recirculation cooler ⇒ page 176 .
ce
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17 - 25 Nm
an
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❑ Renew.
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18 - 15 Nm
wit
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19 - O-ring
ole,
spec
❑ Renew.
t to the co
❑ Renew.
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21 - Support
❑ For turbocharger
ss o
❑ With oil return line
cial p
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f inform
22 - Exhaust gas temperature sender 1 - G235- , 45 Nm
mer
atio
❑ Coat threads with high-temperature paste - G 052 112 A3-
om
n
c
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23 - Heat shield
thi
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sd
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24 - Connection
i
o
pr
cum
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❑ For intake hose for air filter/turbocharger

en
ng
t.
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❑ Assembly overview - air filter ⇒ page 152 . t. Cop py
rig
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25 - 9 Nm p by
co Vo
by lksw
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26 - 9 Nm Prote AG.
1.6 Removing and installing turbocharger,

engine codes BMS, BWB

Caution

for soiling.
ed air routing must be cleaned and the charge air coolerwamust
gen AG
. Volkswagen AG
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Removing ss
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– Remove intake hose ⇒ Item 15 (page 152) .
rm
ab
pe
ility
satelettronica
– Remove connecting pipe ⇒ Item 12 (page 144) from cylinder
ot
wit
, is n
block and disconnect connecting hose ⇒ Item 5 (page 144)
h re
hole
from turbocharger and intake manifold.
spec
es, in part or in w
t to the co
or; Rep. gr. 50 .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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s
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fo
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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.

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gen AG does
swa
Polo Classic 2007 ➤ yV
olk not
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b ara
3-Zyl. Dieselmotor - Edition 05.2014 ris ed
nte
ho eo
aut ra
– Remove securing bolts -1- and remove cover
ss -2- from cylinder c
ce
e
nl
pt
du
an
itte
– Unscrew right drive shaft from gearbox ⇒ Running gear, axles,
y li
erm
ab
steering; Rep. gr. 40 .
ility
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wit
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h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
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not stressed.
nform
ercia

ter ⇒ page 169 .
m
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om
ion
– Remove turbocharger support ⇒ Item 21 (page 140) .
c
in t
or
his
te
– Pull vacuum hose ⇒ Item 3 (page 139) off turbocharger.

a
do
priv
cum
or
– Unbolt oil supply pipe ⇒ Item 4 (page 139) from turbocharger.

f
satelettronica
en
ng
t.
yi Co
– Remove connecting pipe to exhaust gas recirculation cooler . Cop py
⇒ Item 4 (page 176) .
ht rig
rig ht
py by
co Vo
– Unscrew securing bolts for exhaust manifold
by lksw
cted agen
Prote
⇒ Item 13 (page 139) .
AG.
– Tilt the engine forwards in lower mounting and remove turbo‐

charger with exhaust manifold downwards.
Installing
note the following:
– Renew seal ⇒ Item 7 (page 139) , gaskets
⇒ Item 9 (page 139) and ⇒ Item 15 (page 140) , and O-rings
⇒ Item 19 (page 140) .
Note
Specified torque for pendulum support ⇒ page 11 .
1.7 Assembly overview - parts of charge air

cooling
Caution

for soiling.
ed air routing must be cleaned and the charge air cooler must
be renewed, if necessary.

AG. Volkswagen AG d
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Note ss a c
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un
pt
♦ Charge air system must be free of leaks.
an
d
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ab
♦ Checking charge air system for leaks ⇒ page 144 .
ility
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♦ All hose connections of charge air system are secured by
wit
is n
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spring-type clips or by connector couplings.
ole,
spec
♦ Observe fitting instructions for connector couplings
t to the co
⇒ page 134 .
♦ Observe instructions for securing charge air lines with spring-
type clips ⇒ page 135 .
rrectne
♦ For assembly use lubricant (water without additive) if neces‐
sary. Do not use lubricants containing oil.
ss o
cial p
f
♦ When making repairs, remove oil from connection and hose
inform
ends.
mer
atio
om
⇒ “1.7.1 Engine codes AMF, BAY, BNM, BNV”, page 143
n
c
i
or
n thi
e

t
sd
a
satelettronica
iv
o
pr
cum
r
1.7.1 Engine codes AMF, BAY, BNM, BNV

fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
1 - Air duct yri
p by
co Vo
by lksw
cted
2 - Charge air cooler
agen
Prote AG.
3 - 8 Nm
4 - O-ring
5 - Intake manifold pressure
sender - G71- with intake
manifold temperature sender -
G72-
6 - Bracket
7 - 5 Nm
8 - Connecting hose
9 - Connecting pipe
10 - From exhaust gas recircu‐
lation valve
12 - From cylinder head cover
13 - Connecting pipe
16 - Bracket
❑ For connecting pipe
❑ Bolted to sump.

1 - Air duct
2 - Charge air cooler
3 - 8 Nm
4 - Bracket
5 - Connecting hose
6 - Connecting pipe
❑ Charge air cooler/intake
manifold
7 - O-ring
8 - To intake manifold with in‐
take manifold flap motor -
V157- . n AG. Volkswagen AG do
swage es n
9 - 3 Nm yV
olk ot g
satelettronica
d b ua
ran
ir se
10 - Charge air pressure send‐ tho tee
or
er - G31- with intake air tem‐ ss
au ac
perature sender - G42-
ce
le
un
pt
an
11 - From turbocharger
d
itte
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rm
ab
pe
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ot
❑ Turbocharger/charge
wit
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air cooler
hole
spec
13 - 8 Nm
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
1.8 Checking charge air system for leaks
r
te o
thi
s
iva
do

r
rp
cum
fo
en
g
♦ Charge air system tester - V.A.G 1687-

n
t.
yi Co
Cop py
♦ Adapter - V.A.G 1687/10-
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove intake hose -1- from air filter.

– Connect adapter - 1687/10- in intake hose -1- and secure with
clip.
Prepare charge air system tester - V.A.G 1687- as follows:
– Turn pressure regulating valve -2- anti-clockwise onto stop.
satelettronica
– Close valves -3- and -4-.
lkswage es n
o ot g
yV
Note ir se
d b ua
ran
o tee
th or
u
To turn thess pressure regulating valve -2- the knob must be pulled
a ac
upwards.
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Connect charge air system tester - V.A.G 1687- to adapter -

es, in part or in w
1687/10- as shown.
t to the co
Note
rrectness of i
l purpos
A holding pressure test is not possible!

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Connect compressed air hose -1- (compressed air source) to

charge air system tester - V.A.G 1687- .
Note
If there is water in the sight glass, drain at water drain screw -6-.
– Open valve -3-.

– Adjust pressure to 0.5 bar with pressure regulating valve -2-.
Caution
The pressure must not exceed 0.5 bar! If the pressure is too
high this can cause damage to the engine.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary readjust pressure to 0.5 bar.
– Check the charge air system for leaks by hearing, touching,
with commercially available leak detector spray or using ultra‐
satelettronica
sonic tester - V.A.G 1842- . gen AG
. Volkswagen AG
d a oes
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Vol gu
d by ara
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Note ris
tho eo
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c
ss
♦ How to use the ultrasonic tester - V.A.G 1842- ⇒ operating
ce
e
nl
pt
instructions
du
an
itte
y li
erm
♦ If leaks occur, when doing any repair work observe notes for
ab
charge air system ⇒ page 142 . ility
ot p
wit
, is n
♦ Before removing the adapter, depressurise the test circuit by

h re
hole
pulling coupling off adapter - 1687/10- .

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

23 – Mixture preparation - injection

1 Repairing diesel direct injection sys‐
tem
The diesel direct injection system control unit is equipped with an
event memory. Read event memory before and after making re‐
pairs or adjustments ⇒ page 162 .
⇒ “1.1 Safety precautions”, page 147
Volkswa
⇒ “1.3 Assembly overview - intake manifold
agen AG. with intake
gen AG
doemanifold
ksw s no
flap”, page 148 by Vol t gu
a d ran
se
⇒ “1.4 Assembly overview
tho
ri - air filter”, page 152 tee
or
au ac
⇒ “1.5 Assembly soverview
s
- unit injector”, page 152
ce
e
nl
pt
du
⇒ “1.6 Removing and installing unit injector”, page 154
an
itte
y li
erm
ab
⇒ “1.7 Adjusting non-contact gap of unit injectors”, page 156
satelettronica
ility
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⇒ “1.8 Removing and installing O-rings for unit injector”,
wit
, is n
h re
page 156
hole
spec
1.1 Safety precautions
es, in part or in w
t to the co
WARNING
rrectness of i
l purpos

tions:
nf
ercia
orm

m
atio
m

o
n in
c
sitions.
or
thi
te
sd
a

iv
o
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rp
cu
hot components.
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
Note the following if testers and measuring instruments have to
gh ht
pyri by
be used during a road test:
co Vo
by lksw
cted agen
Prote AG.
♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person from this location.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
To prevent injuries to persons and/or destruction of the injection
and glow plug system, the following must be noted:
♦ The ignition must be switched off before connecting or dis‐
connecting injection or glow plug system wiring or tester ca‐
bles.
♦ If the engine is to be turned at starter speed, without starting,
e.g. when checking compressions, disconnect unit injector
connector on cylinder head.
♦ Before disconnecting battery, obtain radio code for radios with
anti-theft coding.
1. Repairing diesel direct injection system 147

♦ Disconnecting and connecting the battery must only be done

with the ignition switched off, as otherwise the control unit for
diesel direction injection system could become damaged.

When working on fuel supply and injection system, pay careful
attention to the following rules for cleanliness:
connecting.
lint-free cloths.
tool boxes etc.).
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
satelettronica
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
1.3 Assembly overview - intake manifold

with intake manifold flap
. Volkswagen AG
a gen AG d
The intake manifold flap is closedVol for approx. 3 seconds when
ksw
oes
not
gu
stopping engine and then opens
ed b again. This reduces the stop jolt.
y ara
n is tee
or
⇒ “1.3.1 Engine code AMF”,
au
th page 148 or
ac
ss
⇒ “1.3.2 Engine codes BAY, BNM, BNV”, page 150
ce
e
nl
pt
du
an

itte
y li
erm
ab

ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
148 Rep. gr.23 - Mixture preparation - injection

1 - Intake manifold
2 - O-ring
❑ Renew.
3 - Exhaust gas recirculation
valve
4 - Intake connecting pipe
❑ With exhaust gas recir‐
culation valve and in‐
take manifold flap.
5 - 10 Nm
7 - Gasket
❑ Renew.
8 - Connecting pipe
❑ To exhaust manifold
9 - 25 Nm
satelettronica
10 - 10 Nm
11 - Bracket
12 - Vacuum actuator
13 - Variable intake manifold
flap changeover valve
14 - Vacuum supply
❑ From vacuum pump
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.

1.3.2 Engine codes BAY, BNM, BNV
1 - Intake manifold
culation valve
3 - O-ring
❑ Renew.
4 - 10 Nm
6 - Intake manifold flap motor -
V157-
7 - 10 Nm
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1 - Gasket
❑ Renew. AG. Volkswagen AG d
agen oes
ksw
❑ Note installation posi‐ by
Vol not
gu
ara
tion. rised
nte
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ut
2 - Intake manifold ss a ra
c
ce
le
3 - Gasket
un
pt
an
d
itte
❑ Renew.
y li
rm
ab
pe
ility
ot
wit
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❑ To remove, remove cyl‐
h re
inder head cover. hole
spec
es, in part or in w
t to the co
V157-
6 - Bracket
rrectness of i
l purpos
satelettronica
8 - 10 Nm
nform
ercia
valve - N18- with exhaust gas

m
recirculation potentiometer -
a
com
ti
G212-
on in
r
te o
thi
10 - Gasket
s
iva
do
❑ Renew.
r
rp
cum
fo
en
g
n
t.
yi Co
op py
❑ To exhaust gas recircu‐ t. C rig
gh ht
lation cooler. yri
p by
o Vo
by c lksw
cted
12 - 22 Nm
agen
Prote AG.
13 - 22 Nm

1.4 Assembly overview - air filter

AG. Volkswagen AG d
agen oes
olksw not
V gu
1 - Air mass meter - G70- d by ara
ise nte
or eo
h
2 - 6 Nm s aut ra
c
s
3 - O-ring
ce
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nl
pt
du
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❑ Renew.
itte
y li
erm
ab
4 - Vacuum hose
ility
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wit
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5 - 8 Nm
h re
hole
spec
6 - Air filter upper part
es, in part or in w
t to the co
7 - Filter element
8 - Air filter lower part
rrectness of i
9 - 10 Nm
l purpos
10 - Rubber bush
11 - 1.6 Nm
nf
ercia
or
satelettronica
12 - Rubber bush
m
m
atio
m
13 - Intake hose
o
n in
or c
thi
❑ To lock carrier.
te
sd
iva
o
r
14 - Rubber bush
rp
cu
o
m
f
en
ng
15 - Intake hose
t.
yi Co
Cop py
❑ To turbocharger.
t. rig
gh ht
pyri by
Vo
o
16 - Spring-type clip by c lksw
cted agen
Prote AG.
17 - Crankcase breather
1.5 Assembly overview - unit injector

♦ Observe rules for cleanliness ⇒ page 148 .
♦ Always renew seals and O-rings

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut Polo Classic
2007 ➤
ra
c
s
s 3-Zyl. Dieselmotor - Edition 05.2014
ce
le
un
pt
an
d
itte
1 - 20 Nm + 90° further
y li
erm
ab
❑ Renew.
ility
ot p
wit
is n
2 - Rocker arm shaft
h re
ole,
❑ With rocker arms
spec
t to the co
⇒ page 154 , removing
and installing unit injec‐
tor
rrectne
3 - Lock nut
s
4 - Adjuster screw
s o
cial p
f
❑ Renew.
inform
mer
5 - Ball stud
atio
m
❑ Renew.
o
n
c
i
or
n thi
e
6 - Unit injector
t
sd
iva
o
r

p
cum
r
fo
⇒ page 154 .
en
ng
t.
yi Co
op
7 - O-ring
C py
t. rig
satelettronica
gh ht
yri
❑ Renew. ⇒ page 156 . p by
o Vo
by c lksw
cted agen
8 - O-ring Prote AG.

9 - O-ring
10 - Heat shield seal
❑ Renew.
11 - Circlip
12 - Cylinder head
13 - Tensioning block
14 - 12 Nm + 3/4 turn (270°)
further
❑ Renew.

AG. Volkswagen AG d
agen oes
ksw
Polo Classic 2007 ➤ by
Vol not
gu
d ara
3-Zyl. Dieselmotor - Edition 05.2014 orise nte
h eo
aut ra
s c
1.6 Removing and installing unit injector s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
equipment required
ot
wit
, is n
h re
♦ Universal dial gauge brack‐
hole
et - VW 387-
spec
es, in part or in w
♦ Socket XZN 10 - 3410-
t to the co
♦ Special wrench, long reach
XZN 6 - T10054-
rrectness of i
♦ Puller - T10055-
l purpos
1331- (5...50 Nm)
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
satelettronica
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
– Remove the upper toothed belt guard and the cylinder head
cover.
– Turn crankshaft until the cam pair point evenly upwards for the
unit injector which is to be removed.
– Loosen lock nuts of adjustment screws -1- and remove ad‐
justment screws.
– Remove rocker arm securing bolts -2- (from outwards to in‐
wards) with socket XZN 10 - 3410- and remove rocker arm
shaft.
– Remove tensioning block securing bolt -3- with special
wrench, long reach - T10054- and remove the block.
– Lever connector off unit injector using a screwdriver. Support
opposite side of connector with light finger pressure to prevent
canting.
Observe unit injector cylinder allocation.

– Insert puller - T10055- in place of clamping block in slot on side

of unit injector.
– Pull unit injector out of cylinder head seat by gently tapping
upwards.
Installing
Note
♦ Each time work is performed which requires adjustment of the

unit injector, the adjustment screw in the rocker arm and also
the unit injector ball stud must be renewed.
♦ New unit injectors are supplied with O-rings and heat shield
seal.
– Heat insulating seal and O-rings must be renewed if old unit

injector is reused ⇒ page 156 .
– Check that the three O-rings and the heat shield seal along
with securing clip are seated correctly before installing unit in‐
jector.
satelettronica
Note
The seals must not be twisted.

AG. Volkswagen AG d
agen oes
lksw not
– Oil the seals and fit the unit injector into the bseaty V in cylinder
o gu
ara
head with great care. orised
nte
h eo
ut
– Push the unit injector evenly into thescylinder
s a head onto its limit ra
c
stop.
ce
e
nl
pt
du
an
– Insert tensioning block in slot on side of unit injector.
itte
y li
erm
ab
ility
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wit
Note
, is n
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spec
If the unit injector is not at right angles to the tensioning block the
es, in part or in w
securing bolt may loosen and this can damage the unit injector or t to the co
the cylinder head.
– Therefore align the unit injector as follows.

rrectness of i
– Screw new securing bolt into clamping block, but do not tighten
l purpos
(it must still be possible to turn the unit injector slightly).

nform
– Now align unit injector at right angles to camshaft mounting

ercia
brackets.
m
at
om
ion
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or
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ate
do
priv
cum
for
en
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Check dimension “a” from outer edge of cylinder head to roun‐

ded edge of unit injector with a vernier gauge (measuring
range at least 400 mm).
Cylinder Dimension “a”
1 245.0 ± 0.8 mm
2 157.0 ± 0.8 mm
3 65.6 ± 0.8 mm
– If necessary, adjust the unit injector and tighten the securing
bolt as follows:
– Tighten securing bolt to 12 Nm and turn 270° (3/4 turn) further
(turning further can be done in several stages).
– Fit rocker arm shaft and tighten new securing bolts as follows.
– First tighten the inner and then both outer bolts hand-tight
evenly. Then using same sequence, tighten to 20 Nm and 90°
(1/4 turn) further evenly.
– Adjust non-contact gap of unit injectors ⇒ page 156 .
satelettronica
1.7 Adjusting non-contact gap of unit injec‐
tors
– Fit dial gauge onto adjustment screw of unit injector as shown.
– Turn crankshaft in direction of engine rotation until roller of
rocker arm is located at tip of drive cam. Roller side
-arrow A- positioned at highest point, dial gauge -arrow nAB-
G. Volkswagen AG d
positioned at lowest point. wage oes
olks not
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db ara
– Remove dial gauge. rise nte
tho eo
– Now turn the adjuster screw into rocker arm until significant au ra
c
ss
resistance can be felt (unit injector is at limit stop).
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Turn adjustment screw 180° back off stop.

hole
spec
– Hold adjuster screw in this position and tighten lock nut to 30

es, in part or in w
t to the co
Nm.
– Connect unit injector connector.
rrectness of i
– Install cylinder head cover ⇒ Item 13 (page 53) .

l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
1.8 Removing and installing O-rings for unit

sd
iva
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cu
injector
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op
Special tools and workshop equipment required C py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

♦ Assembly sleeves - T10056-
Removing
– Remove unit injector ⇒ page 154 .
– Lever old O-rings very carefully out of unit injector.
– Above all ensure that burrs are not caused on O-ring seating.
Installing
satelettronica
Note
♦ Always use the assembly sleeves to fit the O-rings. There is a

danger of damaging the O-rings if the sleeves are not used.
♦ Gradual introduction of O-rings without different coloured
markings. Note the correct allocation of O-rings to grooves:
the thickness of the rings reduces towards injector nozzle.
G. Volkswagen nA AG do
wage es n
♦ Prevent O-rings from rolling when sliding
yV
olks them on. The O-rings ot g
ua
must not be twisted in their seats
ris
ed in unit injector.
b ran
tee
tho or
au ac
– Pull heat shield seal off together
ss with securing clip.
ce
e
nl
pt
– Clean seating surfaces for O-rings on unit injector very care‐

du
an
itte
fully.
y li
erm
ab
ility
– Fit assembly sleeves - T10056/1- onto unit injector to stop.

ot p
wit
, is n
– Push the upper, thicker O-ring carefully onto assembly sleeve

h re
hole
and into seat on unit injector.

spec
es, in part or in w
– Remove assembly sleeve.

t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.


– Slide the middle, thinner O-ring carefully onto assembly sleeve
and into seat on unit injector.

– Push the lower O-ring carefully onto theolkassembly sleeve and
. V swagen AG
into the seat of the unit injector.
swa
gen AG does
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Vol gu
se
db
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nte
ri
ho eo
– Fit new heat shield
au seal together with securing clip.
t ra
c
ss
– Install unit injector ⇒ page 154 .
ce
le
un
pt
satelettronica
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
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cum
fo
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t.
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Cop py
t. rig
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by c lksw
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Prote AG.

2 Engine control unit

⇒ “2.1 Removing and installing engine control unit ”, page 159
⇒ “2.2 Removing and installing anti-theft engine control unit , en‐
gine codes AMF, BAY, BNM, BNV”, page 159
⇒ “2.3 Removing and installing anti-theft engine control unit , en‐
gine codes BMS, BWB”, page 161 n AG. Volkswagen A ge G do
swa es
⇒ “2.4 Reading and clearing engineby
Vocontrol
lk unit event memory”,not gua
page 162 . ris
ed ran
te
tho eo
⇒ “2.5 Adapting functions
ss
aand
u
components”, page 163 . ra
c
ce
e
2.1 Removing and installing engine control

nl
pt
du
an
itte
unit
y li
erm
ab
ility
ot p
If you wish to renew the engine control unit, connect the ⇒ Vehicle
wit
, is n
diagnostic tester and carry out the guided function “Renew control
h re
unit”.
hole
spec
es, in part or in w
t to the co
satelettronica
Removing
rrectness of i
– Release connectors on engine control unit and pull off con‐
l purpos
nector.
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.
– Press clips -arrows A- outwards and pull engine control unit
out to side -B-.
Installing
– Insert new engine control unit and press to the left.
– Fit connectors and lock in position.
– If engine control unit is renewed, clear learnt values and adapt
engine control unit ⇒ Vehicle diagnostic tester “Guided func‐
tions”.
– Read event memory, rectify any faults and then clear event
memory: ⇒ Vehicle diagnostic tester “Guided Fault Finding”.
– The readiness code must be generated if the event memory
has been cleared.
– Carry out a road test.
– Read control unit event memory again.
2.2 Removing and installing anti-theft en‐

gine control unit , engine codes AMF,
BAY, BNM, BNV
2. Engine control unit 159

♦ Hot air blower from wiring harness repair set - VAS 1978-
♦ Nozzle attachment from wiring harness repair set - VAS 1978-

unit”.
Removing
– Remove windscreen wiper arms and cover for plenum cham‐
ber ⇒ Electrical system; Rep. gr. 92 ; Removing and installing
satelettronica
windscreen wipe system .
Note
The shear-head bolt threads are coated with locking compound.

Heating the shear-head bolt with a hot air blower releases the
locking effect of the locking compound. gen AG
. Volkswagen AG
d a oes
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b ara
ed nte
ris
Caution tho eo
au ra
c
ss
Cover brake hose and cable to brake fluid container in order to
ce
e
nl
pt
du
avoid damage.
an
itte
y li
erm
ab
ility
ot p
Perform settings on hot air blower -4- as shown:

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
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o
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t.
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Cop py
t. rig
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pyri by
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co lksw
by
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Prote AG.

– Turn temperature setting potentiometer -2- to maximum heat wagen AG. Volkswagen AG does
output (600°C). olks not
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ed nte
– Set two-stage switch for volume of air -3- to position t3.
ho
ris e or
au ac
ss
ce
le
WARNING
un
pt
an
d
itte
y li
When shear-head bolts are heated up, parts of the protective
rm
ab
pe
housing will be subjected to a large amount of heat. Wear pro‐
ility
ot
tective gloves to avoid possible injury.
wit
, is n
h re
hole
spec
es, in part or in w
– Place nozzle of hot air blower close to shear-head bolt.
t to the co
– Switch on hot air blower and heat bolt for about 20 to 25 sec‐
onds.
rrectness of i
– Unscrew shear-head bolt using mole grips on bolt head.
l purpos
The procedure for the second shear-head bolt is the same.

– Push the clips of the protective housing in the plenum chamber
nform
ercia
together and unhook it from the plenum chamber bulkhead.

m
a
com
ti
– Pull the protective housing off the engine control unit.
satelettronica
on in
r
te o
thi
s
iva
nector.
do
r
rp
cum
fo
Installing
en
ng
t.
yi Co
op
C py
ht. rig
rig ht
py by
– Push the protective housing over the engine control unit. co Vo
by lksw
cted agen
Prote
– Install cover of protective housing using new shear-head bolts.
AG.
– Tighten shear-head bolts evenly until head shears off.

– Hook the protective housing into the plenum chamber bulk‐
head and push the clips into the openings.
– Install windscreen wiper arms and cover for plenum chamber:
⇒ Electrical system; Rep. gr. 92 ; Removing and installing
windscreen wipe system .
tions”.
has been cleared.
2.3 Removing and installing anti-theft en‐

gine control unit , engine codes BMS,
BWB
unit”.

Removing
– Open wiring guide -1- and lift locking device -2-.
– Take engine control unit out of retainer.
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
– Unscrew shear-head bolt -1- using pliers.
hole
spec
es, in part or in w
– Turn engine control unit -2- over and unscrew second shear-
t to the co
head bolt using pliers.
rrectness of i
satelettronica
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
a
– Pull retainer -1- and protective housing -2- off engine control
iv
o
r
rp
cu
unit -3- in -direction of arrow-.
o
m
f
en
ng
t.
yi
Co
op py
nector.
t. C rig
gh ht
pyri by
Vo
o
Installing by c lksw
cted agen
Prote AG.
– Push the protective housing over the engine control unit.
– Install retainer for protective housing using new shear-head
bolts.
– Tighten shear-head bolts evenly until head shears off.
– Insert engine control unit into control unit retainer on plenum

chamber bulkhead until it engages in catches -1-.
– Insert wiring into wiring guide -1- and close guide.
tions”.
has been cleared.
2.4 Reading and clearing engine control unit

event memory


5051B-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
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nl
pt
du
an
itte
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ab
ility
ot p
Procedure
wit
, is n
h re
hole
– Connect Vehicle diagnosis, testing and information system -
spec
VAS 5051B- as follows:
es, in part or in w
t to the co
– Connect diagnosis lead 3m - VAS 5051B/2- or diagnosis lead
5m - VAS 5051B/1- to diagnosis connector.
rrectness of i
satelettronica
l purpos
Only when engine does not start:

– Switch on ignition.
nf
ercia
or
Select operating mode:
m
m
atio
m
– Press button on display for “Vehicle self-diagnosis”.

o
n in
or c
thi
e
Select vehicle system:

t
sd
iva
o
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rp
cu
– Press “01 - Engine electronics” button on display.

o
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ng
t.
yi
The control unit identification and coding are indicated on display.
Co
Cop py
t. rig
Select diagnostic function:
gh ht
pyri by
Vo
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by c lksw
– Press button “02 - Read event memory” on display. cted agen
Prote AG.
– If no fault is stored in engine control unit “0 fault detected” is

displayed.
– If faults are stored in the engine control unit, these are shown
one below the other on the display.
– Press ← button.
– Press button “05 - event memory” on display.
– Select “06-End output” function.
2.5 Adapting functions and components

5051B-

3-Zyl. Dieselmotor - Edition 05.2014AG. Volkswagen
n AG do
wage es n
olks o
Select “Guided fault finding” in vehicle
ed
by
V
diagnosis, testing and in‐ t guara
formation system - VAS 5051B- oris . nte
eo
th
au ra
When all control units have
ss been read: c
ce
e
nl
– Press “GoTo” button.
pt
du
an
itte
y li
– Select “Function/component selection”.
erm
ab
ility
ot p
– “Select power train”.
wit
, is n
h re
– Select “Engine code”.
hole
spec
es, in part or in w
– Select “01 Systems capable of self-diagnosis”.
t to the co
– Select “engine control”.
– Select “Functions”.
rrectness of i
– Select “Function or component”.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
satelettronica
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
horis Polo
nte Classic 2007 ➤
eo
aut 3-Zyl. Dieselmotor - rEdition
ac 05.2014
ss
ce
le
un
pt
an
d
26 – Exhaust system
itte
y li
erm
ab
ility
ot p
wit
is n
1 Exhaust system
h re
ole,
spec
t to the co
Note
♦ After working on the exhaust system, ensure that the system
rrectne
is not under stress and that there is sufficient clearance to the
bodywork. If necessary, loosen repair double clamp and
s
clamping sleeve and align silencer and exhaust pipe so that
s o
sufficient clearance is maintained to the bodywork and the
cial p
f in
support rings are evenly loaded.
form
mer
atio
♦ If the particulate filter or the exhaust gas pressure sensor 1 -
om
G450- is changed, the exhaust gas pressure sensor 1 - G450-
n
c
i
or
n
must always be adapted using diagnosis tester : Guided
thi
te
functions; adapting exhaust pressure sensor 1 - G450- .
sd
iva
o
pr
cum
r
♦ Renew self-locking nuts.

fo
en
ng
t.
yi Co
op
satelettronica
C py
⇒ “1.1 Assembly overview - front exhaust pipe with catalytic con‐ ht. rig
rig ht
verter and silencer”, page 165 py by
co Vo
by lksw
cted agen
⇒ “1.2 Assembly overview - front exhaust pipe with particulate Prote AG.
filter”, page 167

⇒ “1.3 Assembly overview - silencer, vehicles with particulate fil‐
ter”, page 168
⇒ “1.4 Removing and installing front exhaust pipe with particulate
filter”, page 169
⇒ “1.5 Aligning exhaust system free of stress”, page 170
1.1 Assembly overview - front exhaust pipe with catalytic converter and silencer
1. Exhaust system 165

1 - Gasket
❑ Renew.
2 - 25 Nm
❑ Renew.
3 - Retaining ring
4 - Front exhaust pipe with cat‐
alytic converter
5 - Marking
6 - Dimension -a- = approx. olkswage es n
ot g
5 mm d byV ua
ran
ir se tee
7 - Clamp utho
or
a ac
ss
8 - 40 Nm
ce
le
un
pt
an
9 - Mounting
d
itte
y li
rm
ab
❑ With retaining ring.
pe
ility
ot
wit
, is n
satelettronica
h re
10 - 25 Nm
hole
spec
es, in part or in w
11 - Rear silencer
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
fo
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t.
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Cop py
t. rig
gh ht
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co lksw
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Prote AG.
166 Rep. gr.26 - Exhaust system

1.2 Assembly overview - front exhaust pipe with particulate filter
1 - Exhaust gas pressure sen‐

sor 1 - G450-
AG. Volkswagen AG d
2 - Bracket lksw
agen oes
not
Vo gu
y
3 - Nut rise
d b ara
nte
tho eo
4 - Lambda probe - G39- , 50 s au ra
c
Nm s
ce
le
un
pt
❑ Grease only the threads
an
d
itte
y li
rm
ab
paste - G 052 112 A3- ;
pe
ility
high-temperature paste
ot
wit
, is n
- G 052 112 A3- must
h re
not get into the slots of hole
spec
probe body.
es, in part or in w
t to the co
❑ To remove use Lambda
probe open ring span‐
ner set - 3337- .
rrectness of i
5 - Exhaust gas temperature
satelettronica
l purpos
sender 2 for cylinder bank 1 -

G448- , 45 Nm
❑ Lubricate thread of
nform
ercia
sender using high-tem‐

m
perature paste - G 052
a
com
tio
112 A3-
n in
r
te o
thi
6 - Control line, 45 Nm
s
iva
do
r
rp
c
7 - Heat shield
um
fo
en
g
❑ A one-piece heat shield

n
t.
yi Co
op
has been introduced C py
t. rig
gradually.
gh ht
pyri by
Vo
co lksw
by
8 - 9 Nm cted agen
Prote AG.
9 - Clip
10 - Particulate filter
⇒ page 169 .
12 - Marking
❑ For clamp.
❑ Installation position of clamp ⇒ page 168 .
13 - Gasket
❑ Renew.
14 - Clamp, 7 Nm
15 - 25 Nm
16 - Temperature sender after particulate filter - G527- , 45 Nm
❑ Lubricate thread of sender using high-temperature paste - G 052 112 A3-
17 - Bracket
❑ Bolted to cylinder head.
18 - 25 Nm
19 - 8 Nm

Installation position of clamp

– Position clamp at distance -a- = 5 mm from marking on front
exhaust pipe.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
1.3 Assembly overview - silencer, vehicles with particulate filter is n
h re
ole,
spec
t to the co
1 - From particulate filter
2 - Clamp, 40 Nm
rrectne
3 - Retaining ring
satelettronica
ss o
cial p
4 - 25 Nm
f inform
mer
5 - Separating point
atio
m
❑ Marked by impressions
o
n
c
on exhaust pipe.
i
or
n thi
te
❑ As standard, exhaust
sd
iva
o
r
pipe and rear silencer

p
cum
r
fo
are installed as a single
en
ng
t.
yi
component. For repairs,
Co
op py
exhaust pipe and silenc‐ t. C rig
gh ht
er are supplied sepa‐ yri
p by
o Vo
rately with a repair dou‐
c by lksw
cted agen
ble clamp.
Prote AG.
❑ Cut through exhaust

pipe at right angles at
separating point
-arrow A- using e.g.
body saw - V.A.G
1523A- (wear eye pro‐
tection)
❑ During installation, posi‐
tion repair double clamp
at side markings
-arrows B-
❑ Tighten bolts of repair
double clamp evenly,
specified torque: M8 =
25 Nm, M10 = 40 Nm.
❑ Before tightening, align
cold exhaust system
free of tension
⇒ page 170
6 - Silencer
7 - Retaining ring
8 - 25 Nm

1.4 Removing and installing front exhaust

pipe with particulate filter
Removing ⇒ page 169 . AG. Volkswagen A

agen G do
es n
ksw
Installing ⇒ page
by Vol170 . ot g
u
satelettronica
ara
ed nte
ris
1.4.1 au
tho
Removing e or
ac
ss
ce
le
un
pt
an
d

itte
y li
or; Rep. gr. 50 .

rm
ab
pe
ility
ot

wit
, is n
h re

hole
spec

es, in part or in w
t to the co
Note
rrectness of i

l purpos
not stressed.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove securing bolts -1- and remove cover -2- from cylinder
– Unscrew right drive shaft from gearbox ⇒ Running gear, axles,
steering; Rep. gr. 40 .
– Disconnect all connectors for wires leading to particulate filter
and turbocharger (on right suspension strut mounting).
– Unscrew bolt ⇒ Item 19 (page 167) .
– Loosen exhaust gas pressure sensor 1 - G450-
⇒ Item 1 (page 167) from bracket ⇒ Item 2 (page 167) .
– Pull lines out of retainers on engine and on heat shield for
particulate filter; if necessary remove cable ties.
– Unscrew bolts ⇒ Item 8 (page 167) from heat shield for par‐
ticulate filter ⇒ Item 7 (page 167) . n AG. Volkswagen A ge G do
swa es n
– Unscrew bolts ⇒ Item 1 (page 139) and by
Vol
k ot g
ua
⇒ Item 26 (page 140) from heat shield for turbocharger
ris
ed ran
tee
⇒ Item 2 (page 139) . ut
ho or
a ac
ss
Vehicles with one-piece heat shield
ce
le
un
pt
an
– Additionally, remove intake connecting pipe
d
satelettronica
itte
y li
⇒ Item 4 (page 175) .
rm
ab
pe
ility
– Move the two heat shields apart in order to gain access to
ot
wit
, is n
clamp for turbocharger/particulate filter
h re
⇒ Item 14 (page 167) .
hole
spec
es, in part or in w
– Open clamp for turbocharger/particulate filter
t to the co
⇒ Item 14 (page 167) .
– Loosen securing nuts -arrows- of clamp. Then slide clamp off
rrectness of i
front exhaust pipe towards back.
l purpos
Note
nform
mercia
The flexible joint in the front exhaust pipe must not be bent more
a
com
tio
than 10° - otherwise it can be damaged. n in
r
te o
thi
s
iva
– Unscrew bolts ⇒ Item 15 (page 167) .

do
r
rp
cum
fo
– Unhook front exhaust pipe from retaining rings and carefully

en
ng
t.
yi
remove front exhaust pipe with particulate filter.
Co
Cop py
ht. rig
rig ht
py by
1.4.2 Installing
co Vo
by lksw
cted agen
Prote AG.
note the following:
– Renew gasket ⇒ Item 13 (page 167) .
– Align exhaust system free of stress ⇒ page 170 .
1.5 Aligning exhaust system free of stress


AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o e
aut
h
Polo Classic 2007 ➤ or a
s c
s 3-Zyl. Dieselmotor - Edition 05.2014
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Prerequisite
atio
• The exhaust system is cold. om
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Procedure t
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– Loosen threaded connections of foremost clamp.
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– Observe measurement -a- and align clamp on front exhaust Cop py
pipe. Dimension -a- = 5 mm ht. rig
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– Align clamp so that ends of bolts do not protrude beyond lower

edge of clamp -arrow-.
– Tighten threaded connections of foremost clamp lightly.
– Then align exhaust system with mountings under considera‐

tion of dimension -a-. The -arrow- points forwards. Dimension
-a- = 3…7 mm.

– Then evenly tighten securing nuts -arrows- of foremost clamp.

Specified torque: M8 = 25 Nm, M10 = 40 Nm.
– Once clamp has been tightened, check set up dimensions and
correct if necessary.
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2 Exhaust gas recirculation system
Note
Renew self-locking nuts.
⇒ “2.1 Assembly overview - parts of exhaust gas recirculation

system, engine code AMF”, page 173
system, engine codes BAY, BNM, BNV”, page 174
system, engine codes BMS, BWB”, page 175
⇒ “2.4 Assembly overview - exhaust gas recirculation cooler, en‐
gine codes BMS, BWB”, page 176
⇒ “2.5 Removing and installing exhaust gas recirculation cooler,
engine codes BMS, BWB”, page 177
⇒ “2.6 Vacuum hose assembly”, page 178
satelettronica
2.1 Assembly overview - parts of exhaust gas recirculation system, engine code
AMF
1 - Intake manifold
2 - O-ring
❑ Renew.
culation valve and in‐
take manifold flap.
4 - Exhaust gas orecirculation
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❑ Part orisof intake connect‐ tee
h
ut
aing
or
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pipe ac
❑ Can only be renewed to‐
ce
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un
pt
gether with intake con‐

an
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necting pipe
rm
ab
pe
ility
5 - 10 Nm
ot
wit
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hole
spec
7 - Gasket
es, in part or in w
t to the co
❑ Renew.
rrectness of i
l purpos
nform
mercia
a
com
tion in
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te o
thi
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Cop py
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173
agen
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2. Exhaust gas recirculation system
8 - 25 Nm
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2.2 Assembly overview - parts of exhaust gas recirculation system, engine co‐ ise nte
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1 - Intake manifold
erm
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2 - O-ring
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❑ Renew.
h re
hole
spec
es, in part or in w
t to the co
valve
❑ Part of intake connect‐
rrectness of i
ing pipe
l purpos
❑ Can only be renewed to‐
satelettronica
gether with intake con‐
necting pipe
nf
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m
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m
V157-
o
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6 - 10 Nm
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Cop py
9 - Gasket
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❑ Renew.
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10 - Radiator
lation.
11 - 25 Nm
12 - To heat exchanger
13 - 25 Nm
14 - 25 Nm
15 - From cylinder head

2.3 Assembly overview - parts of exhaust gas recirculation system, engine co‐
des BMS, BWB
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1 - Gasket d by
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❑ Renew. hor eo
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tion.
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2 - Intake manifold
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3 - Gasket
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❑ Renew.
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spec
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❑ To remove, remove cyl‐
t to the co
inder head cover.
rrectness of i
V157-
l purpos
6 - Bracket
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nform
ercia
8 - 10 Nm
m
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G212-
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❑ Before installing, check

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sealing surface on in‐ Cop py
take manifold for soiling
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and clean if necessary.
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❑ If the exhaust gas recir‐
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culation valve - N18-
with exhaust gas recir‐
culation potentiometer -
G212- is renewed the
ignition must be switch‐
ed on and off again.
Then wait one minute
for the control unit to run
down (valve learnt, main
relay must click)
❑ Start engine and run at idling speed for at least one minute
❑ Then read engine control unit event memory; event memory must not contain any fault ⇒ page 162 .
❑ If a fault is stored in the event memory, erase event memory and repeat work sequence.
10 - Gasket
❑ Renew.
❑ To exhaust gas recirculation cooler.
❑ Assembly overview - exhaust gas recirculation cooler ⇒ page 176 .
12 - 22 Nm
13 - 22 Nm
2. Exhaust gas recirculation system 175

2.4 Assembly overview - exhaust gas recirculation cooler, engine codes BMS,
BWB
1 - Coolant hose
❑ To connection
diagram, engine code
BMS ⇒ page 101 .
BWB ⇒ page 100 .
2 - Gasket
❑ Renew.
3 - 22 Nm
4 - Connecting pipe
5 - From exhaust manifold
6 - 25 Nm
satelettronica
❑ Renew.
7 - to Exhaust gas recirculation
G212-
cooler
⇒ page 177 .
9 - 10 Nm
ks wage es n
10 - Coolant hose Vol ot g
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❑ From rear coolant pipe orise tee
th or
ss au ac
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nl
BMS ⇒ page 101 .

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BWB ⇒ page 100 .

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2.5 Removing and installing exhaust gas recirculation cooler, engine codes
BMS, BWB

equipment required
♦ Hose clips up to 25 mm Ø -
3094-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1410-
VAS 5024A-
♦ Drip tray for workshop hoist
- VAS 6208-
satelettronica
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Removing nform
ercia

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his
ate
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p
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or
ter ⇒ page 169 .

f
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– Remove support for turbocharger ⇒ Item 21 (page 140) with C py
t. rig
oil return line.
gh ht
pyri by
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– Clamp off coolant hoses ⇒ Item 1 (page 176) and cted agen
Prote AG.
⇒ Item 10 (page 176) with hose clamps, up to Ø 25 mm -
3094- .
– Pull coolant hoses ⇒ Item 1 (page 176) and
⇒ Item 10 (page 176) off exhaust gas recirculation cooler.
– Unbolt connecting pipe ⇒ Item 4 (page 176) .
– Unbolt exhaust gas recirculation cooler ⇒ Item 8 (page 176)
from connection for exhaust gas recirculation valve - N18- with

exhaust gas recirculation potentiometer - G212-

⇒ Item 7 (page 176) .
– Unscrew bolts ⇒ Item 9 (page 176) and remove exhaust gas
recirculation cooler downwards.
Installing
note the following:
– Install exhaust gas recirculation cooler ⇒ Item 8 (page 176)
with new gaskets ⇒ Item 2 (page 176) .
– Fill coolant system with coolant ⇒ page 101 .
– Check engine oil level ⇒ page 87 .
2.6 Vacuum hose assembly

⇒ “2.6.1 Vacuum hose schematic diagram”, page 178
⇒ “2.6.2 Vacuum hose schematic diagram, engine codes BMS,
BWB”, page 178
2.6.1 Vacuum hose schematic diagram
satelettronica
Connector pin assignment on solenoid valve block (not fitted in
all vehicles)
1- Connecting pipe between air filter and turbocharger
2- Vacuum unit on turbocharger
3- Charge air connection on turbocharger
4- Intake manifold flap
5- Air filter
6- Vacuum connection (on non-returnevalve
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7- Exhaust gas recirculation bvalve
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2.6.2 Vacuumss hose schematic diagram, engine codes BMS, BWB au ra
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1 - Air filter
2 - To air filter.
3 - Charge pressure control
solenoid valve - N75-
4 - Vacuum reservoir
5 - To vacuum unit
6 - Non-return valve
7 - Vacuum connection (on
non-return valve for brake ser‐
vo)
8 - Hose connection
9 - To vacuum unit on turbo‐
charger
10 - Vacuum unit on turbo‐ agen
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28 – Glow plug system

1 Checking glow plug system
⇒ “1.1 Removing, installing and checking glow plugs”,
page 180
⇒ “1.2 Characteristics of ceramic glow plugs”, page 181
⇒ “1.3 Removing, installing and checking ceramic glow pin plugs”,
page 181
1.1 Removing, installing and checking glow plugs

equipment required
♦ Jointed wrench 10 mm -
3220-
1331-
satelettronica
♦ Hand-held multimeter -
V.A.G 1526 C- or hand-
held multimeter - V.A.G
1526 A-
♦ Auxiliary measuring set -
V.A.G 1594 C- n AG. Volkswagen AG do
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Test prerequisites t. Cop py
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• Strip fuse for glow plugs in fuse holder on battery OK yri
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• Battery voltage at least 11.5 V
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• Ignition switched off

Test procedure
180 Rep. gr.28 - Glow plug system


– Pull glow plug connectors off glow plugs.
– Connect voltage tester - V.A.G 1527 agen B- cable to battery
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tive (+), using clips from auxiliary not
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V.A.G 1594 C- . ised b ara
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– Place test probe ofs auvoltage
t
tester - V.A.G 1527 B- on each or
ac
glow plug one after the other. Diode lights up: glow plug OK.,
s
ce
e
diode does not light up: renew glow plug.

nl
pt
du
an
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ility
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The glow plug system is monitored by the engine control unit's
wit
, is n
self-diagnosis system.
h re
hole
The necessary checks are performed with Guided fault finding.
spec
es, in part or in w
t to the co
All other vehicles continued
Removing
rrectness of i
– Remove glow plugs using U/J extension and socket - 3220- .
l purpos
Installing
satelettronica
Further assembly is basically the reverse of the dismantling se‐
nform
ercia
quence.
m
at
– Install glow plugs with jointed wrench - 3220- and tighten to 15
om
io
Nm.
n
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ate
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1.2 Characteristics of ceramic glow plugs

p
cum
for
en
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WARNING
C py
t. rig
gh ht
pyri by
Vo
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The ceramic glow plugs ⇒ page 181 are sensitive to jolts and
by c lksw
cted agen
bending. For this reason a glow plug which has dropped from
Prote AG.
even a small height (approx. 2 cm) must not be used, even if

there is no obvious damage. It is absolutely necessary to follow
the installation instructions, otherwise the heater pin of the
glow plug can break and cause engine damage.
Visual features of ceramic glow pin plugs

Vehicles with 2 valves per cylinder head
-A- = Metal glow plug, colour-coded -arrow-.
-B- = Ceramic glow pin plug with support tube -arrow-, not colour-
coded.
Vehicles with 4 valves per cylinder head
-C- = Metal glow plug with colour-code -arrow-.
-D- = Ceramic glow pin plug with support tube -arrow-, not colour-
coded.
Remove, install or check ceramic glow pin plugs ⇒ page 181 .
1.3 Removing, installing and checking ceramic glow pin plugs
1. Checking glow plug system 181


equipment required
♦ Jointed spanner - 3220-
♦ Torque wrench (5 ... 50
Nm) - V.A.G 1331-
♦ Hand-held multimeter - n AG. Volkswagen AG do
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V.A.G 1526 A- byV
o ot g
ua
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ir se
♦ Auxiliary measuring set - utho tee
or
V.A.G 1594 C- ss
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rrectness of i
satelettronica
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nf
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Test prerequisites
• Engine is cold
• Ignition switched off
Procedure
Note
Do not cant ceramic glow plugs when removing and installing.

Remove any components hindering assembly.
– Pull connectors off ceramic glow plugs.

– Remove ceramic glow plugs using U/J extension and socket,
10 mm - 3220- .
note the following:
– Before installing, completely remove any deposits from the
cylinder head hole and thread.
182 Rep. gr.28 - Glow plug system

Note
Do not oil or grease thread of cylinder head bore or of ceramic

glow pin plugs.
– Screw ceramic glow plugs into cylinder head by hand using U/

J extension and socket, 10 mm - 3220- .
– Then tighten the ceramic glow plugs. Specified torque: 15 Nm
WARNING
♦ After installing and before the engine is started, perform a

resistance test on all ceramic glow plugs when engine is
cold.
♦ If the defective ceramic glow plug is broken, remove all
fragments from the engine, otherwise these can cause
damage to the engine.
satelettronica
♦ Specification: max. 1 Ω
– If the specification is exceeded, renew the defective ceramic
glow plug.
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cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
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Cop py
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rig ht
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1. Checking glow plug system 183

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Service

Workshop Manual AG. Volkswagen AG d

Polo Classic 2007 ➤

Service Department. Technical Information

All rights reserved.

Copyright © 2015 Volkswagen AG, Wolfsburg D4B804089DC

1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.3 Renewing crankshaft oil seal - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.4 Removing and installing sealing flange - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

1.6 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

1.8 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

1.9 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

1.3 Installing hose connections with connector couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

1.6 Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

2.6 Vacuum hose assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

1.1 Removing, installing and checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

1.2 Characteristics of ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Engine data ⇒ page 1

Additionally there is a sticker on the toothed belt guard with “en‐

1.2 Engine data

Engine code BMS BWB

Engine code BMS BWB

Firing order 1-2-3 1-2-3

Catalytic converter yes

Diesel particulate filter yes yes

2 Rep. gr.00 - Technical data

10 – Removing and installing engine

1.1 Removing engine

Special tools and workshop

♦ Drip tray - V.A.G 1306- or spec

1. Removing and installing engine 3

♦ Torque wrench - V.A.G

♦ Engine support - T40076- (vehicles with no air conditioner)

♦ Container for removed parts - V.A.G 1698-

4 Rep. gr.10 - Removing and installing engine

Modifying engine bracket - T10012-

Note n AG. Volkswagen AG do

engine is removed downwards without the gearbox.

fluid and vacuum) and electrical wiring in their original po‐

♦ Ensure that there is sufficient clearance to all moving or

– Disconnect battery ⇒ Electrical system; Rep. gr. 27 .

1. Removing and installing engine 5

of repair work on the fuel system!

– Unscrew connecting pipe between charge air cooler and tur‐

– Remove poly V-belt ⇒ page 16 .

– Separate all connecting, coolant, vacuum and intake hoses

– Unscrew cable support bracket securing bolt and locate clutch

– Fit support bracket - 10 - 222 A- as shown and take up weight

6 Rep. gr.10 - Removing and installing engine

– Remove engine carrier -1- and engine console -2-.

Vehicles with engine codes BMS, BWB

– Disconnect selector mechanism from gearbox ⇒ 5-speed

Clutch pedal must not be depressed.