Service: Touran 2003

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Service

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Service Department. Technical Information


Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
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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.

All rights reserved.


No reproduction without prior agreement from publisher.

Copyright © 2015 Volkswagen AG, Wolfsburg K0058972420


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Contents
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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

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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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1.1 Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12


1.2 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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1.4 Assembly overview - crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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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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2.3 Removing and installing sealing flange - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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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

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42


1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.3 Removing, installing and tensioning toothed belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2 Repairing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.3 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.4 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.5 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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

2 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81


2.1 Assembly overview - oil pump, sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3 Oil filter bracket, oil pressure and oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.1 Assembly overview - oil filter bracket and oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.2 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

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 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107


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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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1.3 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

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1.4 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

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1.5 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

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1.6 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

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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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1.11 Checking tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120


1.12 Removing and installing tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
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1.13 Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127


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21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
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1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129


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1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129


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1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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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1.7 Vacuum hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137


1 Repairing diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.3 Assembly overview - unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.4 Removing and installing O-rings for unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.5 Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1.6 Assembly overview - intake manifold with intake manifold flap . . . . . . . . . . . . . . . . . . . . . . 143
1.7 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

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

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151


1 Parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.1 Assembly overview - front exhaust pipe with particulate filter . . . . . . . . . . . . . . . . . . . . . . 151
1.2 Assembly overview - silencer with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2.1 Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2.2 Assembly overview - exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

28 - Glow plug system . . . . . . .en. A.G.. V.o.lk.sw.a.ge.n.A.G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158


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1 Checking glow plug Vosystem . . . . . . . . . . . . . . n. o.t .gu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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1.1 Characteristics
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1.2 Removing,
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Contents iii
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

satelettronica
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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 .

1.1 Engine number


The engine number (“code letters” and “serial number”) can be
found at the joint between engine and gearbox.
The engine number consists of up to nine characters (alphanu‐
meric). The first part (maximum 3 characters) makes up the
“engine code”, and the second part (6 characters), the “serial
number”. If more than 999,999 engines with the same engine
code are produced, the first of the six characters is replaced with
a letter.
Additionally there is a sticker on the
agen Atoothed
G. Volkswbelt
agen guard
AG do with “en‐
es n
gine code” and “serial number”.
olksw ot g
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satelettronica
b ara
ed
The engine code ishalso
or
is included on the vehicle data plate. nte
e
t or
au ac
ss

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1.2 Engine data


nl

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Engine code BMM


ab
ility
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Manufactured wit 05.05 ▸


, is n

h re
Emissions fulfil EU4 standard
hole

spec

Capacity l 2.0
es, in part or in w

t to the co

Output kW at rpm 103/4000


Torque Nm at rpm 320/1750... 2500
rrectness of i

Bore ∅ mm 81.0
Stroke mm 95.5
l purpos

Compression ratio 19.0


Fuel according to DIN EN 590
nform
ercia

Firing order 1-3-4-2


m

at
om

Particulate filter yes


on
c

in t
or

Exhaust gas recirculation yes


his
ate

do
riv

Turbocharging/supercharging yes
p

cum
or

Charge air cooler yes


f

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ng

t.
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Valves per cylinder t. Cop py
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1. Technical data 1
Touran 2003 ➤ gen AG. Volkswagen AG d
wa oes
4-cylinder diesel
yV
olks engine (2.0 l engine, 2-valve,
not
g TDI) - Edition 06.2008
b ua
ed ran
oris tee
th or
10 – Removing and installing engine
au ac
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1 Removing and installing engine
erm

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ility
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Removing engine ⇒ page 2

wit
is n

h re
ole,

Securing engine to assembly stand ⇒ page 7

spec
urposes, in part or in wh

Notes on installing ⇒ page 8

t to the co
Assembly mountings ⇒ page 11 .

1.1 Removing engine

rrectness
Special tools and workshop

o
cial p

f i
equipment required

nform
mer

♦ Lifting tackle -2024 A-

atio
om

n
♦ Engine support -T10012-
c

i
or

n thi
te

sd
♦ Support clamp -VW 313-
iva

satelettronica
pr

cum
r

♦ Engine and gearbox sup‐


fo

en
ng

port -VW 540- or engine


t.
yi Co
op
and gearbox support -VAS
C py
t. rig
gh
6095-
ht
pyri by
Vo
co lksw
by
♦ Workshop crane -V.A.G
cted agen
Prote AG.
1202 A-
♦ Drip tray -V.A.G 1306-

2 Rep. Gr.10 - Removing and installing engine


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

♦ Torque wrench (5...50 Nm)


-V.A.G 1331-
♦ Torque wrench (40...200
Nm) -V.A.G 1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Spring-type clip pliers -VAS
5024-
♦ Stepladder -VAS 5085-

satelettronica
AG. Volkswagen AG d
agen oes
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Not illustrated:
h re
hole

spec
es, in part or in w

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


t to the co

♦ Engine bung set -VAS 6122-


♦ Grease -G 000 100-
rrectness of i

♦ Cable ties
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
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pyri by
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by
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Prote AG.

1. Removing and installing engine 3


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Procedure

Note

♦ Before carrying out further work. disconnect battery earth


strap. First check whether a coded radio is fitted. Obtain anti-
theft code first if necessary.
♦ The engine is removed downwards together with the gearbox.
♦ Leave key in ignition to prevent steering wheel lock from en‐
gaging.
♦ All cable ties which are opened or cut through when the engine
is removed must be replaced in the same position when the
engine is installed.
♦ To prevent damage to removed components, place them in
the container for removed parts -V.A.G 1698- .
♦ Some components cannot be removed, or removed only with
difficulty, with the engine installed. Therefore, you should de‐
termine all defective components before removing engine and
renew them while engine is removed.

satelettronica
n AG. Volkswagen AG do
– Read all fault memories before removal ⇒lksDiagnostic
wage tester es n
VAS 5051; Guided fault finding; Vehicle
d by system test or VAS
Vo ot g
ua
5052; Vehicle self-diagnosis . orise ran
te
h eo
ut ra
– With ignition switched off, disconnect
ss
a earth strap from battery. c

ce
le

– Remove engine cover ⇒ page 4 .


un

pt
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d
itte

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One-piece engine cover
rm

ab
pe

ility
For one-piece engine cover, pull engine cover abruptly upwards
ot

wit
, is n

at front and right -arrows A-, then pull forwards out of rear fas‐
tening -arrow B-. h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

Two-piece engine cover


nform
ercia

For two-piece engine cover, first pull outer engine cover abruptly
m

a
com

upwards at -arrows-, then pull inner engine cover abruptly up‐


ion in

wards at -arrows-.
r
te o

thi
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Prote AG.

4 Rep. Gr.10 - Removing and installing engine


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– 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-.

WARNING
AG. Volkswagen AG d
agen oes
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♦ The fuel and the fuel linesbin y Vthe fuel system can become t gua
ol no
very hot (danger of scalding)!
ris
ed ran
tee
tho or
♦ The fuel system isss also under pressure! Before opening
u

satelettronica
a ac
the system, place cloths around the connections. Then

ce
e
nl

carefully loosen connection to release the pressure!

pt
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itte

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♦ Wear eye and hand protection when performing any type
erm

ab
of repair work on the fuel system!

ility
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wit
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h re
hole

spec
– Remove sound insulation tray ⇒ General body repairs, exte‐
es, in part or in w

rior; Rep. Gr. 50 ; Body front; Assembly overview

t to the co
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. Gr. 50 ; Body front; Lock carrier - service posi‐
tion . rrectness of i
l purpos

– Drain off coolant ⇒ page 93 .


Vehicles with air conditioner
nf
ercia

orm
m

atio

Note
om

n in
or c

thi

To prevent damage to condenser and also to refrigerant lines/


te

sd
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hoses, ensure that the lines and hoses are not stretched, kinked
o
r
rp

cu

or bent.
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t.
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op py
To facilitate removing and installing engine without opening re‐
. C rig
ht ht
rig
frigerant circuit: py by
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cted
– Remove poly V-belt ⇒ page 14 .
agen
Prote AG.

– Remove air conditioner compressor from compact bracket ⇒


Heating, air conditioning; Rep. Gr. 87 ; Removing and instal‐
ling compressor bracket .
– Secure air conditioner compressor to lock carrier so that re‐
frigerant lines are relieved.
Continuation for all vehicles
– Remove engine control unit ⇒ page 148 .
– Release connector on engine control unit and pull off connec‐
tor.
– Remove leadthrough for engine control unit wiring harness.

1. Removing and installing engine 5


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Open all cable guide fasteners -arrows-.


– Remove wiring harness from cable guide on longitudinal mem‐
ber and lay to side on engine.

AG. Volkswagen AG d
agen oes
olksw not
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d by ar
– Separate theoris following connectors (on bulkhead): ante
e
th eo
♦ au 1 for temperature sender before particulate filter
Connector
s
ra
c -
s
G448-

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e
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♦ Connector 2 for exhaust gas temperature sender 1 -G235- .
itte

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♦ Connector 3 for lambda probe -G39-

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♦ Connector 4 for charge pressure control solenoid valve -N75-

h re

satelettronica
hole

spec
– Pull off or disconnect all other electrical connections as nec‐
es, in part or in w

essary from engine and gearbox and lay to side.


– Separate all connection, coolant, vacuum and intake hoses t to the co
from engine.
rrectness of i

Vehicles with manual gearbox.


l purpos

– Remove selector mechanism from gearbox ⇒ 6-speed man‐


ual gearbox 02Q; Rep. Gr. 34 ; Repairing selector mecha‐
nform
ercia

nism .
m

– Separate pressure line for hydraulic clutch control.


at
om

ion
c

Vehicles with manual gearbox.


in t
or

his
ate

– Remove selector mechanism from gearbox ⇒ Direct shift


do
priv

gearbox 02E; Rep. Gr. 34 ; Selector mechanism .


um
for

en
ng

t.
Continuation for all vehicles
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– Pull connector off oil level and oil temperature sender -G266- .
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pyri by
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– Pull retainer for oil level and oil temperature sender -G266- off
cted agen
Prote AG.
subframe.
– Unbolt left and right drive shafts from gearbox ⇒ Running
gear, axles, steering; Rep. Gr. 40 ; Removing and installing
drive shafts .

– Unbolt pendulum support -arrows-.


– Remove subframe and steering box ⇒ Running gear, axles,
steering; Rep. Gr. 40 .
– Release connecting clamp for front exhaust pipe/front silenc‐
er.

Note

The engine is lowered downwards with particulate filter fitted.

6 Rep. Gr.10 - Removing and installing engine


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Insert engine support -T10012- in engine and gearbox jack -


V.A.G 1383 A- .

Note

Support pins must be secured to engine bracket -T10012- as


shown. The threaded support pin must be on the gearbox side.

– Fit engine bracket -T10012- to cylinder block with M10 x 25/


8.8 bolt and tighten to approx. 40 Nm.
– Raise engine and gearbox slightly using engine and gearbox
jack -V.A.G 1383 A- . G. Volkswage
A n AG d
agen oes
olksw not
– y V side from engine bracket
Unbolt assembly mounting on eengine gu
db ara
-arrows-. horis nte
eo
aut ra
ss c

ce
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Note
un

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ab
To remove securing bolts, use stepladder -VAS 5085- .

ility
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satelettronica
wit
is n

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ole,

spec
urposes, in part or in wh

t to the co
rrectne
– Unbolt assembly mounting on gearbox side from gearbox
bracket -arrows-.

ss o
cial p

f
Note

inform
mer

atio
To remove securing bolts, use stepladder -VAS 5085- .
om

n
c

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or

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– Carefully lower engine with gearbox.


te

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pr

cum
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fo

Caution
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t.
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Cop py
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Engine with gearbox must be guided carefully when lowered yri
gh by
ht
to prevent damage to bodywork.
op Vo
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Prote AG.

1.2 Securing engine to assembly stand


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

1. Removing and installing engine 7


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Attach lifting tackle -2024 A- as shown and raise engine out of


engine and gearbox jack -V.A.G 1383 A- using workshop hoist
-V.A.G 1202 A- .
Pulley end: 3rd hole of hook rail in position 1
Flywheel end: 4th hole in hook rail at position 8.

WARNING

The hooks and locating pins must be secured with locking pins.

Note

♦ The positions marked 1...4 on the bar must be towards the


pulley end.
♦ The holes in the hooks are counted up from the hook.

– Using engine and gearbox support -VW 540- , secure engine


to support clamp -VW 313- of assembly stand or to engine and

satelettronica
gearbox support -VAS 6095- .

1.3 Notes on installing

WARNING

When doing any repair work, especially in the engineagen compart‐


AG. Volkswagen AG d
oes
ksw
ment, pay attention to the following due tobythe
Vol cramped condi‐ not
gu
tions: ris
ed ara
nte
tho eo
♦ Route all the various lines (e.g.au for fuel, hydraulics, 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
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an

sitions.
itte

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erm

ab

♦ Ensure that there is sufficient clearance to all moving or


ility
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hot components.
wit
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h re
hole

spec

Installation is carried out in the reverse order. When installing,


es, in part or in w

t to the co

note the following:


– For vehicles with manual gearbox check clutch release bear‐
ing for wear and renew if necessary.
rrectness of i

– Lubricate splines of input shaft lightly with G 000 100.


l purpos

– Check whether dowel sleeves for centring engine and gearbox


are in cylinder block and install if necessary.
nf
ercia

orm

When installing engine, ensure correct position of assembly


m

atio
m

mountings:
o

n in
or c

thi
te

sd
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rp

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f

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t.
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t. rig
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pyri by
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cted agen
Prote AG.

8 Rep. Gr.10 - Removing and installing engine


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– On belt pulley side, ensure that there is a distance -a- of at


least 10 mm between engine support and right longitudinal
member.
– The side surface of the engine support -2- should be located
parallel to the support arm -1-. Dimension -x- must be identical
at top and bottom.

Note

Distance -a- = 10 mm can also be checked with a metal rod of


suitable size, or similar.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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au ra
ss c

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e
nl

pt
du

an
itte

satelettronica
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erm

ab
ility
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
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f

en
ng

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

1. Removing and installing engine 9


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– 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

♦ Specified torques for engine and gearbox mountings


⇒ page 11 .
♦ Electrical connections and routing ⇒ Electrical system; Rep.
Gr. 97

– Install drive shafts ⇒ Running gear, axles, steering; Rep. Gr.


40 ; Removing and installing drive shafts .
Vehicles with manual gearbox.
– Install hydraulic line for hydraulic clutch ⇒ 6-speed gearbox
0AH; Rep. Gr. 30 ; Repairing clutch controls; Assembly over‐
view - hydraulic system .
– Fit selector mechanism to gearbox ⇒ 6-speed manual gear‐
box 02Q; Rep. Gr. 34 ; Repairing selector mechanism .

satelettronica
Vehicles with manual gearbox.
– Fit selector mechanism to gearbox ⇒ Direct shift gearbox 02E;
Rep. Gr. 34 ; Selector mechanism .
Continuation for all vehicles n AG. Volkswagen AG do
swage es n
– Install air conditioner compressor ⇒ Heating,bair y V conditioning;
olk ot g
ua
Rep. Gr. 87 ; Removing and installing compressor
ir se
d bracket. ran
tee
tho
or
– Install poly V-belt ⇒ page 14 . ss
au ac

ce
le

– Install noise insulation tray ⇒ General body repairs, exterior;


un

pt
an
Rep. Gr. 50 ; Body front; Assembly overview.
d
itte

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rm

– Install engine control unit ⇒ page 148 . ab


pe

ility
ot

wit
– Install plenum chamber bulkhead ⇒ General body repairs,
, is n

h re
exterior; Rep. Gr. 50 ; Body front; Plenum chamber bulkhead .
hole

spec

– Fill coolant system with coolant ⇒ page 93 .


es, in part or in w

t to the co

– Carry out road test and then read fault memory ⇒ page 146 .
Specified torques
rrectness of i

Threaded connection Specified torque


l purpos

Bolts, nuts M6 10 Nm
nform
ercia

M8 20 Nm
m

M10 45 Nm
a
com

tion in

M12 60 Nm
r
te o

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ng

t.
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pyri by
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by
cted agen
Prote AG.

10 Rep. Gr.10 - Removing and installing engine


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

1.4 Assembly mountings


Specified torques for engine mounting
A1) = 20 Nm + 90° (1/4 turn) further
B1) = 40 Nm + 90° (1/4 turn) further
C1) = 60 Nm + 90° (1/4 turn) further
1) Renew

Specified torques for gearbox mounting


A2) = 40 Nm + 90° (1/4 turn) further
B2) = 60 Nm + 90° (1/4 turn) further
2) Renew

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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au ra
ss c

ce
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nl

pt
Specified torques for pendulum support
du

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A3) = 40 Nm + 90° (1/4 turn) further
erm

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ility
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B3) = 100 Nm + 90° (1/4 turn) further

wit
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3) Renew
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

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or c

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t.
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Prote AG.

1. Removing and installing engine 11


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

13 – Crankshaft group
1 Dismantling and assembling engine

Note

♦ Finding metal shavings or a large quantity of small metal par‐


ticles during engine repair could indicate that the crankshaft
bearings or conrod bearings are damaged. To prevent this
from causing further damage, perform the following repairs:
AG. Volkswagen AG d
agen
♦ Thoroughly clean oil channels. Volksw
oes
not
by gu
ara
♦ Renew oil spray jets.
d
rise nte
tho eo
u ra
♦ Renew oil cooler ss a c

ce
le

♦ Renew oil filter element.


un

pt
an
d
itte

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rm

ab
Assembly overview - toothed belt drive ⇒ page 12
pe

ility

satelettronica
ot

wit
Assembly overview - crankcase ⇒ page 16
, is n

h re
hole

Assembly overview - poly V-belt drive ⇒ page 14

spec
es, in part or in w

Removing and installing poly V-belt ⇒ page 14 .

t to the co
1.1 Assembly overview - toothed belt drive

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
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do
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cum
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t.
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Prote AG.

12 Rep. Gr.13 - Crankshaft group


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

1 - Toothed belt guard upper


part
2 - 100 Nm
3 - 25 Nm
AG. Volkswagen AG d
agen oes
4 - Camshaft toothed belt pul‐ olksw not
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5 - Hub s aut ra
c
s
❑ With sender wheel.

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❑ Use counterhold tool -

an
d
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T10051- to loosen and

rm

ab
tighten.
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❑ To remove, use puller -
, is n

h re
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
l purpos

satelettronica
7 - Rear toothed belt guard
8 - 25 Nm

nform
ercia

9 - Sealing grommet
m

a
com

tio
❑ Renew if damaged.

n in
r
te o

thi
10 - 20 Nm + 1/8 turn (45 °) fur‐

s
iva

do
r

ther
rp

cum
fo

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ng

t.
11 - Tensioning roller
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12 - 20 Nm rig ht
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13 - Idler roller Prote
cted AG.
agen

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 .

1. Dismantling and assembling engine 13


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

23 - 40 Nm + 1/2 turn (180 °) further


❑ Renew
24 - Toothed belt guard centre part
25 - Engine support

1.2 Assembly overview - poly V-belt drive

1 - Belt pulley and vibration


damper
❑ Can only be installed in
one position. Holes are
offset.
2 - 25 Nm
3 - Alternator
4 - Bracket
❑ For alternator and air

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
tee
th or
u
8 - 25 Nm ss
a ac
ce
le

9 - Dowel sleeves
un

pt
an
d
itte

y li

10 - Poly V-belt
erm

ab
ility

❑ Mark direction of rota‐


ot p

wit

tion before removing.


is n

h re
ole,

❑ Check for wear.


spec
urposes, in part or in wh

❑ Do not kink.
t to the co

❑ Removing and installing


⇒ page 14 .
rrectness o
cial p

f inform
mer

atio
m

1.3 Removing and installing poly V-belt


o

n
c

i
or

n thi
te

sd

Special tools and workshop equipment required


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.

14 Rep. Gr.13 - Crankshaft group


Touran 2003 ➤
n AG. Volkswagen AG do
lkswage4-cylinder diesel engine
es n (2.0 l engine, 2-valve, TDI) - Edition 06.2008
o ot g
byV ua
ed ran
♦ Mandrel -T10060thor A-
is tee
or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
Removing
l purpos

– Remove noise insulation tray ⇒ General body repairs, exteri‐

nf
or; Rep. Gr. 50 ; Body front; Assembly overview .
ercia

orm
m

– Pull fuel filter out of bracket and lay it with hoses to side.

atio
om

n in
c

– Mark direction of rotation of poly V-belt.


or

thi
te

sd
a

– Using an open jaw spanner, swing tensioning element in di‐

satelettronica
iv

o
r
rp

cu
rection of arrow to remove tension from poly V-belt.
o

m
f

en
ng

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

– Lock tensioner with locking pin -T10060 A- .


– Remove poly V-belt.
Installing
– Installation is carried out in the reverse order. When installing,
note the following:

Note

♦ Ensure, before installing poly V-belt, that all ancillaries (alter‐


nator, air conditioner compressor) are secured tightly.
♦ When fitting poly V-belt, check direction of belt rotation and
proper seating of belt in pulleys.
♦ Lastly, place poly V-belt over alternator.

After completing repairs always:


– Start engine and check how belt runs.

1. Dismantling and assembling engine 15


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Belt drive without air conditioner compressor

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

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p
Belt drive with air conditioner compressor

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne

satelettronica
ss o
cial p

f inform
mer

atio
om

n
c

i
1.4 Assembly overview - crankcase
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.

16 Rep. Gr.13 - Crankshaft group


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

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
AG. Volkswagen AG d
oes
lksw not
❑ First fit upper d by left and
Vo gu
ara
lower right
oris bolts and
e nte
eo
thenautighten
th all four bolts ra
diagonally.
ss c
ce
le
un

pt

7 - Bracket
an
d
itte

y li
erm

8 - 20 Nm
ab
ility
ot p

9 - Connection
wit
is n

h re

❑ For thermostat.
ole,

spec
urposes, in part or in wh

10 - 15 Nm
t to the co

11 - O-ring
❑ Renew
rrectne

12 - Thermostat
❑ Removing and installing ⇒ page 101 .
ss o
cial p

❑ Note installation position ⇒ page 101 .


f inform

❑ Checking: heat thermostat in water.


mer

atio

❑ Opening begins at approx. 85 °C


om

n
c

❑ Ends at approx. 105 °C.


i
or

n thi
te

❑ Opening lift min. 7 mm.


sd
iva

o
pr

cum
r

13 - Hexagon bolt
fo

en
ng

t.
yi
❑ Tightening sequence and torque specifications ⇒ Heating, air conditioning; Rep. Gr. 87 ; Removing and
Co
op py
installing compressor bracket .
t. C rig
gh ht
pyri by
Vo
o
14 - Bracket by c lksw
cted agen
Prote AG.
❑ 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 .

1. Dismantling and assembling engine 17


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

18 - 15 Nm

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

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

satelettronica
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.

18 Rep. Gr.13 - Crankshaft group


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

2 Removing and installing sealing


flange and flywheel

Note

♦ Repairing clutch ⇒ 6-speed manual gearbox 02Q; Rep. Gr.


30; ; Repairing clutch .
♦ When working on engine, secure it with engine and gearbox
support -VW 540- to assembly stand or to engine and gearbox
support -VAS 6095- .

Assembly overview - sealing flange and flywheel ⇒ page 19 .


Renewing crankshaft oil seal - belt pulley end ⇒ page 20 .

2.1 Assembly overview - sealing flange and flywheel

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
olksw not
yV gu
❑ Renew crankshaft oil ised b ara
nte
seal - belt pulley end hor eo
ut
⇒ page 20 . ss a ra
c

ce
e

2 - Sealing flange
nl

pt
du

an
itte

❑ Must seat on dowel

y li
erm

ab
sleeves.

ility
ot p

❑ To remove, first remove

wit
, is n

sump ⇒ page 82 .

h re
hole

❑ Removing and installing

spec
es, in part or in w

⇒ page 22 .

t to the co
❑ Install with silicone seal‐
ant -D 176 404 A2-
⇒ page 22 .
3 - Cylinder block rrectness of i
l purpos

❑ Removing and installing


crankshaft
nform
ercia

⇒ page 33 .
m

❑ Dismantling and assem‐


at
om

io

bling pistons and con‐


n
c

in t
r

rods ⇒ page 36 .
o

his
ate

do
riv

4 - 60 Nm + 1/4 turn (90°) fur‐


p

cum
or

ther
f

en
ng

t.
yi Co
❑ Renew ht. Cop py
rig
rig ht
5 - Flywheel py by
co Vo
by lksw
❑ To remove and install cted agen
Prote AG.
flywheel, counterhold
with 3067.
6 - Intermediate plate
❑ Must seat on dowel sleeves.
❑ Do not damage or bend when assembling.

2. Removing and installing sealing flange and flywheel 19


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

7 - 15 Nm AG. Volkswagen AG d
agen
❑ Renew Volksw
oes
not
gu
d by ara
8 - Sealing flange with oil seal o rise nte
eo
h
ut
❑ Renew complete with oil seal and
ss a sender wheel only. ra
c
❑ To remove, first remove sump ⇒ page 82 .

ce
e
nl

pt
du

an
❑ Removing and installing ⇒ page 24 .
itte

y li
erm

ab
9 - Engine speed sender -G28-

ility
ot p

wit
❑ Loosen and tighten using commercially available ball-ended hex key socket.
, is n

h re
❑ 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
l purpos

Special tools and workshop


equipment required

nf
ercia

orm
♦ Oil seal extractor -3203-
m

atio

satelettronica
om

♦ Counterhold tool -3415-

n in
or c

thi
e

♦ Assembly tool -T10053-


t

sd
iva

o
r
rp

cu
♦ Torque wrench -
o

m
f

en
ng

V.A.G 1331-
t.
yi Co
Cop py
♦ Torque wrench -
t. rig
gh ht
yri
V.A.G 1332-
p by
o Vo
by c lksw
cted agen
Prote AG.

Removing
– Remove toothed belt ⇒ page 47 .

20 Rep. Gr.13 - Crankshaft group


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

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


ed belt pulley using counterhold tool -3415- .
– To guide oil seal extractor -3203- , screw central bolt by hand
into crankshaft to stop.
– Unscrew inner part of oil seal extractor two turns
AG. Vo(approx. 3
lkswagen AG
agen screw.
mm) out of outer part and lock withVoknurled does
lksw not
y gu
db ara
– Oil threaded head of oil sealoextractor.
ris
e nte
th eo
s au ra
c
s

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

– Using great pressure, screw oil seal extractor as far as possi‐

wit
, is n

ble into seal.

h re
hole

spec
– Loosen knurled screw and turn inner part against crankshaft
es, in part or in w

until oil seal is pulled out.

t to the co
Installing

rrectness of i
Note

satelettronica
l purpos

The oil seal sealing lip must not be additionally oiled or greased.

nf
ercia

orm
– Remove oil residue from crankshaft journal using clean cloth.
m

atio
om

n in
or c

– Place guide sleeve -T10053/1- onto crankshaft journal.

thi
te

sd
iva

– Slide oil seal over guide sleeve onto crankshaft journal.

o
r
rp

cu
o

m
f

en
ng

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

– Press oil seal in to stop using assembly tool -T10053- and


centre bolt.

2. Removing and installing sealing flange and flywheel 21


Touran 2003 ➤ gen AG
. Volkswagen AG
does
swa
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition
yV
olk 06.2008 not
gu b ara
ed nte
ris
– Install crankshaft toothed belt pulley. To do this, lockauttoothed
ho e or
ac
belt pulley using counterhold tool -3415- . ss

ce
le
un
– Tighten new centre bolt to 120 Nm and then 1/4 turn (90°) fur‐

pt
an
d
itte

y li
ther (turning further can be done in several stages).

erm

ab
ility
ot p

wit
is n
Note

h re
ole,

spec
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

ss o
cial p

f inform
Special tools and workshop
mer

equipment required

atio
om

n
c

♦ Counterhold tool -3415-

i
or

n thi
te

sd
a

♦ Assembly tool -T10053-


iv

o
r

satelettronica
p

cum
r
fo

♦ Torque wrench -

en
ng

t.
V.A.G 1331-
yi Co
Cop py
ht. rig
♦ Torque wrench - rig ht
py by
V.A.G 1332- co Vo
by lksw
cted agen
Prote AG.

Not illustrated:

♦ Silicone sealant -D 176 404 A-


♦ Hand drill with plastic brush attachment
♦ Flat scraper
♦ Eye protection

22 Rep. Gr.13 - Crankshaft group


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Removing AG. Volkswagen AG d


agen oes
ksw
– Remove toothed belt ⇒ page by V 47 .
ol not
gu
ara
d
ise n
– Remove crankshaftthtoothed
or belt pulley. To do this, lock tooth‐ tee o
ed belt pulley using
ss
a counterhold tool -3415- .
u ra
c

ce
– Drain engine oil. e
nl

pt
du

an
itte

y li
– Remove sump ⇒ page 82 .
erm

ab
ility
ot p

– Pull off front sealing flange.

wit
, is n

h re
– Remove sealing flange; if necessary, loosen by applying light
hole

blows with a rubber-headed hammer.

spec
es, in part or in w

– Remove sealant residue on cylinder block with a flat scraper.

t to the co
rrectness of i
– Remove residual sealant from sealing flange using a plastic
l purpos

rotary brush (wear eye protection).


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

nform
ercia

Installing
m

at

satelettronica
om

ion
c

in t
or

Note

his
ate

do
priv

cum
or

♦ Observe expiry date of sealing compound.


f

en
ng

t.
yi Co
♦ Install sealing flange within 5 minutes of applying the silicone Cop py
t. rig
sealant. opyri
gh by
Vo
ht
c by lksw
cted agen
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.

2. Removing and installing sealing flange and flywheel 23


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Apply silicone sealant bead as shown to the clean sealing sur‐


face of sealing flange.
– Install sealing flange immediately and tighten all bolts lightly.

Note

When fitting sealing flange with oil seal installed, use guide sleeve
-T10053/1- .

– Tighten securing bolts for sealing flange to 15 Nm using alter‐


nate and diagonal sequence.
– Install sump ⇒ page 82 .

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
db ara
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).
u ra
c
s

ce
e
nl

pt
du

an
Note
itte

y li
erm

ab
ility
ot p

Thread and shoulder must be free of oil and grease.

wit
, is n

h re
hole

Installing toothed belt and adjusting valve timing ⇒ page 47 .

spec
es, in part or in w

2.4 Renewing crankshaft sealing flange - t to the co


flywheel end
rrectness of i
l purpos

Special tools and workshop equipment required


♦ Assembly tool -T10134-
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

♦ Torque wrench -V.A.G 1331-


♦ Tool insert 24 mm -V.A.G 1332/11-
♦ Vernier gauge
♦ Three hexagon bolts M6 x 35 mm
♦ Two hexagon bolts M7 x 35 mm

24 Rep. Gr.13 - Crankshaft group


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

2.4.1 Pressing out sealing flange with sender


wheel

Note

♦ For the sake of clarity, the work is performed with the engine
removed.
♦ The procedure is identical whether the engine is installed or
removed.

– Remove flywheel.
– Remove intermediate plate.
– Set engine to TDC No. 1 cylinder
– Remove sump ⇒ page 82 .
. Volkswagen AG
gen AG does
– Remove engine speed sender -G28- -arrow-Vusingolks a commer‐
wa not
cially available ball-ended hex key socket.
ed
by gu
ara
is nte
or eo
– Undo sealing flange securing bolts.auth

satelettronica
ra
ss c

ce
le
un

pt
Note

an
d
itte

y li
rm

ab
pe

ility
Sealing flange and sender wheel are pressed off the crankshaft
ot

together using three M6 x 35 mm bolts.

wit
, is n

h re
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

– Screw bolts alternately (maximum 1/2 turn (180 °) for each


bolt) into sealing flange and press sealing flange together with
sender wheel off crankshaft.
nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

2. Removing and installing sealing flange and flywheel 25


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

2.4.2 Pressing in sealing flange with sender


wheel

Note

♦ The sealing flange with a PTFE seal is equipped with a sealing


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

satelettronica
Assembly tool -T10134-
A - Clamping surface
n AG. Volkswagen AG do
B - Hexagon nut lkswage es n
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byV ua
C - Assembly housing ir se
d ran
tee
tho
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D - Locating pin ss
a ac

ce
le

E - Hexagon socket head bolt


un

pt
an
d
itte

F - Guide pin for diesel engines (black knob) y li


erm

ab
ility
ot p

G - Guide pin for petrol engines (red knob) wit


is n

h re
ole,

spec

2.4.3 A - Assembling sealing flange with send‐


urposes, in part or in wh

t to the co

er wheel on assembly appliance -


T10134-
rrectne

– Screw in hexagon nut -B- to just before clamping surface -A-


of threaded spindle.
ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

26 Rep. Gr.13 - Crankshaft group


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Clamp assembly device -T10134- in a vice on clamping sur‐


face -A- of threaded spindle.
– Press assembly hub -C- downwards so that it lies on hexagon
nut -B- -arrow-.

Note

Inner part of assembly tool and assembly housing must be at


same height.

– Remove securing clip -arrow- from new sealing flange.


AG. Volkswagen AG d
agen oes
lksw not
Note byV
o gu
ara
ed
ris nte
ho eo
The sender wheel must not be takens aout
ut of the sealing flange or ra
c
turned. s

ce
e
nl

pt
du

an

satelettronica
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

– 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.
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
g

– Push sealing lip support ring -A- downwards in direction of ar‐


n

t.
yi Co
row until it lies on flat surface. ht. Cop py
rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2. Removing and installing sealing flange and flywheel 27


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Upper edge of sender wheel and front edge of sealing flange


must align -arrows-.

– Place sealing flange with front side on assembly tool -T10134-


so that locating pin -A- can be inserted in sender wheel hole
-A-.

Note

Ensure sealing flange lies flat on assembly tool.

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
ot g
byV ua
d ran
ir se tee
ho
Note aut or
ac
ss

ce
le
un

When installing sealing flange, ensure that sender wheel remains

pt
an
d

fixed in assembly device.


itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

2.4.4 B - Attaching assembling tool -T10134-


with sealing flange to crankshaft flange t to the co

• Crankshaft flange must be free of oil and grease.


rrectne

• Engine positioned at TDC No. 1 cylinder


ss

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


o
cial p

f in

– Press threaded spindle of assembly tool -T10134- in direction


form
mer

of arrow, until hexagon nut -B- lies against assembly hub -A-.
atio
om

– Align flat side of assembly housing on sump side of crankcase


n
c

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or

sealing surface.
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Prote AG.

28 Rep. Gr.13 - Crankshaft group


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Secure assembly tool -T10134- to crankshaft flange using


hexagon socket head bolts -A-.

Note

Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
prox. 5 full turns).

– To guide sealing flange, screw two M7 × 35 mm bolts -A- into


cylinder block. . Volkswag n AG en AG
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2.4.5 C - Bolting assembly tool -T10134- onto

t to the co
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
ercia

nal installation position.


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The guide pin for petrol engines (red knob) -F- must not be inser‐
rp

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ted in threaded hole of crankshaft.


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– Hand tighten both hexagon socket head bolts of assembly rig ht
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– Screw hexagon nut -E- onto threaded spindle by hand until it
is in contact with assembly hub -C-.

2. Removing and installing sealing flange and flywheel 29


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

2.4.6 D - Pressing sender wheel onto crank‐


shaft flange using assembly tool -
T10134-
– Tighten hexagon nut of assembly tool -T10134- to 35 Nm us‐
ing torque wrench -V.A.G 1331- and insert -V.A.G 1332/11- .

Note

After hexagon nut is tightened to 35 Nm torque, a small air gap


must be present between cylinder block and sealing flange.

2.4.7 E - Checking sender wheel installation


position on crankshaft

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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– Set vernier gauge on crankshaft flange.


rrectness of i

– Measure distance -a- between crankshaft flange and sender


l purpos

wheel.
If measurement -a- is too small:
nform
mercia

– Re-press sender wheel ⇒ page 31 .


a
com

tion in

If dimension -a- is attained:


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– Tighten new securing bolts for sealing flange to 15 Nm using


do
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rp

alternate and diagonal sequence.


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cted agen
Prote AG.

30 Rep. Gr.13 - Crankshaft group


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

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


ing bolt to 5 Nm.
– Install sump ⇒ page 82 .
– Install intermediate plate.
– Install flywheel using new bolts. Tighten securing bolts to 60
Nm +1/4 turn (90°).

2.4.8 F - Re-pressing sender wheel


– Secure assembly tool -T10134- to crankshaft flangeausing
gen AG
. Volkswagen AG
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hexagon socket head bolts -A-. V olksw not
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– Hand tighten both hexagon socket head obolts.
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– Push assembly tool -T10134- by hand
ss to sealing flange.
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– Screw hexagon nut -E- onto threaded spindle by hand until it
is in contact with assembly hub -C-.

rrectness of i
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– Tighten hexagon nut of assembly tool -T10134- to 40 Nm us‐
C py
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gh
ing torque wrench -V.A.G 1331- and insert -V.A.G 1332/11- .
ht
pyri by
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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 .

2.4.9 Removing and installing engine speed


sender -G28-
– Remove noise insulation tray ⇒ General body repairs, exteri‐
or; Rep. Gr. 50 ; Body front; Assembly overview - noise
insulation .

2. Removing and installing sealing flange and flywheel 31


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– 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
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by
cted agen
Prote AG.

32 Rep. Gr.13 - Crankshaft group


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

3 Crankshaft

Note

When working on engine, secure it with engine and gearbox sup‐


port -VW 540- to assembly stand or to engine and gearbox
support -VAS 6095- .

Assembly overview - crankshaft ⇒ page 33


Crankshaft dimensions ⇒ page 34 . n AG. Volkswagen AG do
lkswage es n
Pulling needle bearing out of and driving into crankshaft
byV
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1 - Bearing shells 1, 2, 4 and 5
erm

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❑ For bearing cap without
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oil groove.
, is n

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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

❑ To measure radial clear‐


ance, tighten to 65 Nm
m

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i
but not further.

on
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3 - Bearing cap

his
ate

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❑ Bearing cap 1: belt pul‐


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❑ Bearing shell retaining
cted agen
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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

3.2 Crankshaft dimensions


(dimensions in mm)
Honing dimen‐ Crankshaft Conrod
sion main journal ∅ journal ∅
Basic dimension 54.00 -0.022 47.80 -0.022
-0.042 -0.042

3.3 Pulling needle bearing out of and driving


into crankshaft
Only vehicles with direct shift gearbox AG. Volkswagen AG d
agen oes
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Special tools and workshop equipment required by Vol not
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d
ise nte
♦ Puller -T10055- thor eo
au ra
c

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es, in part or in w

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♦ with adapter -T10055/3-
l purpos

♦ Centring mandrel -3176-

nform
mercia

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♦ Or drift -VW 207 C-


♦ Puller, e.g. Kukko -21/2-

Note

For vehicles with direct shift gearbox, needle bearing must be in‐
stalled in rear end of crankshaft.

34 Rep. Gr.13 - Crankshaft group


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Removing
– Pull out using commercially available puller, e.g. Kukko 21/2
-arrow-, adapter -T10055/3- and puller -T10055- .
Installing

Note

The lettering on the needle bearing must be visible when installed.

– Drive in using drift -VW 207 C- or centring mandrel -3176- .

satelettronica
Installation depth: dimension -a- = 2 mm.

AG. Volkswagen AG d
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35
AG.
3. Crankshaft
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

4 Pistons and conrods

Note

When working on engine, secure it with engine and gearbox sup‐


port -VW 540- to assembly stand or to engine and gearbox
support -VAS 6095- .
G. Volkswage
Assembly overview - pistons
lksw
agand
en A conrods ⇒ npage
AG do 36
es n
o ot g
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Checking piston projection
ise
db at TDC ⇒ page 38 . ran
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Piston and cylinder
sa
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Piston rings, cylinder bore and piston installation position
e
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⇒ page 39

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4.1 Assembly overview - pistons and conrods

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1 - Piston rings

spec

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es, in part or in w

❑ Offset gaps by 120 °

t to the co
❑ Remove and install us‐
ing piston ring pliers.

rrectness of i
❑ “TOP” faces towards
piston crown.
l purpos

❑ Checking ring gap


⇒ page 39
nform
ercia

❑ Checking ring-to-groove
clearance ⇒ page 40
m

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ion
c

2 - Piston
in t
or

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e

❑ Mark installation posi‐


at

do
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tion and cylinder num‐


p

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or

ber.
f

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t.
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❑ Installation position and
Co
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allocation of piston to
t. rig
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cylinder ⇒ page 41 . p by
co Vo
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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

36 Rep. Gr.13 - Crankshaft group


AG. Volkswagen AG d
agen oes
olksw not
ara Touran 2003 ➤
V gu
d by
e nte
4-cylinder hordiesel
is
engine (2.0 l engine, 2-valve, TDI) - Edition
eo 06.2008
aut ra
ss c
6 - Bearing shell

ce
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un

pt
❑ Note installation position.

an
d
itte

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❑ 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

❑ Piston and cylinder dimensions ⇒ page 39 .


8 - Conrod bearing cap

nform
ercia

❑ Note installation position.


m

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.
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9 - Oil spray jet

do
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rp

cum
❑ For piston cooling.
fo

en
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satelettronica
n

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10 - 25 Nm t. Cop py
rig
gh
❑ Insert without sealant.
ht
pyri by
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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

4.2 Separating new conrods

4.2.1 Separating new conrod


– Mark cylinder allocation of conrod ⇒ Item 8 (page 37)
– Lightly clamp the conrod in a vice using aluminium vice
clamps, as shown in the illustration.

Note

♦ To prevent damage to the conrod, only clamp conrod in lightly.


♦ Clamp conrod in below the marked line.

– Unscrew the two bolts -arrows- approx. 5 turns.

4. Pistons and conrods 37


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Using a plastic hammer, carefully knock against conrod bear‐


ing cap -arrow- until it is loose.

AG. Volkswagen AG d
agen oes
olksw not
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pt
4.3 Checking piston projection at TDC

an
d
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ab
Special tools and workshop equipment required

ility
ot p

wit
is n

♦ Measuring bridge -VW 382/7-

h re
ole,

spec
urposes, in part or in wh

t to the co

satelettronica
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cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

♦ End dimension plate -VW 385/17-

sd
iva

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pr

cum
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fo

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ng

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

♦ Dial gauge

38 Rep. Gr.13 - Crankshaft group


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

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

Turn engine clockwise to measure piston projection at TDC.

Piston projection Identification


Holes/notches
0.91 mm ... 1.00 mm 1
1.01 mm ... 1.10 mm 2
1.11 mm ... 1.20 mm 3

4.3.1 Cylinder head gasket identification


♦ Part No. = arrow 1

satelettronica
♦ Holes = arrow 2
♦ Production control code = arrow 3 (can be disregarded)
AG. Volkswagen A
agen G do
es n
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y Vol ot g
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b
ed ran
Note oris tee
th or
au ac
ss
If different values are determined during the projection measure‐
ce
le

ment, use the largest dimension for selecting the gasket.


un

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ility
ot p

4.4 Piston and cylinder dimensions


wit
is n

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ole,

Honing dimension Piston ∅ Cylinder bore ∅


spec
urposes, in part or in wh

Basic dimen‐ mm 80.96 81.01


t to the co

sion

4.5 Piston rings, cylinder bore and piston in‐


rrectne

stallation position
ss

Checking piston ring gap


o
cial p

f inform
mer

atio
om

n
c

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or

n thi
te

sd
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fo

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ng

t.
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Cop py
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gh ht
Special tools and workshop equipment required yri
p by
co Vo
by lksw
cted
♦ Feeler gauges
agen
Prote AG.

– Push piston ring squarely from above down to approx. 15 mm


from bottom end of cylinder.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.20...0.40 1.0
2nd compression ring 0.20...0.40 1.0

4. Pistons and conrods 39


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Piston ring New Wear limit


dimensions in mm
Oil scraper ring 0.25...0.50 1.0
Checking ring-to-groove clearance

Special tools and workshop equipment required


♦ Feeler gauges
– Clean groove in piston before checking clearance.

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
d b ara
rise nte
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au ra
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nl

pt
du

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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

Special tools and workshop equipment required


l purpos

♦ Internal dial gauge 50...100 mm


nform
ercia

– Take measurements at 3 positions in both transverse -A- and


longitudinal -B- directions, as illustrated. Difference between
m

at
om

actual and nominal diameter: not more than 0.10 mm.


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.

40 Rep. Gr.13 - Crankshaft group


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Note

Cylinder bores must not be measured when cylinder block is


mounted on a repair stand with engine support bracket -VW 540- ,
as measurements may then be incorrect.

Piston installation position and allocation of piston to cylinder.


Piston in cylinders 1 and 2:
Larger inlet valve chamber -arrows- towards
wage
n AGflywheel.
. Volkswagen AG
doe
olks s no
yV t gu
Piston in cylinders 3 and 4: edb ara
ris nte
Larger inlet valve chamber ho eo
aut towards belt pulley side -arrows-. ra
ss c

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pt
Note

an
d
itte

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erm

ab
ility
♦ New piston allocation to cylinders is shown by a coloured
ot p

marking on piston crown.

wit
is n

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ole,

♦ Piston for cylinders 1 and 2: marked 1/2

spec

satelettronica
urposes, in part or in wh

♦ Piston for cylinders 3 and 4: marked 3/4

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

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pr

cum
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fo

en
ng

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

4. Pistons and conrods 41


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

15 – Cylinder head, valve gear


1 Cylinder head
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Note ised b ara
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or eo
h
ut ra
♦ When installing an exchange
ss a
cylinder head with fitted cam‐ c
shaft, the contact surfaces between the bucket tappets and

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

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ole,

♦ If the cylinder head is renewed, all the coolant in the system

spec
urposes, in part or in wh

must also be renewed.

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

1.1 Assembly overview - cylinder head


o

n
c

i
or

n thi
te

sd
iva

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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.

42 Rep. Gr.15 - Cylinder head, valve gear


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

1 - Toothed belt guard upper


part
2 - Toothed belt
❑ Mark direction of rota‐
tion before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing, installing
and tensioning
⇒ page 47 .
3 - 10 Nm
❑ Renew
4 - 25 Nm AG. Volkswagen AG d
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lksw not
5 - 100 Nm by Vo gu
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6 - Camshaft toothed belt pul‐ uthor eo
ley ss a ra
c

ce
le

7 - Hub
un

pt
an
d
itte

satelettronica
❑ With sender wheel.

y li
erm

ab
❑ Use counterhold tool -

ility
ot p

T10051- to loosen and

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

10 - Hall sender -G40-

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

11 - Cylinder head bolt


um
r
fo

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

18 - To intake hose for air filter/turbocharger


19 - 10 Nm
❑ Note tightening sequence ⇒ page 45 , install cylinder head cover.
20 - Cylinder head cover gasket
❑ Renew if damaged.
❑ Thoroughly clean sealant groove and securing bolts before fitting a new gasket.
❑ Before putting in place, seal transitions with “AMV 174 004 01”, ⇒ page 45 Removing and installing
cylinder head cover.
21 - 20 Nm
22 - Lifting eye AG. Volkswagen AG d
agen oes
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23 - Unit injector byV
ol not
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ara
ed
❑ Removinghand oris installing ⇒ page 140 . nte
eo
aut ra
24 - 10 Nm s s c

ce
e
nl

25 - Central connector

pt
du

an
itte

y li
❑ For unit injector.
erm

ab
ility
ot p

26 - From brake servo

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

❑ From fuel filter ⇒ page 110


❑ White or with white marking.
nform
ercia

❑ Check for secure seating.


m

at
om

io

❑ Secure with spring-type clips.


n
c

in t
or

his
e

29 - Return hose
at

do
riv

❑ To fuel filter ⇒ page 110 .


p

cum
for

en
g

❑ Blue or with blue marking.


n

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

44 Rep. Gr.15 - Cylinder head, valve gear


AG. Volkswagen AG d
agen oes
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by
Vol not
gu Touran 2003 ➤
d ara
4-cylinder
orise diesel engine (2.0 l engine, 2-valve, nTDI)
tee - Edition 06.2008
h
aut or
ac
36 - Tensioning roller ss

ce
le
un

pt
37 - 20 Nm + 1/8 turn (45 °) further

an
d
itte

y li
rm

ab
pe

ility
ot

wit
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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

Special tools and workshop equipment required

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
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by c lksw
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Prote AG.
Note

Reworking diesel cylinder heads is not permissible.

Cylinder head gasket identification


♦ Part No. = arrow 1
♦ Holes = arrow 2
♦ Production control code = arrow 3 (can be disregarded)

Note

♦ Different thicknesses of cylinder head gasket are fitted de‐


pending on the piston projection. When replacing cylinder
head gasket, install new gasket with same identification.
♦ Piston projection at TDC must be determined when installing
new pistons or a short engine. ⇒ page 38

1.2 Removing and installing cylinder head


cover

Special tools and workshop equipment required


♦ Torque wrench (5...50 Nm) -V.A.G 1331-

1. Cylinder head 45
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

♦ Sealant -AMV 174 004 01-


Removing
– Remove engine cover ⇒ page 4 .
– Remove upper toothed belt guard.
– Pull crankcase breather hose off cylinder head cover.
– Remove cylinder head cover.
Installing
Installation is carried out in the reverse sequence of removal. In
the process, note the following:

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
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rise nte
tho eo
au ra
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ce
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nl

pt
du

an
itte

y li
erm

ab
ility
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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

cylinder head at rear of engine.


t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
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sd
a

– Screw on cylinder head cover hand tight in the sequence -1 to


iv

o
r
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.

46 Rep. Gr.15 - Cylinder head, valve gear


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

1.3 Removing, installing andlksw


tensioning
agen AG. Volkswagen AG do
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toothed belts ised by V
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Note

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

stalling and tensioning toothed belt” it is only necessary to remove

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

o
r
rp

cu
o

m
f

en
ng

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

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

Special tools and workshop


equipment required
♦ Locking pin -3359-
♦ Pin wrench -T10020- or
hexagon wrench
♦ Locking pin -T10115-
♦ Crankshaft stop -T10100-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-

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

Special tools and workshop equipment required


orm
m

atio

♦ Support bracket -10-222A- with legs -10-222A/22-


om

n in
or c

thi
te

sd
iva

o
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rp

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o

m
f

en
ng

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

48 Rep. Gr.15 - Cylinder head, valve gear


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

♦ Counterhold tool -T10172- with pin -T10172/4-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
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

– Remove belt pulley with vibration damper.


iv

o
pr

cum
r
fo

– Remove lower and centre parts of toothed belt guard.


en
ng

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

If toothed belt is to be removed in order to remove cylinder head,


set up support bracket -10-222A- with higher adapters -10-222A/
13- . This will provide the space necessary for removing the cyl‐
inder head.

– Pull fuel filter out of bracket.


– Unbolt filler neck for window wash system.

– Unbolt fuel filter bracket from engine mounting -arrows-.


– Unbolt coolant expansion tank and lay to side (hoses remain
connected).

1. Cylinder head 49
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Remove securing bolts between assembly mounting and en‐


gine bracket and between assembly mounting and body
-arrows- and remove complete assembly mounting.

Note

♦ The assembly mounting may only be removed if the engine is


supported with support bracket -10-222A- !
♦ The engine bracket must be loosened only when the assembly
mounting has been removed.

– Raise engine with support bracket -10-222A- until both upper


bolts of engine bracket can be loosened.
– Lower engine with support bracket -10-222A- until both lower
bolts of engine bracket can be loosened.
– Remove refrigerant line securing clamp from longitudinal
member.
– Remove engine bracket rearwards.

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

– Lock hub using locking pin -3359- . To do this, slide locking


ility
ot p

pin through the free elongated hole on left into hole in cylinder
wit
, is n

h re

head.
hole

spec

– Lock crankshaft toothed belt pulley with crankshaft stop -


es, in part or in w

T10100- . To do this, push crankshaft stop into teeth of belt


t to the co

pulley from face side.


rrectness of i

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

stop must insert in the drilling of the sealing flange.


m

at
om

ion

– Mark direction of rotation of toothed belt.


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.

50 Rep. Gr.15 - Cylinder head, valve gear


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Loosen securing bolts -1- of camshaft toothed belt pulley until


camshaft pulley can be moved within the elongated holes.
– Loosen tensioning roller securing nut.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
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

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

satelettronica
rrectness of i
l purpos

– Now turn pin wrench -T10020- clockwise to stop and tighten

nf
ercia

securing nut -1- hand tight.

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
r
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

Adjustment work on toothed belts must be performed only on cold


engines, as the indicator position on the tensioning element varies
depending on the engine temperature.

– Turn crankshaft toothed belt pulley in its elongated holes to


centre position -arrows-.
– Fit toothed belt onto crankshaft toothed belt pulley, tensioning
roller, camshaft toothed belt pulley and idler roller.
– Then fit toothed belt on coolant pump toothed belt pulley.

1. Cylinder head 51
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Note

Ensure that tensioning roller seats correctly in rear toothed belt


guard -arrow-.

– Loosen tensioning roller securing nut and pull out locking pin
-T10115- .

– Now carefully turn tensioning roller clockwise using pin wrench


-T10020- until indicator is in middle of gap in the base plate
-arrow-. gen AG
. Volkswagen AG
d oes a
lksw
not
Ensure that securing
db
y V nut does not turn as well.
o gu
ara
ise nte
r
– Hold tensioning
ut
ho roller in this position and tighten tensioningeo
ra
roller securing
ss a nut as follows: 20 Nm and 45° (1/8 turn) further.
c
ce
e
nl

pt
du

satelettronica
an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec

– Fit counterhold tool -T10172- with pins -T10172/4- as shown.


es, in part or in w

t to the co

Press counterhold tool -T10172- in direction of arrow, keeping


camshaft toothed belt pulley under tension.
– In this position, tighten camshaft toothed belt pulley securing
rrectness of i

bolts -1- to 25 Nm.


l purpos

– Remove locking pin -3359- and crankshaft stop -T10100- .


– Turn crankshaft two rotations in engine direction of rotation
nform
ercia

until crankshaft is just before TDC No. 1 cylinder.


m

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

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


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Loosen securing bolts -1- for camshaft toothed belt pulley.

– Turn crankshaft slightly against engine direction of rotation


until the pin of the crankshaft stop is positioned just before the
hole in the sealing flange -arrow-.
– Now turn crankshaft in engine direction of rotation until crank‐
shaft stop pin engages in sealing flange whilst turning.

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

– Remove locking pin -3359- and crankshaft stop -T10100- .


d
itte

y li
erm

ab

– Turn crankshaft two rotations in engine direction of rotation


ility
ot p

until crankshaft is just before TDC No. 1 cylinder.


wit
is n

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

– Set engine bracket against cylinder block and tighten securing


bolts -arrows- to 40 Nm + 1/2 turn (180 °) further.

Note

Before installing assembly mounting, tighten all engine bracket


bolts to prescribed torque.

– Install assembly mounting between engine and body (renew


securing bolts).
Tightening torque, M8 bolts: 20 Nm + 90° (1/4 turn)
Tightening torque, M10 bolts: 40 Nm + 90° (1/4 turn)
– Bolt engine assembly mounting to engine bracket by bringing
contact surfaces together using support bracket -10-222A- .
Tightening torque: 60 Nm + 90° (1/4 turn)
– Install centre and lower parts of toothed belt guard.
– Install belt pulley vibration damper. Specified torque: 10 Nm +
AG. Volkswagen AG d
90° (1/4 turn) further. agen

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

– Install front right wheel housing liner.


nl

pt
du

an
itte

– Install coolant expansion tank ⇒ page 88 .

y li
erm

ab
ility
ot p

– Bolt fuel filter bracket to engine mount to 8 Nm torque

wit
, is n

-arrows-.

h re
hole

spec
– Engage fuel filter in bracket.
es, in part or in w

– Bolt on filler neck for window wash system. t to the co

– Fit engine cover.


rrectness of i
l purpos

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

greater clearance to engine)


iv

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.

54 Rep. Gr.15 - Cylinder head, valve gear


AG. Volkswagen AG d
agen oes Touran 2003 ➤
olksw not
V
d by 4-cylinder diesel engine gu(2.0 l engine,
ara 2-valve, TDI) - Edition 06.2008
rise nte
tho eo
Special toolsss aand workshop
u ra
c
equipment required

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-.

– Remove connecting pipe between charge air cooler and intake


connecting pipe, to do this, lightly lift retaining clips -arrows-.

satelettronica
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li
– Disconnect fuel supply line -3- and return line -2- by pulling
rm

ab
release tabs.
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

– Pull fuel filter out of bracket -arrow-.


m

a
com

tion in
r
te o

thi
s
iva

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rp

cum
fo

en
ng

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

56 Rep. Gr.15 - Cylinder head, valve gear


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Unscrew bolt at filler neck -2- for washer fluid reservoir.


– Unscrew bracket -3- for fuel filter.
– Separate electrical connector on coolant expansion tank -1-.
– Remove coolant expansion tank, coolant hoses remain con‐
nected. Place it on engine.
– Remove poly V-belt ⇒ page 14 .
– Remove tensioning element for poly V-belt.

– Remove upper toothed belt guard, to do this, loosen retaining


n AG. Volkswagen AG do
clips -arrows-.
olks
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o
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by
– Remove
ris front right wheel housing liner.
ed
ara
nte
tho eo
– Remove
ss
au belt pulley with vibration damper. ra
c

ce
e

– Remove lower and centre parts of toothed belt guard.


nl

pt
du

an
itte

y li
– Turn crankshaft to TDC No. 1 cylinder.
erm

ab

satelettronica
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

Note
rrectness of i

Turn crankshaft until marking on crankshaft pulley and tooth seg‐


l purpos

ment of camshaft pulley is on top. The marking on the rear toothed


belt guard must line up with the marking on the camshaft sender
nf
ercia

wheel -arrow-.
orm
m

atio
m

– Lock hub using locking pin -3359- . To do this, slide locking


o

n in
c

pin through the free elongated hole on left into hole in cylinder
or

thi
e

head.
t

sd
iva

o
r
rp

cu

– Lock crankshaft toothed belt pulley with crankshaft stop -


o

m
f

en

T10100- . To do this, push crankshaft stop into teeth of belt


ng

t.
yi Co
pulley from face side. t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
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.

– Mark direction of rotation of toothed belt.

1. Cylinder head 57
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Loosen securing bolts -1- of camshaft toothed belt pulley until


camshaft pulley can be moved within the elongated holes.

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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ility
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– Loosen tensioning roller securing nut -1-.

wit
is n

h re
– 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

locking tool -T10265- .

t to the co
rrectne

satelettronica
ss o
cial p

f inform
mer

atio
om

n
c

– Now turn eccentric of tensioning roller clockwise -arrow- to

i
or

n thi
e

stop and tighten securing nut -1- hand tight.


t

sd
iva

o
pr

c
– Remove toothed belt first from coolant pump and then from

um
r
fo

remaining toothed belt pulleys.

en
ng

t.
yi Co
op py
Installing t. C rig
gh ht
pyri by
• Camshaft locked with locking pin -3359- .
o Vo
by c lksw
cted agen
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

Adjustment work on toothed belts must be performed only on cold


engines, as the indicator position on the tensioning element varies
depending on the engine temperature.

– Turn crankshaft toothed belt pulley in its elongated holes to


centre position -arrows-.
– Guide toothed belt through gap between engine support and
engine.
– Fit toothed belt onto crankshaft toothed belt pulley, tensioning
roller, camshaft toothed belt pulley and idler roller.
– Then fit toothed belt on coolant pump toothed belt pulley.

58 Rep. Gr.15 - Cylinder head, valve gear


n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
ir se
d ran
tee Touran 2003 ➤
o
h 4-cylinder diesel engine (2.0 l engine, 2-valve,
ut or TDI) - Edition 06.2008
a ac
ss

ce
le
un

pt
an
d
itte
Note

y li
erm

ab
ility
ot p
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

– Remove locking pin -T10265- from tensioning roller.

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
r
fo

Ensure that securing nut does not turn as well.

en
ng

t.
yi Co

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
cted agen
Prote AG.

– Fit counterhold tool -T10172- with pin -T10172/4- as shown in


illustration, and keep the toothed belt under tension on pulling
side, by pressing in -direction of arrow-.
– Tighten bolts -1- of camshaft toothed belt pulley to 25 Nm.
– Remove locking pin -3359- and crankshaft stop -T10100- .
– Turn crankshaft two rotations in engine direction of rotation
until the crankshaft is just before TDC again.

– Lock hub of camshaft with locking pin -3359- whilst turning


engine in direction of rotation.

1. Cylinder head 59
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Check whether crankshaft can be locked with crankshaft stop


-T10100- .
If crankshaft cannot be locked

AG. Volkswagen AG d
agen oes
ksw
– Loosen securing bolts -1- for camshaft toothed belt pulley. yV
ol not
gu

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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

– Now turn crankshaft in engine direction of rotation until crank‐


shaft stop pin engages in sealing flange whilst turning.

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

60 Rep. Gr.15 - Cylinder head, valve gear


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Fit counterhold tool -T10172- with pins -T10172/4- as shown.


Press counterhold tool -T10172- in direction of arrow, keeping
camshaft toothed belt pulleygeunder
n AG. Vtension.
olkswagen AG
d wa oes
olks no
– In this position, tighten
db
y V camshaft toothed belt pulley securing
t gu
ara
bolts -1- to 25 Nm.
orise nte
e h
ut or
– Remove locking
ss
a
pin -3359- and crankshaft stop -T10100- . ac

ce
le
un

– Turn crankshaft two rotations in engine direction of rotation

pt
an
d

until crankshaft is just before TDC No. 1 cylinder.


itte

y li
erm

ab
– Repeat check and adjustment if necessary.

ility
ot p

wit
is n

– Install centre and lower parts of toothed belt guard.

h re
ole,

spec
– Install belt pulley vibration damper. Specified torque: 10 Nm +
urposes, in part or in wh

90° (1/4 turn) further.

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

– Install coolant expansion tank ⇒ page 88 .

atio
om

n
c

i
or

n
– Bolt fuel filter bracket to engine mount to 8 Nm torque

thi
te

sd
-arrows-.
iva

o
pr

cum
r

– Engage fuel filter in bracket.


fo

en
ng

t.
yi Co
– Bolt on filler neck for window wash system. Cop py
t. rig
gh ht
yri
– Fit engine cover. p by
o Vo
by c lksw
cted agen
Prote AG.

1.4 Removing and installing cylinder head

1. Cylinder head 61
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Special tools and workshop


equipment required
♦ Drip tray -V.A.G 1306- or
drip tray -VAS 6208-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
. Volkswagen AG
a gen AG does
♦ Hand vacuum pump with Vol
ksw not
gu
accessories -V.A.G
ed 1390-
by ara
nte
is
or eo
♦ Water drainageau container -
th ra
V.A.G 1390/1-
ss c

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un

pt
♦ Retainer -T10014- (only ve‐

an
d
itte

hicles ▸ 05.05)

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ab
ility
ot p

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is n

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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

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ng

t.
yi Co
Cop py
t. rig
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pyri by
Vo
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cted agen
Special tools and workshop equipment required Prote AG.

♦ Support bracket -10-222A- with adapters -10-222A/13- (only


vehicles ▸ 05.05)

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.

62 Rep. Gr.15 - Cylinder head, valve gear


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

WARNING

When doing any repair work, especially in the engine compart‐ agen
AG. Volkswagen AG d
oes
ksw
ment, pay attention to the following due to the crampedbcondi‐
yV
ol not
gu
tions: ris
ed ara
nte
tho eo
♦ 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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erm

ab
♦ Ensure that there is sufficient clearance to all moving or

ility
ot p
hot components.

wit
, is n

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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

Before removing cylinder head, extract fuel using hand-operated


vacuum pump with accessories -V.A.G 1390- and water drainage

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

– Remove connecting pipe between exhaust manifold/exhaust


o

his
te

gas recirculation cooler ⇒ Item 4 (page 157) .


a

do
priv

cum
or

– Detach rear coolant pipe ⇒ page 90 .


f

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

From 05.05 a modified engine support has been introduced, it is


no longer necessary to remove the engine support and supporting
the engine for the procedure “removing, installing and tensioning
toothed belt” ⇒ page 47

– Remove toothed belt ⇒ page 47 .


– Remove tensioning roller for toothed belt.
– Install hub for camshaft toothed belt pulley ⇒ page 73 , Re‐
moving and installing camshaft.
– Remove rear toothed belt guard securing bolts -2- and -4-.
Only vehicles ▸ 05.05

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

– Screw retainer -T10014- into threaded hole above coolant


pump and tighten to 20 Nm.
– Lift engine slightly using spindle -A- until spindle -B- is relieved.
– Unhook spindle -B- and push it to side.
Continuation for all vehicles
– Remove cylinder head cover ⇒ page 45 .

– Maintain sequence when loosening cylinder head bolts.

satelettronica
– Lift cylinder head slightly and remove from engine laterally
past toothed belt guard.

Note agen
AG. Volkswagen AG d
oes
olksw not
yV gu
The cylinder head must be guided carefully rito
sedprevent damage.
b ara
nte
ho eo
aut ra
ss c

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un

pt
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d
itte

y li
rm

ab
pe

1.4.2 Installing ility


ot

wit
, is n

h re
hole

spec

Note
es, in part or in w

t to the co

♦ Always renew cylinder head bolts.


♦ In cases of repair carefully remove gasket remains from cyl‐
rrectness of i

inder head and cylinder block. Ensure that no long scores or


l purpos

scratches are made on the surfaces. When using abrasive


paper do not use a grade less than 100.
nform
ercia

♦ Carefully remove remains of emery and abrasives.


m

♦ Remove new cylinder head gasket from packaging, just before


a
com

tio

installation.
n in
r
te o

thi

♦ Handle gasket very carefully. Damaging the silicone layer or


s
iva

do

the indented area will lead to leaks.


r
rp

cum
fo

en
ng

t.
yi
– Set crankshaft to TDC mark before fitting cylinder head.
Co
Cop py
ht. rig
– Turn crankshaft opposite engine direction of rotation until all
rig ht
py by
o Vo
pistons are approximately equally placed below TDC. by c lksw
cted agen
Prote AG.
– Fit cylinder head gasket.

Note

Note identification on cylinder head gasket ⇒ page 45 .

64 Rep. Gr.15 - Cylinder head, valve gear


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– 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
d
2- Turn further with rigid wrench: rise nte
tho eo
au ra
Stage III = 1/4 turn (90°) ss c

ce
e
nl

pt
du
Stage IV = 1/4 turn (90°)

an
itte

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erm

ab
ility
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wit
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

after repair work.

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

– After tightening cylinder head, turn camshaft so that cams for


No. 1 cylinder point equally upwards. Turn crankshaft, in en‐

nf
gine direction of rotation, to TDC marking before fitting toothed
ercia

o
belt ⇒ page 47 .

rm
m

atio
m

Observe applicable safety precautions during road test


o

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
o

m
f

en
ng

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

1.5 Checking compression

Note

Before removing glow plugs check idling speed smooth running


control using Vehicle diagnostic, testing and information system
-VAS 5051B- . The compression test is warranted only if one or
more cylinders are conspicuous during this idling speed check.

1. Cylinder head 65
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Special tools and workshop


equipment required
n AG. Volkswagen AG do
♦ U/J extension and socket, lkswage es n
o ot g
10 mm -3220- byV ua
d ran
ir se tee
o
♦ Torque wrench - auth or
ac
V.A.G 1331- ss

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

h re
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

do
r
rp

cum
fo

en
ng

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

Test prerequisite
• Engine oil temperature min. 30 °C.
Test procedure
– Pull off central connector for unit injectors.

Note

Always observe the notes on removing and installing the ceramic


glow plugs ⇒ page 158 .

– Remove all ceramic glow plugs using U/J extension and sock‐
et 10 mm -3220- .

66 Rep. Gr.15 - Cylinder head, valve gear


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Screw in adapter -V.A.G 1381/12- in place of the ceramic glow


plugs.
– Check compression using compression tester -V.A.G 1763- .

Note

Using compression tester ⇒ Operating instructions.

– Operate starter until tester shows no further pressure in‐


crease.
Compression pressures:
New: 25...31 bar, wear limit: 19 bar
Maximum permissible difference between all cylinders: 5 bar

Note

Always observe the notes on removing and installing the ceramic


glow plugs ⇒ page 158 .

satelettronica
– Install ceramic glow plugs using U/J extension and socket 10
mm -3220- .
– Read fault memory of engine control unit ⇒ page 146 .

Note

Disconnecting the central connector for unit injectors causes


faults to be stored. Therefore read and clear fault memory.

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

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
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pyri by
Vo
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by c lksw

67
cted agen
Prote
1. Cylinder head
AG.
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

2 Repairing valve gear


AG. Volkswagen AG d
agen
Note Volksw
oes
not
by gu
d ara
ise nte
Cylinder heads with cracks between uthethor
valve seats may be used eo
without reducing engine life, provided
ss a the cracks are small and ra
c
not more than 0.5 mm wide.

ce
e
nl

pt
du

an
itte

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Assembly overview - valve gear ⇒ page 68 .
erm

ab
ility
ot p

Checking valve guides ⇒ page 70 .

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

2.1 Assembly overview - valve gear

rrectness of i
l purpos

1 - 20 Nm + 1/4 turn (90°) fur‐

satelettronica
ther

nf
ercia

or
❑ Renew

m
m

atio
m

❑ Note sequence when


o

n in
c

loosening and tighten‐


or

thi
e

ing ⇒ page 73 , Re‐


t

sd
iva

moving and installing

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r
rp

cu
camshaft.
o

m
f

en
ng

t.
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2 - Rocker arm shaft t. Cop py
rig
gh
❑ Do not interchange
ht
pyri by
Vo
co lksw
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

68 Rep. Gr.15 - Cylinder head, valve gear


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

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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le
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

❑ Installation sequence ⇒ page 73 , Removing and installing camshaft.


❑ To install, seal parting surfaces of bearing caps 1 and 5 with sealant -AMV 174 004 01- ⇒ page 70 .
nform
mercia

19 - 8 Nm + 1/4 turn (90°) further


a
com

tion in

❑ Renew
r
te o

thi
s
iva

do
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rp

cum
fo

en
ng

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

2. Repairing valve gear 69


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Checking camshaft axial clearance

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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

bearing caps fitted.


Wear limit: max. 0.15 mm

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

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Be careful that no sealant gets into grooves -arrows-.
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Valve dimensions

Note

Valves must not be reworked. Only lapping-in is permitted.

Dimension Inlet valve Exhaust valve


∅a mm 35.95 31.45
∅b mm 6.980 6.956
c mm 89.95 89.95
α ∠° 45 45

2.2 Checking valve guides


Special tools and workshop equipment required

70 Rep. Gr.15 - Cylinder head, valve gear


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

♦ Universal dial gauge bracket -VW 387-

AG. Volkswagen AG d
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♦ Dial gauge aut ra
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Test procedure

ce
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– Insert new valve into guide. The end of the valve stem must

y li
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ab
be flush with the guide. Due to slight differences in stem di‐

ility
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ameters, use only an inlet valve in inlet guide and an exhaust

wit
valve in exhaust guide.
, is n

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hole

– Determine rock. Wear limit: max. 1.3 mm

satelettronica
spec
es, in part or in w

– Cylinder head must be renewed if the rock is greater than the

t to the co
wear limit.

rrectness of i
l purpos

nform
ercia

2.3 Renewing valve stem seals


m

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or

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ate

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for

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Cop py
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Prote AG.

2. Repairing valve gear 71


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Special tools and workshop


equipment required
♦ Assembly tool -2036-
♦ Puller -3047 A-
♦ Fitting tool -3129-
♦ Valve lever -VW 541/1A-
♦ Thrust piece -VW 541/5-

satelettronica
AG. Volkswagen AG d
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aut ra
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un

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ab
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2.3.1 Removing
wit
is n

h re
ole,

(with cylinder head installed)


spec
urposes, in part or in wh

t to the co

– Remove camshaft ⇒ page 73 .


– Remove bucket tappets and place them with the contact sur‐
face downwards. When doing this, ensure that tappets are not
rrectne

interchanged.
– Set piston of respective cylinder to top dead centre (TDC).
ss o
cial p

– Insert valve assembly device -2036- and adjust mounting to


inform

height of studs.
mer

atio
m

– Remove valve springs using valve lever -VW 541/1A- and


o

n
c

press tool -VW 541/5- .


i
or

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te

sd
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pr

cum
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Note
fo

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op
The valves are supported by the piston crown.
C py
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pyri by
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Prote AG.

72 Rep. Gr.15 - Cylinder head, valve gear


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Pull off valve stem seals using puller -3047 A- .

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
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un

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rm

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pe

ility
ot

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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

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rp

cum
fo

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t.
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Cop py
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yri by

73
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cted AG.
agen 2. Repairing valve gear
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Special tools and workshop


equipment required
♦ Counterhold tool -T10051-
♦ Puller -T10052- AG. Volkswagen AG d
agen oes
olksw not
yV gu
♦ Torque wrench (5...50 edNm)
b ara
nte
is
-V.A.G 1331- hor eo
aut ra
c
♦ Torque wrenchs(40...200
s

ce
le

Nm) -V.A.G. 1332-


un

pt
an
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♦ Sealant -AMV 174 004 01-
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

satelettronica
nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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rp

cum
fo

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t.
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Cop py
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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.

74 Rep. Gr.15 - Cylinder head, valve gear


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Loosen hub securing bolt -1-.


– To do this, use counterhold tool -T10051- .
– Loosen hub securing bolt about 2 turns.

– 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

When doing this, hold puller with 30 mm spanner.

satelettronica
– Remove hub from taper of camshaft.
– Remove cylinder head cover.

– Mark rocker arm shafts using a permanent felt tip marker to


prevent interchanging. This will prevent having to perform ba‐
sic settings of unit injectors -arrows-.
– Remove rocker arm shafts.

Note
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First loosen both outer and then
Voinner
lksw securing bolts respectively.
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– Remove tandem pumptho ⇒ page 124 . or
au ac
ss
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pt
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– First remove bearing caps 5, 1 and 3. Then loosen bearing


an
itte

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caps 2 and 4 alternately and diagonally.


erm

ab
ility
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– 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

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or

his
ate

do
priv

cum
for

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ng

t.
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Cop py
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pyri by
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co lksw
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Prote AG.

2. Repairing valve gear 75


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

2.4.2 Installing

Note

♦ When camshaft is installed, No. 1 cylinder cams must point


upwards.
♦ Do not interchange used bearing shells (mark).
♦ When installing the camshaft, ensure proper seating of retain‐
ing lugs in bearing caps and cylinder head.
♦ Before installing bearing caps, ensure that cylinder head bolt
washers are inserted in the cylinder head.

– Oil bearing shell running surfaces.


– Install bearing caps 2 and 4 using new bolts.
– Tighten bearing caps 2 and 4 diagonally and alternately to
8 Nm +1/4 turn (90°).
– Install bearing caps 5, 1 and 3 using new bolts.

satelettronica
Note

♦ Seal parting surfaces of bearing caps 1 and 5 with sealant -


AMV 174 004 01- ⇒ page 70 .
♦ Bearing cap 5 must align flush with outer edge of cylinder
head, because otherwise leaks can develop at tandem pump.

– Tighten bearing caps 5, 1 and 3 likewise to 8 Nm +1/4 turn


(90°).
– Install camshaft oil seal ⇒ page 77 .
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– Renew adjustment screws in rocker arms and ball studs in unit y Volks ot g
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injectors. ise
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– Screw in adjuster screws only one or two threads, but leave
au
or
ac
lock nut loosened. ss
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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

+ 1/4 turn (90°).


wit
is n

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ole,

– Set hub on camshaft.


spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

cum
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fo

en
ng

t.
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Cop py
t. rig
gh ht
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

– Tighten hub securing bolt -1- to 100 Nm.


– To do this, use counterhold tool -T10051- .

– Push camshaft toothed belt pulley onto hub.

Note

The toothed segment -arrow- of the camshaft toothed belt pulley


must be on top.

satelettronica
– Align camshaft toothed belt pulley at centre of elongated
holes.
– Hand tighten securing bolts -1- to camshaft toothed belt pulley
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so that there is no play. kswagen AG does
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– Lock hub using locking pinise-3359-
db . ara
nte
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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
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pt
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d
itte

– Install tandem pump ⇒ page 124 .


y li
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ab
pe

ility

– Install cylinder head cover ⇒ page 45 .


ot

wit
, is n

h re
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

2.5 Removing and installing camshaft oil seal


nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

2. Repairing valve gear 77


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Special tools and workshop


equipment required
♦ Fitting tool -10-203-
♦ Oil seal extractor -3240-
♦ Torque wrench (5...50 Nm)
-V.A.G 1331-
♦ Torque wrench (40...200
Nm) -V.A.G. 1332-
♦ Bolt M12×1.5 × 65

satelettronica
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2.5.1 Removing
pt
du

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y li
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ab

– Remove toothed belt ⇒ page 47 .


ility
ot p

– Remove camshaft toothed belt pulley and hub ⇒ page 73 ,


wit
, is n

h re

Removing and installing camshaft.


hole

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

– Lubricate threaded head of oil seal extractor -3240- , place it


in position and exerting firm pressure, screw it as far as pos‐
rrectness of i

sible into oil seal.


l purpos

– Loosen knurled screw and turn inner part against camshaft


until the oil seal is pulled out.
nf
ercia

orm
m

atio
om

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or c

thi
te

sd
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rp

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o

m
f

en
ng

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

78 Rep. Gr.15 - Cylinder head, valve gear


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

2.5.2 Installing

Note

The oil seal sealing lip must not be additionally oiled or greased.

– Remove oil residue from camshaft journal using a clean cloth.


– Tape over groove in taper of camshaft (e.g. with Sellotape).
– Fit oil seal carefully on camshaft.
– Press in oil seal with press piece of fitting tool -10-203- and
bolt M12×1.5×65 to stop.
– Install and tighten toothed belt ⇒ page 47 .

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

ce
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nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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rp

cu
o

m
f

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ng

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

2. Repairing valve gear 79


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

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

pt
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itte

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Oil capacities ⇒ page 80
erm

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ility
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Engine oil specification ⇒ Maintenance ; Booklet 18.1

wit
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h re
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
l purpos

For vehicles up to 12.05 the oil capacity was determined to 3.8


litres. If this is not the case, fill with 3.8 litres (with oil filter change),
check oil level with oil dipstick and top-up if necessary.

nform
mercia

at
With oil filter change: 4.3 l
om

ion
c

in t
r

Without oil filter change: 4.0 l


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1.2 Checking engine oil level
um
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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.

a - Area of min. mark: must be topped-up, max. 0.5 l of engine oil!


b - Oil level in middle range: can be topped-up with engine oil.
c - Area of max. mark: do not add engine oil!

80 Rep. Gr.17 - Lubrication


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

2 Parts of lubrication system

Caution

Finding metal shavings or a large quantity of small metal par‐


ticles during engine repair could indicate that the crankshaft
bearings or conrod bearings are damaged. To prevent this
from causing further damage, perform the following AG. Volkswagen AG d
repairs:
agen oes
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Thoroughly clean oil channels. edb ua
ran
ris tee
tho
Renew oil cooler au
or
ac
ss
Renew oil filter element.

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nl

pt
du

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itte

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erm

ab
Assembly overview - oil pump, sump ⇒ page 81

ility
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wit
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Removing and installing sump ⇒ page 82

h re
hole

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
l purpos

❑ With seal.
❑ Must seat on dowel
sleeves.

nform
ercia

❑ To remove, first remove


m

at
om

sump ⇒ page 82 .

ion
c

in t
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❑ Removing and installing


o

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⇒ page 22 .
at

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❑ Install with silicone seal‐

um
for

ant -D176404A2-
en
ng

t.
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⇒ page 22 . t. Cop py
rig
❑ Do not additionally oil or
gh ht
pyri by
grease the oil seal seal‐
o Vo
by c lksw
cted
ing lip
agen
Prote AG.

❑ Before installing, re‐


move oil residue from
crankshaft journal using
a clean cloth.
❑ Renew crankshaft oil
seal - belt pulley end
⇒ page 20 .
3 - Chain tensioner with ten‐
sioning rail, 15 Nm
❑ When installing, preten‐
sion spring and fit.
4 - Dipstick
❑ Lugs of oil dipstick and
dipstick guide must
align.
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 80
5 - Dipstick guide
❑ Lugs of oil dipstick and dipstick guide must align.

2. Parts of lubrication system 81


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

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
agen oes
12 - 15 Nm Volksw not
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13 - 15 Nm rise nte
tho eo
au ra
14 - Sump ss c

ce
e
❑ Clean sealing surface before fitting.
nl

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itte
❑ Install with silicone sealant -D176404A2-

y li
erm

ab
❑ Removing and installing ⇒ page 82 .

ility
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wit
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15 - Oil drain plug, 30 Nm

h re
hole

satelettronica
❑ Renew

spec
es, in part or in w

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
ercia

❑ With 12-bar pressure relief valve.

orm
m

❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.

atio
om

❑ Renew if running surfaces and gears are scored.

n in
or c

thi
e

20 - Oil pump chain sprocket


t

sd
iva

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r
rp

cu
21 - Bracket
o

m
f

en
ng

t.
yi
❑ For oil level and oil temperature sender -G266- .
Co
Cop py
t. rig
22 - 20 Nm + 1/4 turn (90°) further
gh ht
pyri by
Vo
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by
❑ Renew cted agen
Prote AG.

23 - Chain
24 - 25 Nm
❑ Insert without sealant.
25 - Oil spray jet
❑ For piston cooling.

2.2 Removing and installing sump


Special tools and workshop equipment required

82 Rep. Gr.17 - Lubrication


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

♦ Torque wrench (5...50 Nm) -V.A.G 1331-

♦ Allen key, long reach -T10058-

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

ce
le

♦ Hand drill with plastic brush attachment


un

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itte

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♦ Silicone sealant -D176404A2-
erm

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ility
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♦ Hand drill with plastic brush attachment

wit
is n

h re
♦ 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

Observe environmental regulations for disposal.


n
c

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

en
ng

t.
yi
– 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.

2. Parts of lubrication system 83


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Remove sealant residue on sump with a rotating brush, e.g. a


hand drill with a plastic brush (wear eye protection).
– Clean sealing surfaces. They must be free of oil and grease.
Installing AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
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Note horis nte
eo
ut ra
s a c
♦ Observe expiry date of sealing compound.
s

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nl

pt
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♦ The sump must be installed within 5 minutes after applying

an
itte

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silicone sealing compound.
erm

ab
ility
ot p

wit
, is n

h re
– Cut off tube nozzle at forward marking (nozzle ∅ approx. 3
hole

mm).

spec
es, in part or in w

– Apply silicone sealing compound, as shown, to clean sealing

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

in t
or

oil suction line strainer.


his
ate

do
priv

cum
for

en
g

– Apply silicone sealing compound bead as shown to the clean


n

t.
yi Co
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.

– Tighten sump bolts diagonally to 15 Nm.


– Tighten sump/gearbox bolts to 45 Nm.

Note

Let sealing compound dry for approx. 30 minutes after installing


sump. Only then fill with engine oil.

Further assembly is basically the reverse of the dismantling pro‐


cedure.

84 Rep. Gr.17 - Lubrication


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

3 Oil filter bracket, oil pressure and oil


cooler
Assembly overview - oil filter bracket and oil cooler ⇒ page 85
Checking oil pressure and oil pressure switch ⇒ page 86

3.1 Assembly overview - oil filter bracket and oil cooler

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
agen oes
not
Vo gu
❑ To turbocharger. ed by ara
nte
ris
o eo
7 - Oil pressure switch -F1- aut
h
ra
ss c
❑ 0.7 bar switch: brown.

ce
e
nl

pt
du

❑ Tighten to 20 Nm

an
itte

y li
❑ If sealing ring is leaking,
erm

ab
ility
nip open and renew.
ot p

wit
, is n

❑ Checking ⇒ page 86 .

h re
hole

spec
8 - Cap, 25 Nm
es, in part or in w

❑ Loosen and tighten with

t to the co
socket 36 mm -
T10125- .

rrectness of i
9 - O-ring
l purpos

❑ Renew
10 - Oil filter element
nf
ercia

❑ See note.
orm
m

atio

❑ Observe change intervals.


om

n in
c

❑ Ensure that "Top" is uppermost when fitting.


or

thi
te

sd
a

11 - Seal
iv

o
r
rp

cu

❑ Renew
o

m
f

en
ng

t.
❑ Oil before installing.
yi Co
Cop py
❑ Fit into lugs on oil cooler.
t. rig
gh ht
pyri by
Vo
o
by c
12 - Oil cooler
lksw
cted agen
Prote AG.
❑ Ensure clearance to adjacent components.
❑ See note ⇒ page 81 .
❑ Checking oil cooler for leaks ⇒ page 104
13 - Seal
❑ Renew

3. Oil filter bracket, oil pressure and oil cooler 85


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

14 - Cap, 25 Nm
❑ Loosen and tighten with socket 36 mm -T10125- .
15 - 10 Nm
16 - Bracket

3.2 Checking oil pressure and oil pressure switch

Special tools and workshop


equipment required
♦ Oil pressure tester -
V.A.G 1342- AG. Volkswagen AG d
agen oes
olksw not
y V gu
♦ Diode test lamp - d b ara
ise nte
V.A.G 1527 B- thor eo
au ra
c
♦ Auxiliary measuring set - ss

ce
le

V.A.G 1594 A-
un

pt
an
d
itte

y li
rm

ab

satelettronica
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

Test procedure

Note

Functional check and servicing of the optical and acoustic oil


pressure indicator: ⇒ Current flow diagrams, Electrical fault find‐
ing and Fitting locations Guided fault finding with VAS 5051.

86 Rep. Gr.17 - Lubrication


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Remove oil pressure switch -F1- and screw into tester.


– Screw tester into oil filter bracket in place of the oil pressure
switch.
– Connect brown wire of tester to earth (-).
– Connect voltage tester -V.A.G 1527 B- to battery positive (+)
and oil pressure switch using cables from auxiliary test set -
V.A.G 1594 A- . LED must not light up.
– Start engine and increase speed slowly.
– At 0.55...0.85 bar the LED must light up; otherwise renew oil
pressure switch.
– Increase engine speed further. At 2000 rpm and an oil tem‐
perature of 80 °C the oil pressure should be at least 2.0 bar.
At higher engine speed, oil pressure must not exceed 7.0 bar. If
necessary renew oil filter bracket.

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

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

3. Oil filter bracket, oil pressure and oil cooler 87


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

19 – Cooling
1 Parts of cooling system

WARNING

When doing any repair work, especially in the engine compart‐


ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant, refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.

satelettronica
Note

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


sure. If necessary, release pressure before beginning repair
work.
♦ Hoses are secured with spring-type clips. In case of repair, AG. Volkswagen A
only use spring-type clips. ksw
agen G do
es n
y Vol ot g
ua
b
♦ Spring-type clip pliers -VAS 5024- or hose clip ris pliers -
ed ran
tee
V.A.G 1921- are recommended for fitting spring-type
tho clips. or
au ac
ss
♦ When installing coolant hoses, route stress-free so that they
ce
e
nl

do not come into contact with other components (observe


pt
du

an
markings on coolant connection and hose).
itte

y li
erm

ab
ility
ot p

Perform cooling system leakage test using cooling system tester


wit
, is n

-V.A.G 1274- , adapter -V.A.G 1274/8- and adapter - h re


V.A.G 1274/9- ⇒ page 102 .
hole

spec
es, in part or in w

Parts of cooling system - body side ⇒ page 88 .


t to the co

Parts of cooling system - engine side ⇒ page 90 .


Coolant hose schematic diagram ⇒ page 92 .
rrectness of i

Draining and filling coolant ⇒ page 93 .


l purpos

Removing and installing fan support with fans ⇒ page 96


nf
ercia

Removing and installing radiator ⇒ page 97 .


orm
m

atio

Removing and installing coolant pump ⇒ page 99 .


om

n in
or c

Removing and installing thermostat ⇒ page 101


thi
te

sd
iva

Checking cooling system for leaks ⇒ page 102


o
r
rp

cu
o

m
f

en
ng

Checking oil cooler for leaks ⇒ page 104


t.
yi Co
Cop py
1.1 Parts of cooling system, body side
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

88 Rep. Gr.19 - Cooling


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

1 - Upper coolant hose


❑ Secured to radiator with
retaining clip.
❑ Check for secure seat‐
ing.
❑ Coolant hose schematic
diagram ⇒ page 92 .
2 - O-ring
❑ Renew
3 - Radiator
❑ Removing and installing
⇒ page 97 .
❑ If renewed, change
coolant in entire system
4 - Sealing strip
❑ Pushed onto top and
bottom of radiator.
5 - Cap

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
er -V.A.G 1274/8- byV
o ot g
ua
d ran
ir se
9 - Bracket utho tee
or
a ac
❑ For radiator. ss
ce
e
nl

pt

10 - 5 Nm
du

an
itte

y li

11 - Support
erm

ab
ility
ot p

12 - 10 Nm
wit
, is n

h re

13 - Fan support
hole

spec

❑ Removing and installing ⇒ page 96 .


es, in part or in w

t to the co

14 - 5 Nm
15 - Radiator fan 2 -V177-
rrectness of i

❑ Removing and installing ⇒ page 96 .


l purpos

16 - Connector
17 - Radiator fan -V7-
nform
ercia

❑ Removing and installing ⇒ page 96 .


m

at
om

io

18 - Bottom coolant hose


n
c

in t
or

❑ Secured to radiator with retaining clip.


his
ate

do
riv

❑ Check for secure seating.


p

cum
for

❑ Coolant hose schematic diagram ⇒ page 92 .


en
ng

t.
yi Co
op py
19 - Securing clip t. C rig
gh ht
yri by
❑ Check for secure seating. cop Vo
by lksw
cted agen
Prote AG.

1. Parts of cooling system 89


AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Touran 2003 ➤ uth o eo
ra
a
4-cylinder diesels engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
s c

ce
e
nl

pt
du
20 - Radiator outlet coolant temperature sender -G83-

an
itte

y li
erm

ab
21 - O-ring

ility
❑ Renew ot p

wit
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h re
hole

spec
es, in part or in w

1.2 Parts of cooling system - engine side

t to the co
rrectness of i
1 - To top of expansion tank.
❑ Coolant hose schematic
l purpos

diagram ⇒ page 92 .
2 - Upper coolant pipe

nform
ercia

❑ Bolted to cylinder head


m

at
cover.
om

ion
c

❑ Coolant hose schematic

in t
or

his
e

diagram ⇒ page 92 .
at

do
priv

c
3 - O-ring

um
for

en
ng

❑ Renew
t.
yi Co
Cop py

satelettronica
. rig
4 - Securing clip
ht ht
rig by
opy Vo
❑ Check for secure seat‐ by c lksw
cted agen
ing. Prote AG.

5 - Coolant temperature send‐


er -G62-
❑ If necessary, release
pressure in cooling sys‐
tem before removing.
6 - To exhaust gas recircula‐
tion cooler.
❑ Coolant hose schematic
diagram ⇒ page 92 .
7 - Connection
8 - 10 Nm
9 - To top of radiator
❑ Coolant hose schematic
diagram ⇒ page 92 .
10 - From heat exchanger
❑ Coolant hose schematic
diagram ⇒ page 92 .
11 - 40 Nm
12 - T-piece
13 - From upper coolant hose T-piece
❑ Coolant hose schematic diagram ⇒ page 92 .
14 - 15 Nm
15 - From bottom of expansion tank
❑ Coolant hose schematic diagram ⇒ page 92 .
16 - Front coolant pipe
❑ Coolant hose schematic diagram ⇒ page 92 .
17 - Seal
❑ Renew

90 Rep. Gr.19 - Cooling


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

18 - Radiator outlet coolant temperature sender -G83-


❑ If necessary, release pressure in cooling system before removing.
19 - 15 Nm agen
AG. Volkswagen AG d
oes
olksw not
V gu
20 - To bottom of radiator ed by ara
nte
ris
❑ Coolant hose schematic diagramut ⇒ page 92 .
ho eo
ra
s a c
s
21 - Connection

ce
le
un

pt
❑ For thermostat.

an
d
itte

y li
❑ Coolant hose schematic diagram ⇒ page 92 .
rm

ab
pe

ility
22 - Thermostat
ot

wit
, is n

h re
❑ 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

23 - Rear coolant pipe

satelettronica
❑ Coolant hose schematic diagram ⇒ page 92 .

nform
mercia

24 - From exhaust gas recirculation cooler

a
com

tio
❑ To recirculating pump -V55- .

n in
r
te o

thi
❑ Coolant hose schematic diagram ⇒ page 92 .

s
iva

do
r
rp

c
25 - To heat exchanger

um
fo

en
g

❑ Coolant hose schematic diagram ⇒ page 92 .


n

t.
yi Co
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.

❑ Removing and installing ⇒ page 99 .


27 - Oil cooler
❑ For engine oil.
❑ Removing and installing ⇒ page 85 .

1. Parts of cooling system 91


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

1.3 Coolant hose schematic diagram

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
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

92 Rep. Gr.19 - Cooling


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

1.4 Draining and filling coolant

Special tools and workshop


equipment required
♦ Refractometer -T10007-
♦ Drip tray -V.A.G 1306-
♦ Spring-type clip pliers -
VAS 5024 A-
♦ Cooling system charging
unit -VAS 6096-
♦ Adapter -V.A.G 1274/8-

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

pt
du

1.4.1 Draining
an
itte

y li
erm

ab
ility
ot p

WARNING
wit
, is n

h re
hole

Hot steam may escape when expansion tank is opened. Place


spec

cloth over cap and open with caution.


es, in part or in w

t to the co

– Open cap on coolant expansion tank.


rrectness of i

– Remove noise insulation tray ⇒ General body repairs, exteri‐


l purpos

or; Rep. Gr. 50 ; Body front; Assembly overview .


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
yri by

93
op Vo
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

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– To drain coolant from engine, also remove coolant hose from


oil cooler -arrow-.

nform
mercia

a
Note
com

tion in
r
te o

thi
Observe environmental regulations for disposal.

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.

94 Rep. Gr.19 - Cooling


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

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
e
nl

pt
du

round with frost and corrosion protection additives.

an
itte

y li
erm

♦ Because of its high boiling point, the coolant improves engine

ab
ility
reliability under heavy loads, particularly in countries with trop‐
ot p

wit
ical climates.
, is n

h re
hole

♦ Frost protection is required down to about -25 °C (in countries

spec
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

amount of G 12 plus-plus can be increased, but only up to 60


% (frost protection to about -40 °C). Otherwise frost protection

nf
ercia

and cooling effectiveness are reduced again.

orm
m

♦ If radiator, heat exchanger, cylinder head or cylinder head

atio
m

gasket is replaced, do not reuse old coolant.


o

n in
or c

thi
e

♦ The refractometer -T10007- is recommended for determining


t

sd
iva

the current anti-freeze concentration.

o
r
rp

cu
o

m
f

en
ng

t.
yi
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.

– Connect coolant hose -arrow-.

1. Parts of cooling system 95


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Connect coolant hose -arrow- to oil cooler.


– Install noise insulation tray ⇒ General body repairs, exterior;
Rep. Gr. 50 ; Body front; Assembly overview .
With cooling system charge unit -VAS 6096-
– Screw adapter -V.A.G 1274/8- onto expansion tank.
– Fill coolant circuit using cooling system charge unit -
VAS 6096- . ⇒ Operating instructions for cooling system
charge unit VAS 6096.
Without cooling system charge unit -VAS 6096-

– Slowly fill coolant to upper marking of shaded field on expan‐


sion tank.
With or without cooling system filler unit -VAS 6096-
– Fit expansion tank cap.
– Start engine and maintain an engine speed of about 2000 rpm
for about 3 minutes.

satelettronica
– Run engine until radiator fan cuts in.

WARNING

Hot steam may escape when expansion tank is opened. Place


cloth over cap and open with caution.

– 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
nte
the shaded field. ut
ho eo
r a ac
ss
ce
e

1.5 Removing and installing fan support


nl

pt
du

an
itte

with fans y li
erm

ab
ility
ot p

Special tools and workshop equipment required wit


, is n

h re
♦ Torque wrench -V.A.G 1331-
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
a

Removing
iv

o
r
rp

cu
o

m
f

– Remove noise insulation tray. ⇒ General body repairs, exte‐


en
ng

t.
yi
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.

96 Rep. Gr.19 - Cooling


AG. Volkswagen AG d
agen oes
olksw not
V
d by gu
ara Touran 2003 ➤
ise nte
thor 4-cylinder diesel engine (2.0e ol engine, 2-valve, TDI) - Edition 06.2008
au ra
ss c
– Separate connector -1- and remove fan support securing bolts

ce
le
un

pt
-arrows-.

an
d
itte

y li
– Remove fan support with fans downwards.
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Separate connection -2- and free wiring.

nform
ercia

– Unclip connector -1- from fan support and free wiring.


m

a
com

t
– Remove securing nuts -arrows- and remove fans.

ion in
r
te o

Installing

thi
s
iva

do
Installation is carried out in the reverse order. When installing,
r
rp

cum
fo

note the following:

en
ng

satelettronica
t.
yi Co
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

1.6 Removing and installing radiator

1. Parts of cooling system 97


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Special tools and workshop


equipment required
♦ Refractometer -T10007-
♦ Drip tray -V.A.G 1306-
♦ Spring-type clip pliers -
VAS 5024 A-
♦ Cooling system charging
unit -VAS 6096-
♦ Adapter -V.A.G 1274/8-
♦ Torque wrench -
V.A.G 1331-

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut
Removing ss a ra
c
ce
e

– Bring lock carrier into service position ⇒ General body repairs,


nl

pt
du

an

exterior; Rep. Gr. 50 ; Body front; Lock carrier - service posi‐


itte

y li

tion.
erm

ab
ility
ot p

– Drain off coolant ⇒ page 93 .


wit
, is n

h re

– Remove fan support with fans ⇒ page 96 .


hole

spec
es, in part or in w

– Pull coolant hoses off radiator.


t to the co

– Remove left and right securing bolts ⇒ Item 10 (page 89) for
radiator mounting.
rrectness of i

– Swing radiator back slightly and remove radiator upwards.


l purpos

Installing
Installation is carried out in the reverse order. When installing,
nform
ercia

note the following:


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– Fill with coolant ⇒ page 93 .


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agen
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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

The air conditioner refrigerant circuit must not be opened.

Note

To prevent damage to condenser and also to refrigerant lines/


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

– Remove retaining clamp(s) for refrigerant lines.


– Pull radiator out of lock carrier.
olkswagen AG
ag en AG. V
– Remove securing bolts -2- from condenser on radiator.
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– Carefully pull radiator slightly to right and remove securing bolt
on side -arrow- from condenser on radiator.

rrectness of i
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1.7 Removing and installing coolant pump
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Prote AG.

1. Parts of cooling system 99


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Special tools and workshop


equipment required
♦ Refractometer -T10007-
♦ Drip tray -V.A.G 1306-
♦ Spring-type clip pliers -
VAS 5024 A-
♦ Cooling system charging
unit -VAS 6096-
♦ Adapter -V.A.G 1274/8-
♦ Torque wrench -
V.A.G 1331-

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Removing
rrectness of i
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Note
nform
ercia

Always renew seals and gaskets.


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– Drain coolant. ⇒ page 93


n
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– Remove poly V-belt. ⇒ page 14


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– Remove toothed belt ⇒ page 47 .


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– Remove securing bolts -1- for coolant pump -2- and carefully
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Prote AG.
Installation is carried out in the reverse order. When installing,
note the following:

100 Rep. Gr.19 - Cooling


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Moisten new O-ring -3- with coolant.


– Insert coolant pump -2- in cylinder nblock
AG. Voand
lkswatighten
gen AG securing
bolts -1- to 15 Nm. olks
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Note au ra
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The coolant pump plug faces downwards.

pt
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– Install toothed belt ⇒ page 47 .

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– Install poly V-belt ⇒ page 14 .
, is n

h re
hole

– Fill coolant system with coolant ⇒ page 93 .

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

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o
♦ Drip tray -V.A.G 1306-

rm
m

atio
m

♦ Spring-type clip pliers -


o

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VAS 5024 A-
or

thi
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iva

♦ Cooling system charging

o
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cu
unit -VAS 6096-
o

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♦ Adapter -V.A.G 1274/8-
Co
Cop py
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♦ Torque wrench -
ht
pyri by
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V.A.G 1331- by c lksw
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Removing

Note

Always renew seals and gaskets.

1. Parts of cooling system 101


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Drain off coolant ⇒ page 93 .


– Remove alternator ⇒ Electrical system; Rep. Gr. 27 ; Re‐
moving and installing alternator and poly V-belt .
– Pull coolant hose off connection.
– Remove securing bolts -1- of connection -2- and remove con‐
nection -2- with thermostat -4-.
– Turn thermostat -4- 1/4 turn (90°) to left and remove it from
connection -2-.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
– Moisten new O-ring -3- with coolant.
. Volkswag AG en AG
agen does
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– Insert thermostat -4- into connection -2- and turn 1/4 turn (90°) spec
es, in part or in w

to right.
t to the co

Note
rrectness of i
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The brace on the thermostat must be almost vertical.


nf
ercia

– Insert connection -2- with thermostat -4- in cylinder block.


orm
m

– Tighten securing bolts -1- to 15 Nm.


atio
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n in
c

– Fill coolant system with coolant ⇒ page 93 .


or

thi
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1.9 Checking cooling system for leaks

102 Rep. Gr.19 - Cooling


AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
tho
2003 ➤eTouran
or
au ac
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
ss

ce
le
un

pt
an
d
Special tools and workshop

itte

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equipment required

rm

ab
pe

ility
♦ Cooling system tester -

ot

wit
, is n
V.A.G 1274-

h re
hole

spec
♦ Adapter for cooling system

es, in part or in w
tester -V.A.G 1274/8-

t to the co
♦ Adapter for cooling system
tester -V.A.G 1274/9-

rrectness of i
l purpos

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mercia

a
com

tion in
r
te o

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satelettronica
rig
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pyri by
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Prote AG.

Test prerequisite
• Engine at operating temperature.
Test sequence:

WARNING

Hot steam may escape when expansion tank is opened. Place


cloth over cap and open with caution.

– Open cap on coolant expansion tank.

1. Parts of cooling system 103


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– 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 1.0 bar.
If pressure drops:
– Find leaks and rectify.

1.9.1 Checking pressure relief valve in filler


cap
– Attach cooling system tester -V.A.G 1274- with cooling system
tester adapter -V.A.G 1274/9- to cap.
– Operate hand pump.
AG. Volkswagen AG d
agen oes
At a pressure of 1.4... 1.6 bar, pressure relief valve must open.
Vol
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1.10 Checking oil cooler for leaks

spec
es, in part or in w

t to the co
rrectness of i
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nf
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104 Rep. Gr.19 - Cooling


AG. Volkswagen AG d
agen oes
olksw not
d byV gu
ara Touran 2003 ➤
e
4-cylinder
horis diesel engine (2.0 l engine, 2-valve,nte TDI)
eo - Edition 06.2008
aut ra
ss c
Special tools and workshop

ce
e
nl
equipment required

pt
du

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itte

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♦ Refractometer -T10007-

erm

ab
ility
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♦ Hose clamps up to Ø 25

wit
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mm -3094-

h re
hole

spec
♦ Cooling system tester -
es, in part or in w

V.A.G 1274-

t to the co
♦ 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
ercia

drip tray -VAS 6208-


m

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n

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Special tools and workshop equipment required


♦ Torque wrench -V.A.G 1331-

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-

1. Parts of cooling system 105


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

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- .

– Pull coolant hoses off oil cooler.

– Slide sealing cap -5- to rear connection of oil cooler -4-.


– Secure sealing plug -2- to breather connection of expansion

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
tee
tho or
– Renew oils acooler
u ⇒ page 85 . ac
s
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Installation is carried out in the reverse order. When installing,


nl

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note the following:


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– Check coolant level, if necessary replenish coolant


ility
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⇒ page 93 .
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t to the co
rrectness of i
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mercia

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Prote AG.

106 Rep. Gr.19 - Cooling


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
AG. Volkswagen AG d
agen oes
20 – Fuel supply system olksw not
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aut ra
1 Removing and installing parts of fuel ss c

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supply system

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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
cial p

f inform
Rules for cleanliness ⇒ page 108 .
mer

atio
Assembly overview - fuel tank ⇒ page 108
m

satelettronica
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or

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Assembly overview - fuel filter ⇒ page 110

thi
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Removing and installing fuel cooler ⇒ page 111


i

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cum
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fo

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Emptying fuel tank ⇒ page 112 .


t.
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Removing and installing fuel tank ⇒ page 114
t. C rig
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pyri by
Vo
Removing and installing fuel delivery unit ⇒ page 116
o
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Removing and installing fuel gauge sender ⇒ page 118
Checking fuel pump ⇒ page 119 .
Checking tandem pump ⇒ page 120
Removing and installing tandem pump ⇒ page 124 .
Assembly overview - accelerator mechanism ⇒ page 127

1.1 Safety precautions when working on


fuel supply system

WARNING

When doing any repair work, especially in the engine compart‐


ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant, refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
♦ 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!

1. Removing and installing parts of fuel supply system 107


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

When removing and installing fuel gauge sender or fuel pump


(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
♦ Before beginning work, place an extraction hose close to
sender opening in fuel tank to extract escaping fuel fumes and
switch on exhaust extraction system. If no exhaust extraction
system is available, a radial fan with a displacement greater
than 15 m3/h can be used providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!

1.2 Rules for cleanliness


When working on the fuel supply and injection systems, pay care‐
ful attention to the following “6 rules” for cleanliness:
♦ Thoroughly clean all unions and adjacent areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Do not use
fluffy cloths!
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.

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
agen oes
♦ Also ensure that no diesel fuel runs on to the coolant hoses. Vol
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gu
Should this occur, the hoses must be cleaned immediately. sed by ara
nte
Damaged hoses must be renewed. tho
ri eo
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1.3 Assembly overview - fuel tank ss

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r
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by c lksw
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Prote AG.

108 Rep. Gr.20 - Fuel supply system


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

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
or
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11 - 20 Nm + 1/ turn (90°) fur‐ 4
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12 - Fuel delivery unit


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❑ With fuel gauge sender


wit
, is n

(G).
h re
hole

spec

❑ Note installation posi‐


es, in part or in w

tion of flange on fuel tank ⇒ page 110 .


t to the co

❑ Removing and installing ⇒ page 116 .


❑ Checking fuel pump ⇒ page 119 .
rrectness of i

❑ Removing and installing fuel gauge sender ⇒ page 118


l purpos

❑ Clean strainer if dirty


13 - Seal
nform
ercia

❑ Renew if damaged.
m

at

❑ Moisten with fuel when installing.


om

ion
c

in t

14 - Union nut, 80 Nm
or

his
ate

❑ Remove and install using union nut tool -3217-


do
priv

cum
or

15 - Supply line
f

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ng

t.
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❑ To fuel filter t. Cop py
rig
gh
❑ Clipped onto fuel tank.
ht
pyri by
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co
❑ Check for secure seating.
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Prote AG.
❑ 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.

1. Removing and installing parts of fuel supply system 109


AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
Touran 2003ut
ho ➤ eo
ra
a
4-cylinder
ss diesel engine (2.0 l engine, 2-valve, TDI) - Edition c 06.2008

ce
e
nl

pt
du
❑ Check for secure seating.

an
itte

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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

Mark on flange must align with mark on fuel tank -arrows-.

t to the co
Black supply line -1- to connection marked -V-.
Return line -2- (blue or with blue marking) to connection marked

rrectness of i
-R-.
l purpos

Note

nf
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orm
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After installing fuel delivery unit flange, check that supply, return

atio
m

and breather lines are still clipped onto fuel tank.


o

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or c

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1.4 Assembly overview - fuel filter


rp

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1 - Fuel filter upper part opyri
gh by
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ht

❑ Observe various types by c lksw


cted agen
⇒ page 111 Prote AG.

2 - Fuel temperature sender -


G81-
❑ Installed in engine re‐
turn line
3 - Seal
❑ Renew
4 - Filter insert
❑ Observe change inter‐
vals.
5 - Seal
❑ Renew
6 - Fuel filter - bottom
7 - 8 Nm
8 - Bracket
9 - Seal
❑ Renew
10 - Securing clip
❑ Check for secure seat‐
ing.
11 - Connection for fuel tem‐
perature sender -G81-
12 - From tandem pump.

110 Rep. Gr.20 - Fuel supply system


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

1.4.1 Fuel filter upper part


Type A ⇒ page 111
Type B ⇒ page 111
Fuel filter upper part, type A
1 - 8 Nm
2 - Plug for water extraction (remove and extract about 100 cm3
liquid using hand-operated vacuum pump with accessories -
V.A.G 1390- and water drainage container -V.A.G 1390/1- , renew
seal)
3 - Fuel tank supply line, white or white marking. Check for secure
seating
4 - Fuel tank return line, blue or blue marking. Check for secure
seating
5 - Engine supply line, white or white marking. Check for secure
seating
6 - Engine return line, blue or blue marking. Check for secure
seating

satelettronica
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
th secure ra
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5 - Engine supply line, white or white marking. Check for secure

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1.5 Removing and installing fuel cooler


wit
, is n

h re
hole

Special tools and workshop equipment required spec


es, in part or in w

t to the co
♦ Torque wrench -V.A.G 1331-
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
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en
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t.
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Removing
Co
Cop py
ht. rig
– Note safety precautions before starting work. ⇒ page 107 rig ht
py by
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by lksw
Observe rules for cleanliness ⇒ page 108 .
cted agen
Prote AG.

1. Removing and installing parts of fuel supply system 111


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Note

The fuel cooler is located in the return line to tank. It is located on


the vehicle underbody.

– Remove underbody trim.


– Separate fuel lines at fuel cooler.
– Remove securing nuts -arrows-.
Installing
Installation is carried out in the reverse sequence of removal.
When doing this, note the following:
♦ Tighten fuel cooler securing nuts to 15 Nm.
n AG. Volkswagen AG do
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1.6 Emptying fuel tank
erm

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ility
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Special tools and workshop equipment required

wit
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h re
♦ Fuel extractor -VAS 5190-
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

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ate

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riv

♦ Fuel tank sender wrench -T10202-


p

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cted agen
Prote AG.

♦ Torque wrench (40...200 Nm) -V.A.G 1332-


– Note safety precautions before beginning work ⇒ page 107 .

112 Rep. Gr.20 - Fuel supply system


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Emptying fuel tank if it is more than 3/4 full ⇒ page 113

Emptying fuel tank if it is less than 3/4 full ⇒ page 114

1.6.1 Emptying fuel tank if it is more than 3/4


full

Caution

Secure earth wire of fuel extractor -VAS 5190- to a bare metal


part of the body.

– 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
agen oes
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ed
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satelettronica
ho eo
aut ra
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nl

pt
du

an
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ab
ility
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wit
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– Remove filler cap from fuel tank filler neck.

h re
hole

– 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
l purpos

nf
ercia

orm
m

atio
om

n in
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thi
te

sd
iva

Note
o
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ng

t.
A ball valve -2- is located at the lower end of filler neck in fuel tank
yi Co
op
-1-, which must not be damaged by the extraction hose -3-.
C py
ht. rig
Therefore push hose into filler neck only as far as marking
rig ht
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-arrow-. by c lksw
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– Empty fuel tank as far as possible.


– Carefully pull out extraction hose.

Note

♦ When no more fuel is extracted, the tank is emptied just


enough for the sender flange to be opened without danger.
♦ If the fuel tank has to be drained fully, proceed as follows:
⇒ page 114

1. Removing and installing parts of fuel supply system 113


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

1.6.2 Emptying fuel tank if it is less than 3/4 full


– Remove seat bench ⇒ General body repairs, interior; Rep.
Gr. 72 ; Rear seat; Removing and installing seat bench .
– Remove cover from fuel delivery unit.

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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does
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or
– Pull connector and fuel lines off flange. auth eo
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ss c

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nl

pt
du

Note

an
itte

y li
erm

ab
Press buttons on hose couplings to do this.

ility
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satelettronica
wit
, is n

h re
– Open locking ring using fuel tank sender tool -T10202- .
hole

spec
es, in part or in w

– Lift sender flange.

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
l purpos

nf
ercia

orm
m

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om

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thi
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sd
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1.7 Removing and installing fuel tank


iv

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m
f

en
ng

Special tools and workshop equipment required


t.
yi Co
op py
♦ Torque wrench -V.A.G 1331-
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

114 Rep. Gr.20 - Fuel supply system


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

♦ Engine and gearbox jack -V.A.G 1383/A-

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ss

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nl

pt
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itte

y li
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ab
ility
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wit
1.7.1 Removing
, is n

h re
hole

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
Note

satelettronica
l purpos

♦ Before carrying out further work, disconnect battery earth


strap. First check whether a coded radio is fitted. Obtain anti-

nform
ercia

theft code first if necessary.


m

♦ When lowering fuel tank, guide it carefully to prevent damage.

at
om

ion
c

in t
or

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

his
ate

do
riv

– Remove rear seat bench ⇒ General body repairs, interior;


p

cum
or

Rep. Gr. 72 ; Rear seat; Removing and installing seat bench .


f

en
ng

t.
yi Co
op
– Remove cover from fuel delivery unit.
C py
t. rig
gh ht
yri by
– Pull 5-pin connector off fuel delivery unit flange. cop Vo
by lksw
cted agen
Prote
– 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!

1. Removing and installing parts of fuel supply system 115


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Separate supply line -1- and return line -2- at connections.

Note
n AG. Volkswagen AG do
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Press in securing ring d by to
Vo release fuel lines. ot g
ua
ran
ir se tee
tho
or
– Support fuel au tank using engine and gearbox jack -V.A.G 1383 ac
ss
A- .

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
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h re
– 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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1.7.2 Installing
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Installation is carried out in the reverse sequence of removal.


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When doing this, note the following:
Co
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♦ Fuel lines are to be installed free of kinks.
ht
pyri by
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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 Removing and installing fuel delivery


unit
Special tools and workshop equipment required
♦ Key -T10202-

116 Rep. Gr.20 - Fuel supply system


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

♦ Torque wrench (40...200 Nm) -V.A.G 1332-

1.8.1 Removing
– Note safety precautions before starting work. ⇒ page 107
AG. Volkswagen AG d
Observe rules for cleanliness ⇒ page 108 . agen oes
olksw not
byV gu
ara
– First check whether a coded radio is fitted. If so, obtain ris anti-
ed
nte
theft coding. aut
ho eo
ra
s c

satelettronica
s
– With the ignition switched off, disconnect battery earth strap.

ce
le
un

pt
an
d

– The fuel tank must not be more than 3/4 full when removing
itte

y li
erm

ab
the fuel delivery unit. Empty fuel tank if necessary

ility
ot p

⇒ page 112 .

wit
is n

h re
– Remove rear seat bench ⇒ General body repairs, interior;
ole,

Rep. Gr. 72 ; Rear seat; Removing and installing seat bench .

spec
urposes, in part or in wh

– Remove cover from fuel delivery unit.

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

f in
♦ The fuel system is also under pressure! Before opening

form
mer

the system, place cloths around the connections. Then

atio
carefully loosen connection to release the pressure!
om

n
c

i
or

n
♦ Wear eye and hand protection when performing any type

thi
e

of repair work on the fuel system!


t

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi
– Pull return line, supply line and 5-pin connector off fuel delivery
Co
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unit flange. ht. rig
rig ht
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co Vo
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cted agen
Prote AG.
Note

Press in securing ring to release fuel lines.

1. Removing and installing parts of fuel supply system 117


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Open locking ring using wrench -T10202- .


– Pull fuel delivery unit and seal out of opening in fuel tank.

Note

If delivery unit is to be renewed, drain old delivery unit before dis‐


posal.

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
yV gu
ara
⇒ page 110 . ris
e nte
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ss
1.9 Removing and installing fuel gauge
ce
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nl

pt
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sender
an
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ab
ility
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1.9.1 Removing
h re
hole

spec

– Remove fuel delivery unit ⇒ page 116 .


es, in part or in w

t to the co

– 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

fuel sender off downwards -arrow-.


l purpos

nform
mercia

at
om

ion
c

in t
or

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ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by

118
co Vo
by lksw
Rep. Gr.20 - Fuel supply system cted agen
Prote AG.
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 .

1.10 Checking fuel pump


Special tools and workshop equipment required
♦ Hand multimeter -V.A.G 1526 B- or multimeter -V.A.G 1715-

satelettronica
♦ Diode test lamp -V.A.G 1527 B-

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♦ Auxiliary measuring set -V.A.G 1594 C-


is n

h re
ole,

Test prerequisite
spec
urposes, in part or in wh

• Fuses must be OK.


t to the co

• The battery voltage must be at least 11.5 V.


rrectne

• All electrical consumers, e.g. lights and rear window heating,


must be switched off.
ss

Checking function and voltage supply


o
cial p

f in

– Remove rear seat bench ⇒ General body repairs, interior;


form
mer

Rep. Gr. 72 ; Rear seat; Removing and installing seat bench .


atio
om

– Remove cover from fuel delivery unit.


n
c

i
or

n thi
e

– Switch on ignition. The fuel pump must be heard to run for


t

sd
va

about 2 seconds.
i

o
pr

cum
r
fo

en
ng

– Switch off ignition.


t.
yi Co
op py
If the fuel pump does not run:
t. C rig
gh ht
pyri by
Vo
o
– Pull 5-pin connector off fuel delivery unit flange.
c by lksw
cted agen
Prote AG.

1. Removing and installing parts of fuel supply system 119


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Connect diode test lamp -V.A.G 1527 B- to outer contacts of


connector using auxiliary cables from auxiliary measuring set
-V.A.G 1594 C- .
– Switch on ignition. The LED must light up for about 2 seconds.
– Switch off ignition.
If LED does not light up
– Check actuation of fuel pump relay and wiring for open circuit
or short circuit. ⇒ Vehicle diagnosis, testing and information
system VAS 5051
If LED lights up (voltage supply OK):
– Remove fuel delivery unit ⇒ page 116 .
– Check that electrical wiring between flange and fuel pump is
connected and has continuity.
If no open circuit can be found:
– Renew fuel delivery unit ⇒ page 116 .
Checking current consumption of fuel pump

satelettronica
– Pull 5-pin connector off fuel delivery unit flange.
AG. Volkswagen AG d
agen oes
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
ra
ss c

ce
le
un

pt
Note
an
d
itte

y li
erm

ab
The current pick-up clamp of multimeter -V.A.G 1715- can also ility
ot p

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


is n

h re
nector and fuel pump.
ole,

spec
urposes, in part or in wh

– Connect contacts -5- of connector and fuel pump using an


t to the co

auxiliary cable from adapter set -V.A.G 1594 C- .


– Start engine and run at idling speed.
rrectne

– Measure current draw of fuel pump: Specification: max. 7.5


Amperes.
ss o
cial p

– If the values measured lie outside the specifications


f inform
mer

– Renew fuel delivery unit ⇒ page 116 .


atio
om

n
c

1.11 Checking tandem pump


i
or

n thi
te

sd
va

Checking delivery pressure ⇒ page 120


i

o
pr

cum
r
fo

en
ng

Checking for internal leaks ⇒ page 122


t.
yi Co
Cop py
1.11.1 Checking delivery pressure
ht. rig
rig ht
py by
co Vo
by lksw
Special tools and workshop equipment required cted agen
Prote AG.

120 Rep. Gr.20 - Fuel supply system


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

♦ Tandem pump tester -VAS 5187-

AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
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ss c

ce
le
un

pt
an
d
itte

y li
♦ Torque wrench (5...50 Nm) -V.A.G 1331-
erm

ab
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

♦ Vehicle diagnostic, testing and information system -VAS 5051-

atio
om

n
c

i
♦ Diagnostic cable -VAS 5051/6A-
or

n thi
te

sd
a

Test prerequisites
iv

o
pr

cum
r
fo

Coolant temperature must be at least 85 °C.

en
ng

t.
yi Co
op
Unit injectors OK
C py
ht. rig
rig ht
py by
Fuel filter and fuel lines must not be blocked. co Vo
by lksw
cted agen
Prote AG.
Procedure
– Remove engine cover ⇒ page 4 .
– Remove screw plug -arrow-.

1. Removing and installing parts of fuel supply system 121


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Connect tandem pump tester -VAS 5187- as shown.


– Start engine and run at idling speed.
– Connect vehicle diagnostic, testing and information system -
VAS 5052- and select operating mode “Vehicle self-diagno‐
sis”.
– Press button “01 - Engine electronics” on display.
– Press diagnostic function “08 - Read data block”.
– Enter display group “1” using number block (key pad) and
confirm entry with Q button.
– Read engine idling speed in display zone “1”.
– Increase engine speed to 4000 rpm.
– Observe pressure indicated on pressure gauge.
Specification: min. 7.5 bar
If the specification is not obtained:
– Using a hose clamp, clamp off return line between fuel filter
and tandem pump.

satelettronica
AG. Volkswagen gen AG do
swa es n
– Increase engine speed to 4000
by
Vol rpm.
k ot g
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ed ran
ris
– Observe pressure indicated on pressure gauge. tee
tho or
au ac
Specification: min. 7.5ssbar ce
le
un

pt
If specification is now obtained:
an
d
itte

y li
erm

Pressure loss at unit injectors.


ab
ility
ot p

– Renew unit injector O-rings.


wit
is n

h re
ole,

If the specification is not obtained:


spec
urposes, in part or in wh

– Renew tandem pump ⇒ page 124 .


t to the co

Note
rrectne

After removing pressure gauge, tighten plug to 25 Nm. Always


s

replace seal.
s o
cial p

f inform
mer

1.11.2 Checking for internal leaks


atio
om

n
c

i
or

n thi
te

sd
a

Note
iv

o
pr

cum
r
fo

en
ng

The tandem pump must be checked for internal leaks between


t.
yi Co
op
fuel side and oil side after reinstalling a used tandem pump, for C py
t. rig
example after renewing or repairing a cylinder head and/or when
gh ht
yri by
installing a "short" engine. When leaking it is possible for the fuel
op Vo
by c lksw
to mix with the oil which may cause the engine to fail.
cted agen
Prote AG.

Special tools and workshop equipment required

122 Rep. Gr.20 - Fuel supply system


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

♦ Tester -V.A.G 1687-

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.
G. Volkswagen nA AG do
wage es n

satelettronica
Prepare test unit -V.A.G 1687-
y V as follows:
olks ot g
ua
b
ed ra
– Unscrew pressurethoregulating
ris valve -2- and close valves -3- ntee o
and -4-. s au ra
c
s

ce
le

– Connect test connection -5- to fuel supply union of tandem


un

pump using a commercially available compressed air connec‐ pt


an
d
itte

tion and a section of fuel hose. Use a spring-type clamp to y li


rm

secure. ab
pe

ility
ot

wit
, is n

h re
hole

Note
spec
es, in part or in w

t to the co

To turn the pressure regulating valve -2- the knob must be pulled
upwards.
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

1. Removing and installing parts of fuel supply system 123


n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
Touran 2003 ➤ ho
ir se tee
t or
4-cylinder diesel engine (2.0 l engine,
au 2-valve, TDI) - Edition 06.2008 ac
ss

ce
e
nl
– Connect compressed air hose -1- (compressed air source) to

pt
du

an
itte
charge air system tester -V.A.G 1687- .

y li
erm

ab
ility
ot p

wit
, is n
Note

h re
hole

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
l purpos

Caution

nf
ercia

The maximum test pressure is 1.3 bar and this must not be

orm
exceeded.
m

atio
om

n in
or c

thi
e

– Open valve -4- and wait until the test circuit is filled. If neces‐
t

sd
iva

o
sary readjust pressure to 1.0 bar.
r
rp

cu
o

m
f

en
ng

– Close valve -3- to retain pressure and observe the pressure


t.
yi Co
op
drop over a period of 1 minute.

satelettronica
C py
t. rig
gh ht
yri
If the pressure does not drop the tandem pump can be reused, if
p by
co Vo
by lksw
the pressure drops the tandem pump must be renewed. Prote
cted AG.
agen

1.12 Removing and installing tandem pump

DANGER!

The tandem pump may, under no circumstances, be disman‐


tled as the vacuum part could otherwise malfunction. This
would result in the failure of the brake servo.

124 Rep. Gr.20 - Fuel supply system


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Special tools and workshop


equipment required
♦ Torque wrench -V.A.G
1331-
♦ Hand vacuum pump with
accessories -V.A.G 1390-
♦ Water drainage container -
V.A.G 1390/1-
♦ Spring-type clip pliers -VAS
5024 A-

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne
Removing
ss o

– Remove engine cover ⇒ page 4 .


cial p

f inform

– 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
e

connecting pipe.
t

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. Removing and installing parts of fuel supply system 125


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– 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
agen oes
– Remove tandem pump -4- from cylinder head.
Vol
ksw not
gu
y
db ara
Installing rise nte
tho

satelettronica
eo
au ra
Installation is carried out in the reverse
ss order. When installing, c
note the following:

ce
e
nl

pt
du

an
itte

y li
erm

ab
Note

ility
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wit
, is n

♦ Ensure that tandem pump coupling seats properly in cam‐

h re
hole

shaft.

spec
es, in part or in w

♦ Always renew tandem pump seals.

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

– Attach return hose (blue marking) to return connection -3- of


tandem pump.
nf
ercia

orm
m

– Attach supply hose (white marking) to supply connection -2-


atio
m

and vacuum hose from brake servo -1- to tandem pump -4-.
o

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

– Attach supply hose -1- (white marking) to 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 -V.A.G 1390- until fuel comes out
of return hose. Be careful that no fuel is sucked into hand vac‐
uum pump.
– Attach return hose (blue marking) to fuel filter.

126 Rep. Gr.20 - Fuel supply system


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

1.13 Assembly overview - accelerator mechanism


AG. Volkswagen AG d
1 - Connector lksw
agen oes
not
Vo gu
❑ Black, 6-pin. ed by ara
nte
ris
o eo
2 - Acceleratoraposition
ut
h
sender ra
-G79- ss c

ce
e
nl

❑ Not adjustable.

pt
du

an
itte

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❑ The accelerator position
erm

ab
sender passes the posi‐

ility
ot p

tion of the accelerator

wit
, is n

on to the engine control

h re
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

❑ Removing and installing


accelerator pedal mod‐

satelettronica
nform
ercia

ule ⇒ page 127


m

3 - 9 Nm

at
om

ion
c

4 - Cap

in t
or

his
ate

do
priv

cum
for

en
ng

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

1.13.1 Removing and installing accelerator


pedal module
Special tools and workshop equipment required
♦ Release tool -T 10269- (for right-hand drive vehicles -
T10297- ).
♦ Torque wrench (5...50 Nm) -V.A.G 1331-

1. Removing and installing parts of fuel supply system 127


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Removing

– Lever off cap ⇒ Item 4 (page 127) using a screwdriver.


– Remove securing bolt beneath it.
– To remove accelerator pedal module, push release tool -T
10269- (for right-hand drive vehicles -T10297- ) into opening
provided to stop.
– Pull connector off accelerator pedal module.
– Pull wiring guide off accelerator pedal module.
– Pull out accelerator pedal module vertically.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
– Attach connector and wiring guide to accelerator pedal mod‐
ule.
– Press accelerator pedal module onto securing pins.
– Insert centring pin into hole in vehicle floor.

satelettronica
AG. Volkswagen AG d
agen oes
lksw not
– 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

ce
e

– Install steering column cover.


nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

128 Rep. Gr.20 - Fuel supply system


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

21 – Turbocharging/supercharging
gen AG
. Volkswagen AG
d a oes
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Vol gu
by
1 Charge air system with turbocharger ris
ed ara
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tho eo
au ra
Safety precautions ⇒ page 129 ss c

ce
le
un
Rules for cleanliness ⇒ page 129 .

pt
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d
itte

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Installing hose connections with connector couplings

rm

ab
pe
⇒ page 130

ility
ot

wit
, is n
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 .

1.1 Safety precautions

rrectness of i
l purpos

WARNING

When doing any repair work, especially in the engine compart‐

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

en
ng

t.
yi Co
♦ Ensure that there is sufficient clearance to all moving or Cop py
t.
hot components.
rig
gh ht
pyri by
Vo
o
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.

1.2 Rules for cleanliness


When working on the turbocharger, pay careful attention to the
following rules of cleanliness:
♦ Thoroughly clean all unions and adjacent areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Do not use
fluffy cloths!
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ Existing transport and protective packaging and sealing caps
must only be removed immediately prior to installation.
♦ When making repairs, remove oil from connection and hose
ends.

1. Charge air system with turbocharger 129


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

♦ When system is open: do not work with compressed air if this


can be avoided. Do not move vehicle unless absolutely nec‐
essary.

1.3 Installing hose connections with con‐


nector couplings AG. Volkswagen AG d
agen oes
olksw not
yV gu
Caution rised b ara
nte
ho eo
aut ra
The seal of the connector coupling can be damaged if sthe se‐
s c
curing clip is in locking position when installing. Leaks could

ce
le
un

pt
occur. Observe installation instructions.

an
d
itte

y li
rm

ab
pe

ility
ot
Removing

wit
, is n

h re
– 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

– Oil sealing surface and seal.


– Bring securing clip to release position -1-.

nform
ercia

– Push charge air hose into coupling to stop.


m

a
com

tion in
r
te o

thi
s
iva

– Bring securing clip to release position -2- and then push

do
r
rp

c
charge air hose again.

um
fo

en
ng

t.
yi
– Check if connector coupling seats correctly and is properly
Co
op py
engaged by pulling hose.
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

130 Rep. Gr.21 - Turbocharging/supercharging


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

1.4 Assembly overview - turbocharger

Note

♦ All hose connections are secured.


♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
♦ Before fitting hose to oil supply line connection, fill turbocharg‐
er with engine oil.
♦ After installing turbocharger, run engine for about 1 minute at
idling speed to insure that oil is supplied to turbocharger.

Observe rules for cleanliness ⇒ page 129


Observe safety precautions ⇒ page 129

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
y gu
ara
hosethowith
ris engine oil nte
e or
au ac
5 - Turbocharger
ss
ce
le

❑ Can only be renewed


un

pt
an
d

with exhaust manifold.


itte

y li
rm

ab

6 - Vacuum hose
pe

ility
ot

wit

❑ Vacuum hose schemat‐


, is n

h re

ic diagram ⇒ page 135


hole

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
r
te o

thi

10 - Exhaust manifold
s
iva

do

❑ Can only be renewed to‐


r
rp

cum
fo

gether with turbocharg‐


en
ng

t.
er
yi Co
Cop py
t. rig
11 - 25 Nm
gh ht
pyri by
Vo
co
❑ Renew
by lksw
cted agen
Prote AG.

1. Charge air system with turbocharger 131


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

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
olksw not
y V gu
b ara
22 - Connection rise
d
nte
ho eo
❑ For intake hose for air filter/turbocharger s aut ra
c
s
❑ Assembly overview - air filter ⇒ page 145 .

ce
le
un

pt
an
d

23 - 9 Nm
itte

y li
erm

ab
24 - 10 Nm

ility
ot p

wit
is n

h re
ole,

spec
Installation position of exhaust gas temperature sender with an‐
urposes, in part or in wh

gled cable guide

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

i
or

n thi
te

sd
iva

o
pr

1.5 Assembly overview - charge air cooling


um
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh
Note
ht
pyri by
Vo
co lksw
by
cted agen
Prote
♦ Charge air system must be free of leaks.
AG.

♦ When making repairs, remove oil from connection and hose


ends.
♦ All charge air system hose connections are secured by spring-
type clips or by push-on connectors.
♦ Checking charge air system for leaks ⇒ page 133 .

132 Rep. Gr.21 - Turbocharging/supercharging


AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho
2003 ➤ eTouran
or
au ac
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008
ss

ce
e
nl

pt
du

an
1 - 8 Nm

itte

y li
erm

ab
2 - Bracket

ility
ot p

wit
❑ Note installation posi‐

, is n

h re
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

carrier service position


4 - Sealing strip

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

o
r
rp

cu
6 - Charge air pressure sender
o

m
f

en
ng

-G31- with intake air tempera‐


t.
yi Co
op
ture sender -G42- C py
t.

satelettronica
rig
gh ht
yri
7 - O-ring
p by
co Vo
by lksw
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.

1.6 Checking charge air system for leaks


Special tools and workshop equipment required
♦ Charge air system tester -V.A.G 1687-
♦ Adapter -V.A.G 1687/10-
– Remove intake hose -1- from air filter.

1. Charge air system with turbocharger 133


AG. Volkswagen AG d
agen oes
olksw not
y V gu
Touran 2003 ➤ rise
d b ara
nte
4-cylinder diesel engine (2.0 l engine, 2-valve,
autho
TDI) - Edition 06.2008 eo
ra
ss c

ce
e
– Connect adapter -1687/10- in intake hose -1- and secure with

nl

pt
du
clip.

an
itte

y li
erm

ab
Prepare charge air system tester -V.A.G 1687- as follows:

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
g

– Unscrew pressure regulating valve -2- and close valves -3-


n

t.
yi

satelettronica
Co
and -4-. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
Note
cted agen
Prote AG.

To turn the pressure regulating valve -2- the knob must be pulled
upwards.

– Connect charge air system tester -V.A.G 1687- to adapter


-1687/10- as shown.

134 Rep. Gr.21 - Turbocharging/supercharging


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

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


charge air system tester -V.A.G 1687- .

Note

If there is water in the sight glass, drain at water drain screw -6-.

– Open valve -3-.


– Adjust pressure to 0.5 bar with pressure regulating valve -2-.

Caution

The pressure must not exceed 0.5 bar! If the pressure is too
high this can cause damage to the engine.

– Open valve -4- and wait until the test circuit is filled. If neces‐
sary readjust pressure to 0.5 bar.
– Check the charge air system for leaks by hearing, touching,
with commercially available leak detector spray or using ultra‐

satelettronica
sonic tester -V.A.G 1842- .

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
nte
th eo
♦ If leaks occur, when doing
ss a any repair work observe notes for
u ra
c
charge air system ⇒ page 132 . ce
le
un

pt
an
d

♦ Before removing the adapter, depressurise the test circuit by


itte

y li
pulling coupling off adapter -1687/10- .
rm

ab
pe

ility
ot

wit
, is n

h re

1.7 Vacuum hose schematic diagram


hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

1. Charge air system with turbocharger 135


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

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
ot g
N345- d byV ua
ran
ir se tee
7 - Vacuum unit utho
or
a ac
❑ For change-over sfor
s
ex‐

ce
e

haust gas recirculation


nl

pt
du

an
cooler.
itte

y li
erm

ab
8 - Vacuum unit

ility
ot p

❑ On turbocharger.

wit
, is n

h re

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
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

136 Rep. Gr.21 - Turbocharging/supercharging


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

23 – Mixture preparation - injection


1 Repairing diesel direct injection sys‐
tem

Note

The diesel direct injection system control unit is equipped with a


fault memory. Read fault memory before and after making repairs
or adjustments ⇒ page 146 .

Safety precautions ⇒ page 137


Rules for cleanliness ⇒ page 138 . n AG. Volkswagen AG do
lkswage es n
o ot g
yV
Assembly overview - unit injector ⇒ page 138 ir se
d b ua
ran
o tee
h
Assembly overview - intake manifold with intake amanifold
ut
flap or
ac
⇒ page 143 . ss

ce
le

satelettronica
un

pt
Assembly overview - air filter ⇒ page 145 .

an
d
itte

y li
erm

ab
1.1 Safety precautions

ility
ot p

wit
is n

h re
ole,

WARNING

spec
urposes, in part or in wh

When doing any repair work, especially in the engine compart‐

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

Observe following if test and measuring instruments are required


iv

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.

1. Repairing diesel direct injection system 137


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

1.2 Rules for cleanliness


When working on fuel supply and injection system, pay careful
attention to the following rules for cleanliness:
♦ Thoroughly clean all unions and adjacent areas before dis‐
connecting.
AG . Volkswagen AG
♦ Place removed parts on a clean surface and cover. Do not use ksw
agen does
not
l
fluffy cloths! by
Vo gu
ara
d
ise nte
♦ Carefully cover opened components or seal if repairs cannot
ut
ho
r eo
be carried out immediately. ss
a ra
c

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

♦ When system is open: do not work with compressed air if this

h re
hole

can be avoided. Do not move vehicle unless absolutely nec‐

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

♦ Observe rules for cleanliness ⇒ page 138

nform
ercia

♦ Always renew seals and O-rings


m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

138 Rep. Gr.23 - Mixture preparation - injection


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

1 - 20 Nm + 1/4 turn (90°) fur‐


ther
❑ Renew
2 - Rocker arm shaft
❑ With rocker arms
❑ Removing and installing
⇒ page 140 .
3 - Lock nut, 30 Nm
4 - Adjuster screw
❑ Renew
5 - Ball stud
❑ Renew
6 - Unit injector
❑ Removing and installing
⇒ page 140 .
7 - O-ring
❑ Renewing ⇒ page 139 .

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
byV gu
ara
13 - Clamping block rised
nte
ho eo
ut
14 - 12 Nm + 3/4 turn (270 °) a ra
ss c
further

ce
e
nl

pt
du

an
❑ Renew
itte

y li
erm

ab
ility
ot p

wit
, is n

1.4 Removing and installing O-rings for unit h re


hole

spec
injector
es, in part or in w

t to the co

Special tools and workshop equipment required


♦ Assembly sleeves -T10056-
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
Removing
py by
co Vo
by lksw
cted agen
– Lever old O-rings very carefully out of unit injector.
Prote AG.

1. Repairing diesel direct injection system 139


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Ensure above all that no burrs are formed on O-ring seat.


Installing

Note

♦ Always use the assembly sleeves to fit the O-rings. There is a


danger of damaging the O-rings if the sleeves are not used.
♦ Gradual introduction of O-rings with no coloured markings.
Note the correct allocation of O-rings to grooves: the thickness
of the rings reduces towards injector nozzle:
♦ Prevent O-rings from rolling when sliding them on. TheeO-rings
n AG. Volkswagen AG
must not be twisted in their seats in unit injector.
olks
wag does
not
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db ara
ise nte
– Pull heat shield seat off together with usecuring
tho
r
clip. eo
a ra
s c
– Clean seating surfaces for O-rings on unit injector very
s care‐

ce
le

fully.
un

pt
an
d
itte

y li
– Slide assembly sleeve -T10056/1- onto limit stop on unit in‐
rm

ab
jector.
pe

ility
ot

satelettronica
wit
, is n

– Push the upper, thicker O-ring carefully onto the assembly

h re
sleeve and into the seat on the unit injector.
hole

spec
es, in part or in w

– Remove the assembly sleeve.

t to the co
rrectness of i
l purpos

nform
ercia

– Slide assembly sleeve -T10056/2- onto limit stop on unit in‐


m

a
com

t
jector.
ion in
r
te o

– Slide the middle, thinner O-ring carefully onto assembly sleeve


thi
s
iva

and into seat on unit injector.


do
r
rp

cum
fo

– Remove the assembly sleeve.


en
ng

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

– Slide assembly sleeve -T10056/3- onto limit stop on unit in‐


jector.
– Push the lower O-ring carefully onto the assembly sleeve and
into the seat of the unit injector.
– Remove the assembly sleeve.
– Fit new heat shield seal together with securing clip.

1.5 Removing and installing unit injector

140 Rep. Gr.23 - Mixture preparation - injection


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Special tools and workshop


equipment required
♦ Universal dial gauge brack‐
et -VW 387-
♦ Allen key, long reach
-3410-
♦ special wrench, long reach
-T10054-
♦ Puller -T10055-
♦ Torque wrench -
V.A.G 1331-

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

– Remove upper toothed belt guard.


– Remove cylinder head cover. ⇒ page 45
nf
ercia

– Turn crankshaft until the cam pair point evenly upwards for the
rm
m

unit injector which is to be removed.


atio
om

n in
c

– Loosen lock nuts of adjustment screws -1- and remove ad‐


or

thi
e

justment screws.
t

sd
iva

o
r
rp

cu

– Remove rocker arm securing bolts -2- (from outwards to in‐


o

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. Repairing diesel direct injection system 141


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Insert puller -T10055- in place of the clamping block in the slot


on the side of the unit injector.
– Pull unit injector out of cylinder head seat with gentle taps.

1.5.2 Installing

satelettronica
Note

♦ Each time work is performed which requires adjustment of the


unit injector, the adjustment screw in the rocker arm and also
the unit injector ball stud must be renewed.
AG. Volkswagen AG d
♦ New unit injectors are supplied with O-rings and heat shield lksw
agen oes
not
seal. d byV
o gu
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ise nte
or eo
th
– Heat shield seal and O-rings must be renewed if olds unit in‐
au ra
c
jector is reused ⇒ page 139 . s

ce
e
nl

pt
du

– Check that the three O-rings and the heat shield seal along

an
itte

y li
with securing clip are seated correctly before installing unit in‐
erm

ab
jector.

ility
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wit
, is n

h re
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.

142 Rep. Gr.23 - Mixture preparation - injection


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Now align unit injector at right angles to camshaft mounting


brackets.
– Check dimension “a” from outer edge of cylinder head to roun‐
ded surface of unit injector with a vernier gauge (measuring
range min. 400 mm).
Cylinder Dimension “a”
1 333.0 ± 0.8 mm
2 245.0 ± 0.8 mm
3 153.6 ± 0.8 mm
4 65.6 ± 0.8 mm
– Align unit injector and tighten securing bolt as follows: 12 Nm
and turn 270° (3/4 turn) further (turning further can be done in
several stages).

– Fit rocker arm shaft and tighten new securing bolts as follows:
– First 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
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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

– Fit dial gauge onto adjustment screw of unit injector as shown.


itte

y li
rm

– Turn the crankshaft in engine direction of rotation until the roll‐ ab


pe

ility
er of the rocker arm is positioned on the peak of the drive cam.
ot

wit
, is n

Roller side -arrow A- is positioned at highest point, dial gauge


h re
hole

-arrow B- is positioned at lowest point.


spec
es, in part or in w

– Remove dial gauge.


t to the co

– 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

– Turn adjuster screw 180° back off stop.


m

a
com

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


ion in

Nm.
r
te o

thi
s
iva

– Connect unit injector connector.


do
r
rp

cum
fo

– Install cylinder head cover ⇒ page 45 .


en
ng

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

1.6 Assembly overview - intake manifold with intake manifold flap

1. Repairing diesel direct injection system 143


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

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
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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

❑ Assembly overview - ex‐


do
priv

haust gas recirculation


um
for

cooler ⇒ page 157


en
ng

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

1.6.1 Cleaning intake manifold flap support

Note

Carbon deposits can occur in the throttle valve support through


the combination of unfavourable factors. If these are found, e.g.
when disassembling the exhaust gas recirculation valve -N18- or
the intake manifold flap motor -V157,- , the support will have to
be cleaned.

144 Rep. Gr.23 - Mixture preparation - injection


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

WARNING

Acetone is highly inflammable. Please observe the accident


prevention regulations and safety notes when handling highly
inflammable fluids. Wear eye protection and protective clothing
to avoid injuries and skin contact.

– Remove the intake manifold flap support


– Remove the exhaust gas recirculation valve -N18- and the in‐
take manifold flap motor -V157- .
olksw
– Thoroughly clean intake manifold flap
agen support, especially
AG. V agen AG
does
ksw
around exhaust gas return valve,
by Vol using commercially available
not
gu
acetone according to DIN
ris 53247 and cleaning brush.
ed ara
nte
tho eo
– Wipe off intake manifold
sa
u flap support using a lint-free cloth. ra
c
s

ce
le

– Allow the acetone to evaporate fully, assemble the cleaned


un

pt
intake manifold flap support, replace the seals and insert it

an
d
itte

y li
back in position.
erm

ab
ility
ot p

1.7 Assembly overview - air filter

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

5 - Air filter upper part


atio
om

6 - 8 Nm
n
c

i
or

n thi
e

7 - Vacuum hose
t

sd
iva

o
pr

❑ Vacuum hose schemat‐


um
r
fo

ic diagram ⇒ page 135


en
ng

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.

10 - Air filter lower part


11 - 10 Nm

1. Repairing diesel direct injection system 145


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

2 Engine control unit


Reading and clearing engine control unit fault memory
⇒ page 146
Adapting functions and components ⇒ page 147
Removing and installing engine control unit ⇒ page 147 .
Removing and installing anti-theft engine control unit
⇒ page 148 .

2.1 Reading and clearing engine control unit


AG. Volkswagen AG d
fault memory
Vol
kswagen oes
not
g
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db ran
Special tools and workshop
or
ise equipment required tee
th o
au
r
♦ Vehicle diagnostic,
ss testing and information system -VAS 5051- ac

ce
le
un

pt
an
d
itte

y li
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

– Connect vehicle diagnostic, testing and information system -


VAS 5051- as follows:
m

a
com

tio

– Connect diagnostic cable as shown to diagnostic connection.


n in
r
te o

thi

– Start engine and run at idling speed.


s
iva

do
r
rp

cum

Only when engine does not start:


fo

en
ng

t.
yi
– Switch on ignition.
Co
Cop py
t. rig
gh ht
Select operating mode: yri
p by
o Vo
by c lksw
cted
– Press button on display for “Vehicle self-diagnosis”.
agen
Prote AG.

Select vehicle system:


– Press button “01 - Engine electronics” on display.
The control unit identification and coding are indicated on the dis‐
play.
Select diagnostic function:
– Press button “02 - Read fault memory” on display.
– If no fault is stored in engine control unit “0 fault detected” is
displayed.
– If faults are stored in the engine control unit, these are shown
one below the other on the display.
– Press the ← button.
– Press button “05 - Clear fault memory” on display.
– Press function “06-End output”.

146 Rep. Gr.23 - Mixture preparation - injection


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

2.2 Adapting functions and components


Special tools and workshop equipment required
♦ Vehicle diagnostic, testing and information system -VAS 5051-

Procedure
– Connect vehicle diagnostic, testing and information system -
VAS 5051- as follows:
. Volkswagen AG
gen AG

satelettronica
d
– Connect diagnostic
Vol
kswcable as shown to diagnostic
a oes
not connection.
y gu
db ar
Select “guidedris fault finding” in vehicle diagnostic, testing
e an and in‐
tee
ho
formationasystem -VAS 5051- .
ut or
a
ss c
After all control units have been read:
ce
le
un

pt
an
d

– Press “GoTo” button.


itte

y li
erm

ab

– Select “Function/component selection”.


ility
ot p

wit
is n

– Select “Drive train”.


h re
ole,

spec

– Select “Engine code”.


urposes, in part or in wh

t to the co

– Select “01-Systems capable of self-diagnosis”.


– Select “Engine management”.
rrectne

– Select “Functions”.
– Select “Function or component”.
ss o
cial p

f in

2.3 Removing and installing engine control


form
mer

unit
atio
om

n
c

i
or

n thi
te

sd
a

Note
iv

o
pr

cum
r
fo

en
ng

Before removing engine control unit, read the control unit identi‐
t.
yi Co
op
fication and, with it, the coding of the current control unit
C py
t. rig
⇒ page 146 .
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
Removing engine control unit
AG.

– Switch off ignition.


– Remove plenum chamber bulkhead ⇒ General body repairs;
Rep. Gr. 50 ; Body front, plenum chamber bulkhead

2. Engine control unit 147


AG. Volkswagen AG d
agen oes
olksw not
Touran 2003 ➤ d byV gu
ara
e
4-cylinder dieselhoengine (2.0 l engine, 2-valve, TDI) - Edition
ris nte06.2008
eo
aut ra
ss c
– Loosen securing nuts -arrows-.

ce
le
un

pt
an
– Release connector on engine control unit and pull off connec‐
d
itte

y li
tor.
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness
– Push bracket -1- off engine control unit.

o
cial p

f inform
Installing engine control unit
mer

atio
– Push bracket onto engine control unit.
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

– Tighten securing nuts -arrows- to 10 Nm.


– Fit connector and lock in position.
– Install plenum chamber bulkhead ⇒ General body repairs;
Rep. Gr. 50 ; Body front, plenum chamber bulkhead .

2.4 Removing and installing anti-theft en‐


gine control unit
Special tools and workshop equipment required
♦ Pliers

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 .

148 Rep. Gr.23 - Mixture preparation - injection


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Twist shear bolts -arrows- out using pliers and remove cover
from protective housing.
– Then remove securing nuts for control unit bracket -arrows-.

– Release connector on engine control unit and pull off connec‐


tor.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
nte

satelettronica
ris
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

– Press catches -1- and -2- outwards. Then pull engine control

wit
, is n

unit off control unit bracket in direction of arrow.

h re
hole

spec
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

nform
mercia

at
om

– Tighten securing bolts -arrows- to 10 Nm. ion


c

in t
or

his
te

– Install cover of protective housing.


a

do
priv

cum
for

en
ng

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

2. Engine control unit 149


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– 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
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

150 Rep. Gr.23 - Mixture preparation - injection


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

26 – Exhaust system
1 Parts of the exhaust system

Note

♦ After working on the exhaust system ensure that the system


is not under stress, and that athere
gen AGis sufficient clearance
. Volkswagen AG do to the
bodywork. If necessary, oloosen
lksw double and single clamps
es n
ot and
yV
align silencer and sexhaust
edb pipe so that sufficient clearance gu
ara is
maintained to the
tho bodywork and the support rings are evenlye or
ri nte
loaded. sa
u ac
s

ce
le

♦ Renew self-locking nuts.


un

pt
an
d
itte

y li
erm

ab
ility
ot p

Note

wit
is n

h re
ole,

If the particulate filter or the exhaust gas pressure sensor 1 -

spec

satelettronica
urposes, in part or in wh

G450- is changed, the exhaust gas pressure sensor 1 -G450-

t to the co
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

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. Parts of the exhaust system 151


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

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
agen oes
olksw not
yV gu
9 - Front exhaust pipe ed b ara
nte
ris
ho eo
10 - Marking aut ra
c
ss
❑ For clamp.
ce
le
un

pt

❑ Installation position of clamp ⇒ page 153 .


an
d
itte

y li
rm

ab

11 - To front silencer
pe

ility
ot

wit

12 - 25 Nm
, is n

h re
hole

13 - Mounting
spec
es, in part or in w

❑ Renew if damaged.
t to the co

14 - Temperature sender after particulate filter -G527-


❑ Lubricate thread of sender using high-temperature paste -G 052 112 A3-
rrectness of i

15 - From turbocharger
l purpos

16 - Clamp, 7 Nm
nform
ercia

17 - Seal
❑ Renew
m

a
com

tio

❑ Note installation position.


n in
r
te o

thi

18 - 40 Nm
s
iva

do
r
rp

19 - Bracket
um
fo

en
ng

t.
❑ Bolted to cylinder head
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

152 Rep. Gr.26 - Exhaust system


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Installation position of clamp


– Position double clamp -a- = 5 mm from marking on front ex‐
haust pipe of particulate filter.

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

ce
le
un

pt
an
d
itte

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erm

ab
ility
ot p

1.2 Assembly overview - silencer with mountings

wit
is n

h re
ole,

spec
urposes, in part or in wh

1 - 25 Nm

t to the co
2 - Double clamp
3 - Retaining ring for front si‐

rrectne
lencer

satelettronica
❑ Renew if damaged.

ss o
cial p

f
4 - Retaining ring for rear si‐

inform
lencer
mer

❑ Renew if damaged.

atio
om

n
c

5 - Front and rear silencers

i
or

n thi
te

sd
❑ For repairs, renew indi‐
iva

o
r

vidually.
p

cum
r
fo

en
ng

6 - 25 Nm
t.
yi Co
Cop py
t. rig
7 - Mounting opyri
gh by
Vo
ht

❑ With retaining ring. by c lksw


cted agen
Prote AG.
❑ Renew if damaged.
8 - Separating point
❑ Marked by impressions
on exhaust pipe.
❑ During production, front
and rear silencers are
installed as a single
component. For repairs,
front and rear silencers
are supplied separately
❑ The connection is made
with a clamp.
❑ Cutting exhaust pipe
⇒ page 154 .
❑ Installation position of
rear clamp (repair dou‐
ble clamp)
⇒ page 154 .
❑ Evenly tighten threaded connections of clamp (repair double clamp).
❑ Specified torques for clamp (repair double clamp): M8 = 25 Nm, M10 = 40 Nm.
❑ Before tightening, align cold exhaust system free of tension ⇒ page 155 .
9 - 25 Nm
10 - Retaining ring
❑ Renew if damaged.

1. Parts of the exhaust system 153


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

11 - Mounting
12 - To front exhaust pipe

Installation position of rear clamp (repair double clamp)


– Install clamp so that end of bolt does not extend beyond lower
edge of clamp.
• Bolt connection faces to left.

1.2.1 Separating
lksw
agefront
n AG. Voand reardsilencers
lkswagen AG
oes
n
o ot g
yV
Special tools and
ise
dworkshop
b equipment required ua
ran
r tee

satelettronica
ho
♦ Pneumatic
sa
ut sabre saw -V.A.G 1523 A- or
ac
s
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectnes

♦ Eye protection
s o
cial p

Procedure
inform
mer

atio
m

WARNING
o

n
c

i
or

n thi
e

Wear eye protection.


t

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi
– Cut exhaust pipe at right angles at separating point
Co
op py
-arrow 2-.
t. C rig
gh ht
pyri by
Vo
– When installing, position repair double clamp -4- at side mark‐
co lksw
by
cted agen
ings -arrow 1- and -arrow 3-. Prote AG.

154 Rep. Gr.26 - Exhaust system


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

– Install repair double clamp so that end of bolt does not extend
beyond lower edge of clamp.
AG. Volkswagen AG d
agen
• Bolted connection faces rear. olksw
oes
not
byV gu
ara
d
– Align cold exhaust system orisfree of stress ⇒ page 155 .
e nte
eo
h
ut ra
– Tighten bolts on repair
s double clamp.
s a c

ce
e
Specified torque, M8: 25 Nm nl

pt
du

an
itte

y li
Specified torque, M10: 40 Nm
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

1.2.2 Aligning exhaust system stress free

t to the co
Test prerequisite

rrectness of i
• Engine must be cold.
l purpos

Procedure
– Loosen bolted connections of clamp between exhaust pipe

nf
ercia

and front silencer.

satelettronica
rm
m

atio
– Position clamp at distance -a- = 5 mm from marking on front
om

exhaust pipe and lightly tighten front connection.

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.

– Push rear silencer forwards into clamp until dimension -a- =


15...17 mm is attained between mounting attachment points
for body and rear silencer. -Arrow- points to front of vehicle.
– Align rear silencer horizontally.
– With parts in this position, tighten bolted connections of clamp.
Specified torque, M8: 25 Nm
Specified torque, M10: 40 Nm
– Once clamp has been tightened, check distance -a- and cor‐
rect if necessary.

1. Parts of the exhaust system 155


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

AG. Volkswagen AG d
agen
2 Exhaust gasVol recirculation system
es n o
ksw ot g
by ua
ed ran
oris tee
th or
au ac
Note ss

ce
e
nl

pt
du

♦ The exhaust gas recirculation system is activated by the diesel

an
itte

y li
direct injection system control unit -J248- via the exhaust gas
erm

ab
recirculation potentiometer -G212- .

ility
ot p

wit
, is n

♦ Renew self-locking nuts.

h re
hole

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
ercia

o
❑ Renew

rm
m

atio
m

satelettronica
2 - Intake manifold
o

n in
or c

thi
3 - Seal
te

sd
iva

o
❑ Renew
r
rp

cu
o

m
f

en
ng

4 - Connection
t.
yi Co
Cop py
5 - Intake manifold flap motor -
t. rig
gh ht
yri
V157-
p by
co Vo
by lksw
cted
❑ 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

156 Rep. Gr.26 - Exhaust system


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

10 - Connecting pipe
❑ For exhaust gas recirculation.
❑ Assembly overview a-gen AG. Volkgas
exhaust
swagen AG
recirculation
does cooler ⇒ page 157
ksw oln ot g
yV ua
11 - 22 Nm sedb ran
ri tee
ho
12 - 22 Nms aut or
ac
s

ce
le
un

pt
an
d
itte

y li
2.2 Assembly overview - exhaust gas recirculation cooler
rm

ab
pe

ility
ot

wit
, is n

h re
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

5 - From exhaust manifold

a
com

tion in
6 - 25 Nm
r
te o

❑ Renew thi
s
iva

do
r
rp

cum

7 - To connection for exhaust


fo

en
g

gas recirculation valve -N18-


n

t.
yi Co
op
with exhaust gas recirculation C py
t. rig
potentiometer -G212-
gh ht
pyri by
Vo
co
❑ Assembly overview - ex‐
by lksw
cted agen
Prote
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

2. Exhaust gas recirculation system 157


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

28 – Glow plug system


1 Checking glow plug system
Characteristics of ceramic glow plugs ⇒ page 158
Removing, installing and checking ceramic glow plugs
⇒ page 158

1.1 Characteristics of ceramic glow plugs

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
c
break and cause damage to the engine.

ce
e
nl

pt
du

an
itte

y li

satelettronica
erm

ab
Visual features of ceramic glow plugs

ility
ot p

wit
Vehicles with 2 valves per cylinder cylinder head
, is n

h re
hole

-A- = Metal glow plug, colour-coded -arrow-.

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

Remove and install or check ceramic glow plugs ⇒ page 158 .


m

at
om

ion
c

1.2 Removing, installing and checking ceramic glow plugs in t


or

his
ate

do
priv

cum
for

en
ng

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

158 Rep. Gr.28 - Glow plug system


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Special tools and workshop


equipment required
♦ U/J extension and socket,
10 mm -3220-
♦ Torque wrench (5...50 Nm)
-V.A.G 1331-
♦ Hand multimeter -
V.A.G 1526 A-
♦ Auxiliary measuring set -
V.A.G 1594 C-

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

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
Test prerequisites

rrectness of i
• Engine is cold
l purpos

• Ignition is switched off


Procedure
nf
ercia

orm
m

atio
m

Note
o

n in
or c

thi
te

Do not cant ceramic glow plugs when removing and installing.


sd
iva

o
r

Remove components hindering the installation.


rp

cu
o

m
f

en
ng

t.
yi Co
– Pull connectors off ceramic glow plugs. Cop py
t. rig
gh ht
yri
– 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.

1. Checking glow plug system 159


Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI) - Edition 06.2008

Note

Never oil or grease thread of cylinder head bore or of ceramic


glow plugs.

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


J extension and socket, 10 mm -3220- .
– Then tighten the ceramic glow plugs. Specified torque: 15 Nm

AG. Volkswagen AG d
WARNING lksw
agen oes
not
Vo gu
by ara
d
♦ 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

y li
ments from the engine, otherwise these can cause dam‐
rm

ab
age to the engine.
pe

ility
ot

wit
, is n

h re
hole

satelettronica
♦ Specification: Max. 1 Ω

spec
es, in part or in w

– If the specification is exceeded, renew the defective ceramic

t to the co
glow plug.

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

160 Rep. Gr.28 - Glow plug system

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