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2000 Volkswagen Passat GLX

2.8L V6 30-VALVE

1998-02 ENGINES
2.8L V6 30-Valve

ENGINE IDENTIFICATION
NOTE:

For repair procedures not covered in this article, see ENGINE OVERHAUL
PROCEDURES article in GENERAL INFORMATION.

Engine can be identified by code and serial number stamped on right side of engine block, in front of right
(passenger side) cylinder head. See ENGINE IDENTIFICATION CODES and Fig. 1 . Engine code is
also identified on vehicle data label.
ENGINE IDENTIFICATION CODES
Engine
Audi
A4 & A6
Volkswagen
Passat

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Code
AHA & ATQ
AHA & ATQ

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2.8L V6 30-VALVE

Fig. 1: Identifying Location Of Engine Code Letters & Serial Number


Courtesy of VOLKSWAGEN UNITED STATES, INC.
ADJUSTMENTS
ACCELERATOR PEDAL

1. Remove clip for accelerator pedal cable on throttle body. Depress and hold accelerator pedal to Wide
Open Throttle (WOT) position.
2. On manual transmission vehicles, reinstall clip for accelerator pedal cable. On automatic transmission
vehicles, disconnect kickdown switch 2-pin harness connector. Using DVOM, ensure continuity exists
between kickdown switch terminals in WOT position. On all models, release accelerator pedal.
Adjustment is complete. After adjusting accelerator pedal, check Closed Throttle Position (CTP)
switch and WOT stops.
VALVE CLEARANCE ADJUSTMENT

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2.8L V6 30-VALVE

Engine is equipped with non-adjustable, non-serviceable hydraulic valve lifters. Irregular valve adjuster
noise during cranking is normal. If valve lifters are noisy under any other condition, see VALVE LIFTERS
under REMOVAL & INSTALLATION.
TROUBLE SHOOTING
To trouble shoot mechanical engine components, see appropriate table in TROUBLE SHOOTING article in
GENERAL INFORMATION.
REMOVAL & INSTALLATION
NOTE:

When battery is disconnected, vehicle computer and memory systems may


lose memory data. Driveability problems may exist until computer systems
have completed a relearn cycle.

NOTE:

For reassembly reference, label all electrical connectors, vacuum hoses and
fuel lines before removal. Place mating marks on engine hood and other
major assemblies before removal.

FUEL PRESSURE RELEASE

NOTE:

For more information on relay identification, see appropriate COMPONENT


LOCATIONS article in ELECTRICAL section.

Remove fuel pump fuse No. 28. from fuse/relay block, under left side of instrument panel. See Fig. 2 . Start
engine. Allow engine to run until it stops. Turn ignition off. Disconnect negative battery cable. Install fuel
pump relay. Slight pressure may remain in system. Before disconnecting any fuel system line, cover
connector with a clean shop towel.

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2000 Volkswagen Passat GLX


2.8L V6 30-VALVE

Fig. 2: Identifying Location Of Fuel Pump Fuse


Courtesy of VOLKSWAGEN UNITED STATES, INC.
DRAINING COOLING SYSTEM

WARNING:

The cooling system is pressurized when the engine is warm. When opening
the expansion tank, wear gloves and other appropriate protection, cover the
cap with a cloth and open carefully to relieve system pressure slowly.

Remove lower engine shield (noise insulator). See Fig. 12 . Open cap on engine coolant expansion tank.
Drain coolant from radiator and at engine coolant drain screw on engine block using (3247) hex ball socket.
See Fig. 32 and Fig. 33 .
COOLING SYSTEM BLEEDING

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2.8L V6 30-VALVE

CAUTION:

Manufacturer recommends using G12 (G012 A8D A1) coolant, or equivalent.


It is Red in color. Do not mix G12 coolant with other types.

A4

1. Expose vent hole on heater pipe, at firewall connection, by pulling back heater hose. See Fig. 3 . Fill
cooling system through expansion tank until coolant comes out of vent hole. Tighten heater hose.
2. Fill expansion tank to proper level. Loosen bleeder screw on lower coolant hose, located under
expansion tank. Unbolt expansion tank if necessary. Top off coolant until it flows from bleed screw.
Close bleed screw.
3. Fill expansion tank to proper level. Loosen bleed screw on front coolant line between power steering
pump and left of cylinder head. Top off coolant until it flows from bleed screw. Close bleed screw.
4. Fill expansion tank to proper level. Install expansion tank cap. Start engine and raise engine speed to
2000 RPM for about 5 minutes. Return engine to idle. Check coolant level in expansion tank. Fill as
necessary.

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2.8L V6 30-VALVE

Fig. 3: Locating Heater Hose Vent Hole


Courtesy of AUDI OF AMERICA, INC.
A6 & Passat

1. Inspect coolant lines for bleed screws. One is located at front of engine near the upper hose
connection. Loosen bleed screws front and on rear coolant pipe.
2. Expose vent hole on heater pipe at firewall connection by pulling back heater hose. See Fig. 3 . Fill
cooling system through expansion tank until coolant comes out of vent hole and bleed screws. Tighten
heater hose and bleed screws.
3. Fill expansion tank to proper level. Install expansion tank cap. Adjust heater controls to maximum
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2.8L V6 30-VALVE

heat position. Start engine and raise engine speed to 2000 RPM for about 3 minutes. Ensure cooling
fan operates. Return engine to idle. Check coolant level in expansion tank. Fill as necessary. Repeat
and recheck.
SERPENTINE DRIVE BELT & VISCOUS COOLING FAN
Remove

1. On Passat, go to step 2 . On A4 and A6, move lock carrier into service position for access to
serpentine belt. See LOCK CARRIER .
2. Remove trim cover from top of engine. See Fig. 31 . Remove engine noise insulation shield from
under engine. See Fig. 12 .
3.
CAUTION: Viscous fan is mounted with a left-handed thread. Turn clockwise to
loosen.
Using Spanner Wrench (3212), hold viscous fan pulley. See Fig. 36 . Using Open End Wrench
(3312), or equivalent, rotate viscous fan clockwise to remove.
4.
NOTE:

If reusing serpentine drive belt, mark direction of rotation on belt.

Using a wrench, rotate ribbed belt tensioner clockwise and install a drift to hold. Remove serpentine
belt. See Fig. 37 .
Installation

1. If reusing original serpentine belt, ensure belt is installed in original direction of rotation.
2. Install viscous fan and tighten to specification. See TORQUE SPECIFICATIONS .
3. Install lock carrier to body. See LOCK CARRIER .
LOCK CARRIER

NOTE:

Lock carrier is slid forward onto alignment tools. This will allow servicing of
front engine components. Lock carrier can be removed at technicians
discretion.

Placing In Service Position (A4 & A6)

NOTE:

It is not necessary to completely removal noise insulation from beneath the


engine. Only remove the quick release fasteners the attach to the front
bumper assembly.

1. Remove front bumper. See FRONT BUMPER .


2. Unbolt air guide between lock carrier and air filter on lock carrier. Inspect headlight and turn signal
electrical connectors and wiring harness (which may hang up when lock carrier is moved forward).
3. On right side, remove bolt (5) and install support tool (3369) in its place. See Fig. 4 and Fig. 5 .

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2.8L V6 30-VALVE

Fig. 4: Identifying Lock Carrier Components (A4 & A6)


Courtesy of AUDI OF AMERICA, INC.

2 2005 . 0:20:00

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2.8L V6 30-VALVE

Fig. 5: Identifying Support Tool (Part No. 3369)


Courtesy of VOLKSWAGEN UNITED STATES, INC.
4. On left side, install support tool (3369) in threaded hole in chassis. See Fig. 6 .

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2.8L V6 30-VALVE

Fig. 6: Installing Support Tool (3369) Into Chassis (A4 & A6)
Courtesy of AUDI OF AMERICA, INC.
5. Remove on both sides, all (No. 2) bolts.See Fig. 4 .
6. Remove on both sides, all (No. 3 and 4) bolts. See Fig. 4 . Slide lock carrier forward unit the rear bolt
hole in lock carrier aligns with the forward threaded fender bolt hole.
7. Secure lock carrier in this position, by placing fender bolts in holes. See Fig. 7 . To install, reverse
placing in service position procedure.

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2.8L V6 30-VALVE

Fig. 7: Securing Lock Carrier In Service Position (A4 & A6)


Courtesy of AUDI OF AMERICA, INC.
Placing In Service Position (Passat, First Design - Up To September, 2000)

1. Remove front bumper. See FRONT BUMPER .


2. Unbolt air guide between lock carrier and air filter on lock carrier. Inspect headlight and turn signal
electrical connectors and wiring harness (which may hang up when lock carrier is moved forward).
3. On right side, remove bolt (3) and install support tool (3369) in its place. See Fig. 5 and Fig. 8 .

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2.8L V6 30-VALVE

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2.8L V6 30-VALVE

Fig. 8: Identifying Lock Carrier Components (Passat, First Design - Up To September, 2000)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
4. On left side, install support tool (3369) in threaded hole in chassis. See Fig. 6 .
5. Remove on both sides, all (No. 2 and 4) bolts. See Fig. 8 . Slide lock carrier forward onto the lock
carrier support (3369) tools. To install, reverse placing in service position procedure.
Placing In Service Position (Passat, Second Design - From October, 2000)

1. Raise vehicle, remove front tires, remove lower front engine shield (noise insulator). See Fig. 12 .
2. Inspect headlight and turn signal electrical connectors and wiring harness (which may hang up when
bumper is being removed). Remove front bumper. See FRONT BUMPER .
3. Unbolt air guide between lock carrier and air filter on lock carrier. Disconnect coolant fan thermal
switch. Disconnect power steering cooling coil from radiator.
4. Remove bolts and replace with guide rods (3411) to right and left longmember. See Fig. 9 and Fig.
11 .
5. Remove bolts (No. 2 and 3). See Fig. 9 . Lock carrier can be pulled forward approximately 4 inches
(10 cm) on guide rods (No. 3411). See Fig. 10 and Fig. 11 . To install, reverse placing in service
position procedure.

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2.8L V6 30-VALVE

Fig. 9: Identifying Lock Carrier Components (Passat; Second Design - From October, 2000)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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2.8L V6 30-VALVE

Fig. 10: Identifying Guide Rods (Part No. 3411)


Courtesy of VOLKSWAGEN UNITED STATES, INC.

2 2005 . 0:20:01

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2.8L V6 30-VALVE

Fig. 11: Identifying Installed Location Of Guide Rods (Part No. 3411)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
FRONT BUMPER
Removal & Installation (A4)

NOTE:

For help in identifying components and component locations, refer to


illustrations. See Fig. 12 -Fig. 19 .

1. Raise vehicle, remove front tires, remove lower front engine shield (noise insulator). See Fig. 12 .
With vehicle raised, loosen appropriate front bumper fasteners at this time. See Fig. 13 -Fig. 19 .
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2.8L V6 30-VALVE

Lower vehicle.
2. Separate hood release lever from hood lock. Disconnect any wiring harness that attach to the front
bumper.
3. Remove front bumper cover. See Fig. 13 or Fig. 16 . Remove bumper cover carrier from impact
absorbers.
4. To install, reverse removal procedure. Adjust front bumper height (A4; Up To VIN 8DXA20000), see
Fig. 15 . To move lock carrier into service position, see LOCK CARRIER .

Fig. 12: Identifying Lower Engine Shield (Noise Insulator) Mounting Points
Courtesy of AUDI OF AMERICA, INC.

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2.8L V6 30-VALVE

Fig. 13: Identifying Front Bumper (A4; Up To VIN 8DXA20000)


Courtesy of AUDI OF AMERICA, INC.

2 2005 . 0:20:01

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2.8L V6 30-VALVE

Fig. 14: Identifying Front Bumper Bracket (A4; Up To VIN 8DXA20000)


2 2005 . 0:20:01

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2.8L V6 30-VALVE

Courtesy of AUDI OF AMERICA, INC.

Fig. 15: Adjusting Front Bumper Height (A4; Up To VIN 8DXA20000)


Courtesy of AUDI OF AMERICA, INC.

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2.8L V6 30-VALVE

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2.8L V6 30-VALVE

Fig. 16: Identifying Front Bumper Components (A4; VIN 8DXA200001 & Up)
Courtesy of AUDI OF AMERICA, INC.

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2.8L V6 30-VALVE

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2.8L V6 30-VALVE

Fig. 17: Identifying Front Bumper Bracket (A4; VIN 8DXA200001 & Up)
Courtesy of AUDI OF AMERICA, INC.

2 2005 . 0:20:01

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2.8L V6 30-VALVE

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2.8L V6 30-VALVE

Fig. 18: Adjusting Front Bumper Height (A4; VIN 8DXA200001 & Up)
Courtesy of AUDI OF AMERICA, INC.

Fig. 19: Removing Inner End Of Air Inlet Grill (A4; VIN 8DXA200001 & Up)
Courtesy of AUDI OF AMERICA, INC.
Removal (A6)

NOTE:

For help in identifying components and component locations, refer to


illustrations. See Fig. 20 -Fig. 24 .

1. Disconnect any wiring harness that attach to the front bumper.


2. Raise vehicle, remove front tires. Remove lower front engine shield (noise insulator). See Fig. 12 .
Loosen the front half of the wheel housing splash shield (liner). See Fig. 20 . Unscrew flange nut (10)
on both sides. See Fig. 22 .
3. Unscrew with/washer assembly (6) from wheel housing liner (5).See Fig. 22 . Remove socket-head
bolts (7) and remove bumper cover together with impact absorbor towards front. See Fig. 22 . To
move lock carrier into service position. See LOCK CARRIER .

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2.8L V6 30-VALVE

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Fig. 20: Identifying Wheel Housing Liner Components (A6)


Courtesy of AUDI OF AMERICA, INC.

2 2005 . 0:20:02

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2.8L V6 30-VALVE

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Fig. 21: Identifying Bumper Cover Attaching Points For Removal & Installation (A6)
Courtesy of AUDI OF AMERICA, INC.

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2.8L V6 30-VALVE

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2.8L V6 30-VALVE

Fig. 22: Identifying Front Bumper Components (A6)


Courtesy of AUDI OF AMERICA, INC.

Fig. 23: Identifying Bumper Attaching Point To Impact Absorbor (A6)


Courtesy of AUDI OF AMERICA, INC.

2 2005 . 0:20:02

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2.8L V6 30-VALVE

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2.8L V6 30-VALVE

Fig. 24: Identifying Bumper Guide Components (A6)


Courtesy of AUDI OF AMERICA, INC.
Installation (A6)

1. Before installing the bumper, ensure the expanding clips are pressed into the fender. See Fig. 21 .
When installing the tabs, the bumper cover must latch into clip (4). See Fig. 22 .
2. Latch bumper cover (1) into guide (2). See Fig. 22 . Tighten flange nuts (10) to 53 INCH lbs. (6 N.m).
3.
NOTE:
The impact absorbor is installed vertical to the cross member and has
height compensating elements. See Fig. 23 .
Screw in socket-head bolts (7) and tighten to 17 ft. lbs. (23 N.m). See Fig. 22 .
Removal & Installation (Passat)

NOTE:

For help in identifying components and component locations, refer to


illustrations. See Fig. 25 -Fig. 30 .

1. Remove grill assembly and hood latch release lever. See Fig. 25 -Fig. 27 .

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2.8L V6 30-VALVE

Fig. 25: Removing Hood Latch Release Lever (Passat)


Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 26: Removing Radiator Grill (Passat - Up To September, 2000)


Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 27: Removing Radiator Grill (Passat - From October 2000 & Up)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
2. Raise vehicle, and remove front tires.
3. Remove lower front engine shield (noise insulator). See Fig. 12 .
4. With vehicle raised, loosen appropriate front bumper cover and bumper cover carrier beam fasteners
at this time. See Fig. 28 -Fig. 29 . Lower vehicle.

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2.8L V6 30-VALVE

Fig. 28: Exploded View Of Front Bumper Assembly (Passat - Up To September, 2000)
Courtesy of VAG. OF AMERICA

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Fig. 29: Exploded View Of Front Bumper Assembly (Passat - From October, 2000)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
5. Disconnect any wiring harness that attach to the front bumper.
6. On Passat produced up to September, 2000, remove front bumper cover. Remove bumper cover
carrier from impact absorbers. See Fig. 28 .
7. On Passat produced after October, 2000, remove front bumper cover, see Fig. 29 . Remove bumper
cover carrier. See Fig. 9 .
8. On all models, reverse removal procedure to install bumper cover. Also see Fig. 30 for bumper
adjustment. To move lock carrier into service position. See LOCK CARRIER .

Fig. 30: Guide Adjustment


Courtesy of VOLKSWAGEN UNITED STATES, INC.
ENGINE

WARNING:

ALWAYS release fuel pressure before disconnecting fuel injection related


component. DO NOT allow fuel to contact engine or electrical components.

NOTE:

Obtain radio code before disconnecting battery. Remove engine, without


transmission, through front of engine compartment.

Removal

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2.8L V6 30-VALVE

1. Release fuel pressure. See FUEL PRESSURE RELEASE . Ensure ignition switch is in the OFF
position. Disconnect battery cables. Remove clip for accelerator pedal cable on throttle body and
remove cable from throttle body.
2. Turn ignition off. Disconnect negative battery cable. Remove engine cover. See Fig. 31 .

Fig. 31: Identifying Engine Cover Mounting Fasteners


Courtesy of AUDI OF AMERICA, INC.
3.
WARNING:

The cooling system is pressurized when the engine is warm. When


opening the expansion tank, wear gloves and other appropriate
protection, cover the cap with a cloth and open carefully to relieve
system pressure slowly.

Remove lower engine shield. See Fig. 12 . Open cap on engine coolant expansion tank. Drain coolant
from radiator and at engine coolant drain screw on engine block using Hex Ball Socket (3247). See
2 2005 . 0:20:03

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2.8L V6 30-VALVE

Fig. 32 -Fig. 33 .

Fig. 32: Identifying Location Of Coolant Drain Plug At Radiator


Courtesy of AUDI OF AMERICA, INC.

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Fig. 33: Identifying Location Of Coolant Drain Plug At Engine Block


Courtesy of AUDI OF AMERICA, INC.
4. Remove complete front bumper assembly. See FRONT BUMPER .
5. Disconnect power steering cooling coil, located at lower left of radiator. Let cooling coil hang free.
See Fig. 34 .

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Fig. 34: Identifying Power Steering Cooler Line Mounting Points


Courtesy of AUDI OF AMERICA, INC.
6.
NOTE:

DO NOT open the air conditioning refrigerant circuit. Disconnect A/C


refrigerant line brackets at support points only. After A/C compressor is
removed from bracket and setting A/C compressor carefully aside.
Avoid damage from bending or kinking refrigerant lines.

Remove left and right side air ducts (4). Remove condenser mounting bolts (1) and (2). Disconnect
harness connector (3) for A/C pressure switch. See Fig. 35 . Pull condenser up out of its bracket,
rotate it to side and use wire to secure it on or near right front wheel.

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2.8L V6 30-VALVE

Fig. 35: Identifying Location Of A/C Pressure Switch


Courtesy of AUDI OF AMERICA, INC.
7. Move lock carrier to service position. See LOCK CARRIER .
8.
CAUTION: Viscous fan is mounted with a left-handed thread. Turn clockwise to
loosen.
Using Spanner Wrench (3212), hold viscous fan pulley. See Fig. 36 . Using Open End Wrench
(3312), or equivalent, rotate viscous fan clockwise to remove. Using a wrench, rotate ribbed belt
tensioner clockwise and install a drift to hold. Remove serpentine belt. See Fig. 37 .

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Fig. 36: Removing Viscous Fan Pulley.


Courtesy of AUDI OF AMERICA, INC.

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Fig. 37: Identifying Placement Of Tool On Serpentine Drive Belt Tensioner


Courtesy of AUDI OF AMERICA, INC.
9. Remove air intake hose between Mass Airflow (MAF) sensor and intake air elbow. Remove
secondary air injection duct by turning it 1/4 turn to the right. See Fig. 38 and Fig. 39 . Remove upper
part of air cleaner assembly. Disconnect cruise control vacuum unit. Disconnect accelerator pedal
cable. DO NOT remove locking clip on accelerator pedal cable bracket.

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Fig. 38: Identifying Air Intake Components Attachment Points


Courtesy of AUDI OF AMERICA, INC.

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Fig. 39: Identifying Secondary Air Duct Removal Procedure


Courtesy of AUDI OF AMERICA, INC.
10. Disconnect fuel supply and return lines. Disconnect coolant, electrical and vacuum connections at
engine. See Fig. 40 . Remove 3 bolts at rear part of intake manifold. Remove engine coolant
expansion tank and position to side.

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Fig. 40: Identifying Engine Wiring Harness Connectors & Mounting Bolts
Courtesy of AUDI OF AMERICA, INC.
11. Disconnect 5 harness connectors below cover of ABS hydraulic control unit. Remove retainer form
ground wire and remove ground electrical connector. See Fig. 41 and Fig. 42 . Remove vacuum
connections at engine.

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Fig. 41: Identifying Harness Connectors At ABS Hydraulic Control Unit


Courtesy of AUDI OF AMERICA, INC.

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Fig. 42: Identifying Retainer & Ground Wire Connection


Courtesy of AUDI OF AMERICA, INC.
12. Remove wiper arms and water deflector. Remove cover from ECM (E-Box). Disconnect wiring
harness connectors from ECM. See Fig. 43 .

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Fig. 43: Identifying Location ECM (E-Box)


Courtesy of AUDI OF AMERICA, INC.
13. Disconnect exhaust manifold connections. Disconnect 4 oxygen sensor harness connectors. Remove
ground wire at engine/cross member. See Fig. 44 . Remove front exhaust pipes with converters.
Disconnect starter and generator electrical connections. Unbolt starter and remove between subframe
and drive axle.

Fig. 44: Identifying Ground Wire Location At Engine/Crossmember


Courtesy of AUDI OF AMERICA, INC.
14. Clamp off two hoses at hydraulic fluid supply line using Hose Clamps(3094). Disconnect supply line
(see arrow) below left cylinder head. See Fig. 45 . Place rag(s) under connection to catch escaping
fluid.

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Fig. 45: Identifying Hydraulic Fluid Supply Line At Left Cylinder Head
Courtesy of AUDI OF AMERICA, INC.
15. Disconnect hydraulic pressure line at rear coolant line. Disconnect hydraulic pressure line at right side
cylinder head. See Fig. 46 .

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2.8L V6 30-VALVE

Fig. 46: Identifying Hydraulic Fluid Supply Lines At Right Cylinder Head
Courtesy of AUDI OF AMERICA, INC.
16. Detach A/C refrigerant line from oil pan at front of engine. See Fig. 47 .

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Fig. 47: Identifying Location Of A/C Refrigerant Line At Front Of Engine


Courtesy of AUDI OF AMERICA, INC.
17. Remove upper engine-to-transmission bolts. Remove lower left and right engine mount nuts. If
equipped with automatic transmission, remove 3 torque converter bolts. See Fig. 48 . Lift engine and
transmission slightly usingHoist Crane (VAG 1202 A) to allow lower engine/transmission connecting
bolts to be removed. Remove lower engine/transmission connecting bolts. See Fig. 49 .

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Fig. 48: Identifying Access To Torque Converter Bolts


Courtesy of AUDI OF AMERICA, INC.

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Fig. 49: Using Hoist Crane (VAG 1202 A) To Raise Engine & Transmission
Courtesy of AUDI OF AMERICA, INC.
18. Mark positions of left and right engine mount locating sleeves from bottom. See Fig. 50 . Position
Support Bridge (10-222A) on bolted flanges of fenders. Engage Support Adaptor (3147) in bolt hole
in bellhousing on transmission. See Fig. 51 .

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Fig. 50: Identifying Location Of Locating Sleeves (Mark Sleeves For Reinstallation)
Courtesy of AUDI OF AMERICA, INC.
19. Attach Engine Sling (2024A) to engine. Using hoist, lift engine from vehicle. See Fig. 51 and Fig.
52 .

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Fig. 51: Installing Support Bridge (10-222A) & Trans Support Adaptor (3147)
Courtesy of AUDI OF AMERICA, INC.

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Fig. 52: Installing Engine Sling (2024) & Hoist Crane (VAG 1202 A)
Courtesy of AUDI OF AMERICA, INC.
Installation

1. To install, reverse removal procedure. Always replace self-locking nuts. Ensure engine and
transmission locating dowel pins and centering sleeves are properly installed in cylinder block and
bell housing. For manual transmission, go to next step. For automatic transmission, go to step 7 .
2. For manual transmission, clean and lubricate transmission input shaft splines with lubricant (G
000100). Make sure clutch disc and pressure plate are properly installed. Make sure pilot needle
bearing is installed. If pilot needle bearing is worn, see PILOT NEEDLE BEARING (MANUAL
TRANSMISSION) . For more information on transmission servicing, see appropriate article in
CLUTCHES.
3. Align engine to transmission bell-housing. Install proper length bolts and torque to specifications. See
Fig. 53 . See TORQUE SPECIFICATIONS .

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Fig. 53: Identifying Manual Transmission-To-Engine Bolt Length Reference


Courtesy of AUDI OF AMERICA, INC.
4. Install engine mounts free of tension by aligning engine with shaking motions prior to tightening
bolts. See TORQUE SPECIFICATIONS .
5. Align exhaust so components are free of stress. Adjust accelerator pedal. See ACCELERATOR
PEDAL under ADJUSTMENTS. Verify engine fluids are filled to proper levels.
6.
NOTE:
Always replace seals and O-rings.
Install vacuum lines. See Fig. 54 . Install serpentine drive belts. See Fig. 56 or Fig. 57 .

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Fig. 54: Identifying Vacuum Line Connections


Courtesy of AUDI OF AMERICA, INC.
7.
CAUTION:

If the torque converter is not installed correctly, drive plate or the ATF
pump will be damaged when the transmission is attached to the engine.

If the torque converter is installed correctly, the distance between contact surfaces at the mounting
holes on the torque converter and contact surface of the bell housing flange will be about 7/8". See
Fig. 55 . If the torque converter was not completely installed, this distance will be about 7/16".

Fig. 55: Checking Torque Converter Installation


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Courtesy of AUDI OF AMERICA, INC.


8. For automatic transmission, when mounting torque converter to drive plate, use only bolts specified
for this use. Before installing engine, align torque converter and drive plate so that one hole in torque
converter and one hole in drive plate are level with opening for starter. See Fig. 48 .
9. Align engine to transmission bell-housing. Install proper length bolts and torque to specification. See
TORQUE SPECIFICATIONS . For more information, see appropriate REMOVAL &
INSTALLATION article TRANSMISSION/TRANSAXLE.
10. Install engine mounts free of tension by aligning engine with shaking motions prior to tightening
engine mounts. See TORQUE SPECIFICATIONS .
11. Align exhaust so components are free of stress. Adjust accelerator pedal. See ACCELERATOR
PEDAL under ADJUSTMENTS. Verify engine fluids are filled to proper levels. Also check ATF
fluid is filled to proper level.
12.
NOTE:
Always replace seals and O-rings.
Install vacuum lines. See Fig. 54 .
13. Install serpentine drive belt. See Fig. 56 or Fig. 57 .

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Fig. 56: Serpentine Drive Belt Routing (With A/C)


Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 57: Serpentine Drive Belt Routing (Without A/C)


Courtesy of VOLKSWAGEN UNITED STATES, INC.
INTAKE MANIFOLD

WARNING:

ALWAYS release fuel pressure before disconnecting fuel injection related


component. DO NOT allow fuel to contact engine or electrical components.

NOTE:

Obtain radio code before disconnecting battery.

NOTE:

Always replace seals, gaskets and O-rings.

Removal & Installation (Audi)

No removal or installation procedure provided by vehicle manufacturer. See Fig. 60 and Fig. 61 for views of
intake manifold components.
Removal & Installation (Passat)

No removal or installation procedure provided by vehicle manufacturer. Manufacturer did provided various
graphics. For removal and installation, refer to illustrations. See Fig. 58 -Fig. 66 . Release fuel pressure
before removing fuel rail. See FUEL PRESSURE RELEASE . Tighten all bolts to specification. See
TORQUE SPECIFICATIONS .
NOTE:

For more information on component locations, see appropriate


COMPONENT LOCATIONS article in ELECTRICAL.

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Fig. 58: Locating Underhood Components (Passat - 1 Of 2)


Courtesy of AUDI OF AMERICA, INC.

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Fig. 59: Locating Underhood Components (Passat - 2 Of 2)


Courtesy of AUDI OF AMERICA, INC.

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Fig. 60: Exploded View Of Intake Manifold & Fuel Management Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 61: Exploded View Of Rotary Change-Over Valve Components


Courtesy of VOLKSWAGEN UNITED STATES, INC.
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Fig. 62: Exploded View Of Air Filter Assembly (Passat)


Courtesy of VOLKSWAGEN UNITED STATES, INC.
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Fig. 63: Identifying Throttle Body Control Module Assembly (Passat)


Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 64: Identifying Fuel Rail Components (Passat)


Courtesy of VOLKSWAGEN UNITED STATES, INC.

2 2005 . 0:20:06

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Fig. 65: Identifying Vacuum Line Connections (Passat - 1 Of 2)


Courtesy of VOLKSWAGEN UNITED STATES, INC.
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Fig. 66: Identifying Vacuum Line Connections (Passat - 2 Of 2)


Courtesy of VOLKSWAGEN UNITED STATES, INC.
EXHAUST MANIFOLD
Removal & Installation

Disconnect exhaust pipe flange connections. Remove upper and lower heat shields. Remove exhaust
manifold bolts and remove manifolds. To install, reverse removal procedures. Ensure exhaust system is
aligned so components are free of stress. Replace all self-locking nuts. Tighten exhaust manifold bolts to
specification. See TORQUE SPECIFICATIONS .
CYLINDER HEAD

WARNING:

ALWAYS release fuel pressure before disconnecting fuel injection related


component. DO NOT allow fuel to contact engine or electrical components.

CAUTION:

Installing cylinder heads supplied as replacement parts can be used on


either the left or right-sides of the engine. A core plug (sealing cap) must be
installed in the front end of the cylinder head in each case.

CAUTION:

DO NOT start engine for about 30 minutes after installing camshafts.


Hydraulic valve lifters must bleed down or valves may strike pistons. Rotate
crankshaft by hand 2 full revolutions before starting engine to ensure valves
do not strike pistons.

NOTE:

Engine must be cool before proceeding with cylinder head removal. DO NOT
position pistons at TDC during removal procedure.

Removal

1. On A4 and A6 models, remove front bumper. See FRONT BUMPER . Place lock carrier into service
position. See LOCK CARRIER .
2. On all models, remove trim cover from top of engine. Remove noise insulation panel from under
engine. See Fig. 12 .
3. Release fuel pressure. See FUEL PRESSURE RELEASE . Obtain radio anti-theft code (if
equipped), and disconnect negative battery cable.
4. Drain coolant from radiator. Remove coolant drain plug from engine. See DRAINING COOLING
SYSTEM . Remove air intake hose with MAF sensor and throttle valve control module. Disconnect
accelerator pedal cable.
5. Noting installed position for reassembly reference, disconnect all necessary electrical and vacuum
connections to facilitate cylinder head removal. Remove intake manifold securing plate at rear of
manifold.
6. Remove serpentine drive belt. See SERPENTINE DRIVE BELT & VISCOUS COOLING FAN .
7. Remove timing belt from camshaft sprockets. See TIMING BELT . It is not necessary to completely
remove timing belt from crankshaft sprocket.
8. Disconnect exhaust pipes from cylinder heads. Unbolt exhaust system from transmission bracket.
Disconnect fuel supply and return lines.
9. Remove fuel injector harness connectors from fuel injectors. Unbolt fuel rail from intake manifold.
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Remove fuel rail and injectors as an assembly.


10. Unbolt bracket for ignition coils and set aside. Remove intake manifold. Remove secondary air
system connection pipe below intake manifold. Unbolt coolant pipe at rear of cylinder head.
11. On driver side cylinder head, remove camshaft sprocket using sprocket puller. See Fig. 77 . Remove
rear (inboard) timing belt from drive side cylinder head.
12. Unbolt coolant pipe at front of cylinder head. Remove cylinder head covers. Remove cylinder head
bolts in REVERSE order of installation tightening sequence. See Fig. 67 .

Fig. 67: Identifying Cylinder Head Bolt Tightening Sequence


Courtesy of AUDI OF AMERICA, INC.
Inspection

Measure cylinder head height and warpage. If warpage exceeds specification, machine cylinder head. See
CYLINDER HEAD table under ENGINE SPECIFICATIONS. If machining causes cylinder head height to
2 2005 . 0:20:06

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be less than specification, replace cylinder head.


Installation

CAUTION:

Manufacturer requires using NEW cylinder head bolts on installation.

1. Clean all oil and coolant from blind holes in cylinder block.
2. Carefully clean cylinder head and cylinder block sealing surfaces, ensuring nor scoring or scratches
are formed.
3. Only remove new cylinder head gasket immediately before installation. Install cylinder head gasket
with "oben" mark or part number facing up.
4. Before installing cylinder head, ensure camshafts are set to TDC of No. 3 cylinder. Place No. 3 piston
at TDC, and turn crankshaft back slightly.
5. Install cylinder heads on cylinder block.
6. Install NEW cylinder head bolts. Hand tighten cylinder head bolts. Tighten cylinder head bolts in
correct sequence. See Fig. 67 . It is not necessary to retorque cylinder head bolts after completing
repairs.
7. To complete installation, reverse removal procedure. Tighten all fasteners to specification. See
TORQUE SPECIFICATIONS .
8. Before installing valve cover and new gasket, apply small amount of sealant at 4 corners of cylinder
head mating surface.
9. Install timing belt. See TIMING BELT . Install viscous fan and serpentine belt. See SERPENTINE
DRIVE BELT & VISCOUS COOLING FAN .
10. Fill and bleed air from cooling system. See COOLING SYSTEM BLEEDING .
CORE PLUG (CYLINDER HEAD)

CAUTION:

Installing cylinder heads supplied as replacement parts can be used on


either the left or right-sides of the engine. A core plug (sealing cap) must be
installed in the front end of the cylinder head in each case.

Removal

Removal procedure of core plug not provided by manufacturer.


Installation

Coat outside circumference of core plug (sealing cap) with sealant (AMV 188 001 02). Using needle
Bearing Drift (VW295), drive in core plug until outside rim is flush with end of chamfer in cylinder head.
See Fig. 68 .

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Fig. 68: Identifying Installed Depth Of Core Plug (Sealing Cap)


Courtesy of VOLKSWAGEN UNITED STATES, INC.
CRANKSHAFT FRONT OIL SEAL

NOTE:

During this procedure. No. 1. piston must be placed at Top Dead Center
(TDC).

Removal

1. Remove sealing plug from hole in left side of cylinder block. Position crankshaft to Top Dead Center
(TDC) for cylinder No. 1. Ensure TDC hole can be seen or felt through sealing plug hole. Install
Crankshaft Holder (3242) into sealing plug hole to prevent crankshaft from rotating. See Fig. 69 .

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Fig. 69: Installing Crankshaft Holder (3242)


Courtesy of VAG
2. Remove timing belt. See TIMING BELT .
3. Using Seal Remover (3203), remove crankshaft seal. Unscrew inner part of Oil Seal Extractor (3202)
2 turns (about 3 mm) out of outer part and lock with knurled screw. See Fig. 70 .

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Fig. 70: Identifying Crankshaft Front Oil Seal Extractor (3202)


Courtesy of VOLKSWAGEN UNITED STATES, INC.
4. Lubricate thread head of oil seal extractor, place it in position while applying firm pressure screw it as
far as into oil seal. Loosen knurled screw and turn inner part of extractor against crankshaft until oil
seal has been extracted. See Fig. 70 .
PTFE Seal Installation Precautions

Some engines may be equipped with a PTFE (Teflon(R)) type oil seal. This seal can be identified by a wider
sealing lip that is threaded. There is also no annual sealing ring on the seal. If the engine is equipped with a
PTFE type seal, the replacement seal must be a PTFE seal.
Do NOT lubricate the sealing surface of the PTFE seal. It is installed dry. The seal MUST be installed with
the direction arrow on the face of the seal facing the direction of rotation of the crankshaft.
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Installation

NOTE:

Manufacturer requires replacing crankshaft sprocket center bolt if loosened


or removed.

Using Guide Sleeve (3202/1) and Installing Sleeve (3265), install dry (do not lube) crankshaft oil seal over
guide sleeve. Press seal in flush with Installing Sleeve (3265). See Fig. 71 . Tighten crankshaft sprocket bolt
to specification. See TORQUE SPECIFICATIONS . Reassemble in reverse order.

Fig. 71: Identifying Crankshaft Front Oil Seal Installer (3265)


Courtesy of VOLKSWAGEN UNITED STATES, INC.
TIMING BELT

CAUTION:

If reusing old serpentine accessory drive belt and/or timing belt, mark the

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running direction of belt with crayon or marker. Reinstalling a used belt in


reversed direction could damage the belt, and cause engine damage.
NOTE:

Obtain radio code before disconnecting battery.

NOTE:

For cylinder head removal. DO NOT position pistons at TDC during removal
procedure.

Removal

1. For Passat, go to next step. For A4 and A6, move lock carrier into service position. See LOCK
CARRIER .
2. On all models, remove serpentine belt and viscous fan. See SERPENTINE DRIVE BELT &
VISCOUS COOLING FAN .
3. Remove noise insulation panel from under engine. See Fig. 12 . Remove trim cover from top of
engine. See Fig. 31 .
4. Rotate crankshaft using center bolt so that timing marks are aligned. See Fig. 72 . Remove upper
timing belt guards.

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Fig. 72: Aligning Crankshaft Timing Marks


Courtesy of AUDI OF AMERICA, INC.
5. Check position of camshafts. Larger holes of camshaft securing plates (located on front of camshaft
sprockets) must be on inside and must align. See Fig. 73 . If camshafts are in correct position, go to
next step. If larger holes are positioned to the outside, rotate crankshaft one turn further. Go to next
step.

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Fig. 73: Aligning Camshaft Securing Plates


Courtesy of VOLKSWAGEN UNITED STATES, INC.
6.
WARNING:

Do NOT turn crankshaft while checking TDC hole in crankshaft.


Personal injury may result if using finger to check for TDC hole.

Remove sealing plug from alignment access hole in left side of engine block. Ensure that hole in
crankshaft is visible or be felt through alignment access hole. Install Crankshaft Holder (3242) into
alignment access hole to prevent crankshaft from rotating. See Fig. 74 .

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Fig. 74: Installing Crankshaft Holder (3242)


Courtesy of VOLKSWAGEN UNITED STATES, INC.
7. Remove serpentine belt tensioner.
8. Remove center and right timing belt covers. If timing belt is to be reused, mark belt running direction
with marker or crayon.
9.
NOTE:
Timing belt tensioner is oil-dampened; compress it by slowly applying
constant pressure. Compressing tensioner too quickly could damage it
internally.
Using an 8-mm wrench, turn timing belt tensioning roller clockwise until tensioning lever compresses
tensioner so that a pin (2 mm in diameter) can be inserted into plunger. See Fig. 75 . Insert pin and
release tension.

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Fig. 75: Compressing Timing Belt Tensioner


Courtesy of VOLKSWAGEN UNITED STATES, INC.
10.
NOTE:

When removing vibration damper, it is not necessary to remove center


bolt on vibration damper. If removed, the center bolt must be replaced
with new bolt.

Remove vibration damper bolts around center bolt. See Fig. 76 . Remove vibration damper. Remove
serpentine belt idler pulley. Remove timing belt cover. Remove timing belt.

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Fig. 76: Removing Vibration Damper Bolts & Serpentine Belt Idler Pulley
Courtesy of VOLKSWAGEN UNITED STATES, INC.
Installation

1. Remove camshaft sprocket securing bolts and securing plates. Install a 10 mm bolt in center of
camshaft. Install Sprocket Puller (3032) on camshaft sprocket. See Fig. 77 . Remove camshaft
sprockets.

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Fig. 77: Removing Camshaft Sprocket Using Sprocket Puller (3032)


Courtesy of VOLKSWAGEN UNITED STATES, INC.
2. Reinstall both camshaft sprockets, together with locking plate, and hand tighten bolts. Camshaft
sprocket must be able to move on tapered camshaft. Repeat for each camshaft.
3. Install timing belt. See Fig. 78 .

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Fig. 78: Installing Timing Belt


Courtesy of VOLKSWAGEN UNITED STATES, INC.
4. Install Camshaft Holding Bar (3391). See Fig. 79 .

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Fig. 79: Installing Camshaft Holding Bar (3391)


Courtesy of VOLKSWAGEN UNITED STATES, INC.
5. Use an 8-mm wrench to turn timing belt tensioning roller clockwise until tensioning lever compresses,
and remove spring pin. See Fig. 75 .
6. Using a torque wrench with an 8 mm hex bit, apply 11 ft. lbs. (15 N.m) to timing belt tensioner roller
(pulley bearing). This ensures timing belt tensioner has expanded completely and properly tensioning
belt.
7. Tighten camshaft sprockets to specification. See TORQUE SPECIFICATIONS . To complete
installation, reverse removal procedure.
8. Install serpentine belt and viscous fan. See SERPENTINE DRIVE BELT & VISCOUS COOLING
FAN . On A4 and A6, secure lock carrier to body. See LOCK CARRIER .
CAMSHAFTS

CAUTION:

DO NOT start engine for about 30 minutes after installing camshafts.


Hydraulic valve lifters must bleed down or valves may strike pistons. With
ignition off, rotate crankshaft by hand 2 full revolutions before starting
engine to ensure valves do not strike pistons.

NOTE:

For help in identifying components and component locations, refer to


illustrations. See Fig. 104 and Fig. 105 .

Removal

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1. Remove timing belt. See TIMING BELT . Turn crankshaft back slightly (moves pistons off Top
Dead Center TDC).
2. Remove camshaft drive sprocket bolt. Remove camshaft drive sprocket using puller. See Fig. 77 .
3. Disconnect Camshaft Position (CMP) sensor housing and sensor rotor. Remove rear (inboard) timing
belt guard. Remove valve cover.
4. Clean camshaft drive chain and chain sprockets. Moving only the camshafts, align the marks on the
camshaft sprocket with arrows on the bearing caps. See Fig. 80 . Using paint, mark chain and
sprockets opposite arrows on bearing caps. Distance between both arrows (and between paint
markings) is 16 rollers on the chain.

Fig. 80: Identifying Marks On Camshaft Chain Gears & Arrows On Camshaft Bearing Caps
Courtesy of VOLKSWAGON UNITED STATES INC.
5.
CAUTION:

Do NOT overtighten camshaft adjuster or it will be damaged.

Carefully compress camshaft adjuster using Chain Tensioner (3366). Tighten to keep slight pressure
on chain between camshafts. DO NOT overtighten camshaft adjuster. See Fig. 81 .

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Fig. 81: Compressing Camshaft Adjuster Using Chain Tensioner (3366)


Courtesy of VOLKSWAGEN UNITED STATES, INC.
6. Unbolt camshaft adjuster. Remove the following bearing caps. See Fig. 82 . Evenly loosen bearing
caps No. 1, 3, 5 and 7 alternately and diagonally. Identify each cap for installation in original position.
z No. 1 (Double Bearing Cap)
z No. 3 (Center Bearing Cap)
z No. 5 (Cap Located Behind Chain)
z No. 7 (Cap Next To Camshaft Adjuster)

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Fig. 82: Identifying Camshaft Bearing Caps


Courtesy of AUDI OF AMERICA, INC.
7. Evenly loosen bearing caps No. 2 and No. 4 alternately and diagonally. Remove and place in correct
order for reassembly in original position.
8. Remove camshafts together with camshaft adjuster. If reusing camshafts, inspect for wear. See
CAMSHAFT table under ENGINE SPECIFICATIONS.
9. To check camshaft axial (end) play, see CYLINDER HEAD under OVERHAUL.
Installation

NOTE:

This is an interference engine. Pistons must not be positioned at TDC during


assembly.

1. Apply clean engine oil to camshaft contact surfaces. Install chain onto both camshafts. Install
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2.
3.

4.

5.
6.
7.

camshaft adjuster between camshafts. Before installing camshafts, verify position of chain and chain
sprockets (paint markings). See Fig. 80 . Distance between both arrows (and between paint markings)
is 16 rollers on the chain.
Install both camshafts in cylinder head together with camshaft adjuster.
Install camshaft bearing capsNo. 2 and No. 4. See Fig. 82 . Casting of arrows on intake side point to
chain. On exhaust side, arrows point to exhaust manifold. Evenly tighten bearing caps No. 2 and 4 for
both camshafts, alternating in a diagonal sequence. See TORQUE SPECIFICATIONS .
Lightly bearing caps No. 1 and 7 mating surface with (AMV 174 004 01) sealant before installation.
See Fig. 82 . Install bearing caps No. 1, 3, 5 and 7. Evenly tighten bearing cap bolts to specification.
See TORQUE SPECIFICATIONS .
Remove Chain Tensioner (3366). Before installing valve cover and new gasket, apply small amount
of sealant at 4 corners of cylinder head mating surface.
Install timing belt. See TIMING BELT .
To complete installation, reverse removal procedure.

VALVE LIFTERS

WARNING:

ALWAYS release fuel pressure before disconnecting fuel injection related


component. DO NOT allow fuel to contact engine or electrical components.

CAUTION:

DO NOT start engine for about 30 minutes after installing camshafts.


Hydraulic valve lifters must bleed down or valves may strike pistons. Rotate
crankshaft by hand 2 full revolutions before starting engine to ensure valves
do not strike pistons.

NOTE:

Valve lifters are not repairable or adjustable. Replace faulty lifters. Irregular
valve train noise is normal when starting engine.

Checking

1. Start engine and run until cooling fan cycles at least once. Increase engine speed to 2500 RPM for 2
minutes or test drive vehicle and observe valve train noise. If valve train noise is still considered
noisy, go to next step.
2. Turn engine off. Remove valve cover. Rotate crankshaft until camshaft lobes point upward on lifter
being checked. Using a wooden or plastic wedge, push down on top of lifter. See Fig. 83 .

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Fig. 83: Placement Of Wedge On Lifter (Push Down)


Courtesy of VOLKSWAGEN UNITED STATES, INC.
3. Try inserting a .008" (.20 mm) feeler gauge between top of lifter and camshaft. If feeler gauge fits
between top of lifter and camshaft, replace faulty lifter.
4. If irregular valve noise occurs repeatedly on short trips and disappears after extended driving, oil
check valve must be replaced. See OIL CHECK VALVE REPLACEMENT .
CAMSHAFT OIL SEALS

NOTE:

For help in identifying components and component locations, refer to Fig.


104 and Fig. 105 .

NOTE:

Various oil seal configurations may be used, ensure proper seal application
is used.

Removal (Left Side Camshaft)

1. Remove timing belt. See TIMING BELT .


2. Remove camshaft drive sprocket bolt. Remove camshaft drive sprocket.
3. Unscrew inner part of Oil Seal Extractor (3240) oil seal extractor 2 turns (about 3 mm) out of outer
part and lock with knurled screw. See Fig. 84 .

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Fig. 84: Identifying Camshaft Oil Seal Extractor (3240)


Courtesy of VOLKSWAGEN UNITED STATES, INC.
4. Lubricate thread head of Oil Seal Extractor (3240), place it in position while applying firm pressure
screw it as far as into oil seal. Loosen knurled screw and turn inner part of extractor against camshaft
until oil seal has been extracted.
Installation (Left Side Camshaft)

DO NOT oil sealing lip or outer circumference of oil seal. Clean contact surface and sealing surface. Using
Seal Installer (3241/2 guide sleeve and 3241/6 bolt), install new camshaft oil seal flush into cylinder head.
See Fig. 85 . Install camshaft drive sprocket. Reassemble in reverse order.

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Fig. 85: Identifying Camshaft Oil Seal Installer Usage


Courtesy of VOLKSWAGEN UNITED STATES, INC.
Removal (Right Side Camshaft)

1. Remove timing belt. See TIMING BELT .


2. Unbolt Camshaft Position (CMP) sensor housing. Remove CMP sensor shutter bolt and conical
washer. See Fig. 105 . Noting installed position for reassembly, carefully pry off shutter.
3. Screw Oil Seal Extractor (2058/1 bolt) into camshaft. See Fig. 86 . Unscrew inner part of (2058) 2
turns (about 3 mm) out of outer part and lock with knurled screw. See Fig. 87 .

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Fig. 86: Installing Camshaft Oil Seal Extractor (2085/1)


Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 87: Removing Camshaft Oil Seal


Courtesy of VOLKSWAGEN UNITED STATES, INC.
4. Lubricate thread head of oil seal extractor, and place it in position. While applying firm pressure,
screw it as far as into oil seal. Loosen knurled screw and turn inner part of extractor against camshaft
until oil seal has been extracted.
Installation (Right Side Camshaft)

1. Clean contact surface and sealing surface (head and camshaft). DO NOT oil sealing lip or outer
circumference of oil seal. Using seal installer with Press Sleeve (3241/1) and Bolt (3241/3), install
new camshaft oil seal flush into cylinder head. See Fig. 88 .

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Fig. 88: Identifying Camshaft Seal Installer Usage (3241/1 & 3241/3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
2. Install CMP sensor and conical washer in original position. See Fig. 105 . Install and tighten bolt. See
TORQUE SPECIFICATIONS . Reassemble in reverse order.
DRIVE PLATE (A/T)

NOTE:

The following procedure is given assuming the transmission has been


removed or the engine has been removed for servicing.

Removal

1. Holding drive plate stationary, remove drive plate bolts. Manufacturer requires using NEW drive plate
bolts on installation.
2. BEFORE removing shims and drive plate, note installed position for reassembly reference. See Fig.
89 . Mark drive plate and shims for reference.

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Fig. 89: Identifying Washer, DrivePlate & Shim


Courtesy of VOLKSWAGEN UNITED STATES, INC.
3. For vehicles equipped with an automatic transmission, inspect bushing at crankshaft flange. See Fig.
91 . See BEARING BUSHING FOR TORQUE CONVERTER .
Installation

1. Install drive plate and shims in original locations. Install OLD bolts into flange. Check dimension "A"
at 3 evenly space points. Find average of readings. Specification should be approximately 12.3 mm
(0.484". See Fig. 90 . If specification is not correct, different size shims are available from
manufacturer to obtain correct clearance.

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Fig. 90: Calculating Drive Plate Installed Dimension For Shim Selection
Courtesy of VOLKSWAGEN UNITED STATES, INC.
2. When correct shim size is installed, install NEW drive plate bolts. Tighten to specification. See
TORQUE SPECIFICATIONS .
3. If installing new crankshaft or engine block, ensure torque converter bearing bushing is installed
correctly. See Fig. 91 . See BEARING BUSHING FOR TORQUE CONVERTER .

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Fig. 91: Identifying Location Of Bearing Bushing For Torque Converter


Courtesy of VOLKSWAGEN UNITED STATES, INC.
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DUAL-MASS FLYWHEEL (M/T)


Removal

NOTE:

The following procedure is given assuming the transmission the engine has
been removed for servicing.

1. Remove sealing plug from hole in left side of cylinder block. Position crankshaft to Top Dead Center
(TDC) for cylinder No. 1. Ensure TDC hole can be seen or felt through sealing plug hole.
2. Install Crankshaft Holder (3242) into sealing plug hole to prevent crankshaft from rotating. See Fig.
69 .
3. Mark the position of the dual-mass flywheel (M/T) with the block and the crank. Loosen the bolts in a
cross pattern and remove drive plate.
4. Inspect pilot needle bearing. See PILOT NEEDLE BEARING (MANUAL TRANSMISSION) . If
installing new drive plate, install pilot needle bearing.
Installation

NOTE:

Manufacturer requires replacing flywheel bolts on installation.

Install flywheel in reverse order of removal. Tighten NEW bolts to specification. See TORQUE
SPECIFICATIONS . If reusing original pressure plate and flywheel, check for White alignment marks. If
present, align marks on reassembly.
PILOT NEEDLE BEARING (MANUAL TRANSMISSION)
Removal & Installation

1. Remove transmission. For M/T, see appropriate article in CLUTCHES.


2. Remove flywheel. See DUAL-MASS FLYWHEEL (M/T) .
3. Using an appropriate puller, remove pilot needle bearing. See Fig. 92 . To complete installation,
reverse removal procedure. Use Bearing Driver (3264), or equivalent, to install pilot needle bearing.

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Fig. 92: Removing Pilot Needle Bearing


Courtesy of VOLKSWAGEN UNITED STATES, INC.
BEARING BUSHING FOR TORQUE CONVERTER

NOTE:

Ensure completed engine or crankshaft has bearing bushing installed. The


bushings must be installed before installing the driveplate. See Fig. 91 .

Removal and installation procedure not provided by manufacturer. To gain access to bearing bushing, see
DRIVE PLATE (A/T) .
CRANKSHAFT REAR OIL SEAL

NOTE:

If possible, replace oil seal together with flange.

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Removal & Installation

1. Remove transmission. For M/T, see appropriate article in CLUTCHES. For A/T, see
TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING.
2. Remove drive plate or flywheel. See DRIVE PLATE (A/T) or DUAL-MASS FLYWHEEL (M/T) .
3. If not replacing seal together with flange, go to step 5 . If replacing seal together with flange, drain
engine coolant before removing flange. See DRAINING COOLING SYSTEM . Remove flange and
oil seal together.
4. Install NEW flange and oil seal. Tighten crankshaft oil seal carrier bolts to specification. See
TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure. Fill and bleed
cooling system. See COOLING SYSTEM BLEEDING .
5. Using Seal Extractor (10-221), remove seal from carrier. See Fig. 93 . Clean running and sealing
surfaces. DO NOT lubricate sealing lip or outer edge of seal before installing. Using assembly aid (if
provided with new seal ) press seal onto crankshaft. Using Seal Installer (2003/3), press new seal into
carrier. See Fig. 94 . To complete installation, reverse removal procedure.

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Fig. 93: Identifying Seal Extractor (10-221) Usage


Courtesy of AUDI OF AMERICA, INC.

Fig. 94: Installing Crankshaft Rear Main Seal


Courtesy of AUDI OF AMERICA, INC.
THERMOSTAT

NOTE:

Obtain radio code before disconnecting battery.

Removal & Installation

1. Drain engine coolant. See DRAINING COOLING SYSTEM .


2. Remove complete front bumper assembly. See FRONT BUMPER . Place lock carrier in service
position. See LOCK CARRIER .
3. Remove serpentine belt. See SERPENTINE DRIVE BELT & VISCOUS COOLING FAN .
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4. Remove timing belt guard. Remove timing belt from camshaft sprockets. See TIMING BELT .
5. Remove thermostat housing bolts. Housing is located near front of passenger side cylinder head. See
Fig. 95 and Fig. 96 . Remove thermostat.
6. Lube new O-ring gasket with coolant. Install thermostat with bleeder valve at top (12 o'clock)
position. Tighten thermostat housing bolts to specification. See TORQUE SPECIFICATIONS . To
complete installation, reverse removal procedure.
7. Fill and bleed cooling system. See COOLING SYSTEM BLEEDING .

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Fig. 95: Exploded View Of Water Pump & Engine Cooling System Components (1 of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 96: Exploded View Of Water Pump & Engine Cooling System Components (2 of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
WATER PUMP

NOTE:

Obtain radio code before disconnecting battery.

NOTE:

Water pump is driven by the timing belt. Timing belt removal is required.

Removal & Installation

1. Drain engine coolant. See DRAINING COOLING SYSTEM . Remove complete front bumper
assembly. See FRONT BUMPER . Disconnect all necessary electrical connectors from front of
vehicle.
2. Remove complete front bumper assembly. See FRONT BUMPER . Place lock carrier in service
position. See LOCK CARRIER .
3.
CAUTION: Viscous fan is mounted with a left-handed thread. Turn clockwise to
loosen.
Remove serpentine belt and viscous fan. See SERPENTINE DRIVE BELT & VISCOUS
COOLING FAN .
4. Remove timing belt guard. Remove timing belt from camshaft sprockets. See TIMING BELT .
5. Remove bracket for viscous fan. Remove water pump bolts and remove pump. See Fig. 95 and Fig.
96 .
6. To install, reverse removal procedure. Install new gasket with water pump. Tighten water pump
fasteners to specification. See TORQUE SPECIFICATIONS . Fill and bleed cooling system. See
COOLING SYSTEM BLEEDING .
OIL PAN(A4 & A6)

CAUTION:

Wear eye protection

NOTE:

Obtain radio code before disconnecting battery. For help in identifying


components and component locations, refer to illustrations Fig. 108 -Fig.
109 .

Removal (Lower Pan- A4 & A6)

1. Disconnect negative battery cable.


2. Remove engine noise insulator (undercover). See Fig. 12 . Drain engine oil.
3. Unbolt left and right swaybar stabilizer bracket bolts (4) from mounting bracket. See Fig. 98 . Lower
swaybar stabilizer not more than 10cm (3.94 INCHES) and secure with heavy wire.
4. If vehicle is equipped with automatic transmission, unbolt oil cooler pipe (line) bracket from right side
oil pan.
5. Remove lower oil pan. To install oil pan (lower), see INSTALLATION (LOWER OIL PAN- A4 &
A6) .
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Installation (Lower Oil Pan- A4 & A6)

1. Ensure oil pan surfaces are clean and dry. Remove residual sealant from oil pan, if necessary, with
hand drill and plastic brush instead of a flat scrapper. See Fig. 99 . Install gasket.
2. Install 2 bolts diagonal to each other (to hold up pan). Install the rest of the bolts and hand tighten.
3.
NOTE:
If engine is out of car, ensure oil pan is aligned with cylinder block on
flywheel side.
Starting at center and moving outward, tighten lower oil pan to upper oil pan bolts to 10 N.m (89
INCH lbs.). Tighten oil pan drain plug 30 N.m (22 ft. lbs.). Wait 30 minutes before filling with engine
oil. Tighten all bolts to specification. See TORQUE SPECIFICATIONS .
4. To complete installation, reverse removal procedure. Fill and bleed cooling system. See COOLING
SYSTEM BLEEDING .
Removal (Upper Oil Pan- A4 & A6)

1. Disconnect negative battery cable. Remove oil dipstick. Unbolt oil dipstick tube at front of cylinder
head. Remove oil dipstick tube.
2. Remove engine noise insulator (undercover). See Fig. 12 . Drain engine oil.
3. Move lock carrier into service position. See LOCK CARRIER . This will allow servicing of front
engine components and facilitate removal of oil pan.
4. Open coolant expansion tank cap, drain cooling system at radiator. Open the coolant pump bearing
housing drain plug. Located at bottom of block near transmission bell housing, drivers side of vehicle.
See Fig. 32 -Fig. 33 . If vehicle is equipped with automatic transmission, unbolt oil cooler pipe (line)
bracket from right side oil pan.
5. Position Engine Support (10-222A) with (10-222A/3) engine support adapter, or equivalent, on bolted
flanges of fenders. Connect support bracket to front and rear engine lifting eyes. Lift up engine as far
as possible. DO NOT use excessive force to raise engine.
6. Cut tie wraps and open bracket supporting starter wiring. See Fig. 97 . Disconnect electrical
connection at starter.

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Fig. 97: Identifying Starter Cable Wiring Harness Retainer


Courtesy of AUDI OF AMERICA, INC.
7. Unbolt torque arm at front of engine.
8. Unbolt coolant pipe from oil pan at front of engine. Disconnect oil pressure switch at left side of oil
pan. Disconnect 2 oil cooler lines at oil cooler below oil filter.
9. Remove lift and right nuts from lower engine mount. See Fig. 50 . Mark positions threaded assembly
and guide sleeves of left and right engine mount locating sleeves from bottom. See Fig. 50 . Remove
left and right engine mount nuts. Using hoist, lift engine up as far as possible.
10.
NOTE:
To avoid changing wheel alignment settings, DO NOT remove the rear
subframe bolts. Loosen or lower only the front subframe bolts.
First remove front bolts (2) and (3) from left and right-sides of subframe. Then remove bolts (1). See
Fig. 98 . Swing stabilizer down. Remove starter.
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Fig. 98: Identifying Location Of Engine Mount / Swaybar Bracket Mounting Points To
Subframe
Courtesy of AUDI OF AMERICA, INC.
11. With bolts still installed, using a screw jack, lower front subframe, (DO NOT let weight of subframe
rest solely on bolt heads). This should allow access to oil pan bolt.
12. Remove oil pan (lower part) and oil pan (upper parts). Remove both brackets for oil supply pipe. See
Fig. 131 . Pull longer oil supply pipe out of oil pan upper part.
13. Remove oil pump mounting bolts (remove the bolts but DO NOT remove the oil pump). Remove
shorter oil supply pipe. See Fig. 133 .
14.
NOTE:
When removing upper oil pan. There are two M6 and two M8 bolts that
are install vertically in the rear of the oil pan in front of connection
between engine and transmission. Ensure these bolts are removed or
damage to parts may occur.

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Remove bolts from between oil pan (upper part) and transmission. Unbolt oil pan (upper part) from
engine.
15. Remove appropriate lower and/or upper parts of oil pan from engine as needed for repair.
Installation (Upper Oil Pan- A4 & A6)

NOTE:

Ensure excessive sealant is not used, too much sealant may find its way into
the oil pan and may plug the oil pickup screen.

1. Ensure oil pan surfaces are clean and dry. Remove residual sealant from oil pan, if necessary, with
hand drill and plastic brush instead of a flat scrapper. See Fig. 99 . Apply a bead of 0.04-0.12 in (2-3
mm) sealant (D 454 300 2) on the cylinder block. Ensure sealant is applied at overlap joints between
sealing flanges and oil pan at front and rear.

Fig. 99: Cleaning Sealing Mating Surface Using Plastic Wheel


Courtesy of VOLKSWAGEN UNITED STATES, INC.
2. Install all the bolts between the pan and the block, and between the pan and transmission. Tighten all
bolts finger tight.
3. With all bolts in place, tighten upper oil pan to engine bolts to 5 N.m (44 in. lbs.). Tighten oil pan to
transmission housing bolts to 45 N.m (33 ft. lbs.).In second step, tighten upper oil pan to engine block
bolts again in a diagonal sequence to 15 N.m (11 ft. lbs.). Tighten M10 bolts between upper oil pan
and engine block to 45 N.m (33 ft. lbs.).
OIL PAN (PASSAT)

CAUTION:

Wear eye protection. Obtain radio code before disconnecting battery.

NOTE:

No upper oil pan removal or installation procedure provided by vehicle


manufacturer. For help in identifying components and component locations,
refer to illustrations Fig. 109 -Fig. 110 .

Removal (Lower Pan - Passat)

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1. Disconnect negative battery cable.


2. Remove engine noise insulator (undercover). See Fig. 12 . Drain engine oil.
3. Remove lower oil pan.
Installation (Lower Oil Pan)

NOTE:

Oil pan may be sealed with either a gasket or silicone, check parts for proper
gasket type.

1. For oil pan that uses silicone sealer, go to step 3 . For oil panthat use a solid gasket, ensure oil pan
surfaces are clean and dry. Remove residual sealant from oil pan, if necessary, with hand drill and
plastic brush instead of a flat scrapper. See Fig. 99 . Install new gasket to oil pan. Install 4 bolts
diagonal to each other (to hold up pan). Install the rest of the bolts and hand tighten.
2. Starting from middle and working outward, final tighten lower oil pan to upper oil pan bolts to 10
N.m (89 INCH lbs.). Tighten oil pan drain plug to 30 N.m (22 ft. lbs.).
3. For oil pans that use silicone sealer, ensure oil pan surfaces are clean and dry. Remove residual
sealant from oil pan, if necessary, with hand drill and plastic brush instead of a flat scrapper. See Fig.
99 .
4. Apply a bead of 0.04-0.12 in (2-3 mm) sealant (D 454 300 2) on the oil pan flange. See Fig. 100 .
Ensure sealant is applied at overlap joints between sealing flanges and oil pan at front and rear. Install
pan immediately and tighten all bolts lightly.

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Fig. 100: Apply Sealant To Oil Pan Flange Surface(Passat)


Courtesy of VOLKSWAGEN UNITED STATES, INC.
5. Starting at center and moving outward, tighten lower oil pan to upper oil pan bolts to 10 N.m (89
INCH lbs.).Tighten oil pan drain plug 30 N.m (22 ft. lbs.). Wait 30 minutes before filling with engine
oil. Tighten all bolts to specification. See TORQUE SPECIFICATIONS . To complete installation,
reverse removal procedure.
OVERHAUL
NOTE:

For help in identifying components and component locations, refer to


illustrations. See Fig. 95 and Fig. 96 . Also see Fig. 101 to Fig. 110 .

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Fig. 101: Exploded View Of External Engine Block Components (1 of 2)


Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 102: Exploded View Of External Engine Block Components (2 of 2)


Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 103: Exploded View Of External Cylinder Head Components (Left Side Shown)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 104: Exploded View Of Cylinder Head Components (1 of 2)


Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 105: Exploded View Of Cylinder Head Components (2 of 2)


Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 106: Exploded View Piston & Rod Assembly Components


Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 107: Exploded View Crankshaft & Lower Engine Block Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 108: Exploded View Of Oil Pump & Other Oiling System Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 109: Exploded View Of Oil Pan, Oil Cooler & Other Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 110: Identifying Components Of Chain Driven Oil Pump


Courtesy of VOLKSWAGEN UNITED STATES, INC.
CYLINDER HEAD

CAUTION:

DO NOT start engine for about 30 minutes after installing camshafts.


Hydraulic valve lifters must bleed down or valves may strike pistons. Rotate
crankshaft by hand 2 full revolutions before starting engine to ensure valves
do not strike pistons.

Cylinder Head Resurfacing

1. Measure cylinder head warpage, measure at several points along gasket surface using straight edge
and feeler gauge. See Fig. 111 .

Fig. 111: Checking Cylinder Head For Warpage


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Courtesy of VOLKSWAGEN UNITED STATES, INC.


2. If warpage exceeds specification, machine cylinder head. See CYLINDER HEAD table under
ENGINE SPECIFICATIONS. If machining causes cylinder head height to be less than specification,
replace cylinder head. When checking dimensions for cylinder head height, measure at (A) through
the holes for the head bolts. See Fig. 112 .

Fig. 112: Checking Cylinder Head Height


Courtesy of VOLKSWAGEN UNITED STATES, INC.
Camshaft Axial Play

Measure camshaft axial play with lifter and camshaft chain removed, and camshaft bearing caps No. 2. and
No. 4. installed. See Fig. 82 . See CAMSHAFT table under ENGINE SPECIFICATIONS. See Fig. 113 .

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Fig. 113: Checking Camshaft Axial Play


Courtesy of VOLKSWAGEN UNITED STATES, INC.
Valves

WARNING:

Sodium-filled exhaust valves must not be disposed of until they have been
properly treated as follows: Saw the valves into two sections using a metal
saw at a point between the center of the valve stem and the valve head. The
valves must not come into contact with water when this is done. Throw the
valves into a bucket of water (not more than ten at a time) and step back. A
sudden chemical reaction will occur during which the sodium filling burns.
After this treatment the valves can be disposed of as normal scrap.

Valves must not be refaced by grinding. Hand lap only. If lapping does not produce proper sealing, check
valve seat. See VALVE SEAT .
Valve Guides Checking

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NOTE:

Intake valve stem diameter differs from exhaust valve stem diameter. Use
intake valves in intake guides and exhaust valves in exhaust guides when
measuring valve guide wear.

1. To measure valve guide wear, attach dial indicator to cylinder head. Insert valve into guide until valve
stem tip is even with top end of guide.
2. Lightly push edge of valve head against dial indicator tip. Zero dial indicator. Push valve away from
dial indicator, in direction opposite of camshaft axis.
3. Maximum allowable deflection is .032" (.8 mm) on intake or exhaust valve. See Fig. 114 . If
deflection does not exceed specification, guide is okay. If deflection exceeds specification, recheck
using new valve. If deflection still exceeds specification, replace worn guides.

Fig. 114: Checking Valve Guide Wear


Courtesy of VOLKSWAGEN UNITED STATES, INC.
Valve Guide Removal

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NOTE:

Valve guide replacement procedure is for Passat only. No procedure is given


from manufacturer for Audi A4 or A6.

NOTE:

First ensure valve seats and cylinder head sealing surface can be refaced. If
a problem is found in either case, valve guides should not be replaced.

1. Set the cylinder support (3361) as soon. See Fig. 115 .

Fig. 115: Identifying Cylinder Head Support Fixture (3361) & Settings
Courtesy of VOLKSWAGEN UNITED STATES, INC.
2. Install mounting pins for cylinder head bolts (A) into threaded holes (2) and (3). See Fig. 115 .
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3. Install pin (B) into relevant hole for valve angle.


z Outer inlet valves: 21.5 degrees
z Center Inlet valve: 15 degrees
z Exhaust valve: 20 degrees
4. Press worn valve guides out with drift (3360) from camshaft side. See Fig. 116 .

Fig. 116: Pressing Valve Guide From Cylinder Head


Courtesy of VOLKSWAGEN UNITED STATES, INC.
Valve Guide Installing

NOTE:

When the shoulder on guide makes contact, the pressure must not exceed
10 kN (1.0 ton). Shoulder may break off if pressure is exceeded.

1. Coat new valves guides with clean oil. Using drift (3360) press into cold cylinder head from camshaft
side. See Fig. 116 . Stop when shoulder makes contact.
2. Ream guides out with hand reamer (3363), ensure plenty of cutting fluid is used.
3. Reface valve seats. See VALVE SEAT .
Valve Seat

NOTE:

When repairing engines with leaking valves, it is not sufficient to replace or

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renew valve seats and valves. It is also necessary to check the valve guides
for wear. This is particularly important on high mileage engines. The valve
seats should only be refaced just enough to produce a perfect seating
pattern. The maximum permissible refacing dimension must be calculated
before beginning refacing. If the refacing dimension is exceeded, the
function of the hydraulic valve lifters can no longer be guaranteed and the
cylinder head should be replaced. If the valve is to be replaced as part of a
repair, use a new valve for the calculation.
1. Insert valve into guide. Press valve tightly against valve seat. Lay a straightedge across top of cylinder
head. Measure distance between valve stem tip and bottom of straightedge. This is valve installed
height. If a new valve is going to be installed, use new valve to make this measurement.
2. If valve stem height is less than 1.339" (34.0 mm) on intake valve (outer), 1.327" (33.7 mm) intake
valve (center), or 1.354" (34.4 mm) on exhaust valve, install a new valve and measure again. See Fig.
117 .
3. If valve stem height measurement is still less than specification, replace cylinder head. If valve stem
height exceeds specification, seat can be machined; however, DO NOT machine enough material
away from seat to cause valve stem height to be less than minimum specification.

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Fig. 117: Calculating Stem Height & Valve Seat Refacing Dimension
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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Valves Stem Seals Replacement (Head Installed)

1. Remove camshafts. See CAMSHAFTS under REMOVAL & INSTALLATION.


2. Remove valve lifters and place them with contact surface downward. During removal make sure
lifters are not interchanged.
3. Remove spark plugs with spark plug removal tool (3122B).
4. Set piston of relevant cylinder to Bottom Dead Center (BDC).
5. Screw VW pressure hose (653/3) into spark plug thread. See Fig. 118 .
6.
NOTE:
DO NOT remove valve springs at this time.
Secure (3362) valve spring compressor to cylinder head with tool securing bolt and position installing
tool for compressing valve springs to following positions. Outer intake valves: lower position, Center
intake valve: upper position and Exhaust valve: lower position. See Fig. 118 .

Fig. 118: Installing Air Pressure Hose (653/3) Into Spark plug Hole & Valve Spring Compressor
(3362) Onto Cylinder Head.
Courtesy of VOLKSWAGEN UNITED STATES, INC.
7. Connect pressure hose to compressed air system supplying at least 6 bar (87 psi) and remove valve
springs.
8. Remove valve stem seals with puller (3364) for valve shaft seal. See Fig. 119 .

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Fig. 119: Identifying Valve Stem Seal Puller (3364)


Courtesy of VOLKSWAGEN UNITED STATES, INC.
Valves Stem Seals Installing (Head Installed)

1. Slide plastic sleeve (A) supplied over relevant valve stem. This will prevent the new valve stem seal
(B) from being damaged. See Fig. 120 .
2. Place new valve stem seal into installation tool (3365).
3. Oil valve stem seal sealing lip and press carefully onto the valve guide. See Fig. 120 . To assemble,
reverse removal procedures.
CAUTION:

DO NOT start engine for about 30 minutes after installing camshafts.


Hydraulic valve lifters must bleed down or valves may strike pistons.
Rotate crankshaft by hand 2 full revolutions before starting engine to
ensure valves do not strike pistons.

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Fig. 120: Identifying Plastic Sleeve Placement, Valve Stem Seal & Installation Tool (3365)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
Valve Lifters

Valve lifter operation is checked with lifters installed in vehicle. See VALVE LIFTERS under REMOVAL
& INSTALLATION.
CYLINDER BLOCK ASSEMBLY

CAUTION:

DO NOT scribe or scratch piston crown. Surface has a coating that must not
be damaged.Before removing or disassembling components, mark
components for assembly and installation in original location and
orientation.

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Fitting Pistons

CAUTION:

For accurate measurement, do NOT measure piston bores with cylinder


block mounted on an engine stand.

1. Measure cylinder bore diameter in 3 places: at center of bore and .39" (10 mm) from top and bottom
of bore. If cylinder bore diameter is not within specification, hone cylinder bore until diameter meets
first oversize specification. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS.
2. Measure piston diameter at 90-degree angle to piston pin, about .39" (10 mm) from bottom of piston
skirt. See Fig. 121 . If piston diameter is not within specification, replace piston. See PISTONS,
PINS & RINGS table under ENGINE SPECIFICATIONS. When measuring piston diameter,
maximum allowable difference between actual measurement and standard specification is .0016" (.04
mm).

Fig. 121: Measuring Piston Diameter


Courtesy of VOLKSWAGEN UNITED STATES, INC.
Piston Rings

1. Install piston ring with TOP mark (if present) facing upward. Insert ring from bottom of cylinder
block to a depth of about .591" (15 mm) to measure ring end gap. See Fig. 122 .

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Fig. 122: Checking Piston Ring End Gap


Courtesy of VOLKSWAGEN UNITED STATES, INC.
2. Measure ring side clearance. See Fig. 123 . If ring end gap and side clearance are not within
specification, replace ring and/or piston as necessary. See PISTONS, PINS & RINGS table under
ENGINE SPECIFICATIONS. Space ring end gaps 120 degrees apart.

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Fig. 123: Checking Piston Ring Side Clearance


Courtesy of VOLKSWAGEN UNITED STATES, INC.
Piston & Connecting Rod Assembly

1.
2.
3.
4.
5.

Mark connecting rod and piston assemblies to identify which cylinder they belong to.
If replacing rods, replace entire set.
Replace bearing cap bolts and nuts with NEW nuts and bolts after each use.
Ensure arrow on piston (top or bottom) faces front end of engine when piston is installed.
NOTE:

This engine may be equipped with one of 2 different design connecting


rods as of 1998.

A serrated connecting rod was placed into production on some engines starting in 1998. To identify
the connecting rod type, see Fig. 124 .

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Fig. 124: Identifying Connecting Rod Type (From 1998)


Courtesy of VOLKSWAGEN UNITED STATES, INC.
6.
CAUTION:

Incorrect tightening torque could result in engine damage.

The different design connecting rods use different size bolts. The serrated connecting rod uses M8 and
M8.5 bolts. ALWAYS measure the threads as different tightening torques are used. See TORQUE
SPECIFICATIONS .
7. Make sure connecting rods are installed in original positions. See Fig. 125 .

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Fig. 125: Exploded View Of Piston & Connecting Rod


Courtesy of VOLKSWAGEN UNITED STATES, INC.
8. If piston pin is difficult to remove, heat piston to 140F (60C).
Connecting Rod Bearings

1. If using Plastigage to check rod bearing oil clearance, DO NOT fully tighten bearing cap bolts.
Instead, tighten bolts to 15 ft. lbs. (20 N.m). See Fig. 106 . Lubricate threads and contact surface.
2. If rod bearing oil clearance is not within specification, replace rod bearings. See CRANKSHAFT,
MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.
3. Replace rod bearing cap bolts after first use. Tighten bolts to specification. See TORQUE
SPECIFICATIONS .
Crankshaft & Main Bearings

1. Main bearing cap No. 1 is located at front (timing belt) end of engine. Main bearing cap No. 4 is
located at rear of engine. See Fig. 126 .

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Fig. 126: Identifying Main Bearing Cap Locations


Courtesy of VOLKSWAGEN UNITED STATES, INC.
2. If main bearing oil clearance is not within specification, replace main bearings with oversize bearings.
See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE
SPECIFICATIONS.
3. Do NOT reuse main bearing cap bolts. Install main bearing cap side bolts hand tight before fully
tightening them. See Fig. 107 . Replace main bearing cap bolts and tighten to specification. See
TORQUE SPECIFICATIONS .
Thrust Bearing

NOTE:

For help in identifying components and component locations, refer to


illustrations. See Fig. 107 .

Mount dial indicator on oil pump with plunger contacting crankshaft web. Push crankshaft toward dial
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2.8L V6 30-VALVE

indicator. Zero dial indicator. Push crankshaft away from dial indicator. If measured distance (end play) is
not within specification, replace thrust bearing and/or crankshaft. See CRANKSHAFT, MAIN &
CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.
Cylinder Block

Measure cylinder bore diameter in 3 places: at center of bore and .39" (10 mm) from top and bottom of bore.
See Fig. 127 . If cylinder bore diameter is not within specification, hone cylinder bore until diameter meets
first oversize specification. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS. When
measuring cylinder bore, maximum allowable difference between actual measurement and standard
specification is .0031" (.08 mm).

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Fig. 127: Identifying Locations For Checking Cylinder Bore


Courtesy of VOLKSWAGEN UNITED STATES, INC.
ENGINE OILING
ENGINE LUBRICATION SYSTEM
Crankcase Capacity

See CRANKCASE CAPACITY SPECIFICATIONS table for oil capacity specifications.


CRANKCASE CAPACITY SPECIFICATIONS
(1)

Application
Audi A4 & A6
VW Passat
(1)

Qts. (L)
6.3 (6.0)
6.5 (6.2)

Includes oil filter.

Oil Pressure

With engine oil temperature at least 176F (80C), oil pressure should be 29 psi (2.0 bar) minimum at 2000
RPM.
Oil Viscosity & Type

Use a multi-grade oil with an API specification of at least SJ or SL. To select correct oil viscosity, see .

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Fig. 128: Selecting Correct Oil Viscosity


Courtesy of VOLKSWAGEN UNITED STATES, INC.
OIL PUMP

NOTE:

Two types of oil pumps where used on the 1997-98 AHA engine, the early
flange type is driven off the snout of the crankshaft with cogs that engage
the oil pump. The oil pump is part of front engine cover (flange). The second
later chain driven type is used on both the AHA and ATQ engine and is
driven by a chain, turned via a gear on the crankshaft. The oil pump is
located in the oil pan.

NOTE:

For help in identifying components and component locations, refer to


illustrations. See Fig. 108 and Fig. 110 .

Removal & Installation (Cog Driven)

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1. Oil pump drive components are located behind front engine cover. Drain engine coolant. See
DRAINING COOLING SYSTEM .
2. Remove oil pan. See OIL PAN under REMOVAL & INSTALLATION.
3. Remove timing belt. See TIMING BELT under REMOVAL & INSTALLATION.
4. Remove idler pulley. Remove crankshaft gear. Remove oil spray jet valve from front cover. Remove
timing belt tensioner. See Fig. 108 and Fig. 109 .
5. Remove lever for timing belt tensioner. Remove oil pump. To install, reverse removal procedure.
Ensure drive cog on oil pump engages crankshaft. Replace oil seal. See CRANKSHAFT FRONT
OIL SEAL under REMOVAL & INSTALLATION.
6. Tighten components to specification. See TORQUE SPECIFICATIONS .
7. Refill and bleed air from cooling system. See COOLING SYSTEM BLEEDING under REMOVAL
& INSTALLATION.
Removal & Installation (Chain Driven)

NOTE:

Oil pump is not serviceable.

NOTE:

For help in identifying chain driven oil pump components and component
locations, refer to illustrations. See Fig. 130 .

1. Drain engine coolant. See DRAINING COOLING SYSTEM .


2. Drain engine oil. Unbolt hardware from oil pan. Remove oil pan. See OIL PAN under REMOVAL &
INSTALLATION.

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Fig. 129: Identifying Front Engine Cover (Oil Seal Carrier) Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 130: Identifying Chain Driven Oil Pump Components


Courtesy of VOLKSWAGEN UNITED STATES, INC.
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3. Once access is gained, check chain tensioner condition. See CHAIN TENSIONER (OIL PUMP) .
4. Remove both brackets for oil supply pipe. See Fig. 131 .

Fig. 131: Identifying Oil Supply Pipe Securing Brackets


Courtesy of VOLKSWAGEN UNITED STATES, INC.
5. Pull longer oil supply pipe out of oil pan upper part. Unbolt chain sprocket from oil pump and pull
down off oil pump drive shaft. See Fig. 132 . Remove oil pump mounting bolts together with shorter
oil supply pipe. See Fig. 133 .

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Fig. 132: Identifying Oil Pump Sprocket Mounting Bolt


Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 133: Identifying Location Of Oil Pump Mounting Bolts


Courtesy of VOLKSWAGEN UNITED STATES, INC.
6. To install, reverse removal procedure. Insert shorter supply pipe with NEW O-ring into oil pump, then
install oil pump. Ensure chain sprocket is properly install on shaft.
7. Ensure gasket surfaces are clean of grease and oil. Use silicone gasket material on oil pan. Tighten
components to specification. See TORQUE SPECIFICATIONS .
8. Refill and bleed air from cooling system. See COOLING SYSTEM BLEEDING under REMOVAL
& INSTALLATION.
CHAIN TENSIONER (OIL PUMP)
Checking Procedure

1. Insert a screwdriver between chain and chain tensioner and pry carefully against tensioner in direction
of arrow. See Fig. 134 .
2. If there is no spring tension or drive chain is slack, chain tensioner is malfunctioning and must be
replace. To replace tensioner, timing belt and front engine cover must be removed. See OIL PUMP .

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Fig. 134: Identifying Placement Of Screwdriver For Checking Chain Tensioner


Courtesy of VOLKSWAGEN UNITED STATES, INC.
OIL CHECK VALVE REPLACEMENT

NOTE:

If irregular valve noise occurs repeatedly after short trips of driving and
disappears after long periods of driving, the oil check valve must be
replaced.

Removal & Installation

1. Gain access to oil check valves, remove intake manifold. See INTAKE MANIFOLD .
2. Remove cover under intake manifold. Locate check valves and replace them. See Fig. 135 .

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Fig. 135: Identifying Location Of Oil Check Valves & Oil Distribution Pipe
Courtesy of VOLKSWAGEN UNITED STATES, INC.
3. To install, reverse removal procedure. Tighten cover bolts to 10 N.m (89 INCH lbs.). Install intake
manifold. Tighten all bolts to specification. See TORQUE SPECIFICATIONS .
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application (1)
Camshaft Sprocket Bolt

2 2005 . 0:20:15

Ft. Lbs. (N.m)


40 (55)

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Connecting Rod Bolts (M8) (2)


Step 1
Step 2

22 (30)
Additional 1/4 Turn

Connecting Rod Bolts (M8.5) (2)


Step 1
Step 2
Crankshaft Rear Oil Seal Carrier Bolts

30 (40)
Additional 1/4 Turn
14-18 (20-25)

Cylinder Head Bolts (2)


Step 1
Step 2

44 (60)
(4)

Additional 1/2 Turn

Drive Plate Bolts (A/T) (2)


Step 1
Step 2

44 (60)
Additional 1/4 Turn

Dual-Mass Flywheel Bolts (M/T) (2)


Step 1
Step 2
Engine Support-To-Engine Mount Nut
Exhaust Manifold-To-Cylinder Head Bolt
Exhaust Pipe-To-Manifold Nut
Idler Pulley Bolt

44 (60)
Additional 1/2 Turn
33 (45)
18 (25)
18 (25)
33 (45)

Main Bearing Cap Bolts (2)


Step 1
Step 2

44 (60)
Additional 1/2 Turn
18 (25)

Main Bearing Cap Side Bolts (3)


Oil Check Valves
Oil Cooler Retaining Nuts

18 (25)
22 (30)

Oil Pan Bolts (Upper-To-Cylinder Block) (5)


M6
M8

7 (10)
15 (20)

Oil Pan Bolts (Upper-To-Transmission) (5)


M8
M10
Oil Cooler Nut
Oil Pressure Switch

18 (25)
33 (45)
22 (30)
18 (25)
18 (25)

Oil Pump Chain Sprocket Bolt (6)


Oil Pump Pressure Relief Valve Plug (6)
Oil Spray Jet Valve
Pressure Plate-To-Dual-Mass Flywheel Bolts
Screws & Nuts
M8
2 2005 . 0:20:15

30 (40)
30 (40)
18 (25)
15 (20)
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M10
M12
Starter Bolts
Upper Bolt
Lower Bolt
Timing Belt Idler Pulley Center Bolt
Timing Belt Tensioner Roller
Timing Belt Tensioner Arm-To-Block Bolt
Transmission-To-Engine Bolts
M10
M12
Torque Arm-To-Engine Bolt
Torque Converter-To-Drive Plate Bolt
Vibration Damper-To-Timing Belt Sprocket Bolt
A4 & A6
Passat

33 (45)
44 (60)
33 (45)
48 (65)
33 (45)
15 (20)
15 (20)
33 (45)
48 (65)
18 (25)
63 (85)
15 (20)
18 (25)

Vibration Damper Center Bolt (2) , (4)


Step 1
Step 2

147 (200)
Plus Additional 180 Degree
Turn

Viscous Fan-To-Pulley Nut


Using Torque Wrench & Spanner Wrench (3312)
Using Torque Wrench Without Spanner wrench
(3312)
Wheel Bolts
Camshaft Bearing Cap Bolt
Coolant Line-To-Oil Pan
Cylinder Head (Valve) Cover Nuts
Intake Manifold Bolts
Oil Pan Bolts (Lower-To-Upper Pan)
M6

27 (37)
52 (70)
89 (120)
INCH Lbs. (N.m)
89 (10)
89 (10)
89 (10)
89 (10)
89 (10)
89 (10)

Oil Pump-To-Engine Block Bolts (Flange Type) (6)


Oil Pump-To-Engine Block Bolts (Chain Driven) (6)
Screws & Nuts
M6
Thermostat Housing Bolt
Timing Belt Tensioner-To-Engine Block Bolt
Water Pump Bolts

177 (20)
89 (10)
89 (10)
89 (10)
89 (10)

(1)

Replace all self-locking nuts after removal.

(2)

Always use NEW bolts. For connecting rods, oil threads and contact areas.

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2.8L V6 30-VALVE

(3)

Hand tighten main bearing cap bolts before final tightening to specified torque.

(4)

Two turns of 90 degrees are allowed.

(5)

Oil pan requires special tightening sequence. See OIL PAN(A4 & A6) or OIL
PAN (PASSAT) for replacement procedure.
(6) For more information on oil pump tightening torques, see Fig. 108 -Fig. 110 .
ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS
Application
Displacement
Bore
Stroke
Compression Pressure
New
Wear Limit
Maximum Difference Between Cylinders
Compression Ratio
Fuel System

Specification
169 Cu. In. (2.8L)
3.248" (82.50 mm)
3.402" (86.40 mm)
131-203 psi (9-14 bar)
109 psi (7.5 bar)
44 psi (3 bar)
10.6:1
Bosch Motronic

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS


Application
In. (mm)
Crankshaft End Play
Standard
.0028-.0091 (.07-.23)
Service Limit
.0098 (.25)
Main Bearings
Journal Diameter
Standard
2.5590 (65.00)
Maximum
2.5599 (65.022)
Minimum
2.5574 (64.958)
First Undersize
2.5492 (64.75)
Maximum
2.5501 (64.77 2)
Minimum
2.5476 (64.708)
Second Undersize
2.5394 (64.50)
Maximum
2.5402 (64.522)
Minimum
2.5377 (64.458)
Third Undersize
2.5296 (64.25)
Maximum
2.5304 (64.272)
Minimum
2.5279 (64.208)
Oil Clearance
Standard
.0007-.0018 (.018-.045)
Service Limit
.0039 (.10)
2 2005 . 0:20:16

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Connecting Rod Bearings


Journal Diameter
Standard
Maximum
Minimum
First Undersize
Maximum
Minimum
Second Undersize
Maximum
Minimum
Third Undersize
Maximum
Minimum

2.12598 (54.00)
2.1268 (54.022)
2.1243 (53.958)
2.1170 (53.75)
2.1169 (53.772)
2.1144 (53.708)
2.1060 (53.50)
2.1072 (53.522)
2.1046 (53.458)
2.096 (53.25)
2.0973 (53.272)
2.0948 (53.208)

Oil Clearance (1)


Standard
Service Limit
(1)

.0006-.0024 (.015-.062)
.0047 (.12)

When checking connecting rod bearing oil clearance, tighten connecting rod bolt
to 15 ft. lbs. (20 N.m).

PISTONS, PINS & RINGS


Application

In. (mm)

Piston Pin
Piston Diameter
Standard
First Oversize
Second Oversize
Maximum Allowable Deviation From Nominal Dimension
Rings
End Gap
Ring No. 1
Standard
Service Limit
Ring No. 2
Standard
Service Limit
Ring No. 3
Standard
Service Limit
Side Clearance
Standard
Service Limit
2 2005 . 0:20:16

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(1)

3.2472 (82.48)
3.2575 (82.74)
3.2671 (82.985)
.0016 (.04)

.014-.020 (.35-.50)
.039 (1.0)
.020-.028 (.50-.70)
.043 (1.4)
.010-.020 (.25-.50)
.031 (.80)
.0008-.31 (.02-.08)
.004 (.10)

2004 Mitchell Repair Information Company, LLC.

2000 Volkswagen Passat GLX


2.8L V6 30-VALVE

(1)

Piston pin information not available from manufacturer.

CYLINDER BLOCK
Application
Cylinder Bore Diameter
Standard
First Oversize
Second Oversize
Maximum Difference Between Actual & Nominal Dimension
VALVES & VALVE GUIDES
Application
Intake Valve
Face Angle

In. (mm)
3.248 (82.51)
3.258 (82.76)
3.268 (83.01)
.0031 (.08)

Specification
(1)

45
(2)

Installed Height
Stem Diameter
Valve Guide Side Play (3)
Valve Length
Exhaust Valve
Face Angle

.2346-.2350" (5.96-5.97 mm)


.032" (.8 mm)
4.128-4.147" (104.84-105.34 mm)
(1)

45
(2)

Installed Height
Stem Diameter
Valve Guide Side
Valve Length
(1)

Play (3)

.2339-.2343" (5.94-5.95 mm)


.032" (.8 mm)
4.080-4.100" (103.64-104.14 mm)

Valves must not be refaced by grinding. Only hand lapping is allowed.

(2)

VALVE SEAT procedure gives information on valve installed height. See


CYLINDER HEAD under OVERHAUL.
(3) See CYLINDER HEAD under OVERHAUL for correct valve guide side play
checking procedure.
CYLINDER HEAD
Application
Cylinder Head Height
Maximum Warpage
Valve Guides

Specification
5.482" (139.25 mm)
.002" (.05 mm)
(1)
(2)

Valve Seat & Valve Stem Height


(1)

VALVE GUIDES procedure gives information on how to determine if valve


guides are worn enough to require replacement. See CYLINDER HEAD under
OVERHAUL.
(2) VALVE SEAT procedure gives information on how to determine if valve seats
can be resurfaced. Also see VALVE SEAT. See CYLINDER HEAD under
2 2005 . 0:20:16

Page 181

2004 Mitchell Repair Information Company, LLC.

2000 Volkswagen Passat GLX


2.8L V6 30-VALVE

OVERHAUL.
CAMSHAFT
(1)

Application
End Play
New
Service Limit
Oil Clearance
Service Limit
Lateral Run Out (Maximum)
(1)

In. (mm)

.002-.006 (.05-.15)
.008 (.20)
.004 (.10)
.0004 (.01)

Make all measurements with lifters removed.

2 2005 . 0:20:16

Page 182

2004 Mitchell Repair Information Company, LLC.

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