Volkswagen 1999 Golf User manual

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Bentley Publishers
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eBahn
®
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Select aVehicle
12/2/2005
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Select a topic
00 - General,Technicaldata
10 - Engine-Assembly
13 - Engine-Crankshaft, Cylinderblock
15 - Engine-Cylinder head,Valvetrain
17 - Engine-Lubrication
19 - Engine-Coolingsystem
20 - Fuel Supply
26 - Exhaustsystem,Emissioncontrols
Additional Information
SystemOverviews
OtherTopics
24-Valve VR6 Variable CamshaftTiming Operation
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2.8Liter VR64V EngineMechanical,Engine Code(s): BDF
12/2/2005
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00-1
Technicaldata
Enginenumber
The engine number(engine code
and serial number)are located next
to the vibration damper on the
cylinder block.
The engine numberconsists ofup to
nine characters (alphanumeric). The
first part (maximal 3 characters)
makes upthe engine code and the
second part (6 characters), the serial
number. If morethan 999,999
engines with the same engine code
are produced, the first of the six
characters is replaced with a letter.
Additionally there is a stickeron the
intake manifold with the engine code
and serial number.
The engine code is additionally
included onthe vehicledata plate.
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Technical data
12/2/2005
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00-2
Enginedata
Engine code BDF
Manufactured08.01
Cylinder application VR1)
Cylinder angle 15.0
Capacity ltr.2.8
Output kW at rpm147/6200
Torque Nmat rpm 265/3200
Borediameter mm81.0
Stroke mm90.3
Compression ratio 10.75
RON min. 98 unleaded2)
Systemdesignation Motronic ME7.1.1
1) VR = V-arrangement in compact in-linedesign
2) 91 and95 RON are also permitted, butwith reduced output
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Technical data
12/2/2005
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00-3
Engine code BDF
Exhaust emissions level LEV1)
On Board Diagnostic (OBD) OBD II
Knockregulation 2knock sensors
Oxygen sensor control 2sensors
Catalytic converter yes
Exhaust gas recirculationno
Chargingno
Secondary air systemyes
Electronic powercontrol (EPC)yes
Variable intakemanifold yes
Variable valve timing yes2)
1) LEV = Low EmissionVehicles (exhaust emissions max. 0.075 g/mi HC).
2) Two independently variable camshafts.
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Technical data
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10-1
Engine,
removing
and
installing
Special tools and
equipment
3033 Lifting
tackle
3269 Engine
bracket
3395 Engine
bracket
VW 313
Support clamp
VW 540/1 B
Supplementary
set
T10095 Puller
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Engine,removing and installing
12/2/2005
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10-2
VAG 1202 A
Workshop crane
VAG 1306 Drip tray
VAG 1331 Torque
wrench (5...50Nm)
VAG 1332 Torque
wrench (40...200
Nm)
VAG 1383 A
Engine/transmission
jack
VAS5024
Assembly tool for
spring-
type clips
VAS5085 Step
ladder
G000 100 Grease
(models with
manual
transmission)
Cable tie
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Engine,removing and installing
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10-3
Notes onremoving
The engine is removed downward togetherwith
the transmission.
CAUTION!
Whenperformingrepairwork, especially due
totheconfinedconditionsinthe engine
compartment, pay attentiontothe following:
Route all types oflines (e.g. forfuel,
hydraulics, EVAPsystem, coolant,
refrigerant, brake fluidandvacuum)as well
as electrical wiringsothat the original
positions are restored.
Ensure sufficientclearance toallmovingor
hotcomponents.
All cable ties which are opened orcut open when
removing engine, mustbe replaced in the same
position wheninstalling the engine.
Worksequence
-Remove engine cover.
-First check whether a coded radio is installed. If
so, obtainanti-theft coding.
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Engine,removing and installing
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10-4
-
With ignition switchedoff disconnect battery
Ground strap.
Note:
Mark connectorandcomponent before
disconnecting.
Repair Manual, 2.8 Liter VR6 4V Engine
Mechanical, Engine Code(s): BDF,Repair Group
24
-
Disconnect connectors fromignition coils 1...6.
-
Remove ignition coils with finalout stage for
cylinders 1...6 using puller T10095.
-Remove batteryand battery retainer.
-Remove aircleaner with intake hose:
Note:
Press buttons on hose couplings to disconnect.
-
Disconnect followinghose connections and
collect fluids that may leak out with a cloth:
1-
vacuum hose toThrottle valve controlmodule
J338-,
2-fuel return hose (withblue markings),
3-fuel supplyhose (withwhite markings).
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Engine,removing and installing
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