Service: Touran 2003
Service: Touran 2003
Service: Touran 2003
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Touran 2003 ➤
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4-cylinder diesel engine (2.0 l engine, 2-valve, TDI)
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Engine ID BMM
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Edition 06.2008
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Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
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20 - Fuel supply system yV
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21 - Turbocharging/supercharging horis tee
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23 - Mixture preparation - injection
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26 - Exhaust system
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Contents
AG. Volkswagen AG d
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00 - Technical data . . . . . . . . . . . . . . . . .d b.y.V . . . . . . . . . . . . . . . . . . .no.t .gu.a . . . . .
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1 Technical data . . . . . . . . . . . . . th.o.ris. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . te. e.o . .
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1.1 Engine number . . . . . . . . . . s.s a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ac. ....... 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
spec
1.3 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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1.4 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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2 Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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2.1 Assembly overview - sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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2.2 Renewing crankshaft oil seal - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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2.4 Renewing crankshaft sealing flange - flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.3 Pulling needle bearing out of and driving into crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.2 Separating new conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.3 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.4 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.5 Piston rings, cylinder bore and piston installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 39
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.1 Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.2 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Contents i
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1 Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.1 Parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.2 Parts of cooling system - engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.3 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.4 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.5 Removing and installing fan support with fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.6 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.7 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.8 Removing and installing thermostat . . . . . . . . . . . .. V. o.lk.s.w.ag.e. . . . . . . . . . . . . . . . . . . . . . . . 101
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1.9 Checking cooling system for leaks . . . . o.lk.s.w.ag.e. . . . . . . . . . . . . . d. o.e.s n. o. . . . . . . . . . . . . . . . . 102
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1.10 Checking oil cooler for leaks . . . . .e.d b. y. . . . . . . . . . . . . . . . . . . . . . . . . . .ua.ra.n. . . . . . . . . . . . 104
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20 - Fuel supply system . . . . . . . .ss. . . .
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1.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 107
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1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
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1.7 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.8 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
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1.9 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.10 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
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21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
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1.3 Installing hose connections with connector couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . t. Cop py
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1.4 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
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1.5 Assembly overview - charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.6 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
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ii Contents
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
2.1 Reading and clearing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
2.2 Adapting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
2.3 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
2.4 Removing and installing anti-theft engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
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Contents iii
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
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iv Contents
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
00 – Technical data
1 Technical data
Engine number ⇒ page 1
Engine data ⇒ page 1 .
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Bore ∅ mm 81.0
Stroke mm 95.5
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10 – Removing and installing engine
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Assembly mountings ⇒ page 11 .
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♦ Engine support -T10012-
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Procedure
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– Read all fault memories before removal ⇒lksDiagnostic
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One-piece engine cover
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– Remove bolt -arrow- and pull air filter housing upwards out of
mounting.
– Remove air filter housing together with air mass meter and
connecting pipe.
– Remove battery and battery tray.
– Remove plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. Gr. 50 ; Body front; Plenum chamber bulkhead.
– Pull off fuel supply hose -2-, fuel return hose -1- and coolant
hose -3-.
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♦ The fuel system isss also under pressure! Before opening
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♦ Wear eye and hand protection when performing any type
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– Remove sound insulation tray ⇒ General body repairs, exte‐
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– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. Gr. 50 ; Body front; Lock carrier - service posi‐
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– Remove poly V-belt ⇒ page 14 .
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– Separate theoris following connectors (on bulkhead): ante
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♦ au 1 for temperature sender before particulate filter
Connector
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♦ Connector 2 for exhaust gas temperature sender 1 -G235- .
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♦ Connector 3 for lambda probe -G39-
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– Pull off or disconnect all other electrical connections as nec‐
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– Pull connector off oil level and oil temperature sender -G266- .
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– Pull retainer for oil level and oil temperature sender -G266- off
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subframe.
– Unbolt left and right drive shafts from gearbox ⇒ Running
gear, axles, steering; Rep. Gr. 40 ; Removing and installing
drive shafts .
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To remove securing bolts, use stepladder -VAS 5085- .
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– Unbolt assembly mounting on gearbox side from gearbox
bracket -arrows-.
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To remove securing bolts, use stepladder -VAS 5085- .
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WARNING
The hooks and locating pins must be secured with locking pins.
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gearbox support -VAS 6095- .
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– Ensure that the edges of the support arm on the gearbox as‐
sembly mounting -2- and gearbox support -1- are parallel.
Dimension -x- must be identical at top and bottom.
Note
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Vehicles with manual gearbox.
– Fit selector mechanism to gearbox ⇒ Direct shift gearbox 02E;
Rep. Gr. 34 ; Selector mechanism .
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– Install air conditioner compressor ⇒ Heating,bair y V conditioning;
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Rep. Gr. 87 ; Removing and installing compressor
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– Install poly V-belt ⇒ page 14 . ss
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Rep. Gr. 50 ; Body front; Assembly overview.
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– Install plenum chamber bulkhead ⇒ General body repairs,
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exterior; Rep. Gr. 50 ; Body front; Plenum chamber bulkhead .
hole
spec
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– Carry out road test and then read fault memory ⇒ page 146 .
Specified torques
rrectness of i
Bolts, nuts M6 10 Nm
nform
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M8 20 Nm
m
M10 45 Nm
a
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tion in
M12 60 Nm
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Specified torques for pendulum support
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13 – Crankshaft group
1 Dismantling and assembling engine
Note
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Assembly overview - toothed belt drive ⇒ page 12
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Assembly overview - crankcase ⇒ page 16
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1.1 Assembly overview - toothed belt drive
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❑ Use counterhold tool -
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T10051- to loosen and
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tighten.
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T10052- .
hole
spec
❑ Removing and installing
es, in part or in w
⇒ page 73 , Removing
t to the co
and installing camshaft.
6 - 10 Nm
rrectness of i
❑ Renew
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7 - Rear toothed belt guard
8 - 25 Nm
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9 - Sealing grommet
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10 - 20 Nm + 1/8 turn (45 °) fur‐
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12 - 20 Nm rig ht
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13 - Idler roller Prote
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14 - Coolant pump
❑ Removing and installing
⇒ page 99 .
15 - Crankshaft toothed belt pulley
16 - 120 Nm + 1/4 turn (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 - Toothed belt guard lower part
19 - Belt pulley and vibration damper
❑ Can only be installed in one position. Holes are offset.
20 - 10 Nm + 1/4 turn (90°) further
21 - Cover
22 - Toothed belt
❑ Mark direction of rotation before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing, installing and tensioning ⇒ page 47 .
satelettronica
conditioner compressor.
5 - Tensioning device for poly
V-belt
❑ Swing with open-jaw
spanner to slacken poly
V-belt.
n AG. Volkswagen AG do
6 - 25 Nm lkswage es n
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7 - Air conditioner compressor. orised ran
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8 - 25 Nm ss
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9 - Dowel sleeves
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10 - Poly V-belt
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❑ Do not kink.
t to the co
f inform
mer
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n
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or
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– Pull fuel filter out of bracket and lay it with hoses to side.
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rection of arrow to remove tension from poly V-belt.
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Belt drive with air conditioner compressor
wit
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spec
urposes, in part or in wh
t to the co
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mer
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1.4 Assembly overview - crankcase
or
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rig ht
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Prote AG.
1 - Cylinder block
❑ Removing and installing
sealing flange and fly‐
wheel ⇒ page 19 .
❑ Removing and installing
crankshaft
⇒ page 33 .
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 36 .
2 - Bracket
❑ For charge air pipe.
3 - 10 Nm
4 - Seal
❑ Renew
5 - Oil filter bracket
❑ Assembly overview
⇒ page 85
satelettronica
6 - 15 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew agen
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❑ First fit upper d by left and
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lower right
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7 - Bracket
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8 - 20 Nm
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9 - Connection
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❑ For thermostat.
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spec
urposes, in part or in wh
10 - 15 Nm
t to the co
11 - O-ring
❑ Renew
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12 - Thermostat
❑ Removing and installing ⇒ page 101 .
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13 - Hexagon bolt
fo
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t.
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❑ Tightening sequence and torque specifications ⇒ Heating, air conditioning; Rep. Gr. 87 ; Removing and
Co
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installing compressor bracket .
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14 - Bracket by c lksw
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❑ For alternator and, if fitted, air conditioner compressor.
15 - Tensioning device for poly V-belt
16 - 25 Nm
17 - Sump
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant -D 176 404 A2- ⇒ page 82 .
18 - 15 Nm
AG. Volkswagen AG d
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satelettronica
t to the co
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mer
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Cop py
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rig ht
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co Vo
by lksw
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Prote AG.
Note
1 - Seal
satelettronica
❑ Do not additionally oil or
grease the oil seal seal‐
ing lip
❑ Before installing, re‐
move oil residue from
crankshaft journal using AG. Volkswagen AG d
a clean cloth agen oes
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❑ Renew crankshaft oil ised b ara
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seal - belt pulley end hor eo
ut
⇒ page 20 . ss a ra
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2 - Sealing flange
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sump ⇒ page 82 .
h re
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spec
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⇒ page 22 .
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❑ Install with silicone seal‐
ant -D 176 404 A2-
⇒ page 22 .
3 - Cylinder block rrectness of i
l purpos
⇒ page 33 .
m
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r
rods ⇒ page 36 .
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rig ht
5 - Flywheel py by
co Vo
by lksw
❑ To remove and install cted agen
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flywheel, counterhold
with 3067.
6 - Intermediate plate
❑ Must seat on dowel sleeves.
❑ Do not damage or bend when assembling.
7 - 15 Nm AG. Volkswagen AG d
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8 - Sealing flange with oil seal o rise nte
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❑ Renew complete with oil seal and
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❑ To remove, first remove sump ⇒ page 82 .
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❑ Removing and installing ⇒ page 24 .
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9 - Engine speed sender -G28-
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❑ Loosen and tighten using commercially available ball-ended hex key socket.
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❑ Specified torque: 5 Nm
hole
spec
❑ Removing and installing ⇒ page 31 .
es, in part or in w
t to the co
2.2 Renewing crankshaft oil seal - pulley end
rrectness of i
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nf
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♦ Oil seal extractor -3203-
m
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♦ Torque wrench -
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♦ Torque wrench -
t. rig
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V.A.G 1332-
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by c lksw
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Removing
– Remove toothed belt ⇒ page 47 .
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– Loosen knurled screw and turn inner part against crankshaft
es, in part or in w
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Installing
rrectness of i
Note
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l purpos
The oil seal sealing lip must not be additionally oiled or greased.
nf
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– Remove oil residue from crankshaft journal using clean cloth.
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– Tighten new centre bolt to 120 Nm and then 1/4 turn (90°) fur‐
pt
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ther (turning further can be done in several stages).
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Note
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urposes, in part or in wh
Thread and shoulder must be free of oil and grease.
t to the co
– Install and tension toothed belt ⇒ page 47 .
rrectne
2.3 Removing and installing sealing flange - pulley end
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Special tools and workshop
mer
equipment required
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♦ Torque wrench -
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V.A.G 1331-
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♦ Torque wrench - rig ht
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V.A.G 1332- co Vo
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Not illustrated:
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– Drain engine oil. e
nl
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– Remove sump ⇒ page 82 .
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– Remove sealing flange; if necessary, loosen by applying light
hole
spec
es, in part or in w
t to the co
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– Remove residual sealant from sealing flange using a plastic
l purpos
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Installing
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♦ Install sealing flange within 5 minutes of applying the silicone Cop py
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sealant. opyri
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ht
c by lksw
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Prote AG.
– Cut off tube nozzle at forward marking (nozzle ∅ approx. 3
mm).
Note
♦ Sealant bead must not be wider than 2...3 mm, because oth‐
erwise excess sealant can enter sump and clog strainer in oil
pump suction pipe as well as drip onto crankshaft oil seal.
♦ Before applying sealant bead, cover sealing surface of oil seal
with a clean rag.
Note
When fitting sealing flange with oil seal installed, use guide sleeve
-T10053/1- .
Note
After fitting, allow sealant to dry for approx. 30 minutes. Only then
fill with engine oil.
satelettronica
Install crankshaft toothed belt pulley. To do this, lock toothed belt
n AG. Volkswagen AG
pulley using counterhold tool -3415- . lkswage does
not
Vo y gu
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Tighten new centre bolt to 120 Nm and then ris 1/4 turn (90°) further
e nte
tho eo
(turning further can be done in severals astages).
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Cop py
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by
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Prote AG.
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
– Remove sump ⇒ page 82 .
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gen AG does
– Remove engine speed sender -G28- -arrow-Vusingolks a commer‐
wa not
cially available ball-ended hex key socket.
ed
by gu
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– Undo sealing flange securing bolts.auth
satelettronica
ra
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un
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Note
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Sealing flange and sender wheel are pressed off the crankshaft
ot
wit
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hole
spec
es, in part or in w
t to the co
– Screw three M6 x 35 mm bolts into threaded holes 35 mm
rrectness of i
-arrows- of sealing flange.
l purpos
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tion in
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Prote AG.
Note
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Assembly tool -T10134-
A - Clamping surface
n AG. Volkswagen AG do
B - Hexagon nut lkswage es n
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C - Assembly housing ir se
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D - Locating pin ss
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spec
t to the co
f inform
mer
atio
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c
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Cop py
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Prote AG.
Note
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satelettronica
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– Locating hole -A- on sender wheel -C- must align with marking
t to the co
-B- on sealing flange.
– Place sealing flange with front side downwards on a clean flat
rrectness of i
surface.
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nform
mercia
at
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or
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row until it lies on flat surface. ht. Cop py
rig
rig ht
py by
co Vo
by lksw
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Prote AG.
Note
satelettronica
– 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 n AG. Volkswagen AG do
sender wheel hole. olkswage es n
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spec
urposes, in part or in wh
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of arrow, until hexagon nut -B- lies against assembly hub -A-.
atio
om
i
or
sealing surface.
thi
te
sd
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fo
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t.
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Cop py
t. rig
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pyri by
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Prote AG.
Note
Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
prox. 5 full turns).
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un
pt
an
d
satelettronica
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pe
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crankshaft flange
rrectness of i
– Push assembly hub -C- by hand in direction of arrow until
sealing lip support ring -B- contacts crankshaft -A-.
l purpos
– Push guide pin for diesel engines (black knob) -D- into hole in
crankshaft. This ensures that the sender wheel reaches its fi‐
nform
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a
com
tion in
r
Note
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The guide pin for petrol engines (red knob) -F- must not be inser‐
rp
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Cop py
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– Hand tighten both hexagon socket head bolts of assembly rig ht
py by
tool. co Vo
by lksw
cted agen
Prote AG.
– Screw hexagon nut -E- onto threaded spindle by hand until it
is in contact with assembly hub -C-.
Note
satelettronica
– Screw hexagon nut -E- to end of threaded spindle.
– Remove the two bolts -A- from cylinder block.
– Screw the three knurled screws -B- out of sealing flange.
– Remove assembly tool -T10134- .
– Remove sealing lip support ring.
AG. Volkswagen AG d
agen oes
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– The sender wheel ed by V is in the correct installation position
gu
ara on the
crankshafthifo a gap -a- = 0.5 mm exists between crankshaft
ris nte
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flange -A-
s autand sender wheel -B-. ra
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un
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an
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wheel.
If measurement -a- is too small:
nform
mercia
tion in
thi
s
iva
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
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nl
pt
satelettronica
du
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itte
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
– Screw hexagon nut -E- onto threaded spindle by hand until it
is in contact with assembly hub -C-.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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op
– Tighten hexagon nut of assembly tool -T10134- to 40 Nm us‐
C py
t. rig
gh
ing torque wrench -V.A.G 1331- and insert -V.A.G 1332/11- .
ht
pyri by
Vo
co lksw
by
cted
– Check installation position of sender wheel on crankshaft
agen
Prote AG.
again ⇒ page 30 .
If dimension -a- is too small again:
– Tighten hexagon nut for assembly tool -T10134- to 45 Nm.
– Check installation position of sender wheel on crankshaft
again ⇒ page 30 .
– Clamp off coolant hoses at oil cooler using hose clamp and
pull off hoses.
– Remove oil filter bracket.
– Loosen securing bolt in crankcase through opening -arrow-
and pull out engine speed sender -G28- .
Installation is performed in the reverse order, observing the fol‐
lowing: specified torques for engine speed nsender
AG. Volks-G28- securing
wagen AG do
bolt: 5 Nm. lkswage es n
Vo ot gu
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th
au ra
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an
d
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ab
ility
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is n
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spec
urposes, in part or in wh
t to the co
satelettronica
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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sd
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Cop py
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Prote AG.
3 Crankshaft
Note
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1 - Bearing shells 1, 2, 4 and 5
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❑ For bearing cap without
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oil groove.
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satelettronica
h re
❑ For cylinder block with
hole
spec
oil groove
es, in part or in w
t to the co
❑ Do not interchange
used bearing shells
(mark).
rrectness of i
2 - 65 Nm + 1/4 turn (90°) fur‐
l purpos
ther
❑ Renew
nform
ercia
at
om
i
but not further.
on
c
in t
or
3 - Bearing cap
his
ate
do
riv
cum
or
ley end.
f
en
ng
t.
yi
❑ Bearing cap 3 with re‐
Co
op py
cesses for thrust wash‐
t. C rig
gh ht
yri
ers. p by
co Vo
by lksw
❑ Bearing shell retaining
cted agen
Prote AG.
lugs in cylinder block
and bearing caps must
align.
4 - Thrust washer
❑ For bearing cap 3.
❑ Note fixing arrange‐
ment.
5 - Needle roller bearing
❑ Only vehicles with direct
shift gearbox
❑ Removing and installing
⇒ page 34 .
6 - Crankshaft
❑ Axial clearance new: 0.07...0.17 mm, wear limit: 0.37 mm
❑ Check radial clearance with Plastigage new: 0.03...0.08 mm, wear limit: 0.17 mm
❑ Do not rotate crankshaft when checking radial clearance.
❑ Crankshaft dimensions ⇒ page 34 .
3. Crankshaft 33
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
7 - Thrust washer
❑ For cylinder block, bearing 3
satelettronica
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
♦ with adapter -T10055/3-
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.
Note
For vehicles with direct shift gearbox, needle bearing must be in‐
stalled in rear end of crankshaft.
Removing
– Pull out using commercially available puller, e.g. Kukko 21/2
-arrow-, adapter -T10055/3- and puller -T10055- .
Installing
Note
satelettronica
Installation depth: dimension -a- = 2 mm.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
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ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
cu
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m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
35
AG.
3. Crankshaft
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
Note
ce
Piston rings, cylinder bore and piston installation position
e
nl
pt
du
⇒ page 39
an
itte
y li
erm
ab
4.1 Assembly overview - pistons and conrods
ility
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wit
, is n
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hole
1 - Piston rings
spec
satelettronica
es, in part or in w
t to the co
❑ Remove and install us‐
ing piston ring pliers.
rrectness of i
❑ “TOP” faces towards
piston crown.
l purpos
❑ Checking ring-to-groove
clearance ⇒ page 40
m
at
om
ion
c
2 - Piston
in t
or
his
e
do
riv
cum
or
ber.
f
en
ng
t.
yi
❑ Installation position and
Co
Cop py
allocation of piston to
t. rig
gh ht
yri
cylinder ⇒ page 41 . p by
co Vo
by lksw
cted
❑ Arrow on piston crown
agen
Prote AG.
points to pulley end.
❑ Install using piston ring
clamp.
❑ Cracks on piston skirt,
renew piston
❑ Checking piston projec‐
tion at TDC
⇒ page 38 .
3 - Piston pin
❑ If difficult to remove,
heat piston to 60 °C.
❑ Remove and install with
drift -VW 222- .
4 - Circlip
5 - Conrod
❑ Mark with cylinder number -A-.
❑ Installation position: Marking -B- faces towards pulley end.
❑ With industrially cracked conrod cap
ce
le
un
pt
❑ Note installation position.
an
d
itte
y li
❑ Do not interchange used bearing shells.
rm
ab
pe
ility
❑ Insert bearing shells centrally.
ot
wit
, is n
❑ Check for secure seating.
h re
hole
spec
❑ Axial clearance: wear limit: 0.37 mm
es, in part or in w
❑ Check radial clearance with Plastigage: Wear limit: 0.08 mm, do not rotate crankshaft when checking
t to the co
radial clearance.
7 - Cylinder block
rrectness of i
❑ Checking cylinder bores ⇒ page 40 .
l purpos
nform
ercia
a
com
t
❑ The caps only fit in one position and only on the appropriate conrod due to the breaking procedure
ion in
(cracking) separating the cap from the conrod.
r
te o
thi
s
iva
do
r
rp
cum
❑ For piston cooling.
fo
en
g
satelettronica
n
t.
yi Co
10 - 25 Nm t. Cop py
rig
gh
❑ Insert without sealant.
ht
pyri by
Vo
o
by c lksw
11 - Conrod bolt, 30 Nm + 1/4 turn (90°) further
cted agen
Prote AG.
❑ Renew
❑ Lubricate threads and contact surface
❑ Use old bolt for measuring radial clearance
Note
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
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au ra
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ce
le
un
pt
4.3 Checking piston projection at TDC
an
d
itte
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erm
ab
Special tools and workshop equipment required
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
satelettronica
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Dial gauge
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 projection, according to following
table:
Note
satelettronica
♦ Holes = arrow 2
♦ Production control code = arrow 3 (can be disregarded)
AG. Volkswagen A
agen G do
es n
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ua
b
ed ran
Note oris tee
th or
au ac
ss
If different values are determined during the projection measure‐
ce
le
pt
an
d
itte
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erm
ab
ility
ot p
h re
ole,
sion
stallation position
ss
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Special tools and workshop equipment required yri
p by
co Vo
by lksw
cted
♦ Feeler gauges
agen
Prote AG.
satelettronica
Piston ring New Wear limit
dimensions in mm
1. compression ring 0.06...0.09 0.25
2. compression ring 0.05...0.08 0.25
Oil scraper ring 0.03...0.06 0.15
Checking cylinder bores
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
tho eo
au ra
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
at
om
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.
Note
ce
le
un
pt
Note
an
d
itte
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erm
ab
ility
♦ New piston allocation to cylinders is shown by a coloured
ot p
wit
is n
h re
ole,
spec
satelettronica
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
un
pt
the cam must be oiled before installing the cylinder head cov‐
an
d
itte
er.
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erm
ab
ility
♦ The plastic packing pieces for protecting the open valves must
ot p
wit
not be removed until immediately before fitting cylinder head.
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
Assembly overview - cylinder head ⇒ page 42 .
rrectne
Removing and installing cylinder head cover ⇒ page 45
satelettronica
Removing, installing and tensioning toothed belts ⇒ page 47
ss o
Removing and installing cylinder head ⇒ page 61
cial p
f inform
Checking compression ⇒ page 65
mer
atio
m
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
7 - Hub
un
pt
an
d
itte
satelettronica
❑ With sender wheel.
y li
erm
ab
❑ Use counterhold tool -
ility
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wit
is n
tighten.
h re
ole,
spec
❑ To remove, use puller -
urposes, in part or in wh
T10052- .
t to the co
❑ Removing and installing
⇒ page 73 , Removing
and installing camshaft.
rrectne
8 - Rear toothed belt guard
ss
9 - Sealing grommet
o
cial p
f in
❑ Renew if damaged.
form
mer
atio
om
n
❑ For camshaft position
c
i
or
n thi
e
❑ To remove sealing grommet ⇒ Item 9 (page 43) , unbutton from toothed belt guard.
t
sd
iva
o
pr
en
ng
t.
❑ Observe sequence when loosening and tightening ⇒ page 61 .
yi Co
Cop py
❑ Before installing, place washers in cylinder head ⇒ Item 4 (page 68) .
t. rig
gh ht
pyri by
Vo
o
12 - Fuel return line
c by lksw
cted agen
Prote AG.
13 - Fuel supply line
14 - Coolant line
15 - Cylinder head cover
❑ With pressure relief valve for crankcase breather and vacuum reservoir
❑ Thoroughly clean sealant groove and securing bolts before fitting a new gasket.
❑ Before fitting, thoroughly clean sealing surface of cylinder head with clean cloth.
❑ Removing and installing ⇒ page 45 .
16 - Vacuum hose
❑ To connecting piece between tandem pump and brake servo
❑ Vacuum hose schematic diagram ⇒ page 135
17 - Cap
❑ Renew seal if damaged
1. Cylinder head 43
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
ce
e
nl
25 - Central connector
pt
du
an
itte
y li
❑ For unit injector.
erm
ab
ility
ot p
satelettronica
wit
, is n
h re
27 - Tandem pump
hole
spec
❑ For fuel and vacuum supply.
es, in part or in w
t to the co
❑ Checking ⇒ page 120 .
❑ Removing and installing ⇒ page 124 .
❑ Must not be taken apart
rrectness of i
28 - Supply hose
l purpos
at
om
io
in t
or
his
e
29 - Return hose
at
do
riv
cum
for
en
g
t.
yi Co
op
❑ Check for secure seating.
C py
ht. rig
rig ht
❑ Secure with spring-type clips. py by
co Vo
by lksw
cted agen
30 - Seal Prote AG.
❑ Renew
31 - Bracket
32 - 25 Nm
33 - Cylinder head
❑ Removing and installing ⇒ page 61 .
❑ If renewed, change coolant in entire system
34 - Cylinder head gasket
❑ Renew
❑ Note marking ⇒ page 45
❑ If renewed, change coolant in entire system
35 - Ceramic glow plug
❑ 15 Nm
❑ Installation instructions and notes should be strictly adhered to ⇒ page 158
ce
le
un
pt
37 - 20 Nm + 1/8 turn (45 °) further
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
Checking cylinder head for distortion
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
♦ Straight edge
rp
cum
fo
satelettronica
en
g
♦ Feeler gauges
n
t.
yi Co
Cop py
t.
Max. permissible distortion: 0.1 mm.
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
Note
1. Cylinder head 45
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
Note
♦ Renew cylinder head cover gasket and seal for bolts if dam‐
aged.
♦ The cylinder head cover gasket can be renewed only together
with the cylinder head cover.
satelettronica
– Place a drop of sealant -AMV 174 004 01- (∅ approx. 5 mm)
-arrows- on edges of both sealing surfaces of bearing cap and
cylinder head at front of engine.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
– Place a drop of sealant -AMV 174 004 01- (∅ approx. 5 mm)
hole
spec
-arrows- on edges of both sealing surfaces of bearing cap and
es, in part or in w
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
a
o
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rp
13.-
cu
o
m
f
en
ng
t.
– Tighten bolts to 10 Nm in the sequence 1 to 13.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
From 05.06 a modified engine support (with greater clearance to
y li
erm
ab
engine) has been introduced. For the procedure “removing, in‐
ility
ot p
wit
, is n
the engine support and support the engine when changing the
h re
tensioning roller (e.g. type of service). The toothed belt can be
hole
spec
removed and installed without removing the engine support.
es, in part or in w
t to the co
– Determine which type of engine support is installed in the ve‐
hicle.
rrectness of i
-1-: Engine support with less clearance to engine (removal nec‐
l purpos
essary) ⇒ page 47 .
-2-: Engine support with greater clearance to engine (removal not
nf
ercia
necessary) ⇒ page 54
orm
m
atio
m
satelettronica
o
n in
or c
thi
te
sd
iva
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r
rp
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o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.3.1 Removing and installing toothed belt (vehicles with engine support with less
clearance to engine)
1. Cylinder head 47
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
AG. Volkswagen AG d
agen oes
olksw not
yV gu
satelettronica
d b ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
atio
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
Removing
wit
is n
h re
ole,
spec
urposes, in part or in wh
Note
t to the co
Adjustment work on toothed belts must be performed only on cold
engines, as the indicator position on the tensioning element varies
rrectne
depending on the engine temperature.
satelettronica
ss
– Remove engine cover ⇒ page 4 .
o
cial p
f in
– Remove poly V-belt ⇒ page 14 .
form
mer
atio
– Remove tensioning element for poly V-belt.
om
n
c
i
– Remove front right wheel housing liner.
or
n thi
te
sd
a
o
pr
cum
r
fo
t.
yi Co
op
– Set up support bracket -10-222A- with adapters -10-222A/22-
C py
t. rig
gh
and support engine in installation position.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
1. Cylinder head 49
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
Note
satelettronica
– Turn crankshaft to TDC No. 1 cylinder.
n AG. Volkswagen AG do
wage es n
Note yV
olks ot g
ua
d b ran
ir se tee
Turn crankshaft until marking
utho
on crankshaft pulley and tooth seg‐ or
ment of camshaft pulley
ss
a
is on top. The marking on the rear toothed ac
belt guard must line up with the marking on the camshaft sender
ce
e
nl
pt
du
wheel -arrow-.
an
itte
y li
erm
ab
pin through the free elongated hole on left into hole in cylinder
wit
, is n
h re
head.
hole
spec
Note
l purpos
The marks on the crankshaft toothed belt pulley and the crank‐
shaft stop must align. When doing this, the pin of the crankshaft
nform
ercia
at
om
ion
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.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
– Turn pin wrench -T10020- anti-clockwise until toothed belt
ce
e
nl
pt
tensioning roller can be locked with locking pin -T10115- . du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nf
ercia
orm
m
atio
– Remove toothed belt first from coolant pump and then from
om
remaining pulleys.
n in
or c
thi
e
Installing
t
sd
iva
o
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rp
cu
• Camshaft locked with locking pin -3359- .
o
m
f
en
ng
t.
yi
• Crankshaft locked in position with crankshaft stop -T10100- .
Co
Cop py
ht. rig
• Tensioning roller locked with locking pin -T10115- on right
rig ht
py by
o Vo
stop. by c lksw
cted agen
Prote AG.
Note
1. Cylinder head 51
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
Note
– Loosen tensioning roller securing nut and pull out locking pin
-T10115- .
pt
du
satelettronica
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
t to the co
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
– Lock hub with locking pin -3359- whilst turning engine in di‐
f
en
ng
t.
rection of rotation.
yi Co
Cop py
ht. rig
– Check whether crankshaft can be locked with crankshaft stop rig ht
py by
-T10100- . co Vo
by lksw
cted agen
Prote AG.
If crankshaft cannot be locked
satelettronica
Volkswa
– Fit counterhold tool -T10172- with wagpins
en AG-T10172/4-
.
asdshown.
gen AG
oes
Press counterhold tool -T10172- Volks in direction of arrow, keeping
not
gu
by ara
camshaft toothed belt pulley
ris
ed under tension. nte
tho eo
– In this position, tighten
ss
au camshaft toothed belt pulley securing ra
c
bolts -1- to 25 Nm.
ce
le
un
pt
an
y li
erm
ab
h re
– Repeat check.
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 53
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
Note
satelettronica
sw oes
lk n o ot g
yV ua
– Install poly V-belt ⇒ page 14 . ris
edb ran
tee
ho
– Install upper toothed belt guard.aut or
ac
ss
ce
e
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
-arrows-.
h re
hole
spec
– Engage fuel filter in bracket.
es, in part or in w
nf
ercia
orm
m
atio
om
n in
c
1.3.2 Removing and installing toothed belt (vehicles with engine support with
or
thi
te
sd
a
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.
ce
le
un
pt
an
♦ Locking pin for diesel injec‐
d
itte
y li
tion pump -3359-
rm
ab
pe
ility
♦ Mandrel -T10060 A-
ot
wit
, is n
h re
♦ Crankshaft stop -T10100-
hole
spec
♦ Counterhold tool -T10172-
es, in part or in w
t to the co
♦ Socket -T10264-
♦ Locking tool -T10265-
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
satelettronica
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Remove engine cover ⇒ page 4 .
WARNING
♦ In extreme cases the fuel lines and the fuel can reach a
temperature of 100 °C on vehicles with unit injector en‐
gine. Allow the fuel to cool down before disconnecting the
lines - danger of scalding.
♦ Wear protective gloves.
♦ Wear eye protection.
1. Cylinder head 55
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
– Pull fuel supply hose -1- and fuel return hose -2- off fuel lines.
– Pull off coolant line -3-.
– Remove bolts -1-.
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– Disconnect fuel supply line -3- and return line -2- by pulling
rm
ab
release tabs.
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ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
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tion in
r
te o
thi
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– Turn crankshaft to TDC No. 1 cylinder.
erm
ab
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ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
Note
rrectness of i
wheel -arrow-.
orm
m
atio
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c
pin through the free elongated hole on left into hole in cylinder
or
thi
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head.
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pulley from face side. t. Cop py
rig
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Note
cted agen
Prote AG.
The marks on the crankshaft toothed belt pulley and the crank‐
shaft stop must align. When doing this, the pin of the crankshaft
stop must insert in the drilling of the sealing flange.
1. Cylinder head 57
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
AG. Volkswagen AG d
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– Turn eccentric of tensioning roller anti-clockwise -arrow- using
ole,
spec
socket -T10264- , until the tensioning roller can be locked with
urposes, in part or in wh
t to the co
rrectne
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ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
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sd
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pr
c
– Remove toothed belt first from coolant pump and then from
um
r
fo
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t.
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op py
Installing t. C rig
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pyri by
• Camshaft locked with locking pin -3359- .
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Prote AG.
• Crankshaft locked with crankshaft stop -T10100- .
• Tensioning roller locked with locking pin -T10265- and se‐
cured to right stop with securing nut.
Note
ce
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un
pt
an
d
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Note
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ility
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Ensure that tensioning roller seats correctly in rear toothed belt
wit
is n
guard -arrow-.
h re
ole,
spec
urposes, in part or in wh
t to the co
– Loosen tensioning roller securing nut -1-.
rrectness o
cial p
f
– Turn eccentric of tensioning roller clockwise -arrow- using
inform
socket -T10264- until indicator -2- is in middle of gap in base
mer
plate.
atio
om
n
c
i
or
n thi
e
Note
t
sd
iva
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pr
cum
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fo
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ng
t.
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satelettronica
Cop py
. rig
– Hold tensioning roller in this position and tighten tensioning
t
gh ht
yri by
roller nut to 20 Nm + 45° (1/8 turn).
cop Vo
by lksw
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Prote AG.
1. Cylinder head 59
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
AG. Volkswagen AG d
agen oes
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– Loosen securing bolts -1- for camshaft toothed belt pulley. yV
ol not
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or eo
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es, in part or in w
t to the co
– Turn crankshaft slightly against engine direction of rotation
rrectness of i
until the pin of the crankshaft stop is positioned just before the
hole in the sealing flange -arrow-.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
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iva
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cum
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Cop py
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– Repeat check and adjustment if necessary.
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spec
– Install belt pulley vibration damper. Specified torque: 10 Nm +
urposes, in part or in wh
t to the co
– Install poly V-belt ⇒ page 14 .
– Install upper toothed belt guard.
rrectne
– Install connecting pipe between charge air cooler and intake
s
connecting pipe.
s o
cial p
f i
– Install front right wheel housing liner.
satelettronica
form
mer
atio
om
n
c
i
or
n
– Bolt fuel filter bracket to engine mount to 8 Nm torque
thi
te
sd
-arrows-.
iva
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pr
cum
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t.
yi Co
– Bolt on filler neck for window wash system. Cop py
t. rig
gh ht
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– Fit engine cover. p by
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by c lksw
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Prote AG.
1. Cylinder head 61
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
ce
le
un
pt
♦ Retainer -T10014- (only ve‐
an
d
itte
hicles ▸ 05.05)
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erm
ab
ility
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spec
urposes, in part or in wh
t to the co
satelettronica
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f inform
mer
atio
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n
c
i
or
n thi
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t.
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Cop py
t. rig
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Special tools and workshop equipment required Prote AG.
Note
All cable ties which are opened or cut through when cylinder head
is removed must be replaced in the same position when cylinder
head is installed.
WARNING
When doing any repair work, especially in the engine compart‐ agen
AG. Volkswagen AG d
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ment, pay attention to the following due to the crampedbcondi‐
yV
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tions: ris
ed ara
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♦ Route all the various lines (e.g. for fuel, hydraulics,
au acti‐ ra
c
ss
vated charcoal filter system, coolant, refrigerant, brake
ce
e
nl
fluid and vacuum) and electrical wiring in their original po‐
pt
du
an
sitions.
itte
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♦ Ensure that there is sufficient clearance to all moving or
ility
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hot components.
wit
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hole
spec
es, in part or in w
1.4.1 Removing
t to the co
Note
rrectness of i
l purpos
satelettronica
container -V.A.G 1390/1- ⇒ page 124 .
nform
mercia
at
– Remove particulate filter from engine ⇒ page 151 .
om
ion
c
in t
r
his
te
do
priv
cum
or
en
ng
t.
yi Co
– Unbolt support for turbocharger with oil return line . Cop py
⇒ Item 19 (page 132) .
ht rig
rig ht
py by
co Vo
– Remove exhaust gas recirculation cooler ⇒ page 157 .
by lksw
cted agen
Prote AG.
Note
Note
Both lifting eyes for the support are located on the cylinder head,
so an additional bracket for supporting the engine must be se‐
cured on the cylinder block.
1. Cylinder head 63
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
satelettronica
– Lift cylinder head slightly and remove from engine laterally
past toothed belt guard.
Note agen
AG. Volkswagen AG d
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The cylinder head must be guided carefully rito
sedprevent damage.
b ara
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rm
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spec
Note
es, in part or in w
t to the co
tio
installation.
n in
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te o
thi
do
cum
fo
en
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t.
yi
– Set crankshaft to TDC mark before fitting cylinder head.
Co
Cop py
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– Turn crankshaft opposite engine direction of rotation until all
rig ht
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pistons are approximately equally placed below TDC. by c lksw
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Prote AG.
– Fit cylinder head gasket.
Note
– Fit cylinder head and tighten all cylinder head bolts hand-tight.
– Tighten cylinder head in four stages in sequence as shown as
follows:
1- Tighten initially with torque wrench:
Stage I = 35 Nm
AG. Volkswagen AG d
agen oes
Stage II = 60 Nm Volksw not
gu
by ara
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2- Turn further with rigid wrench: rise nte
tho eo
au ra
Stage III = 1/4 turn (90°) ss c
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nl
pt
du
Stage IV = 1/4 turn (90°)
an
itte
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ility
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Note
, is n
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hole
spec
Cylinder head bolts do not have to be torqued down again later
es, in part or in w
t to the co
The remaining installation steps are carried out in the reverse se‐
quence. When doing this, note the following:
rrectness of i
satelettronica
l purpos
nf
gine direction of rotation, to TDC marking before fitting toothed
ercia
o
belt ⇒ page 47 .
rm
m
atio
m
n in
c
⇒ page 137 .
or
thi
te
sd
iva
– Carry out road test and then read fault memory ⇒ page 146 .
o
r
rp
cu
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m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
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co lksw
by
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Prote AG.
Note
1. Cylinder head 65
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
ce
le
un
pt
♦ Adapter -V.A.G 1381/12-
an
d
itte
y li
♦ Compression tester -
rm
ab
pe
ility
V.A.G 1763-
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
satelettronica
m
a
com
tion in
r
te o
thi
s
iva
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t.
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Cop py
t. rig
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by
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Prote AG.
Test prerequisite
• Engine oil temperature min. 30 °C.
Test procedure
– Pull off central connector for unit injectors.
Note
– Remove all ceramic glow plugs using U/J extension and sock‐
et 10 mm -3220- .
Note
Note
satelettronica
– Install ceramic glow plugs using U/J extension and socket 10
mm -3220- .
– Read fault memory of engine control unit ⇒ page 146 .
Note
AG. Volkswagen AG d
agen oes
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pt
du
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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t. rig
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67
cted agen
Prote
1. Cylinder head
AG.
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
ce
e
nl
pt
du
an
itte
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Assembly overview - valve gear ⇒ page 68 .
erm
ab
ility
ot p
wit
, is n
h re
Renewing valve stem seals ⇒ page 71
hole
spec
Removing and installing camshaft ⇒ page 73
es, in part or in w
t to the co
Removing and installing camshaft seal ⇒ page 77
rrectness of i
l purpos
satelettronica
ther
nf
ercia
or
❑ Renew
m
m
atio
m
n in
c
thi
e
sd
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camshaft.
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f
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ng
t.
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2 - Rocker arm shaft t. Cop py
rig
gh
❑ Do not interchange
ht
pyri by
Vo
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by
3 - Cylinder head bolt cted agen
Prote AG.
❑ Renew
❑ Note sequence when
loosening and tighten‐
ing ⇒ page 61 , Remov‐
ing and installing cylin‐
der head.
❑ Before installing, insert
washers
⇒ Item 4 (page 68) in
cylinder head.
4 - Washer
❑ For cylinder head bolts.
❑ Set in cylinder head be‐
fore installing bearing
caps.
5 - Bucket tappet
❑ Do not interchange
❑ With hydraulic valve
clearance compensa‐
tion.
❑ Store with cam contact
surface downwards
❑ Before installing check camshaft axial clearance ⇒ page 70 .
❑ Lubricate contact surface
❑ Before removing, remove camshaft bearing caps
6 - Cotters
7 - Valve spring plate
8 - Outer valve spring
❑ Removing and installing: with cylinder head removed, use valve spring compressor -2037- ; with cylinder
head installed ⇒ page 71 , Renewing valve stem seals.
9 - Inner valve spring
❑ Removing and installing: with cylinder head removed, use valve spring compressor -2037- ; with cylinder
head installed ⇒ page 71 , Renewing valve stem seals.
10 - Valve stem seal
❑ Renewing ⇒ page 71 .
11 - Valve guide
❑ Checking ⇒ page 70 .
12 - Unit injector
❑ Removing and installing ⇒ page 140 .
13 - Cylinder head
❑ See note ⇒ page 68 .
satelettronica
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, tape over groove in taper of camshaft w(e.g.
agen using Sellotape).
AG. Volkswagen AG d
oes
olks not
❑ Removing and installing ⇒ page 77 . db
y V gu
ar
e an
ris tee
15 - Valves utho or
a ac
❑ Valve dimensions ⇒ page 70 . ss
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un
pt
16 - Bearing shell
an
d
itte
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❑ Do not interchange used bearing shells (mark).
rm
ab
pe
ility
❑ Ensure proper seating of retaining lugs in bearing caps and cylinder head.
ot
wit
, is n
h re
17 - Camshaft
hole
spec
❑ Checking axial clearance ⇒ page 70 .
es, in part or in w
t to the co
❑ Removing and installing ⇒ page 73 .
❑ Check radial clearance with plastigage, wear limit: 0.11 mm
❑ Runout: max. 0.01 mm.
rrectness of i
18 - Bearing cap
l purpos
tion in
❑ Renew
r
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thi
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cum
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t.
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Cop py
t. rig
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by
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Prote AG.
AG. Volkswagen AG d
agen oes
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ara
ed
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ility
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wit
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hole
spec
Special tools and workshop equipment required
es, in part or in w
t to the co
♦ Universal dial gauge bracket -VW 387-
♦ Dial gauge
rrectness of i
Check with bucket tappets removed and with first, third and last
l purpos
nform
ercia
satelettronica
Seal parting surfaces of bearing caps 1 and 5 with sealant -AMV
m
a
174 004 01- .
com
tion in
r
– Apply sealant -AMV 174 004 01- thinly and evenly to surfaces
te o
thi
-1-.
s
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cum
fo
en
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t.
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Note
Co
Cop py
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rig ht
Be careful that no sealant gets into grooves -arrows-.
py by
co Vo
by lksw
cted agen
Prote AG.
Valve dimensions
Note
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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♦ Dial gauge aut ra
c
ss
Test procedure
ce
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nl
pt
du
an
itte
– Insert new valve into guide. The end of the valve stem must
y li
erm
ab
be flush with the guide. Due to slight differences in stem di‐
ility
ot p
wit
valve in exhaust guide.
, is n
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hole
satelettronica
spec
es, in part or in w
t to the co
wear limit.
rrectness of i
l purpos
nform
ercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
satelettronica
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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aut ra
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un
pt
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ility
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2.3.1 Removing
wit
is n
h re
ole,
t to the co
interchanged.
– Set piston of respective cylinder to top dead centre (TDC).
ss o
cial p
height of studs.
mer
atio
m
n
c
n thi
te
sd
iva
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pr
cum
r
Note
fo
en
ng
t.
yi Co
op
The valves are supported by the piston crown.
C py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2.3.2 Installing
– Place the plastic sleeve -A- supplied on the respective valve
stem. This will prevent the new valve stem seal -B- being
damaged.
– Insert new valve stem seal in fitting tool -3129- .
– Lubricate sealing lip of valve stem seal and carefully push on
valve guide.
satelettronica
2.4 Removing and installing camshaft
AG. Volkswagen AG d
agen oes
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d by ara
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un
pt
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ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
yi Co
Cop py
t. rig
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73
op Vo
by c lksw
Prote
cted AG.
agen 2. Repairing valve gear
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
ce
le
pt
an
d
itte
y li
♦ Sealant -AMV 174 004 01-
rm
ab
pe
ility
ot
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
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
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2.4.1 Removing
– Remove toothed belt ⇒ page 47 .
– Remove securing bolts for camshaft toothed belt pulley -1-.
– Pull camshaft toothed belt pulley off hub.
– Apply puller -T10052- and screw securing bolts -1- into hub.
– Apply tension to hub by evenly tightening puller until hub sep‐
arates from taper of camshaft.
Note
satelettronica
– Remove hub from taper of camshaft.
– Remove cylinder head cover.
Note
. Volkswagen AG
gen AG d
First loosen both outer and then
Voinner
lksw securing bolts respectively.
a oes
not
g
by ua
ed ran
ris tee
– Remove tandem pumptho ⇒ page 124 . or
au ac
ss
ce
e
nl
pt
du
y li
ab
ility
ot p
– Remove camshaft.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
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co lksw
by
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Prote AG.
2.4.2 Installing
Note
satelettronica
Note
pt
an
d
itte
– Install rocker arm shafts and tighten securing bolts, first the y li
erm
ab
inner -2- and then the outer -1-, evenly and diagonally to 20 Nm ility
ot p
h re
ole,
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote
76
AG.
Rep. Gr.15 - Cylinder head, valve gear
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
Note
satelettronica
– Align camshaft toothed belt pulley at centre of elongated
holes.
– Hand tighten securing bolts -1- to camshaft toothed belt pulley
. Volkswagen AG
so that there is no play. kswagen AG does
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– Lock hub using locking pinise-3359-
db . ara
nte
r
ho eo
– Install toothed belt and
sa
uadjust
t
valve timing ⇒ page 47 . ra
c
s
– Adjust non-contact gap of unit injectors ⇒ page 143 .
ce
le
un
pt
an
d
itte
ab
pe
ility
wit
, is n
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hole
spec
Note
es, in part or in w
t to the co
When new bucket tappets have been installed the engine must
not be started for about 30 minutes. Hydraulic valve compensa‐
tion elements have to settle (otherwise valves will strike pistons).
rrectness of i
l purpos
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
satelettronica
n AG. Volkswagen AG do
lkswage es n
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2.5.1 Removing
pt
du
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ab
h re
spec
– Unscrew inner part of oil seal extractor -3240- two turns (ap‐
es, in part or in w
prox. 3 mm) out of outer part and lock with knurled screw.
t to the co
orm
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Cop py
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Prote AG.
2.5.2 Installing
Note
The oil seal sealing lip must not be additionally oiled or greased.
AG. Volkswagen AG d
agen oes
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or eo
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satelettronica
aut ra
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nl
pt
du
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ab
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spec
es, in part or in w
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Cop py
t. rig
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Prote AG.
17 – Lubrication
1 Engine oil
AG. Volkswagen AG d
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Note ised b ara
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The oil level must not be above the max.
s mark - danger of damage
s a c
to catalytic converter!
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nl
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du
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Oil capacities ⇒ page 80
erm
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ility
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Checking engine oil level ⇒ page 80
hole
spec
1.1 Oil capacities
es, in part or in w
t to the co
Note
rrectness of i
satelettronica
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at
With oil filter change: 4.3 l
om
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1.2 Checking engine oil level
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Markings on oil dipstick Cop py
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1 - Min. mark py by
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2 - Max. mark Prote AG.
Caution
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Assembly overview - oil pump, sump ⇒ page 81
ility
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spec
2.1 Assembly overview - oil pump, sump
es, in part or in w
t to the co
satelettronica
1 - 15 Nm
rrectness of i
2 - Sealing flange
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❑ With seal.
❑ Must seat on dowel
sleeves.
nform
ercia
at
om
sump ⇒ page 82 .
ion
c
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⇒ page 22 .
at
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❑ Install with silicone seal‐
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for
ant -D176404A2-
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t.
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⇒ page 22 . t. Cop py
rig
❑ Do not additionally oil or
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ing lip
agen
Prote AG.
6 - Guide tube
7 - Dowel sleeves
8 - O-ring
❑ Renew
9 - 15 Nm
10 - Suction line
❑ Clean strainer if dirty
11 - Baffle plate
AG. Volkswagen AG d
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12 - 15 Nm Volksw not
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13 - 15 Nm rise nte
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14 - Sump ss c
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❑ Clean sealing surface before fitting.
nl
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❑ Install with silicone sealant -D176404A2-
y li
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❑ Removing and installing ⇒ page 82 .
ility
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satelettronica
❑ Renew
spec
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16 - 10 Nm
t to the co
17 - Oil level and oil temperature sender -G266-
rrectness of i
18 - Seal
❑ Renew
l purpos
19 - Oil pump
nf
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❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
atio
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21 - Bracket
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❑ For oil level and oil temperature sender -G266- .
Co
Cop py
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22 - 20 Nm + 1/4 turn (90°) further
gh ht
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❑ Renew cted agen
Prote AG.
23 - Chain
24 - 25 Nm
❑ Insert without sealant.
25 - Oil spray jet
❑ For piston cooling.
satelettronica
AG. Volkswagen AG d
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♦ Silicone sealant -D176404A2-
erm
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♦ Eye protection
ole,
spec
urposes, in part or in wh
♦ Flat scraper
t to the co
Removing
– Remove sound insulation tray: ⇒ General body repairs, exte‐
rrectne
rior; Rep. Gr. 50 ; Body front; Assembly overview .
– Drain engine oil.
ss o
cial p
f inform
Note
mer
atio
om
i
or
n thi
te
sd
va
– Pull 3-pin connector off oil level and oil temperature sender -
i
o
pr
cum
G266- .
r
fo
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t.
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– Remove sump.
Co
Cop py
ht. rig
ht
– Loosen sump with light blows of a rubber headed hammer if
rig by
opy Vo
necessary. by c lksw
cted agen
Prote AG.
– Remove sealant residue on cylinder block with a flat scraper.
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nl
pt
du
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silicone sealing compound.
erm
ab
ility
ot p
wit
, is n
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– Cut off tube nozzle at forward marking (nozzle ∅ approx. 3
hole
mm).
spec
es, in part or in w
t to the co
surface on sump. Sealing compound bead must be:
♦ 2...3 mm thick.
rrectness of i
♦ Run bead along inner side of bolt holes -arrows-.
l purpos
satelettronica
nform
Note
mercia
at
The sealing compound bead must not be thicker, otherwise ex‐
om
ion
cess sealing compound will enter the oil sump and may block the
c
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or
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priv
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for
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sealing surface of the sump. (The figure shows the position of Cop py
t. rig
the sealant bead on the cylinder block.) gh ht
pyri by
Vo
co lksw
by
– Install sump immediately and tighten all sump bolts lightly. Prote
cted AG.
agen
Ensure that sump is flush against intermediate plate and gear‐
box flange.
Note
When installing sump with engine out of vehicle, ensure that sump
is flush with cylinder block at flywheel end.
Note
1 - Seal
❑ Renew
2 - 15 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew
❑ First fit upper left and
lower right bolts and
then tighten all four bolts
diagonally.
3 - Oil filter bracket
satelettronica
4 - Seal
❑ Renew
5 - Union, 30 Nm
AG. Volkswagen AG d
6 - Oil supply line, 22 Nm lksw
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not
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❑ To turbocharger. ed by ara
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7 - Oil pressure switch -F1- aut
h
ra
ss c
❑ 0.7 bar switch: brown.
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pt
du
❑ Tighten to 20 Nm
an
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❑ If sealing ring is leaking,
erm
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nip open and renew.
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❑ Checking ⇒ page 86 .
h re
hole
spec
8 - Cap, 25 Nm
es, in part or in w
t to the co
socket 36 mm -
T10125- .
rrectness of i
9 - O-ring
l purpos
❑ Renew
10 - Oil filter element
nf
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❑ See note.
orm
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c
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11 - Seal
iv
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❑ Renew
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❑ Oil before installing.
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Cop py
❑ Fit into lugs on oil cooler.
t. rig
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12 - Oil cooler
lksw
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Prote AG.
❑ Ensure clearance to adjacent components.
❑ See note ⇒ page 81 .
❑ Checking oil cooler for leaks ⇒ page 104
13 - Seal
❑ Renew
14 - Cap, 25 Nm
❑ Loosen and tighten with socket 36 mm -T10125- .
15 - 10 Nm
16 - Bracket
ce
le
V.A.G 1594 A-
un
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an
d
itte
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ab
satelettronica
pe
ility
ot
wit
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spec
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mercia
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com
tion in
r
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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Prote AG.
Test procedure
Note
satelettronica
AG. Volkswagen AG d
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spec
urposes, in part or in wh
t to the co
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mer
atio
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n
c
i
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.
19 – Cooling
1 Parts of cooling system
WARNING
satelettronica
Note
an
markings on coolant connection and hose).
itte
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ab
ility
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spec
es, in part or in w
atio
n in
or c
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satelettronica
❑ Check using cooling
system tester -
V.A.G 1274- and adapt‐
er -V.A.G 1274/9-
❑ Test pressure: 1.4...1.6
bar.
6 - Connector
7 - 5 Nm
8 - Expansion tank
❑ Check using cooling
system tester -
V.A.G 1274- and adapt‐ n AG. Volkswagen AG do
lkswage es n
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9 - Bracket utho tee
or
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❑ For radiator. ss
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nl
pt
10 - 5 Nm
du
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11 - Support
erm
ab
ility
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12 - 10 Nm
wit
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13 - Fan support
hole
spec
t to the co
14 - 5 Nm
15 - Radiator fan 2 -V177-
rrectness of i
16 - Connector
17 - Radiator fan -V7-
nform
ercia
at
om
io
in t
or
do
riv
cum
for
t.
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op py
19 - Securing clip t. C rig
gh ht
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❑ Check for secure seating. cop Vo
by lksw
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Prote AG.
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pt
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20 - Radiator outlet coolant temperature sender -G83-
an
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21 - O-ring
ility
❑ Renew ot p
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spec
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t to the co
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1 - To top of expansion tank.
❑ Coolant hose schematic
l purpos
diagram ⇒ page 92 .
2 - Upper coolant pipe
nform
ercia
at
cover.
om
ion
c
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diagram ⇒ page 92 .
at
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3 - O-ring
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❑ Renew
t.
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Cop py
satelettronica
. rig
4 - Securing clip
ht ht
rig by
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❑ Check for secure seat‐ by c lksw
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ing. Prote AG.
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❑ For thermostat.
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❑ Coolant hose schematic diagram ⇒ page 92 .
rm
ab
pe
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22 - Thermostat
ot
wit
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❑ Removing and installing ⇒ page 101 .
hole
spec
❑ Observe installation position ⇒ page 101 , Removing and installing thermostat.
es, in part or in w
t to the co
❑ Checking: heat thermostat in water.
❑ Opening begins at approx. 85 °C
❑ Ends at approx. 105 °C.
rrectness of i
❑ Opening lift min. 7 mm.
l purpos
satelettronica
❑ Coolant hose schematic diagram ⇒ page 92 .
nform
mercia
a
com
tio
❑ To recirculating pump -V55- .
n in
r
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thi
❑ Coolant hose schematic diagram ⇒ page 92 .
s
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25 - To heat exchanger
um
fo
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t.
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Cop py
t.
26 - Coolant pump
rig
gh ht
pyri by
Vo
❑ Check for ease of movement.
o
by c lksw
cted agen
Prote
❑ Note installation position.
AG.
1 - Expansion tank
2 - Rear coolant pipe
3 - Exhaust gas recirculation
cooler
4 - Intake manifold
5 - Heater unit heat exchanger
6 - Connection
7 - Upper coolant pipe
8 - Front coolant pipe
9 - Oil cooler
❑ For engine oil.
10 - Upper coolant hose
11 - Radiator
satelettronica
12 - Bottom coolant hose
13 - Coolant pump and ther‐
mostat
14 - Cylinder head/cylinder
block
15 - Circulation pump -V55-
16 - Auxiliary heater
n AG. Volkswagen AG do
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spec
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t to the co
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nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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pt
du
1.4.1 Draining
an
itte
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ab
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WARNING
wit
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t to the co
at
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ion
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ate
do
priv
cum
for
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t.
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Cop py
t. rig
gh ht
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93
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by c lksw
Prote
cted AG. 1. Parts of cooling system
agen
n AG. gen AG Volkswa
Touran 2003 ➤ wage does
Volks not
4-cylinder diesel engine (2.0 l engine, 2-valve,
ed by TDI) - Edition 06.2008 gu
ara
ris nte
utho eo
– Pull off bottom coolant hose retaining and remove clip
ss -arrow-
a ra
c
coolant hose from quick-release connection of radiator.
ce
le
un
pt
an
d
itte
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rm
ab
pe
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, is n
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spec
es, in part or in w
t to the co
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nform
mercia
a
Note
com
tion in
r
te o
thi
Observe environmental regulations for disposal.
s
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cum
satelettronica
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.4.2 Filling
Note
olkswagen AG
en AG. V
♦ Use only coolant additive G12 plus-plus
olksin accordance with
wag does
not
“TL VW 774 G”. d by V gu
ara
rise nte
♦ G 12 plus-plus marked “conforming
utho
to TL VW 774 G” prevents eo
ra
frost and corrosion damage, scaling and also raises boiling
s a c
s
point of coolant. Therefore, the system must be filled all year
ce
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pt
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reliability under heavy loads, particularly in countries with trop‐
ot p
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with arctic climates: down to about -35 °C).
es, in part or in w
t to the co
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The anti-
freeze must be at least 40% of mixture.
rrectness of i
♦ If for climatic reasons greater frost protection is required, the
satelettronica
l purpos
nf
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orm
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atio
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Recommended mixture proportions:
Co
Cop py
t. rig
gh ht
Frost Anti-freeze G 12 plus- Water4)
pyri by
Vo
co
protection to proportion plus4)
by lksw
cted agen
Prote AG.
-25 °C 40 % 3.2 l 4.8 l
-35 °C 50 % 4.0 l 4.0 l
4) The quantity of coolant can vary depending upon vehicle equipment.
satelettronica
– Run engine until radiator fan cuts in.
WARNING
– Check coolant level and top-up if necessary. When the engine swa
gen AG
. Volkswagen AG
does
is at normal operating temperature, the coolant levelbymust
Volk be not
gu
at the upper mark; when the engine is cold, in therisemiddle
d of ara
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the shaded field. ut
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with fans y li
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♦ Torque wrench -V.A.G 1331-
hole
spec
es, in part or in w
t to the co
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nf
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Removing
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rior; Rep. Gr. 50 ; Body front; Assembly overview .
Co
Cop py
ht. rig
– Remove intake air duct from air filter ⇒ page 145 .
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
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un
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-arrows-.
an
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– Remove fan support with fans downwards.
rm
ab
pe
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wit
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spec
es, in part or in w
t to the co
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l purpos
nform
ercia
a
com
t
– Remove securing nuts -arrows- and remove fans.
ion in
r
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Installing
thi
s
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Installation is carried out in the reverse order. When installing,
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fo
en
ng
satelettronica
t.
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op
Specified torques: C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Component Nm
Radiator fans to fan support 10
Fan support to radiator 5
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
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Removing ss a ra
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du
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es, in part or in w
– Remove left and right securing bolts ⇒ Item 10 (page 89) for
radiator mounting.
rrectness of i
Installing
Installation is carried out in the reverse order. When installing,
nform
ercia
at
om
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
98
agen
Prote AG.
Rep. Gr.19 - Cooling
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
Additional notes and assembly work for vehicles with air condi‐
tioner
WARNING
Note
satelettronica
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
– Carefully pull radiator slightly to right and remove securing bolt
on side -arrow- from condenser on radiator.
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
1.7 Removing and installing coolant pump
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
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ir se tee
tho
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a ac
ss
ce
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nl
pt
du
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itte
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erm
ab
ility
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wit
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spec
es, in part or in w
t to the co
Removing
rrectness of i
l purpos
Note
nform
ercia
at
om
io
in t
or
do
priv
en
ng
t.
– Remove securing bolts -1- for coolant pump -2- and carefully
yi Co
op py
remove coolant pump. t. C rig
gh ht
yri by
Installing
cop Vo
by lksw
cted agen
Prote AG.
Installation is carried out in the reverse order. When installing,
note the following:
ce
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nl
pt
du
an
itte
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erm
ab
– Install toothed belt ⇒ page 47 .
ility
ot p
wit
– Install poly V-belt ⇒ page 14 .
, is n
h re
hole
spec
es, in part or in w
t to the co
1.8 Removing and installing thermostat
rrectness of i
Special tools and workshop
l purpos
equipment required
♦ Refractometer -T10007-
nf
ercia
satelettronica
o
♦ Drip tray -V.A.G 1306-
rm
m
atio
m
n in
c
VAS 5024 A-
or
thi
te
sd
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rp
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unit -VAS 6096-
o
m
f
en
ng
t.
yi
♦ Adapter -V.A.G 1274/8-
Co
Cop py
t. rig
gh
♦ Torque wrench -
ht
pyri by
Vo
o
V.A.G 1331- by c lksw
cted agen
Prote AG.
Removing
Note
ce
e
nl
pt
du
satelettronica
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– Insert thermostat -4- into connection -2- and turn 1/4 turn (90°) spec
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♦ Adapter for cooling system
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tester -V.A.G 1274/8-
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♦ Adapter for cooling system
tester -V.A.G 1274/9-
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Test prerequisite
• Engine at operating temperature.
Test sequence:
WARNING
satelettronica
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equipment required
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♦ Refractometer -T10007-
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mm -3094-
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♦ Cooling system tester -
es, in part or in w
V.A.G 1274-
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♦ Adapter for cooling system
tester -V.A.G 1274/8-
rrectness of i
♦ Spring-type clip pliers -VAS
l purpos
5024 A-
♦ Drip tray -V.A.G 1306- or
nform
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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 tray.
– Clamp supply and return lines off oil cooler using hose clamps
to Ø 25 mm -VAS 3094- .
– Loosen hose clamps -arrows- using spring type clip pliers -
VAS 5024- .
Note
Collect escaping coolant with drip tray -V.A.G 1306- or drip tray -
VAS 6208- .
satelettronica
tank -1-.
– Secure coolant hose -3- to oil cooler and expansion tank.
– Fill expansion tank up to “Max” marking.
– Attach cooling system tester -V.A.G 1274- with cooling system
tester adapter -V.A.G 1274/8- to expansion tank.
– Use hand pump on tester to create a pressure of about 1.6 bar.
– Watch pressure drop on pressure gauge. A pressure drop
AG. Volkswagen AG d
within 10 minutes is not
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If pressure drops:rised b ran
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– Renew oils acooler
u ⇒ page 85 . ac
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⇒ page 93 .
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supply system
pt
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Note
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spec
♦ Hose connections are secured with either spring-type or
urposes, in part or in wh
clamp-type clips.
t to the co
♦ Always renew clamp-type clips with spring-type clips.
♦ Spring-type clip pliers -VAS 5024- or hose clip pliers -V.A.G
rrectne
1921- are recommended for installation of spring-type clips.
ss
Safety precautions ⇒ page 107
o
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Rules for cleanliness ⇒ page 108 .
mer
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Assembly overview - fuel tank ⇒ page 108
m
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Assembly overview - fuel filter ⇒ page 110
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WARNING
satelettronica
♦ 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.
AG. Volkswagen AG d
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♦ Also ensure that no diesel fuel runs on to the coolant hoses. Vol
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Should this occur, the hoses must be cleaned immediately. sed by ara
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Damaged hoses must be renewed. tho
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1.3 Assembly overview - fuel tank ss
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1 - Cap
2 - 1.5 Nm
3 - Tank flap unit
❑ Removing and installing
⇒ General body repairs,
exterior; Rep. Gr. 55 ;
Tank flap unit .
4 - Earth connection
❑ Check for secure seat‐
ing.
5 - 10 Nm
6 - Pressure retention valve
with connecting hose
7 - Gravity/overflow valve
8 - Fuel tank
❑ When removing, sup‐
port using engine and
gearbox jack -V.A.G
satelettronica
1383/A-
❑ Removing and installing
⇒ page 114 .
9 - Heat shield n AG. Volkswagen AG do
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❑ For fuel tank. d byV ua
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10 - Securing strapautho
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11 - 20 Nm + 1/ turn (90°) fur‐ 4
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spec
❑ Renew if damaged.
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14 - Union nut, 80 Nm
or
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15 - Supply line
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❑ To fuel filter t. Cop py
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❑ Clipped onto fuel tank.
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❑ Check for secure seating.
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❑ Black
❑ To pull off flange, press release button on connecting piece.
16 - Return line
❑ From fuel cooler
❑ Blue or with blue marking.
❑ Clipped onto fuel tank.
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pt
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❑ Check for secure seating.
an
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❑ To pull off flange, press release button on connecting piece.
erm
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Fitting position of fuel delivery unit flange
hole
spec
es, in part or in w
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Black supply line -1- to connection marked -V-.
Return line -2- (blue or with blue marking) to connection marked
rrectness of i
-R-.
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nf
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After installing fuel delivery unit flange, check that supply, return
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1 - Fuel filter upper part opyri
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Fuel filter upper part, type B
1 - 5 Nm
2 - Fuel tank return line, blue or blue marking. Check for secure
seating
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3 - Fuel tank supply line, white or white marking. Check
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4 - Engine return line, blue or blue marking.au Check for
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5 - Engine supply line, white or white marking. Check for secure
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♦ Torque wrench -V.A.G 1331-
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Removing
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Observe rules for cleanliness ⇒ page 108 .
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Note
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nl
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1.6 Emptying fuel tank
erm
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♦ Fuel extractor -VAS 5190-
hole
spec
es, in part or in w
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c
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Caution
– Pull cone piece -2- off fuel extractor -VAS 5190- shaft -1-.
– Make a mark -arrow- on hose with insulating tape from end of
hose at distance -a- = 1,180 mm.
AG. Volkswagen AG d
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– Screw shaft -1- of fuel extractor -VAS 5190- onto fuel tank filler
spec
es, in part or in w
neck.
t to the co
– Push extraction hose into fuel tank until marking on hose
-arrow- coincides with shaft end.
rrectness of i
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nf
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A ball valve -2- is located at the lower end of filler neck in fuel tank
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-1-, which must not be damaged by the extraction hose -3-.
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rig ht
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Note
WARNING
The fuel supply line is under pressure! Wear eye protection and
protective clothing to avoid injuries and skin contact. Before
loosening hose connections, wrap a cloth around the connec‐
tion. Then release pressure by carefully pulling hose off con‐
nection. swa
gen AG
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– Pull connector and fuel lines off flange. auth eo
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Press buttons on hose couplings to do this.
ility
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– Open locking ring using fuel tank sender tool -T10202- .
hole
spec
es, in part or in w
t to the co
– Insert extraction hose of fuel extractor -VAS 5190- as deeply
as possible into fuel tank and extract fuel.
rrectness of i
If intention was just to empty fuel tank, reinstall sender flange
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1.7.1 Removing
, is n
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spec
– Note safety precautions before starting work. ⇒ page 107
es, in part or in w
t to the co
Observe rules for cleanliness. ⇒ page 108
rrectness of i
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– Remove cover from fuel delivery unit.
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– Pull 5-pin connector off fuel delivery unit flange. cop Vo
by lksw
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– Open fuel tank flap.
AG.
– Unscrew securing bolt and remove tank flap unit with rubber
cup.
– Empty fuel tank ⇒ page 112 .
– Remove right rear wheel.
– Remove rear right wheel housing liner. ⇒ General body re‐
pairs, exterior; Rep. Gr. 66 ; Removing and installing wheel
housing liner .
– Remove bolts from filler neck -arrows-.
– Unclip wire from filler neck.
– Remove front and rear silencers ⇒ page 153 .
WARNING
♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure! Before opening
the system, place cloths around the connections. Then
carefully loosen connection to release the pressure!
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!
Note
n AG. Volkswagen AG do
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Press in securing ring d by to
Vo release fuel lines. ot g
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– Support fuel au tank using engine and gearbox jack -V.A.G 1383 ac
ss
A- .
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– Remove bolts -A- and -B- and remove retaining straps.
hole
spec
– Remove heat shield for fuel tank.
es, in part or in w
t to the co
– Slowly lower fuel tank and pull it forwards.
– Tilt fuel tank to get it past rear axle.
rrectness of i
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satelettronica
nform
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1.7.2 Installing
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When doing this, note the following:
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♦ Fuel lines are to be installed free of kinks.
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♦ Do not interchange supply and return lines (return line blue or
cted agen
Prote AG.
with blue markings, supply line black).
♦ Ensure that fuel line connections are tight.
♦ Connections for fuel lines must engage audibly when joined.
♦ Check earth connection between body and filler pipe for prop‐
er seating.
♦ Clip supply and return lines onto fuel tank.
1.8.1 Removing
– Note safety precautions before starting work. ⇒ page 107
AG. Volkswagen AG d
Observe rules for cleanliness ⇒ page 108 . agen oes
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– First check whether a coded radio is fitted. If so, obtain ris anti-
ed
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theft coding. aut
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– With the ignition switched off, disconnect battery earth strap.
ce
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– The fuel tank must not be more than 3/4 full when removing
itte
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the fuel delivery unit. Empty fuel tank if necessary
ility
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⇒ page 112 .
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– Remove rear seat bench ⇒ General body repairs, interior;
ole,
spec
urposes, in part or in wh
t to the co
WARNING
rrectne
♦ The fuel and the fuel lines in the fuel system can become
s
very hot (danger of scalding)!
s o
cial p
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♦ The fuel system is also under pressure! Before opening
form
mer
atio
carefully loosen connection to release the pressure!
om
n
c
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or
n
♦ Wear eye and hand protection when performing any type
thi
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t.
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– Pull return line, supply line and 5-pin connector off fuel delivery
Co
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unit flange. ht. rig
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Note
Note
1.8.2 Installing
– Installation of fuel delivery unit is carried out in reverse order.
Note
♦ When inserting fuel delivery unit, ensure that fuel gauge send‐
er is not bent.
satelettronica
♦ Insert seal for flange or fuel delivery unit dry into opening of
fuel tank.
♦ Moisten seal with fuel only when installing flange or fuel de‐
livery unit.
♦ Fuel lines are to be installed free of kinks.
♦ Do not interchange supply and return lines (return line blue or
with blue markings, supply line black).
♦ Ensure fuel hoses are tight.
♦ Connections for fuel lines must engage audibly when joined.
♦ After installing fuel delivery unit, check that supply and return
lines are still clipped onto fuel tank.
agen
AG. Volkswagen AG d
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olks not
♦ Observe fitting position of
d b fuel delivery unit flange
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⇒ page 110 . ris
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1.9 Removing and installing fuel gauge
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1.9.1 Removing
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– Release connector tabs of wires -3- and -4- and pull them off.
– Raise retaining tabs -1- and -2- using a screwdriver and pull
rrectness of i
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ate
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Rep. Gr.20 - Fuel supply system cted agen
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Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
1.9.2 Installing
– Insert fuel sender into guides on fuel delivery unit and press
upwards until it engages.
– Install fuel delivery unit ⇒ page 116 .
satelettronica
♦ Diode test lamp -V.A.G 1527 B-
n AG. Volkswagen AG do
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Test prerequisite
spec
urposes, in part or in wh
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i
or
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about 2 seconds.
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satelettronica
– Pull 5-pin connector off fuel delivery unit flange.
AG. Volkswagen AG d
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lksw not
– Set multimeter to measuring ranged20 by A and connect in series
Vo gu
ara
between contacts -1- of connector oris and fuel pump using auxil‐
e nte
iary cables from auxiliary measuring
aut
h set -V.A.G 1594 C- . eo
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un
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Note
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The current pick-up clamp of multimeter -V.A.G 1715- can also ility
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nector and fuel pump.
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♦ Torque wrench (5...50 Nm) -V.A.G 1331-
erm
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urposes, in part or in wh
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mer
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♦ Diagnostic cable -VAS 5051/6A-
or
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Test prerequisites
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Unit injectors OK
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Fuel filter and fuel lines must not be blocked. co Vo
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Prote AG.
Procedure
– Remove engine cover ⇒ page 4 .
– Remove screw plug -arrow-.
satelettronica
AG. Volkswagen gen AG do
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– Increase engine speed to 4000
by
Vol rpm.
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– Observe pressure indicated on pressure gauge. tee
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Specification: min. 7.5ssbar ce
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If specification is now obtained:
an
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Note
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replace seal.
s o
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Note
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Procedure
– Pull fuel supply hose (white marking) ⇒ Item 28 (page 44) and
fuel return hose (blue marking) ⇒ Item 29 (page 44) off tandem
pump.
– Seal fuel return union on tandem pump with a plug. Secure
sealing plug with a spring-type clamp.
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Prepare test unit -V.A.G 1687-
y V as follows:
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– Unscrew pressurethoregulating
ris valve -2- and close valves -3- ntee o
and -4-. s au ra
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Note
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To turn the pressure regulating valve -2- the knob must be pulled
upwards.
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– Connect compressed air hose -1- (compressed air source) to
pt
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charge air system tester -V.A.G 1687- .
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Note
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spec
If there is water in the sight glass, drain at water drain screw -6-.
es, in part or in w
t to the co
– Open valve -3-.
– Adjust pressure to 1.0 bar with pressure regulating valve -2-.
rrectness of i
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Caution
nf
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The maximum test pressure is 1.3 bar and this must not be
orm
exceeded.
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atio
om
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or c
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– Open valve -4- and wait until the test circuit is filled. If neces‐
t
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sary readjust pressure to 1.0 bar.
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en
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If the pressure does not drop the tandem pump can be reused, if
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the pressure drops the tandem pump must be renewed. Prote
cted AG.
agen
DANGER!
satelettronica
AG. Volkswagen AG d
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urposes, in part or in wh
t to the co
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Removing
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– Remove bolt -arrow- and pull air filter housing upwards out of
mer
atio
mounting.
om
n
c
– Remove air filter housing together with air mass meter and
or
n thi
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connecting pipe.
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– Pull off supply hose -1- (white marking) and return hose -2-
(blue marking) from fuel filter.
– Connect hand vacuum pump with accessories -V.A.G 1390-
and water drainage container -V.A.G 1390/1- to return hose
-2-.
– Operate hand vacuum pump until no more fuel comes out of
return hose. Be careful that no fuel is sucked into hand vacuum
pump.
– Pull vacuum line from brake servo -1- off tandem pump -4-.
– Pull supply hose -2- (white marking) and return hose -3- (blue
marking) off tandem pump -4-.
– Remove securing bolts -arrows-.
AG. Volkswagen AG d
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– Remove tandem pump -4- from cylinder head.
Vol
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Installing rise nte
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Installation is carried out in the reverse
ss order. When installing, c
note the following:
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Note
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hole
shaft.
spec
es, in part or in w
t to the co
– Install tandem pump and tighten top securing bolts to 20 Nm.
rrectness of i
– Tighten bottom securing bolts to 10 Nm.
l purpos
orm
m
and vacuum hose from brake servo -1- to tandem pump -4-.
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❑ Not adjustable.
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❑ The accelerator position
erm
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sender passes the posi‐
ility
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unit.
hole
spec
❑ Release using release
es, in part or in w
t to the co
tool -T 10269- (use -
T10297- for right-hand
drive vehicles).
rrectness of i
-A- openings for release tool.
l purpos
satelettronica
nform
ercia
3 - 9 Nm
at
om
ion
c
4 - Cap
in t
or
his
ate
do
priv
cum
for
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t.
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Prote AG.
Removing
satelettronica
AG. Volkswagen AG d
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– Secure accelerator pedal module with securing bolt -3-. Speci‐ by
Vo gu
ara
fied torque: 9 Nm rised
nte
ho eo
ut
– Attach cap. ss a ra
c
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ility
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es, in part or in w
t to the co
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ion
c
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or
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ate
do
priv
cum
for
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21 – Turbocharging/supercharging
gen AG
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1 Charge air system with turbocharger ris
ed ara
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Safety precautions ⇒ page 129 ss c
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un
Rules for cleanliness ⇒ page 129 .
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Installing hose connections with connector couplings
rm
ab
pe
⇒ page 130
ility
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Assembly overview - turbocharger ⇒ page 131
h re
hole
spec
Assembly overview - charge air cooling ⇒ page 132
es, in part or in w
t to the co
Checking charge air system for leaks ⇒ page 133 .
rrectness of i
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WARNING
nform
ercia
satelettronica
ment, pay attention to the following due to the cramped condi‐
m
tions:
a
com
tion in
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
r
te o
thi
vated charcoal filter system, coolant, refrigerant, brake
s
iva
do
fluid and vacuum) and electrical wiring in their original po‐
r
rp
cum
sitions.
fo
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ng
t.
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♦ Ensure that there is sufficient clearance to all moving or Cop py
t.
hot components.
rig
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pyri by
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by c lksw
cted agen
Prote AG.
Observe following if test and measuring instruments are required
during a road test:
♦ Test and measuring instruments must be secured to rear seat
and operated by a second person from this location.
If test and measuring instruments are operated from 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.
ce
le
un
pt
occur. Observe installation instructions.
an
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pe
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Removing
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– Release push-on connection by pulling locking clip -arrow-.
hole
spec
Separate hose and pipe without tools.
es, in part or in w
t to the co
Installing
– If renewed, place seal in groove of charge air hose. Ensure
rrectness of i
the seal is correctly seated in the groove.
satelettronica
l purpos
nform
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a
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tion in
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te o
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s
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charge air hose again.
um
fo
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t.
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– Check if connector coupling seats correctly and is properly
Co
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engaged by pulling hose.
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rig by
copy Vo
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Prote AG.
Note
1 - 10 Nm
2 - Bracket
satelettronica
3 - Heat shield
4 - Oil supply hose
❑ To oil supply line con‐
nection on turbocharger
❑ Before installing oil sup‐
ply line, ensure that it is
not blocked.
AG. Volkswagen AG d
agen
❑ Before installing, Volksw fill tur‐
oes
not
bocharger ed b via oil supply
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ara
hosethowith
ris engine oil nte
e or
au ac
5 - Turbocharger
ss
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pt
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rm
ab
6 - Vacuum hose
pe
ility
ot
wit
h re
spec
7 - Seal
es, in part or in w
t to the co
❑ Renew
❑ Note installation posi‐
tion.
rrectness of i
8 - To particulate filter
l purpos
9 - Clamp, 7 Nm
nform
ercia
❑ For turbocharger/partic‐
ulate filter
m
a
com
ti
❑ Renew
on in
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10 - Exhaust manifold
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iva
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er
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Cop py
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11 - 25 Nm
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co
❑ Renew
by lksw
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Prote AG.
12 - 25 Nm
13 - Seal
❑ Renew
14 - Connecting pipe
❑ For exhaust gas recirculation.
❑ Assembly overview - exhaust gas recirculation cooler ⇒ page 157
15 - 25 Nm
❑ Renew
16 - 15 Nm
17 - O-ring
❑ Renew
18 - Banjo bolt, 60 Nm
19 - Support
❑ For turbocharger
❑ With oil return line
20 - Exhaust gas temperature sender 1 -G235- , 45 Nm
satelettronica
❑ Lubricate thread of sender using high-temperature paste -G 052 112 A3-
❑ Note installation position for temperature sender with angled cable guide ⇒ page 132
AG. Volkswagen AG d
21 - Heat shield agen oes
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22 - Connection rise
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❑ For intake hose for air filter/turbocharger s aut ra
c
s
❑ Assembly overview - air filter ⇒ page 145 .
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23 - 9 Nm
itte
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ab
24 - 10 Nm
ility
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spec
Installation position of exhaust gas temperature sender with an‐
urposes, in part or in wh
t to the co
Note
rrectne
When installing the exhaust gas temperature sender with angled
ss
cable guide, it is absolutely necessary to keep to dimension -a-
o
cial p
f
of 3...5 mm when tightening the turbocharger support.
inform
mer
atio
om
n
c
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or
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Note
ht
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Prote
♦ Charge air system must be free of leaks.
AG.
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pt
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1 - 8 Nm
itte
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erm
ab
2 - Bracket
ility
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❑ Note installation posi‐
, is n
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tion.
hole
spec
3 - Charge air cooler
es, in part or in w
t to the co
❑ To remove, bring lock
carrier into service posi‐
tion ⇒ General body re‐
rrectness of i
pairs, exterior; Rep. Gr.
50 ; Body - front; Lock
l purpos
nf
ercia
or
❑ Pushed onto top and
m
m
atio
bottom of charge air
om
cooler
n in
or c
thi
e
5 - 3 Nm
t
sd
iva
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6 - Charge air pressure sender
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satelettronica
rig
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7 - O-ring
p by
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cted
❑ Renew if damaged.
agen
Prote AG.
8 - Bracket
9 - 5 Nm
10 - Connecting hose
11 - Charge air pipe
12 - Connecting hose
❑ To intake manifold flap
motor -V157-
❑ Assembly overview - in‐
take manifold with in‐
take manifold flap motor
⇒ page 143
13 - 8 Nm
14 - Connecting hose
❑ To turbocharger.
ce
e
– Connect adapter -1687/10- in intake hose -1- and secure with
nl
pt
du
clip.
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itte
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erm
ab
Prepare charge air system tester -V.A.G 1687- as follows:
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
g
t.
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satelettronica
Co
and -4-. t. Cop py
rig
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pyri by
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by
Note
cted agen
Prote AG.
To turn the pressure regulating valve -2- the knob must be pulled
upwards.
Note
If there is water in the sight glass, drain at water drain screw -6-.
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- .
Note
AG. Volkswagen AG d
agen oes
ksw
♦ How to use the ultrasonic tester -V.A.G
by Vol
1842- ⇒ operating not
gu
ara
instructions orise
d
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th eo
♦ If leaks occur, when doing
ss a any repair work observe notes for
u ra
c
charge air system ⇒ page 132 . ce
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un
pt
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pulling coupling off adapter -1687/10- .
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ab
pe
ility
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wit
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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fo
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t.
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Cop py
t. rig
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Vo
co lksw
by
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Prote AG.
1 - Air filter
2 - Charge pressure control
solenoid valve -N75-
3 - Cylinder head cover
4 - Non-return valve
❑ Note installation posi‐
tion
5 - Vacuum line to brake servo
6 - Exhaust gas recirculation n AG. Volkswagen AG do
cooler change-over valve - olkswage es n
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N345- d byV ua
ran
ir se tee
7 - Vacuum unit utho
or
a ac
❑ For change-over sfor
s
ex‐
ce
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pt
du
an
cooler.
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ab
8 - Vacuum unit
ility
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❑ On turbocharger.
wit
, is n
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satelettronica
❑ With position sender for
hole
spec
charge pressure posi‐
es, in part or in w
tioner -G581-
t to the co
rrectness of i
l purpos
nf
ercia
orm
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om
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or c
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te
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
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Prote AG.
Note
ce
le
satelettronica
un
pt
Assembly overview - air filter ⇒ page 145 .
an
d
itte
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erm
ab
1.1 Safety precautions
ility
ot p
wit
is n
h re
ole,
WARNING
spec
urposes, in part or in wh
t to the co
ment, pay attention to the following due to the cramped condi‐
tions:
rrectne
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant, refrigerant, brake
s
fluid and vacuum) and electrical wiring in their original po‐
s o
sitions.
cial p
f inform
♦ Ensure that there is sufficient clearance to all moving or
mer
hot components.
atio
om
n
c
i
or
n thi
te
sd
a
o
pr
c
during a test drive:
um
r
fo
en
ng
t.
yi
♦ Test and measuring instruments must be secured to rear seat
Co
op py
and operated by a second person from this location. t. C rig
gh ht
pyri by
♦ If test and measuring instruments are operated from front pas‐
co Vo
by lksw
cted
senger seat and the vehicle is involved in an accident, there
agen
Prote AG.
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 damage to 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.
♦ Disconnecting and connecting the battery must only be un‐
dertaken when the ignition is switched off otherwise the diesel
direct injection system control unit may be damaged.
ce
le
♦ Install clean components only. Do not remove replacement
un
pt
an
d
parts from packing until immediately before installing. Do not
itte
y li
use parts that have not been stored in their packing (e.g. in
rm
ab
pe
tool boxes etc.).
ility
ot
wit
, is n
h re
hole
spec
essary.
es, in part or in w
t to the co
♦ Also ensure that no diesel fuel runs on to the coolant hoses.
Should this occur, the hoses must be cleaned immediately.
Damaged hoses must be renewed.
satelettronica
rrectness of i
1.3 Assembly overview - unit injector
l purpos
nform
ercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
8 - O-ring
❑ Renewing ⇒ page 139 .
9 - O-ring
❑ Renewing ⇒ page 139 .
10 - Heat shield seal
❑ Renew
11 - Circlip
AG. Volkswagen AG d
12 - Cylinder head agen oes
olksw not
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13 - Clamping block rised
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14 - 12 Nm + 3/4 turn (270 °) a ra
ss c
further
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pt
du
an
❑ Renew
itte
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ab
ility
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spec
injector
es, in part or in w
t to the co
nf
ercia
orm
m
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om
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or c
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te
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t.
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Cop py
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rig ht
Removing
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co Vo
by lksw
cted agen
– Lever old O-rings very carefully out of unit injector.
Prote AG.
Note
ce
le
fully.
un
pt
an
d
itte
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– Slide assembly sleeve -T10056/1- onto limit stop on unit in‐
rm
ab
jector.
pe
ility
ot
satelettronica
wit
, is n
h re
sleeve and into the seat on the unit injector.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
a
com
t
jector.
ion in
r
te o
cum
fo
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.5.1 Removing
rrectness of i
l purpos
– Turn crankshaft until the cam pair point evenly upwards for the
rm
m
n in
c
thi
e
justment screws.
t
sd
iva
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rp
cu
m
f
wards) with socket -3410- and take rocker arm shaft off.
en
ng
t.
yi Co
op py
– Remove tensioning block securing bolt -3- with special t. C rig
gh ht
wrench, long reach -T10054- and remove tensioning block. yri
p by
co Vo
by lksw
cted
– Lever connector off unit injector with a screwdriver. To avoid
agen
Prote AG.
canting, support opposite side of connector with light finger
pressure.
Observe unit injector cylinder allocation.
1.5.2 Installing
satelettronica
Note
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e
nl
pt
du
– Check that the three O-rings and the heat shield seal along
an
itte
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with securing clip are seated correctly before installing unit in‐
erm
ab
jector.
ility
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wit
, is n
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hole
Note
spec
es, in part or in w
t to the co
The seals must not be twisted.
– Oil the seals and fit the unit injector into the cylinder head with
rrectness of i
great care.
l purpos
– Push the unit injector evenly into the cylinder head onto its limit
stop.
nf
ercia
– Insert the clamping block in the slot on the side of the unit
rm
m
injector.
atio
om
n in
or c
thi
te
Note
sd
iva
o
r
rp
cu
o
m
f
If the unit injector is not at right angles to the tensioning block the
en
ng
t.
yi Co
securing bolt may loosen and this can damage the unit injector or Cop py
the cylinder head. ht. rig
rig ht
py by
co Vo
by lksw
cted
– Therefore align the unit injector as follows.
agen
Prote AG.
– Screw the new securing bolt into the tensioning block until the
unit injector can still be turned easily.
– Fit rocker arm shaft and tighten new securing bolts as follows:
– First evenly tighten inner bolts -2- and then outer bolts -1-
hand-tight. Then using same sequence, tighten to 20 Nm and
90° (1/4 turn) further evenly.
satelettronica
– Adjust non-contact gap of unit injectors ⇒ page 143 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
1.5.3 Adjusting non-contact gap of unit injec‐ or eo
th
au ra
tors ss c
ce
le
un
pt
an
d
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rm
ility
er of the rocker arm is positioned on the peak of the drive cam.
ot
wit
, is n
– Now turn adjustment screw into rocker arm until a firm resist‐
ance is felt (unit injector positioned at stop).
rrectness of i
l purpos
nform
ercia
a
com
Nm.
r
te o
thi
s
iva
cum
fo
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1 - Seal
❑ Renew
2 - Intake manifold
3 - Seal
❑ Renew
4 - Connection
❑ Remove any carbon de‐
posits ⇒ page 144
5 - Intake manifold flap motor -
V157- AG. Volkswagen AG d
agen oes
❑ The intake manifold flap olksw not
yV gu
is closed for approx. 3 ed b ara
nte
is
seconds when stopping hor eo
ut
engine and then opens ss a ra
c
again. This reduces the
ce
e
nl
stop jolt.
pt
du
an
itte
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6 - From charge air cooler
erm
ab
ility
ot p
7 - 10 Nm
wit
satelettronica
, is n
h re
8 - Exhaust gas recirculation
hole
spec
valve -N18- with exhaust gas
es, in part or in w
recirculation potentiometer -
t to the co
G212-
❑ Assembly overview - ex‐
haust gas recirculation
rrectness of i
⇒ page 156
l purpos
9 - Seal
❑ Renew
nform
ercia
10 - Connecting pipe
m
at
om
i
❑ For exhaust gas recircu‐
on
c
in t
lation cooler.
or
his
ate
t.
yi Co
op
11 - 22 Nm
C py
ht. rig
rig ht
py by
12 - Bracket co Vo
by lksw
cted agen
Prote AG.
13 - 22 Nm
Note
WARNING
ce
le
pt
intake manifold flap support, replace the seals and insert it
an
d
itte
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back in position.
erm
ab
ility
ot p
satelettronica
wit
is n
h re
ole,
spec
urposes, in part or in wh
1 - Intake hose
t to the co
❑ To turbocharger.
2 - Air mass meter -G70-
rrectne
3 - O-ring
❑ Renew if damaged.
ss o
cial p
f
4 - 8 Nm
inform
mer
6 - 8 Nm
n
c
i
or
n thi
e
7 - Vacuum hose
t
sd
iva
o
pr
t.
yi Co
op py
8 - Filter element t. C rig
gh ht
pyri by
9 - Air duct
co Vo
by lksw
cted agen
Prote
❑ To lock carrier.
AG.
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le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
satelettronica
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Procedure
nform
ercia
a
com
tio
thi
do
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– Switch on ignition.
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Select operating mode: yri
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– Press button on display for “Vehicle self-diagnosis”.
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Procedure
– Connect vehicle diagnostic, testing and information system -
VAS 5051- as follows:
. Volkswagen AG
gen AG
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– Connect diagnostic
Vol
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a oes
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Select “guidedris fault finding” in vehicle diagnostic, testing
e an and in‐
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formationasystem -VAS 5051- .
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After all control units have been read:
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– Select “Functions”.
– Select “Function or component”.
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Note
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Before removing engine control unit, read the control unit identi‐
t.
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fication and, with it, the coding of the current control unit
C py
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⇒ page 146 .
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Removing engine control unit
AG.
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– Release connector on engine control unit and pull off connec‐
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– Push bracket -1- off engine control unit.
o
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f inform
Installing engine control unit
mer
atio
– Push bracket onto engine control unit.
om
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Cop py
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Note
Before removing engine control unit, read the control unit identi‐
fication and, with it, the coding of the current control unit
⇒ page 146 .
Removing
– Switch off ignition.
– Remove plenum chamber bulkhead ⇒ General body repairs;
Rep. Gr. 50 ; Body front; Plenum chamber bulkhead .
– Twist shear bolts -arrows- out using pliers and remove cover
from protective housing.
– Then remove securing nuts for control unit bracket -arrows-.
AG. Volkswagen AG d
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– Press catches -1- and -2- outwards. Then pull engine control
wit
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Installing
es, in part or in w
t to the co
– Push engine control unit onto control unit bracket until it en‐
gages in catches.
– Fit connector to engine control unit and lock in position.
rrectness of i
l purpos
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or
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do
priv
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en
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– Tighten new shear bolts -arrows- evenly until heads shear off.
– Install plenum chamber bulkhead ⇒ General body repairs;
Rep. Gr. 50 ; Body front, plenum chamber bulkhead .
satelettronica
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26 – Exhaust system
1 Parts of the exhaust system
Note
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must always be adapted using diagnostic tester : Guided
functions; Adapting exhaust gas pressure sensor 1 -G450- .
rrectne
Assembly overview - front exhaust pipe with particulate filter
⇒ page 151
ss
Assembly overview - silencer with mountings ⇒ page 153
o
cial p
f inform
1.1 Assembly overview - front exhaust pipe with particulate filter
mer
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1 - 8 Nm
2 - Exhaust gas pressure sen‐
sor 1 -G450-
3 - Bracket
❑ For control lines
4 - 10 Nm
5 - Control line, 45 Nm
6 - Lambda probe -G39- , 50
Nm
❑ Grease threads only
with high-temperature
paste -G 052 112 A3- ,
high-temperature paste
-G 052 112 A3- must not
get into the slots of
probe body.
❑ To remove use lambda
probe open ring span‐
ner set -3337-
satelettronica
7 - Temperature sender before
particulate filter -G448- , 45
Nm
❑ Lubricate thread of
sender using high-tem‐
perature paste -G 052
112 A3-
8 - Particulate filter
❑ Remove subframe to re‐
move ⇒ Running gear,
axles, steering; Rep.
Gr. 40 AG. Volkswagen AG d
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9 - Front exhaust pipe ed b ara
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10 - Marking aut ra
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❑ For clamp.
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11 - To front silencer
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12 - 25 Nm
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13 - Mounting
spec
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❑ Renew if damaged.
t to the co
15 - From turbocharger
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16 - Clamp, 7 Nm
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17 - Seal
❑ Renew
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18 - 40 Nm
s
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19 - Bracket
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❑ Bolted to cylinder head
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1 - 25 Nm
t to the co
2 - Double clamp
3 - Retaining ring for front si‐
rrectne
lencer
satelettronica
❑ Renew if damaged.
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4 - Retaining ring for rear si‐
inform
lencer
mer
❑ Renew if damaged.
atio
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❑ For repairs, renew indi‐
iva
o
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vidually.
p
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6 - 25 Nm
t.
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7 - Mounting opyri
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11 - Mounting
12 - To front exhaust pipe
1.2.1 Separating
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Special tools and
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♦ Pneumatic
sa
ut sabre saw -V.A.G 1523 A- or
ac
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spec
urposes, in part or in wh
t to the co
rrectnes
♦ Eye protection
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Procedure
inform
mer
atio
m
WARNING
o
n
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– Cut exhaust pipe at right angles at separating point
Co
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-arrow 2-.
t. C rig
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– When installing, position repair double clamp -4- at side mark‐
co lksw
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ings -arrow 1- and -arrow 3-. Prote AG.
– Install repair double clamp so that end of bolt does not extend
beyond lower edge of clamp.
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• Bolted connection faces rear. olksw
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– Align cold exhaust system orisfree of stress ⇒ page 155 .
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– Tighten bolts on repair
s double clamp.
s a c
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Specified torque, M8: 25 Nm nl
pt
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Specified torque, M10: 40 Nm
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Test prerequisite
rrectness of i
• Engine must be cold.
l purpos
Procedure
– Loosen bolted connections of clamp between exhaust pipe
nf
ercia
satelettronica
rm
m
atio
– Position clamp at distance -a- = 5 mm from marking on front
om
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AG. Volkswagen AG d
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2 Exhaust gasVol recirculation system
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direct injection system control unit -J248- via the exhaust gas
erm
ab
recirculation potentiometer -G212- .
ility
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spec
Assembly overview - exhaust gas recirculation ⇒ page 156
es, in part or in w
t to the co
Assembly overview - exhaust gas recirculation cooler
⇒ page 157
rrectness of i
2.1 Assembly overview - exhaust gas recirculation
l purpos
1 - Seal
nf
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o
❑ Renew
rm
m
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m
satelettronica
2 - Intake manifold
o
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3 - Seal
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❑ Renew
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4 - Connection
t.
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5 - Intake manifold flap motor -
t. rig
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p by
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❑ The intake manifold flap
agen
Prote AG.
is closed for approx. 3
seconds when stopping
engine and then opens
again. This reduces the
stop jolt.
6 - From charge air cooler
7 - 10 Nm
8 - Exhaust gas recirculation
valve -N18- with exhaust gas
recirculation potentiometer -
G212-
❑ Before installing check
sealing surfaces on in‐
take manifold for soiling,
clean if necessary.
❑ If the exhaust gas recir‐
culation valve -N18-
with exhaust gas recir‐
culation potentiometer -
G212- is renewed the
ignition must be switch‐
ed off and then on 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 one minute.
❑ Then read engine control unit fault memory, there must not be a fault stored ⇒ page 146 .
❑ If a fault is stored, clear fault memory and repeat work sequence.
9 - Seal
❑ Renew
10 - Connecting pipe
❑ For exhaust gas recirculation.
❑ Assembly overview a-gen AG. Volkgas
exhaust
swagen AG
recirculation
does cooler ⇒ page 157
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11 - 22 Nm sedb ran
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12 - 22 Nms aut or
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2.2 Assembly overview - exhaust gas recirculation cooler
rm
ab
pe
ility
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1 - Coolant hose
hole
spec
❑ To connection
es, in part or in w
t to the co
❑ Coolant hose schematic
diagram ⇒ page 92 .
2 - Seal
rrectness of i
❑ Renew
l purpos
3 - 22 Nm
nform
ercia
satelettronica
4 - Connecting pipe
m
a
com
tion in
6 - 25 Nm
r
te o
❑ Renew thi
s
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t.
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with exhaust gas recirculation C py
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potentiometer -G212-
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co
❑ Assembly overview - ex‐
by lksw
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haust gas recirculation
AG.
⇒ page 156
8 - Exhaust gas recirculation
cooler
9 - 10 Nm
10 - Coolant hose
❑ From rear coolant pipe
❑ Coolant hose schematic
diagram ⇒ page 92 .
11 - Connecting hose
12 - Exhaust gas recirculation
cooler change-over valve -
N345-
13 - Connecting pipe
14 - Vacuum actuator
❑ For bypass flap.
❑ Renew only together with exhaust gas recirculation cooler
❑ Vacuum hose schematic diagram ⇒ page 135
WARNING
The ceramic glow plugs ⇒ page 158 are susceptible to shocks gen AG
. Volkswagen AG
does
swa
and bends. For this reason, glow plugs falling down -even y Volkfrom not
gu
a small height (approx. 2 cm)- must never be used, ised b this also ara
nte
applies when no damage is visible. It is absolutelyut
hor
necessary eo
to follow installation instructions, otherwise sthe
s glow plug can
a ra
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break and cause damage to the engine.
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nl
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satelettronica
erm
ab
Visual features of ceramic glow plugs
ility
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Vehicles with 2 valves per cylinder cylinder head
, is n
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hole
spec
es, in part or in w
-B- = Ceramic glow plug with support tube -arrow-, not colour-
t to the co
coded.
Vehicles with 4 valves per cylinder cylinder head
rrectness of i
-C- = Metal glow plug, colour-coded -arrow-.
l purpos
-D- = Ceramic glow plug with support tube -arrow-, not colour-
coded.
nform
ercia
at
om
ion
c
his
ate
do
priv
cum
for
en
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t.
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Cop py
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Prote AG.
satelettronica
AG. Volkswagen AG d
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ab
ility
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, is n
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spec
es, in part or in w
t to the co
Test prerequisites
rrectness of i
• Engine is cold
l purpos
orm
m
atio
m
Note
o
n in
or c
thi
te
o
r
cu
o
m
f
en
ng
t.
yi Co
– Pull connectors off ceramic glow plugs. Cop py
t. rig
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– Remove ceramic glow plugs using U/J extension and socket, p by
co Vo
10 mm -3220- .
by lksw
cted agen
Prote AG.
Installation is carried out in the reverse order. When installing,
note the following:
– Before installing, all deposits must be removed completely
from cylinder head bore and thread.
Note
AG. Volkswagen AG d
WARNING lksw
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not
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♦ After installing and beforerise the engine is started, always nte
ho eo
perform a resistances a test on all ceramic glow plugs when
ut ra
c
engine is cold. s
ce
le
un
pt
♦ If a defective ceramic glow plug is broken remove all frag‐
an
d
itte
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ments from the engine, otherwise these can cause dam‐
rm
ab
age to the engine.
pe
ility
ot
wit
, is n
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hole
satelettronica
♦ Specification: Max. 1 Ω
spec
es, in part or in w
t to the co
glow plug.
rrectness of i
l purpos
nform
mercia
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com
tion in
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iva
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Cop py
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co lksw
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Prote AG.