Volkswagen Golf Jetta 1999 2005 Service Manual

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Select a Vehicle

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Select a topic

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de 12.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF

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00 - General, Technical data
10 - Engine - Assembly
13 - Engine - Crankshaft, Cylinder block
15 - Engine - Cylinder head, Valvetrain
17 - Engine - Lubrication
19 - Engine - Cooling system
20 - Fuel Supply
26 - Exhaust system, Emission controls

Additional Information

System Overviews

Other Topics

24-Valve VR6 Variable Camshaft Timing Operation

00-1

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Technical data

Engine number

The engine number (engine code
and serial number) are located next
to the vibration damper on the
cylinder block.

The engine number consists of up to
nine characters (alphanumeric). The
first part (maximal 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
intake manifold with the engine code
and serial number.

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

00-2

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Engine data

Engine code

Manufactured
Cylinder application

Cylinder angle

BDF

08.01
VR1)

15.0
Capacity ltr. 2.8
Output kW at rpm 147/6200
Torque Nm at rpm 265/3200
Bore diameter mm 81.0
Stroke mm 90.3
Compression ratio 10.75
RON min.

98 unleaded2)

System designation Motronic ME7.1.1

1)

VR = V-arrangement in compact in-line design

2)

91 and 95 RON are also permitted, but with reduced output

00-3

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Engine code

Exhaust emissions level

LEV1)

BDF

On Board Diagnostic (OBD) OBD II
Knock regulation 2 knock sensors
Oxygen sensor control 2 sensors
Catalytic converter yes
Exhaust gas recirculation no
Charging no
Secondary air system yes
Electronic power control (EPC) yes
Variable intake manifold yes
Variable valve timing

1)

LEV = Low Emission Vehicles (exhaust emissions max. 0.075 g/mi HC).

yes2)

2)

Two independently variable camshafts.

10-1

Special tools and

Supplementary

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Engine,
removing
and
installing

equipment

3033 Lifting
tackle

3269 Engine
bracket

3395 Engine
bracket

VW 313
Support clamp

VW 540/1 B
set

T10095 Puller

10-2

Workshop crane

VAG 1306 Drip tray

VAG 1331 Torque

wrench (5...50 Nm)

VAG 1332 Torque

wrench (40...200

Engine/transmission

Assembly tool for

type clips

VAS 5085 Step

G 000 100 Grease

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VAG 1202 A

Nm)
VAG 1383 A

jack
VAS 5024

spring-

ladder

(models with
manual
transmission)

Cable tie

10-3

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Notes on removing

The engine is removed downward together with

the transmission.
CAUTION!
When performing repair work, especially due

to the confined conditions in the engine

compartment, pay attention to the following:

Route all types of lines (e.g. for fuel,

hydraulics, EVAP system, coolant,
refrigerant, brake fluid and vacuum) as well
as electrical wiring so that the original
positions are restored.

Ensure sufficient clearance to all moving or

hot components.

All cable ties which are opened or cut open when

removing engine, must be replaced in the same

position when installing the engine.

Work sequence

- Remove engine cover.

- First check whether a coded radio is installed. If
so, obtain anti-theft coding.

10-4

With ignition switched off disconnect battery

Repair Manual, 2.8 Liter VR6 4V Engine

Mechanical, Engine Code(s): BDF, Repair Group

Disconnect connectors from ignition coils 1...6.

Remove ignition coils with final out stage for

Press buttons on hose couplings to disconnect.

Disconnect following hose connections and

collect fluids that may leak out with a cloth:

vacuum hose to Throttle valve control module

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­Ground strap.

-

Note:

Mark connector and component before
disconnecting.

­cylinders 1...6 using puller T10095.

- Remove battery and battery retainer.

- Remove air cleaner with intake hose:

24

-

1 ­J338-,

2 - fuel return hose (with blue markings),
3 - fuel supply hose (with white markings).

Note:

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WARNING!
Fuel system is under pressure! Before

opening the system place a cloth around the
connection. Then release pressure by
carefully loosening the connection.

10-5

- Seal lines to avoid contamination of fuel
system.

- Observe rules for cleanliness Page 20-14 .

- Remove center, left and right insulation trays:

Repair Manual, Body Exterior, Repair Group

50

- Pull connectors off thermal switch and coolant
fan.

- Remove front bumper:

Repair Manual, Body Exterior, Repair Group

63

- Bring lock carrier into service position:

Repair Manual, Body Exterior, Repair Group

50

10-6

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- Remove intake manifold Page 15-16 ,
Removing and installing cylinder head cover.

Note:
Seal the intake ports in the intake manifold or in

the cylinder head with a clean cloth.

- Remove ribbed belt Page 13-19 .

- Remove power steering pump on compact
bracket and place to side; hoses remain
connected:

Repair Manual, Suspension, Wheels,

Steering, Repair Group 48

- Remove securing clamps for power steering
pressure line.

Vehicles with air conditioning

- Observe additional information and removal
work Page 10-22 .

Models with a manual transmission

- Disconnect selector mechanism from
transmission:

Repair Manual, 5 & 6 Spd. Manual

Transmission 02M, Repair Group 34

10-7

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- Separate hydraulic line to slave cylinder for
hydraulic clutch:

Repair Manual, 5 & 6 Spd. Manual

Transmission 02M, Repair Group 30

Models with an automatic transmission

- Remove gate selector lever cable from
transmission:

Repair Manual, 5 Spd. Automatic

Transmission 09A, Repair Group 37

Continuation for all vehicles

- Disconnect vacuum and breather hoses from
engine.

- Separate connectors on following
components:

Note:
Mark connector and component before

disconnecting.

Engine Coolant Temperature (ECT) sensor ­G62- with Engine Coolant Temperature
(ECT) sensor -G2-,

After-run coolant pump -V51-,

Valve -1- for camshaft adjustment -N205-,

10-8

Installation locations:

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Camshaft adjustment valve 1 (exhaust) ­N318-,

Camshaft Position (CMP) sensor -G40-,

Camshaft Position (CMP) sensor 2 -G163­,

Injectors (-N30- to -N33-, -N83- and -N84­),

Engine speed (RPM) sensor -G28-,

Knock Sensor (KS) 1 -G61-,

Knock Sensor (KS) 2 -G66-,

Repair Manual, 2.8 Liter VR6 4V Engine

Mechanical, Engine Code(s): BDF, Repair Group
24

- Disconnect all electric wires from transmission,
alternator and starter and them move clear.

- Disconnect all other electrical connections from
engine as necessary and place to one side.

- Drain coolant Page 19-15 .

- Disconnect coolant hoses quick release
couplings from radiator.

10-9

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- Pull all coolant hoses off to engine using
assembly tool for spring-type clamps VAS 5024.

- Removing drive shafts:

Repair Manual, Suspension, Wheels,

Steering, Repair Group 40

- Remove pendulum support:

Repair Manual, Suspension, Wheels,

Steering, Repair Group 40

- Remove front exhaust pipe with catalytic
converter Page 26-1 , Removing and
installing parts of the exhaust system.

- Remove alternator and compact bracket:

Repair Manual, Electrical Equipment, Repair

Group 27

- Unscrew bracket for Secondary Air Injection
(AIR) pump motor -V101- from oil pan and
cylinder block Page 26-26 , item - 17 -.

- Install engine bracket 3395 onto
engine/transmission jack VAG 1383 A.

10-10

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- Install engine bracket 3395 to
cylinder block and tighten
securing nuts -1- to 40 Nm.

- Lift engine and transmission
slightly using engine/transmission
jack VAG 1383 A.

- Unbolt engine side of assembly
mounting from engine bracket at
top (arrows).

Note:

Use ladder VAS 5085 to remove
securing bolts.

10-11

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- Unbolt transmission side of
assembly mounting from top of
transmission carrier (arrows).

Note:

Use ladder VAS 5085 to remove
securing bolts.

- Carefully lower engine with
transmission.

Note:

Engine with transmission must be
guided carefully, when lowering, to
prevent damage to bodywork.

Securing engine to assembly stand

secured to assembly stand VW 313 using engine

bracket 3269 or VW 540 and supplementary set

Secure torque converter to prevent it falling out

after engine and transmission are separated.

Install engine bracket 3269 or VW 540 and

supplementary set 540/1 B to cylinder block.

Attach lifting device 3033 as follows and lift

engine from engine/transmission jack VAG 1383

- Install engine in support clamp VW 313 using

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Note:
When working on the engine it should be

540/1 B.

10-12

Work sequence

- Remove transmission.

Models with an automatic transmission

-

Continuation for all vehicles

-

­using workshop crane VAG 1202.

Vibration damper end: Position 3
Flywheel end: Position 11

workshop crane VAG 1202 A.

10-13

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Notes on installation

Install in reverse sequence ; note the following

points:

- Check whether dowel sleeves for centering
engine/transmission are installed in cylinder
block and install if necessary.

Models with a manual transmission

- Check clutch and clutch operating mechanism
and install:

Repair Manual, 5 & 6 Spd. Manual

Transmission 02M, Repair Group 30

- Clean drive shaft splines and lightly grease with
G 000 100.

Models with an automatic transmission

- When securing torque converter to drive plate,
only use nuts which are authorized for this
purpose, Parts catalog.

10-14

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Continuation for all vehicles

- When installing engine/transmission assembly,
ensure sufficient clearance to engine and
transmission mountings and radiator.

- Align engine and transmission mountings

Page 10-18 .

Note:
Torque settings for assembly mountings Page

10-21 .

- Install compact bracket and alternator:

Repair Manual, Electrical Equipment, Repair

Group 27

- Install front exhaust pipe with catalytic converter

Page 26-1 , Removing and installing parts of

the exhaust system.

- Install pendulum support:

Repair Manual, Suspension, Wheels,

Steering, Repair Group 40

- Install drive shafts:

Repair Manual, Suspension, Wheels,

Steering, Repair Group 40

10-15

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Models with a manual transmission

- Install gear selector mechanism:

Repair Manual, 5 & 6 Spd. Manual

Transmission 02M, Repair Group 34

- If necessary adjust gear selector cables:

Repair Manual, 5 & 6 Spd. Manual

Transmission 02M, Repair Group 34

- Install hydraulic line to hydraulic clutch slave
cylinder:

Repair Manual, 5 & 6 Spd. Manual

Transmission 02M, Repair Group 30

- Bleed clutch system:

Repair Manual, 5 & 6 Spd. Manual

Transmission 02M, Repair Group 30

Models with an automatic transmission

- Install gate selector lever cable on transmission,
adjust if necessary:

Repair Manual, 5 Spd. Automatic

Transmission 09A, Repair Group 37

10-16

, Removing

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Continuation for all vehicles

- Install power steering pump:

Repair Manual, Suspension, Wheels,

Steering, Repair Group 48

- Install intake manifold Page 15-16
and installing cylinder head cover.

- Install air cleaner with intake hose:

Repair Manual, 2.8 Liter VR6 4V Engine

Mechanical, Engine Code(s): BDF, Repair Group
24

- Install battery and battery retainer.

- Install ribbed belt Page 13-19 .

- Check electrical connections and routing:

Repair Manual, Electrical Equipment, Repair

Group 97

- Install center, left and right insulation trays:

Repair Manual, Body Exterior, Repair Group

50

- Top up coolant level Page 19-15 .

- Perform test drive and check DTC memory:

Repair Manual, 2.8 Liter VR6 4V Fuel Injection

& Ignition, Engine Code(s): BDF, Repair Group
01

10-17

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- Adapt (match) engine control module to throttle
valve control module:

Repair Manual, 2.8 Liter VR6 4V Engine

Mechanical, Engine Code(s): BDF, Repair Group
24

- Perform work sequence "Procedure after
interrupting voltage supply":

Repair Manual, 2.8 Liter VR6 4V Engine

Mechanical, Engine Code(s): BDF, Repair Group
24

- Read readiness code:

Repair Manual, 2.8 Liter VR6 4V Fuel Injection

& Ignition, Engine Code(s): BDF, Repair Group
01

- If DTC memory has been erased or engine
control module separated from permanent
positive supply, generate readiness code again:

Repair Manual, 2.8 Liter VR6 4V Fuel Injection

& Ignition, Engine Code(s): BDF, Repair Group
01

Models with an automatic transmission

- Perform adaptation for Transmission Control
Module (TCM):

Repair Manual, 5 Spd. Automatic

Transmission 09A On Board Diagnostic (OBD),
Repair Group 01

10-18

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Aligning engine and
transmission mountings

Special tools and equipment

Support device 10-222 A with
legs 10-222 A/1 and adapter 10­222 A/3

WARNING!
Before loosening bolts, secure

assembly using support device
10-222A.

10-19

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Engine mounting
a = 14.0 mm
b = at least 10.0 mm
Both bolt heads -1- must be flush

with edge -c-.

Transmission assembly mounting
Edges -a- and -b- must be parallel to

each other.
Note:

Torque settings for assembly
mountings Page 10-21 .

10-20

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Torque settings

Bolted connections

Torque

setting

Bolts, nuts M6 10 Nm
M7 15 Nm
M8 25 Nm
M10 40 Nm
M12 60 Nm
Deviations
Connecting bolts, engine to

M10 60 Nm

transmission
Connecting bolts, engine to

M12 80 Nm

transmission
Starter to engine and transmission 45 Nm

Note:
Torque settings for assembly mountings Page

10-21 .

10-21

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Assembly mounting

Torque settings

Engine mounting

1

Mounting to

-

body1)

2

Support to

-

mounting at
body1)

3

Mounting to

-

engine bracket

1)

Replace bolts

Transmission assembly mounting

40 Nm +
90(1/4

turn)
20 Nm +

90(1/4
turn)

100 Nm

1

Mounting to

-

body1)

2

Mounting to

-

body1)

3

Mounting to

-

transmission
console

1)

Replace bolts

40 Nm +
90(1/4

turn)
20 Nm +

90(1/4
turn)

100 Nm

10-22

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Additional information and assembly
work on models with air conditioning

WARNING!
The air conditioning refrigerant circuit must

not be opened.

Note:

To facilitate removal and installation of the

The refrigerant circuit must only be opened in
workshops with trained personnel and the
necessary range of tools and workshop
equipment.

To prevent damage to the condenser as well as
to the refrigerant lines/hoses, ensure that lines
and hoses are not stretched, kinked or bent.

engine without having to open the refrigerant
circuit:

Repair Manual, Heating & Air Conditiioning,

- Remove retaining clamp(s) from refrigerant
lines.

- Remove air conditioner compressor:

Repair Group 87; Removing and installing
compressor bracket

- Secure air conditioning compressor to body so
that refrigerant lines/hoses are not under stress.

13-1

disassembling

When working on

the engine it should

assembly stand

3269 or VW 540

and supplementary

If when repairing an

shavings or large

amounts of small

metal particles are

found in the engine

partial seizure of

conrod bearings,

Thoroughly

return valve

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Engine,
and

assembling

Note:

be secured to
VW 313 using

engine bracket

set 540/1 B.

engine, metal

oil, caused by
crankshaft or
perform the

following work
sequences to
prevent
consequential
damage once
repairs are
complete:

- ­clean oil
passages

- - Replace oil
spray jets

- - Replace oil
cooler

- - Replace oil
filter

- - Replace oil
non-

13-2

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I Page 13-3

II Page 13-

12

13-3

of oil seal

Removing

Removing

Disassembling

for soiling

direction of

(installation

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Part I

1 - Control

housing

Lubricate
contact
surfaces

when
installing

and
installing

Page

15-69 ,

and
installing
camshaft

and
assembling

Page 15-64 ,

Fig. 6

Check
screen of
control
housing

before
installing

Page

15-64 ,

Fig. 7

2 - 8 Nm

Replace

3 - Camshaft

roller
chain

Mark
rotation

before
removing

position)

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Fig. 1

Installing

Page

15-39 ,

Adjusting
valve
timing

13-4

camshaft

Marking:

over only

camshaft

adjustment

Installing

Adjusting

5

Intermediate

Insert with

compound

D 000 600

Tensioning

camshaft

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4 - Exhaust

timing
adjuster

32A

Turn
engine

when
timing

adjuster
is
installed

Check
camshaft
timing

Page

15-82

15-39 ,

valve
timing

-

shaft

6 - Thrust

washer

7 - 8 Nm

locking

A2

8 -

plate

For

Page

roller
chain
item 3

9 -

Mounting

tensioning

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stud, 10
Nm

For
plate item

8

13-5

10

tensioner,

camshaft

over only

tensioner

damaged

Installing

Adjusting

camshaft

Installing

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Chain

­40 Nm

For
roller

chain
item 3

Turn
engine

when
chain

is
installed

11 - Seal

Replace
if

or
leaking

12 - Chain

sprocket

For
roller
chain
item
17

Page

15-39 ,

valve
timing

13 - Chain

sprocket

For
roller

chain
item 3

Page

15-39 ,

Adjusting

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valve
timing

13-6

14

to loosen

Adjusting

15

tensioning

release the

screwdriver

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60 Nm

-

plus
additional

1

/4 turn

(90 )
further

Replace

Use
counter
support
T10069

and
tighten

Page

15-39 ,

valve
timing

Chain

-

tensioner
with

rail

For
roller
chain
item
17

Before
installation

locking
device in
the chain
tensioner
with a
small

and press
the
tensioning
plate
against the
chain
tensioner

Turn

over only

tensioner

Adjusting

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engine
when

chain
is

installed

16 - Drive

sprocket

Integral
part of
crankshaft

Ground
down
tooth
aligned
with
main
bearing
joint =
TDC cyl.
1

Page 15­39 ,

valve
timing

13-7

direction of

(installation

Installing

Adjusting

Adjusting

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17 - Roller

chain

Mark
rotation

before
removing

position)

Fig. 1

Page

15-39 ,

valve
timing

18 - Guide

rail

For
roller
chain
item
17

Remove
and
install
together
with
roller
chain

Page 15­39 ,

valve
timing

19 - Stud

without
collar,
10 Nm

For
guide
rail
item
18

20 - 10 Nm

For

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guide
rail
item
24

21 - 23 Nm

For
guide
rail
item
24

13-8

22

camshaft

Marking:

over only

camshaft

adjustment

Installing

Adjusting

23

of sensor

bolt head

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Intake

­timing
adjuster

24E

Turn
engine

when
timing

adjuster
is
installed

Check
camshaft
timing

Page

15-82

Page

15-39 ,

valve
timing

60 Nm

-

plus
additional

1

/4 turn

(90)
further

Replace

Contact
surface

wheel on
must be

dry for
assembly

To
remove

and

to counter

Removing

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install,
use a 32
mm open
jaw
spanner
on
camshaft

support

Page

15-69 ;

and
installing
camshaft

13-9

camshaft

25

adjustment

adjustment

component

26

adjustment

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24 - Guide

rail

For
roller

chain
item 3

Camshaft

­valve 2
(exhaust) ­N318-

Check
camshaft
timing

Page

15-82

Mark
connector
and

before
pulling
connector
off

Checking
activation:

Repair

Manual, 2.8
Liter VR6 4V
Fuel Injection &
Ignition, Engine
Code(s): BDF,
Repair Group
01

Valve 1 for

-

camshaft

-N205-

For
intake
camshaft

Check
camshaft

timing

adjustment

component

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Page

15-82

Mark
connector
and

before
pulling
connector
off

Checking
activation:

Repair

Manual, 2.8
Liter VR6 4V
Fuel Injection &
Ignition, Engine
Code(s): BDF,
Repair Group
01

13-10

camshaft

Clipped

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27 - Guide

rail

For
roller

chain
item 3

into
control
housing

13-11

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Fig. 1 Marking roller chains

- Mark roller chains before
removing (e.g. with paint, arrow
pointing in direction of rotation).

Note:

Do not mark chain with a punched
mark, notch or similar!

13-12

Secured

to intake

exceed

Markings

Secured

by a bolt

to intake

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Part II

1 - 45 Nm
2 - Engine

bracket

3 - 8 Nm

manifold

4 - Dipstick

The oil
level
must
not

the
max.
mark!

Page

17-8 ,

Fig. 2

5 - Guide

tube

For
dipstick

manifold

13-13

Removing

Removing

crankshaft

Disassembling

Installation

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6 - Cylinder

block

and
installing
sealing
flange
and dual­mass
flywheel

Page

13-22

and
installing

Page

13-34

and
assembling
piston and
conrod

Page 13-39

7 - Knock

Sensor
(KS) 1 ­G61-

3-pin

location:
Between
cyl. 1 and
cyl. 3

The
contact
surfaces
between
knock
sensor
and
cylinder
block
must be
free of

corrosion,

dirt and

influences

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grease.

Checking:

Repair Manual,

2.8 Liter VR6 4V
Fuel Injection &
Ignition, Engine
Code(s): BDF,
Repair Group 01

8 - 20 Nm

Torque
setting

the
function
of knock
sensor

13-14

Lubricate

installation

14

Intermediate

Install with

compound

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9 - 10 Nm

10 - Oil pump

11 - O-ring

12 - Oil pump

13 - Oil non-

drive
cover

Replace

before
installing

drive

return
valve, 5
Nm

Observe
position

Clean if
badly
soiled

See
note

Page
13-1

shaft

-

15 - Thrust

washer

16 - 10 Nm

locking
"D6"

17 - Drive

shaft

For oil
pump
drive

13-15

Disassembling

compound

Insert with

compound

D 000 600

Removing

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18 - Oil pump

and
assembling

Page 17-12

19 - 23 Nm
20 - 8 Nm

Coat oil
pressure
pipe at
cylinder
block and
oil pump
housing
with
sealing

AMV 188
001 02

locking

A2

21 - Oil drain

plug, 30
Nm

Replace
if leaking

22 - Oil pan

and
installing

Page

17-15

23 - 12 Nm

13-16

Disassembling

connection

Removing

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24 - Oil filter

housing

See note

Page

13-1

and
assembling

Page 17-9

Coolant
hose

diagram

Page 19­11

25 - Vibration

damper

and
installing
ribbed
belt

Page 13­19

26 - 100 Nm

plus
additional

1

/4 turn

(90)
further

Replace
Use

counter
support
T10069
to loosen
and
tighten

Fig. 1

Tighten
using
torque
wrench
VAG

1601

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13-17

Installation

corrosion,

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27 - Knock

Sensor
(KS) 2 ­G66-

2-pin

location:
Between
cyl. 4 and
cyl. 6

The
contact
surfaces
between
knock
sensor
and
cylinder
block
must be
free of

dirt and
grease.

Checking:

Repair

Manual, 2.8
Liter VR6 4V
Fuel Injection
& Ignition,
Engine Code
(s): BDF,
Repair Group
01

28 - Engine

speed
(RPM)
sensor

-G28-

Checking:

Repair

Manual, 2.8
Liter VR6 4V
Fuel Injection
& Ignition,

Engine Code

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(s): BDF,
Repair Group
01

13-18

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Fig. 1 To loosen and tighten

securing bolt, hold
vibration damper with
counter support T10069

Note:

Vibration damper securing bolt
must be replaced.

Tighten securing bolt with torque
wrench VAG 1601.

13-19

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Ribbed belt, removing and installing

Special tools and equipment

VAS 5024 Assembly tool for spring-type
clips

Hex bolt M8x45

Removing ribbed belt

Note:
Mark ribbed belt direction of rotation before

removing. Make sure ribbed belt is seated
correctly in pelt pulley when installing.

- Remove engine cover.

13-20

until ribbed belt is no longer under

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- Pull off return hose -1- (with blue
marking) and collect fuel that may
leak out with a cloth.

- Seal lines to avoid contamination
of fuel system.

- Observe rules for cleanliness

Page 20-14 .

- Removing right hand insulation
tray:

Repair Manual, Body Exterior,

Repair Group 50

- Mark direction of rotation of
ribbed belt.

- Screw M8x45 bolt into threaded
hole -A- of tensioning element

tension.

Note:

Screw bolt in sufficiently so that the
ribbed belt can be removed and no
further, otherwise the tensioner
element housing may be damaged.

- Remove ribbed belt.

13-21

Make sure, before installing ribbed belt, that all

compressor, power steering pump) are secured

When installing the ribbed belt observe belt

direction of rotation and that the belt is seated

Repair Manual, Body Exterior, Repair Group 50

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Installing ribbed belt

- Install in reverse order.

Note:

ancillaries (alternator, air conditioning
tightly.

correctly in the belt pulleys.

- Install ribbed belt.

- Remove M8 bolt from tensioner!

After completing repairs always:

- Start engine and check belt running.

- Install right-hand insulation tray:

- Install engine cover.

13-22

supplementary

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Sealing
flanges
and dual­mass
flywheel,
removing
and
installing

Note:

Servicing
clutch:

Repair Manual,

5 & 6 Spd.
Manual
Transmission
02M, Repair
Group 30

When working
on the engine
it should be
secured to
assembly
stand VW 313
using engine
bracket 3269
or VW 540
and

set 540/1 B.
The sealing

flange (item
7 ) can be
removed and
installed when
cylinder head
is installed.

13-23

additional

T10069 to

Replacing

crankshaft

Tighten

wrench

Vibration

Removing

Marking:

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mass flywheel, removing and installing

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1 - 100 Nm

plus

1

/4 turn

(90)
further

Replace

Use
counter
support

loosen
and
tighten

Page 13­27 ,

oil seal ­vibration
pulley end

using
torque

VAG
1601

2 -

damper

and
installing
ribbed
belt

Page 13­19

3 - 8 Nm
4 - Seal

PTFE
seal
version

With no
inner

coil

additionally

remove oil

crankshaft

Replacing

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spring

Do not
lubricate

the oil seal
sealing lip

Before
installing,

remains
from

journal
with a
clean
cloth

Page

13-27

13-24

compound

Removing

crankshaft

Disassembling

compound

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5 - Sealing

flange

Coat
sealing
surfaces
with
sealing

AMV 188
001 02

6 - Cylinder

block

and
installing

Page

13-34

and
assembling
piston and
connecting
rod Page

13-39

7 - Sealing

flange

Coat
sealing
surfaces
with
sealing

AMV 188
001 02

Seal
sealing
surface
to cover

Page

15-39 ,

Adjusting
timing

13-25

inner coil

additionally

extractor

remove oil

crankshaft

onto limit

stop with

9

flywheel/drive

Removing

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8 - Seal

PTFE
seal
version

Marking:
With no

spring

Do not
lubricate

the oil seal
sealing lip

Remove
with

hook
2086

Before
installing,

remains
from

journal
with a
clean
cloth.

Install
over
sleeve
2003/2A

Pull in

press
sleeve
2003/1

Dual-mass

­plate

and
installing

drive

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mass flywheel, removing and installing

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plate

Page 13­31

13-26

10

additional

counter

support

T10069

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11 - 23 Nm

60 Nm

-

plus

1

/4 turn

(90)
further

Replace

Use

to
loosen
and
tighten

13-27

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Crankshaft
oil seal
(vibration
damper
end),
replacing

Special tools
and
equipment

3203 Oil
seal
extractor

3266
Sleeve

T10069
Counter
support

T10053/1
Guide
sleeve

VAG 1601
Torque
wrench
(150...800
Nm)

VAG 1332
Torque
wrench
(40...200
Nm)

13-28

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Removing

- Remove ribbed belt Page 13-

19 .

- Remove vibration damper. To do
this, hold vibration damper with
counter support T10069.

- Unscrew inner part of oil seal
extractor 3203 three turns
(approx. 4 mm) out of the outer
part and lock with knurled screw.

- Lubricate threaded head of oil
seal extractor 3203, place it in
position and exerting firm
pressure screw it as far as
possible into oil seal.

- Loosen knurled screw and turn
inner part against crankshaft until
oil seal is pulled out.

13-29

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mass flywheel, removing and installing

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Installing

Note:

A PTFE seal (Teflon) -2- is gradually
being introduced instead of the inner
coil spring type seal-1-. This has a
wider sealing lip. PTFE seals are
fitted free of oil and grease. When a
PTFE seal is installed, then only
such a seal may be installed as a
replacement part!

- Before installing, remove oil
remains from crankshaft journal
with a clean cloth.

- Install guide sleeve T10053/1
onto crankshaft journal and
carefully slide seal onto guide
sleeve

13-30

Press seal against limit stop using

Install vibration damper and lock it

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-

mass flywheel, removing and installing

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­press sleeve from 3266. Use old
mounting bolt for vibration
damper for this purpose.

­with counter support T10069.

- Tighten new bolt to 100 Nm plus
additional 90 (1/4 turn - turning

further can be done in several
stages).

Note:

Vibration damper securing bolt
must be replaced.

Tighten securing bolt with torque
wrench VAG 1601.

- Install ribbed belt Page 13-19 .

13-31

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mass flywheel, removing and installing

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Drive plate, removing and
installing

Special tools and equipment

T10069 Counter support

VAG 1332 Torque wrench
(40...200 Nm)

Depth gauge
Straight edge

13-32

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-

mass flywheel, removing and installing

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Removing

- Remove drive plate. To do this,
hold vibration damper with
counter support T10069.

- Loosen drive plate securing bolts
using cross-over sequence and
remove them.

- Remove drive plate.

Installing

- Position drive plate on crankshaft

- Insert at least 3 old bolts and
tighten to 30 Nm.

- Check dimension -a- through
three holes for securing torque
converter using a straightedge
and depth gauge and calculate
average.

- Compare average (measured
distance + thickness of
straightedge) with specification.

Specification: 15.7...16.5 mm

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If the specification is not obtained:

- Remove drive plate again and
install appropriate shim -1-.

Note:

Only one shim of the appropriate
thickness may be used to
compensate.

If the specification is obtained:

- Install new cylinder head bolts
and tighten hand tight.

- Tighten securing bolt to 60 Nm
plus additional 90 (1/4 turn -

13-33

turning further can be done in
several stages).

13-34

Crankshaft,

6

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removing
and
installing

Note:

When working
on the engine
it should be
secured to
assembly
stand VW 313
using engine
bracket 3269
or VW 540
and
supplementary
set 540/1 B.

Before
removing the
crankshaft,
ensure that a
suitable place
has been
prepared to
ensure that
the sensor
wheel (item -

-) does not
make contact
or become
damaged.

When
changing
bearing shells
ensure that
bearing shells
of same color
code are used.

1 - Bearing

cap

Bearing
cap 1:
Vibration
damper
end

Bearing

cap 5 with

Bearing shell

retaining lugs

block/bearing

cap) must be

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recesses
for thrust
washers

(cylinder

on the same
side

13-35

additional

further is

removing

bearing

without

cylinder

interchange

bearing

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2 - 30 Nm

plus

1

/2 turn

(180)
further

Replace

Turning 2
x 90

permitted

3 - Bearing

shells

1...7

Observe
note
before

Page

13-34

For
cap
oil

groove

For
block

with oil
groove

Do not
used

bearing
shells
(mark
location)

4 - Thrust

bearing

For
cap 5

Check

locating

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point

13-36

0.07...0.24

Plastigage,

59.958...59.978

53.958...53.978

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5 - Crankshaft

Observe
note
before
removing

Page

13-34

Axial
clearance
new:

mm, Wear
limit: 0.30
mm

Check
radial
clearance
with

New:

0.02...0.06
mm, Wear
limit: 0.10
mm

Do not
turn
crankshaft
when
checking
the radial
clearance

Crankshaft
dimensions:
Main bearing:

mm Conrod
bearing:

mm

6 - Sensor

wheel

For
Engine
speed
(RPM)

sensor -

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G28­Replace
Installing

Fig. 1

13-37

additional

sequence

tightening

bearing

locating

crankshaft

pressure:

Removing

, Fig.

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7 - 10 Nm

plus

1

/4 turn

(90)
further

Replace

Observe
when

Fig. 1

8 - Thrust

bearing

For
cap 5

Check
point

9 - Oil

spray
jet

For
bearings

2...7
For

piston
cooling

Opening

2.0 bar

and
installing

Page

17-7

1

See
note

Page

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13-1

13-38

VAG 1331 Torque wrench (5...50

to 10 Nm

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Fig. 1 Installing sensor wheel

to crankshaft

Special tools and equipment

Nm)
D 000 600 A2 Locking compound

Work sequence

Make sure crankshaft/sensor wheel
contact surfaces are free of oil and
grease.

- Apply a thin coat of locking
compound D 000 600 A2 to
contact surfaces of crankshaft
and sensor wheel for additional
security.

- Check that when installing
"VR6" (arrow) is marked at
individual threaded holes.

- Tighten all new securing bolts
lightly by hand.

- Tighten securing bolt -1­plus additional 90 (1/4 turn).

- Tighten securing bolts -2- to 10
Nm plus additional 90 (1/4 turn).

13-39

disassembling

Offset gaps by

Use piston

ring pliers to

remove and

"TOP" faces

towards piston

Checking ring

Fig. 1

Checking ring

installation

connecting rod

and cylinder

Flatter side of

piston crown

faces toward

cylinder block

Install with

installation tool

(funnel) 3278

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Piston and
connecting
rod,

and
assembling

1 - Piston rings

120

install

crown

gap

to groove
clearance

Fig. 2

2 - Piston

Checking

Fig. 3

Mark
position to

center of

piston

Fig. 5

3 - Snap ring

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13-40

replace

position

cylinder

Installation

above one

installation

interchange

clearance,

0.05...0.35

mm, Wear

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4 - Conrod

Only
as a

set

Mark
to

-B-

position:
Marks -A­must be
aligned

another

5 - Bearing

shell

Observe
position

Do not
used

bearing
shells

Lugs on
bearing
shells
must fit
tightly in
recesses

Axial
New:

limit: 0.40
mm

Check
radial
clearance
with

Plastigage:

New:

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0.02...0.07
mm, Wear
limit: 0.10
mm. Do
not turn
crankshaft
when
checking
radial
clearance

13-41

position

cylinder

Installation

above one

additional

contact

clearance

Cylinder

Checking

Removing

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7 - 30 Nm

6 - Conrod

bearing
cap

Mark
to

-B-

position:
Marks -A­must be
aligned

another

plus

1

/4 turn

(90 )
further

Replace

Oil
thread
and

surface

To
measure
radial

tighten to
30 Nm,
but do
not turn
further

8 -

block

cylinder
bore

Fig. 4

and

installing

crankshaft

dimensions

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Page

13-34

Piston and
cylinder

Page

13-48

13-42

remove,

Remove

with drift

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9 - Piston

pin

If
difficult
to

heat
piston
to 60

C

and
install

VW
222a

13-43

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Fig. 1 Checking piston ring gap

Special tools and equipment

Feeler gauge

Test sequence

- Push ring squarely from above down
to approx. 15 mm from bottom end of
cylinder. To do this use a piston
without rings.

Piston ring

Gap

New Wear

limit

Compression

mm 0.20...0.40 1.0

ring
Tapered-

mm 0.20...0.40 1.0

stepped ring
Oil scraper

mm 0.25...0.50 1.0

ring

13-44

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Fig. 2 Checking ring to groove

clearance

Special tools and equipment

Feeler gauge

Test sequence

- Clean ring groove before checking.

Piston ring

Ring to groove

clearance

New Wear

limit

Compression

mm 0.04...0.08 0.15

ring
Tapered-

mm 0.02...0.06 0.15

stepped ring
Oil scraper

mm 0.03...0.06 0.15

ring

13-45

- Take measurement approx. 6 mm

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Fig. 3 Checking piston

Special tools and equipment

External micrometer 75...100 mm

Test sequence

from lower edge of piston skirt
and offset 90 to piston axis.

Deviation from nominal

dimension: max. 0.04 mm

13-46

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Fig. 4 Checking cylinder bores

Special tools and equipment

Internal dial gauge 50...100 mm

Test sequence

- Measure bores at 3 locations in
both directions -A- across engine
and -B- in line with crankshaft.

Deviation from nominal

dimension: max. 0.08 mm

Note:

The cylinder bores must not be
measured if the cylinder block is
mounted on a repair stand with
engine bracket 3269 or VW 540, as
incorrect measurements would then
result.

13-47

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Fig. 5 Installing pistons with

piston installation tool
(funnel) 3278

Special tools and equipment

3278 Funnel

Note:

If a new installation tool (funnel) is
used to install the pistons, first pass
piston with oiled piston rings through
the funnel twice and remove the
resulting metal shavings if
necessary. Only then install piston
with piston rings.

Work sequence

- Push piston by hand into oiled
installation tool (funnel). Flat side
of piston crown must face toward
tab on funnel (arrow).

- Hold installation tool (funnel) on
upper edge and press piston in
with both thumbs.

- Push piston in until it protrudes
approx. 15 mm from lower edge
of tool (funnel).

- Insert piston into appropriate
cylinder bore. Tab on tool (arrow)
must face center of cylinder block.

- Press installation tool (funnel)
tightly against cylinder block and
push piston in.

13-48

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Cylinder

bore

Piston and cylinder dimensions

Honing
dimension

Piston

diameter

diameter

Basic

mm 80.965 81.010

dimension
1st oversize mm 81.465 81.510
2nd oversize mm 81.965 82.010

15-1

roller rocker

valves must

immediately

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Cylinder
head,
servicing

Note:

If an
exchange
cylinder
head is
installed, all
contact
surfaces
between
bearing
elements,

fingers and
cam
running
surfaces of
camshaft
must be
oiled before
installing
cylinder
head cover.

The plastic
protectors
installed to
protect the
open

only be
removed

before
installing
the cylinder
head.

When
replacing
the cylinder
head the
entire
coolant
quantity
must be
replaced.

15-2

Removing and

Removing and

Disassembling

Removing and

Supporting

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installing
intake
manifold

Page 15-16 ;

installing
cylinder head.

and
assembling
intake
manifold:

Repair Manual,

2.8 Liter VR6 4V
Fuel Injection &
Ignition, Engine
Code(s): BDF,
Repair Group 24

installing
cover Page

15-11 .

Checking
compression
pressure

Page 15-48 .

1 - 8 Nm
2 - Bracket

For fuel
lines

3 -

frame

4 - 8 Nm

With
spacer
sleeve
and
sealing
ring

Replace
sealing
ring if

damaged

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15-3

Lubricate

ignition

Cylinder

Removing

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5 - O-ring

Replace
if
damaged

before
installing

For
coils

with
final
output
stage

6 - Sealing

cap

Replace
seal if
damaged

7 - Boot

Replace
if
damaged

8 -

head
cover

Replace
if
damaged

and
installing

Page

15-16

9 - Lifting

eye

10 - 23 Nm

15-4

direction of

(installation

Installing

Adjusting

Removing

Removing

secondary

Checking

adjustment

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11 - Camshaft

roller
chain

Mark
rotation.

before
removing

position)

Page 13­11 , Fig. 1

Page

15-39 ,

valve
timing

12 - Combi-

valve

and
installing

Page

26-24 ,

and
installing
parts of
the

air system

Page

26-41

13 - Valve -1-

for
camshaft

-N205-

For
intake
camshaft

Check
camshaft