Engine ASZ

Service 5

Service Department. Technical Information Printed in Czech RepublicS00.5327.00.20

Workshop ManualFABIA 20001.9/96 TDI Engine, MechanicsEdition 07.03Engine code ASZ

Service5

The Workshop Manual is intended only for use within the Organisation Škoda.It is not permitted to pass it on to other persons.

© ŠKODA AUTO a. s.

Printed in Czech RepublicS00.5327.00.20

FABIA 2000 1.9/96 TDI Engine, Mechanics

List of SupplementsEdition 07.03S00.5327.00.20

List of Supplements to Workshop ManualFABIA 20001.9/96 TDI Engine, MechanicsEdition 07.03

Supple-ment Edition Subject Article Number

07.03 Basic Edition S00.5327.00.20


List of Supplements Edition 07.03S00.5327.00.20


Table of ContentsEdition 07.03S00.5327.00.20

I

Table of Contents

00 – Technical DataTechnical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 – Removing and Installing EngineRemoving and Installing Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 – CrankgearRemoving and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing, tightening the timing belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft, Piston and Conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 – Cylinder Head, Valve GearRemoving and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve seats, valves guides, valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 – LubricationRemoving and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Disassembling and assembling oil filter holder .. ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 – CoolingParts of cooling system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing radiator, coolant pump and coolant thermostat . . . . . . . . . . . . . . . .

20 – Fuel SupplyRemoving and installing parts of the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing the accelerator control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 – TurbochargingCharge air system with turbocharger I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing exhaust turbocharger with component parts ..... .. . . . . . . . . . . . . . . . . .- Removing and installing parts of the charge air cooling ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Connection diagram for vacuum hoses ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Charge air system with turbocharger II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Remove exhaust turbocharger ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Checking charge pressure control ... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 – Exhaust SystemRemoving and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Aligning exhaust system free of stress ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Procedure .. ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Replacing middle or rear silencer .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Checking the exhaust system for leaks ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

00-1 page 1

10-1 page 1

13-1 page 1

13-2 page 1

13-3 page 1

13-4 page 1

15-1 page 1

15-2 page 1

15-3 page 1

15-4 page 1

17-1 page 117-1 page 2

17-2 page 1

17-3 page 1

19-1 page 1

19-2 page 1

20-1 page 1

20-2 page 1

21-1 page 121-1 page 121-1 page 221-1 page 2

21-2 page 121-2 page 121-2 page 1

26-1 page 126-1 page 226-1 page 226-1 page 226-1 page 326-2 page 1


Table of Contents Edition 07.03S00.5327.00.20II

- Testing mechanical exhaust gas recirculation valve .... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-2 page 2


Technical DataEdition 07.03S00.5327.00.20

00-1 page 1

00

00-1 Technical DataEngine number

The engine number („engine identification characters“ and „serial number“) is located at the engine/gearbox joint -arrow-.

In addition, a sticker with the „engine identification char-acters“ and „serial number“ is affixed to the timing belt guard.

The engine identification characters are also indicated on the vehicle data sticker.

Engine characteristics

00 – Technical Data

Engine identification characters ASZManufactured 06.03 Exhaust limits conforming to EU-3Displacement l 1,896Power output kW at rpm 96/4000Torque Nm at rpm 310/1900Bore ∅ mm 79,5Stroke mm 95,5Compression 19,0 : 1Firing order 1-3-4-2min. CN 49Catalytic converter yesExhaust gas recirculation yesTurbocharging yesCharge air cooler yes


Technical Data Edition 07.03S00.5327.00.2000-1 page 2

00


Removing and Installing EngineEdition 07.03S00.5327.00.20

10-1 page 1

10

10-1 Removing and Installing Engine

⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 10

⇒ Gearbox 0A8; Rep. Gr. 30 und 34

The removing of the 1.9/96 TDI Engine can differ in cer-tain details from the removing of the 1.9/74 TDI Engine.

10 – Removing and Installing Engine

Note


Removing and Installing Engine Edition 07.03S00.5327.00.2010-1 page 2

10


Removing and installing V-ribbed beltEdition 07.03S00.5327.00.20

13-1 page 1

13

13-1 Removing and installing V-ribbed belt


13 – Crankgear


Removing and installing V-ribbed belt Edition 07.03S00.5327.00.2013-1 page 2

13


Removing and installing, tightening the timing beltEdition 07.03S00.5327.00.20

13-2 page 1

13

13-2 Removing and installing, tightening the timing belt



Removing and installing, tightening the timing belt Edition 07.03S00.5327.00.2013-2 page 2

13


Removing and installing sealing flange and flywheelEdition 07.03S00.5327.00.20

13-3 page 1

13

13-3 Removing and installing sealing flange and fly-wheel



Removing and installing sealing flange and flywheel Edition 07.03S00.5327.00.2013-3 page 2

13


Crankshaft, Piston and ConrodEdition 07.03S00.5327.00.20

13-4 page 1

13

13-4 Crankshaft, Piston and Conrod



Crankshaft, Piston and Conrod Edition 07.03S00.5327.00.2013-4 page 2

13


Removing and installing cylinder headEdition 07.03S00.5327.00.20

15-1 page 1

15

15-1 Removing and installing cylinder head


15 – Cylinder Head, Valve Gear


Removing and installing cylinder head Edition 07.03S00.5327.00.2015-1 page 2

15


Repairing Valve GearEdition 07.03S00.5327.00.20

15-2 page 1

15

15-2 Repairing Valve Gear⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 15


Repairing Valve Gear Edition 07.03S00.5327.00.2015-2 page 2

15


CamshaftEdition 07.03S00.5327.00.20

15-3 page 1

15

15-3 Camshaft⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 15


Camshaft Edition 07.03S00.5327.00.2015-3 page 2

15


Valve seats, valves guides, valve stem sealsEdition 07.03S00.5327.00.20

15-4 page 1

15

15-4 Valve seats, valves guides, valve stem seals



Valve seats, valves guides, valve stem seals Edition 07.03S00.5327.00.2015-4 page 2

15


Removing and installing parts of the lubrication systemEdition 07.03S00.5327.00.20

17-1 page 1

17

17-1 Removing and installing parts of the lubrication system

♦ If considerable quantities of metal swarf or abrasion is found in the engine oil when carrying out engine repairs, carefully clean the oil galleries in order to avoid consequential damage and additionally replace the oil cooler.

♦ Testing oil pressure and oil pressure switch ⇒ Chapter 17-3.♦ The oil level must never exceed the „max“ marking - risk of damage to catalytic converter!

Check the oil level, amount of oil and oil specification:

⇒ Inspection and Maintenance

1 - 15 Nm2 - Bracket

For cable to oil level and oil temperature sender

3 - DipstickOil level must not exceed „max“ marking!

4 - Filler funnelRemove for extracting oil

5 - Guide tube6 - Fitting sleeve

For centering oil pump/cylin-der block

7 - O-ringReplace

8 - Suction lineClean strainer if dirty

9 - Baffle10 - Oil pan

Before installing, coat with silicone sealant -D 176 404 A2- ⇒ Chapter 17-2

11 - Gasket ringReplace

12 - Oil drain plug, 30 Nm13 - 10 Nm14 - Oil level and oil temperature

sender -G266-Test ⇒ Electrical System; Rep. Gr. 90

15 - Oil pumpWith pressure relief valve 1.2 MPaBefore installing, check whether both dowel sleeves for centering oil pump/cylinder block are presentIf there is any scoring on contact surfaces and gears, replace

16 - Oil pump sprocketFits onto oil pump shaft in one position only

17 - 25 Nm

17 – Lubrication

Note


Removing and installing parts of the lubrication system Edition 07.03S00.5327.00.2017-1 page 2

17

18 - Sealing flangeBefore installing, it must not be dirtyBefore installing, coat with silicone sealant -D 176 404 A2- ⇒ Chapter 13-3Replacing crankshaft seal ⇒ Chapter 13-3

19 - Oil pump chain20 - Chain tensioner, 15 Nm

When installing, pretension spring and attach21 - Oil injection nozzle

For piston coolingPay attention to SP No. (right-angle bend)

22 - 27 Nm

Disassembling and assembling oil filter holder

1 - Cap, 25 Nm2 - Gasket

Replace3 - Oil cooler

When installing, move up against the anti-twist lock (in direction of tightening)

4 - GasketReplaceInsert into lugs on oil cooler

5 - Oil pressure switch -F1-, 20 Nm

Brown0.07 MPa (0.7 bar)Cut open gasket ring if leak-ing and replaceInspect ⇒ Chapter 17-3

6 - Oil filter holderWith integrated overpressure valve

7 - 15 Nm + torque a further 1/4 turn (90°)

ReplaceBefore tightening, turn in by hand first

8 - Gasket ringReplace

9 - Connection fitting, 30 Nm10 - Oil feed line

For exhaust turbochargerTighten to 22 Nm

11 - O-ringReplace

12 - Oil filter elementWhen changing oil, fit new O-rings ⇒ item 11


Removing and installing oil panEdition 07.03S00.5327.00.20

17-2 page 1

17

17-2 Removing and installing oil pan



Removing and installing oil pan Edition 07.03S00.5327.00.2017-2 page 2

17


Testing oil pressure and oil pressure switchEdition 07.03S00.5327.00.20

17-3 page 1

17

17-3 Testing oil pressure and oil pressure switch



Testing oil pressure and oil pressure switch Edition 07.03S00.5327.00.2017-3 page 2

17


Parts of cooling system - Summary of componentsEdition 07.03S00.5327.00.20

19-1 page 1

19

19-1 Parts of cooling system - Summary of components


19 – Cooling


Parts of cooling system - Summary of components Edition 07.03S00.5327.00.2019-1 page 2

19


Removing and installing radiator, coolant pump and coolant thermostat

Edition 07.03S00.5327.00.20

19-2 page 1

19

19-2 Removing and installing radiator, coolant pump and coolant thermostat



Removing and installing radiator, coolant pump and coolant thermostat

Edition 07.03S00.5327.00.2019-2 page 2

19


Removing and installing parts of the fuel supply systemEdition 07.03S00.5327.00.20

20-1 page 1

20

20-1 Removing and installing parts of the fuel supply system


20 – Fuel Supply


Removing and installing parts of the fuel supply system Edition 07.03S00.5327.00.2020-1 page 2

20


Repairing the accelerator controlEdition 07.03S00.5327.00.20

20-2 page 1

20

20-2 Repairing the accelerator control



Repairing the accelerator control Edition 07.03S00.5327.00.2020-2 page 2

20


Charge air system with turbocharger IEdition 07.03S00.5327.00.20

21-1 page 1

21

21-1 Charge air system with turbocharger I

Removing and installing exhaust turbocharger with component partsPay attention to rules for cleanliness ⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 21.

♦ The hose connections are secured with clamps.♦ The charge-air system must be tight.♦ Always replace self-locking nuts.

1 - Oil feed line2 - 22 Nm3 - Sealing sleeve4 - 5 Nm5 - 10 Nm6 - Connection fitting, 30 Nm7 - Gasket ring

Replace8 - Gasket

ReplaceCheck fitting position

9 - SupportExhaust turbocharger - cylin-der block

10 - Washer11 - 25 Nm

ReplaceCoat stud bolts with -G 052 112 A3-

12 - 40 Nm13 - Connecting tube

Between turbocharger and air filter

14 - Flange15 - Connecting hose16 - Connection fitting, 40 Nm17 - Oil return line

To cylinder blockTighten to 30 Nm

18 - 15 Nm19 - Gasket

Replace20 - Exhaust turbocharger

Can only be replaced complete with exhaust manifoldRemoving and installing ⇒ Chapter 21-2Inspecting charge pressure control ⇒ Chapter 21-2Charge pressure regulating valve and vacuum unit for charge pressure regulating valve are component parts of the exhaust turbocharger and cannot be replaced individually

21 – Turbocharging

Note


Charge air system with turbocharger I Edition 07.03S00.5327.00.2021-1 page 2

21

After installing the turbocharger, run engine at idling speed for about 1 minute to ensure that oil is supplied to the turbocharger

21 - Vacuum lineTo the solenoid valve for charge pressure limitation -N75-

22 - 20 Nm23 - 20 Nm

Replace24 - Shield25 - Front exhaust pipe with catalytic converter26 - Bracket27 - Intake manifold28 - 6 Nm

Removing and installing parts of the charge air cooling⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 21

Connection diagram for vacuum hoses

1 - Valve blockComponent parts of the valve block are:

♦ Changeover valve for intake manifold flap -N239-

♦ Solenoid valve for exhaust gas recir culation -N18-

♦ Solenoid valve for charge pressure control -N75-

2 - Connecting stripPay attention to the coding when connecting the vacu-um hoses

3 - Connecting piece4 - Vacuum unit

For charge pressure controlComponents of the exhaust gas turbocharger cannot be replaced individually

5 - Vacuum unit6 - To air filter7 - Vacuum unit

For intake manifold flap8 - Mechanical exhaust gas recir-

culation valve9 - Tandem pump

10 - Distributor partWith non-return valve for brake servo unit

11 - Brake servo unitS21-0043

1 23

4

5

78910

11

6


Charge air system with turbocharger IIEdition 07.03S00.5327.00.20

21-2 page 1

21

21-2 Charge air system with turbocharger II

Remove exhaust turbocharger⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 21

Checking charge pressure control

Special tools, test and measuring equipment and auxiliary items required

♦ Hand vacuum pump (e.g. -V.A.G 1390-)♦ Hand multimeter (e.g. -V.A.G 1715-)♦ Vehicle system tester -V.A.G 1552-♦ Diagnostic cable -V.A.G 1551/3, 3A, 3B, 3C-♦ Adapter cable set (e.g. -V.A.G 1594 C-)♦ Test box -V.A.G 1598/31-

Test conditions

• No fault stored in fault memory ⇒ 1.9/96 TDI Engine, Fuel Injection; Rep. Gr. 01

• No leaks on the intake and exhaust side

• No fault on the engine/fuel injection system

• Engine oil temperature at least 80 °C

Test sequenceIf test and measuring devices are required during test drives observe the following:

♦ Always secure the test and measuring devices on the rear seat and have a second person operate them there.

If the test and measuring equipment is operated from the front passenger seat, this can result in injuries to the persons sitting on that seat in the event of an ac-cident which involves the front passenger airbag be-ing deployed.

– The charge pressure is measured with vehicle system tester -V.A.G 1552- when the engine is idling and dur-ing a road test.

– Connect up the Vehicle system tester -V.A.G 1552- and select the address word 01 „Engine electronics“ (the engine must be idling at the time) ⇒ 1.9/96 (TDI) Engine, Fuel Injection; Rep. Gr. 01.

– Select function „Initiate basic setting“ and dis-play group .

Readout on display:

0 40 1 1

Basic setting 11 ->1400 rpm OFF 982 mbar 99 %


Charge air system with turbocharger II Edition 07.03S00.5327.00.2021-2 page 2

21

After selecting display group number 011, the idling speed is increased by the engine control unit in display block 1 to 1380…1420 rpm.

The display in display field 2 must switch between „off“ and „on“ every 10 seconds.

The following readouts must fluctuate in display fields 3 and 4:

Display field 2: off.

♦ Specification in display field 3: Atmospheric pressure in mbar

♦ Specification in display field 4: 98…100%

Display field 2: on.

♦ Specification in display field 3: Atmospheric pressure in mbar + 100…250 mbar

♦ Specification in display field 4: 0…2%

Continue the test as follows:

Press .

– Read function „Read measured value block“ and select display group .

– Accelerate vehicle in 2nd gear from about 1000 rpm to 3200 rpm. While doing so the accelerator pedal must be fully pressed down.

– At about 3000 rpm read off value indicated in display block.

Specification in display field 3: 2100…2600 mbar

If the specified value is not reached:

– Conduct final control diagnosis for charge pressure control solenoid valve -N75- ⇒ 1.9ltr./96 (TDI) En-gine, Fuel Injection; Rep. Gr. 01.

Charge pressure control solenoid valve must operate for this test. While doing so the linkage of the charge pres-sure control vacuum unit at the bottom of the turbocharg-er must move back and forward. This linkage must move at least 3…4 times as long as a vacuum is present in the vacuum system.

If the linkage moves and the nominal charge pressure is not reached:

– Replace turbocharger.

If the linkage does not move because the charge pres-sure control solenoid valve is not operating:

– Inspect charge pressure control solenoid valve -N75- ⇒ 1.9/96 (TDI) Engine, Mechanics; Rep. Gr. 23.

– Inspect vacuum hoses ⇒ Chapter 21-1 .

If the linkage does not move although the charge pres-sure control solenoid valve is operating:

Note

→

0 80 1 1

Reading measured value block 11 ->3090 rpm 2346 mbar 2281 mbar 6


Charge air system with turbocharger IIEdition 07.03S00.5327.00.20

21-2 page 3

21

– Connect hand vacuum pump to vaccum unit for charge pressure control valve and inspect linkage for unobstructed movement.

If the linkage only moves with difficulty or does not move at all:

– Replace turbocharger.

N21-0078

V.A.G 1390


Charge air system with turbocharger II Edition 07.03S00.5327.00.2021-2 page 4

21


Removing and installing parts of the exhaust systemEdition 07.03S00.5327.00.20

26-1 page 1

26

26-1 Removing and installing parts of the exhaust sys-tem

♦ The exhaust manifold is a component part of the ex-haust turbocharger and therefore must not be re-placed individually; removing and installing ⇒ Chap. 21-2.

♦ Always replace gaskets and self-locking nuts.♦ After performing installation work on the exhaust sys-

tem, make sure the exhaust system is not mounted under tension, the individual components have ade-quate clearance from the vehicle body and the weight of the exhaust system is evenly distributed over the hangers.

1 - GasketReplace

2 - Front exhaust pipe with cata-lytic converter

3 - 25 NmReplaceCoat stud bolts of exhaust turbocharger with hot bolt paste -G 052 112 A3- be-fore installing.

4 - Retaining loopPress off from cross member ⇒ item 5 to remove front ex-haust pipe with catalytic con-verter

5 - Cross member6 - 25 Nm7 - Double clamp

Align exhaust system free of stress before tightening ⇒ 26-1 page 2Fitting position: bolts at bot-tom and horizontalTighten bolted connections evenly

8 - 40 NmReplace

9 - Spring hangerPay attention to part number

10 - Separation pointFor repairs ⇒ 26-1 page 2

11 - Middle and rear silencerReplace individually when carrying out repairs ⇒ 26-1 page 2Align exhaust system free of stress ⇒ 26-1 page 2

26 – Exhaust System

Note


Removing and installing parts of the exhaust system Edition 07.03S00.5327.00.2026-1 page 2

26

Aligning exhaust system free of stress


♦ Torque wrench

Procedure• The exhaust system is aligned when cold.

– Slacken bolted connections of double clamp between front silencer with catalytic converter and middle and rear silencer and replace nuts.

– Position double clamp at the distance -a- = 5 mm from the marking on the pipe of the catalytic converter (bolts at bottom and horizontal) and tighten front bolt-ed connection slightly.

– Push middle silencer -1- sufficiently far forward into the double clamp until the dimension -b- of 3...7 mm is achieved between hanger of body and hanger of mid-dle silencer.

-Arrow- points in direction of travel.

– Tighten bolted connections on the double clamp in this position.

Tightening torque: 40 Nm

After tightening the double clamp, inspect dimension -b- and adjust if necessary.

Replacing middle or rear silencer


♦ Torque wrench♦ Body saw (e.g. -V.A.G.1523-)

A separation point is provided for repair purposes for re-placing the middle silencer or rear silencer.

– Separate exhaust pipe at right angles at the separa-tion point -arrow 1- with body saw.

– When installing, position double clamp -4- at the side markings -arrow 2- and -arrow 3-.

– Align exhaust system free of stress ⇒ 26-1 page 2.

– Align rear silencer horizontally.

– Tighten bolted connections of the double clamp even-ly to 40 Nm.

Installation position of double clamp: Bolts positioned vertically at front of exhaust pipe.

S26-0064a

Note


Removing and installing parts of the exhaust systemEdition 07.03S00.5327.00.20

26-1 page 3

26

Checking the exhaust system for leaks– Start engine and run in idle.

– Seal off tail pipe for the test duration with suitable plugs.

– Check the connection points for leaks by listening: Cylinder head/exhaust manifold, exhaust turbocharg-er/front exhaust pipe with catalytic converter, double clamp at middle or also at rear silencer.

– Rectify any fault found.


Removing and installing parts of the exhaust system Edition 07.03S00.5327.00.2026-1 page 4

26


Exhaust gas recirculation systemEdition 07.03S00.5327.00.20

26-2 page 1

26

26-2 Exhaust gas recirculation system

♦ The exhaust gas recirculation system is operated by the diesel direct injection system control unit -J248- via the EGR valve -N18- to the mechanical exhaust gas recirculation valve.

♦ Inspecting exhaust gas recirculation ⇒ 1.9/96 (TDI) Engine, Fuel Injection; Rep. Gr. 23 and exhaust gas recirculation valve -N18- ⇒ 1.9/96 (TDI) Engine, Fuel Injection; Rep. Gr. 01.

♦ The mechanical exhaust gas recirculation valve with conically shaped valve tappet makes it possible to achieve different opening cross-sections at different valve strokes.

♦ Connection diagram for vacuum hoses ⇒ Chap. 21-1.

1 - Intake manifold2 - O-ring

Replace3 - Vacuum setting element4 - 5 Nm5 - Mechanical exhaust gas recir-

culation valveComponent part of the induc-tion pipeMust be replaced together with the induction pipeCheck ⇒ 26-2 page 2

6 - Induction pipeWith mechanical exhaust gas recirculation valve and control flap

7 - 10 Nm8 - Gasket

Replace9 - 25 Nm

10 - Connecting tube11 - Gasket

ReplaceCheck fitting position

12 - 6 Nm13 - Sealing sleeve

Note


Exhaust gas recirculation system Edition 07.03S00.5327.00.2026-2 page 2

26

Testing mechanical exhaust gas recircu-lation valve


♦ Hand vacuum pump (e.g. -V.A.G 1390-)

Test sequence

– Remove engine cover -arrows-.

– Disconnect vacuum hose on mechanical exhaust-gas recirculation valve.

– Connect hand vacuum pump to valve and operate pump.

The diaphragm rod must move in the direction of the vacuum connection -Pfeil-.

– Detach hose of hand vacuum pump from mechanical exhaust gas recirculation valve.

The diaphragm rod must move back to its original po-sition against the -direction of the arrow-.

V.A.G 1390

S13-0161

Engine ASZ

Documents

Transcript of Engine ASZ