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
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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
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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
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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
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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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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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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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10-5
WARNING!
Fuel systemis underpressure! Before
openingthe systemplace a clotharoundthe
connection. Thenrelease pressure by
carefully looseningthe connection.
-Seallines to avoidcontamination of fuel
system.
-Observe rules for cleanliness Page 20-14 .
-Remove center, left andright insulation trays:
Repair Manual, Body Exterior, Repair Group
50
-Pull connectors off thermalswitchand coolant
fan.
-Remove front bumper:
Repair Manual, Body Exterior, Repair Group
63
-Bring lock carrier into service position:
Repair Manual, Body Exterior, Repair Group
50
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10-6
-Remove intake manifold Page 15-16 ,
Removing and installing cylinder head cover.
Note:
Sealthe intakeports in the intake manifold orin
the cylinderheadwith a cleancloth.
-Remove ribbed belt Page 13-19 .
-Remove power steering pump on compact
bracket and place to side;hoses remain
connected:
Repair Manual, Suspension, Wheels,
Steering, Repair Group 48
-Remove securing clamps forpowersteering
pressure line.
Vehicleswithairconditioning
-Observe additionalinformation and removal
work Page 10-22 .
Models withamanual transmission
-Disconnect selector mechanism from
transmission:
Repair Manual, 5&6 Spd. Manual
Transmission 02M, RepairGroup 34
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10-7
-Separatehydraulicline to slave cylinder for
hydraulic clutch:
Repair Manual, 5&6 Spd. Manual
Transmission 02M, RepairGroup 30
Models withanautomatic transmission
-Remove gate selector levercable from
transmission:
Repair Manual, 5Spd. Automatic
Transmission 09A, Repair Group 37
Continuationforall vehicles
-Disconnect vacuum and breatherhoses from
engine.
-Separateconnectors on following
components:
Note:
Mark connectorandcomponent before
disconnecting.
Engine Coolant Temperature (ECT) sensor -
G62- withEngine Coolant Temperature
(ECT) sensor -G2-,
After-run coolant pump -V51-,
Valve -1-for camshaft adjustment -N205-,
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10-8
Camshaft adjustment valve 1(exhaust) -
N318-,
Camshaft Position(CMP) sensor -G40-,
Camshaft Position(CMP) sensor 2-G163-
,
Injectors (-N30- to -N33-,-N83-and -N84-
),
Engine speed(RPM) sensor -G28-,
KnockSensor (KS) 1-G61-,
KnockSensor (KS) 2-G66-,
Installation locations:
Repair Manual, 2.8 LiterVR64V Engine
Mechanical, Engine Code(s): BDF,Repair Group
24
-Disconnect all electric wires from transmission,
alternator and starter and them moveclear.
-Disconnect all other electrical connections from
engine as necessary and place to one side.
-Drain coolant Page 19-15 .
-Disconnect coolant hoses quick release
couplings from radiator.
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10-9
-Pull all coolant hoses off to engine using
assembly tool for spring-type clamps VAS 5024.
-Removing drive shafts:
Repair Manual, Suspension, Wheels,
Steering, Repair Group 40
-Remove pendulumsupport:
Repair Manual, Suspension, Wheels,
Steering, Repair Group 40
-Remove front exhaust pipe with catalytic
converterPage 26-1 , Removingand
installing parts of the exhaust system.
-Remove alternator and compact bracket:
Repair Manual, Electrical Equipment, Repair
Group27
-Unscrew bracket forSecondary AirInjection
(AIR)pump motor -V101-fromoil pan and
cylinder blockPage 26-26 , item - 17 -.
-Install engine bracket 3395 onto
engine/transmission jack VAG 1383 A.
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10-10
-Install engine bracket 3395 to
cylinder blockand tighten
securing nuts -1- to 40 Nm.
-Lift engine and transmission
slightly using engine/transmission
jack VAG 1383 A.
Note:
UseladderVAS 5085to remove
securing bolts.
-Unbolt engine side ofassembly
mounting from engine bracket at
top (arrows).
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10-11
Note:
UseladderVAS 5085to remove
securing bolts.
Note:
Engine with transmission must be
guided carefully, when lowering, to
prevent damage to bodywork.
-Unbolt transmission sideof
assembly mountingfromtop of
transmission carrier (arrows).
-Carefully lowerengine with
transmission.
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10-12
Securingenginetoassemblystand
Note:
When workingon the engineit should be
securedto assembly standVW 313 using engine
bracket 3269 or VW 540 and supplementary set
540/1 B.
Worksequence
-Remove transmission.
Models withanautomatic transmission
-
Secure torque converter to prevent it falling out
after engine and transmission are separated.
Continuationforall vehicles
-
Install engine bracket 3269 or VW 540and
supplementary set 540/1 B to cylinderblock.
-
Attach lifting device3033 as follows andlift
engine from engine/transmission jack VAG 1383
using workshop crane VAG1202.
Vibration damperend: Position3
Flywheel end: Position 11
-
Install engine in support clamp VW313 using
workshop crane VAG 1202 A.
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10-13
Notes oninstallation
Install in reverse sequence; notethe following
points:
-Check whether dowel sleeves forcentering
engine/transmission areinstalled in cylinder
block and install if necessary.
Models withamanual transmission
-Check clutch and clutch operating mechanism
and install:
Repair Manual, 5&6 Spd. Manual
Transmission 02M, RepairGroup 30
-Clean driveshaft splines and lightlygrease with
G000 100.
Models withanautomatic transmission
-When securing torque converter to drive plate,
only use nuts which are authorized for this
purpose, Parts catalog.
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10-14
Continuationforall vehicles
-When installing engine/transmissionassembly,
ensuresufficient clearanceto engine and
transmission mountings and radiator.
-Align engine and transmission mountings
Page 10-18 .
Note:
Torque settings forassembly mountings Page
10-21 .
-Install compact bracket andalternator:
Repair Manual, Electrical Equipment, Repair
Group27
-Install front exhaust pipe withcatalytic converter
Page 26-1 , Removingand installing parts of
the exhaust system.
-Install pendulum support:
Repair Manual, Suspension, Wheels,
Steering, Repair Group 40
-Install driveshafts:
Repair Manual, Suspension, Wheels,
Steering, Repair Group 40
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