VOLKS CITY BEECH AVENUE CATTEDOWN PLYMOUTH PL4 0QQ Telephone: 01752 667007 Fax: 01752 663399 Email: mail@volkscity.com Notes Specified value Measured value Vehicle identification No. of cylinders Type 5/DOHC Capacity (Fiscal) cc 2226 (2210) Compression ratio :1 9,3 Suitable for unleaded petrol Yes Minimum octane rating RON 95 Ignition system Type Motronic M2.3.2 Ignition system Description Map-DI Trigger location Cam / Crankshaft Fuel system Make Bosch Fuel system Type Motronic M2.3.2 Fuel system Description MFI-s Air metering Type Mass Combined ignition and fuel ECM Yes Diagnostic socket Yes Ignition system Ignition coil Make Bosch Ignition coil supply voltage + with ballast V 11,0 Firing order 1-2-4-5-3 Tuning and emissions 38 Tuning conditions Ignition timing - basic BTDC Engine/rpm Not adjustable Ignition advance checks Engine/rpm ECM Controlled Idle speed rpm 800±30 Not adjustable Oil temperature for CO test C 80 CO level at idle speed - tailpipe (Cat) Vol. % CO 0,5 Max Not adjustable CO level at idle speed - sample pipe Vol. % CO 0,5-0,9 Not adjustable HC level at idle speed ppm 100 CO2 level at idle speed Vol. % CO2 14,5-16 O2 level at idle speed Vol. % O2 0,1-0,5 Increased idle speed for CO test rpm 2500-2800 CO content at increased idle speed Vol. % 0,3 Lambda at increased idle λ 0,97-1,03 Spark plugs Spark plugs Original equipment NGK Spark plug Type PFR7B Electrode gap mm 0,7 Spark plugs Make Beru Spark plug Type UXF56 Spark plugs Make Bosch Spark plug Type F5DPOR Electrode gap mm 0,6 Spark plugs Make Champion Spark plug Type C6BYC Electrode gap mm 0,8
Spark plugs Make NGK Spark plug Type PFR7B Electrode gap mm 0,7 Fuel system System pressure bar 4,0-4,2 Regulated pressure with vacuum bar 3,5-3,7 Crankshaft position (CKP) sensor/engine speed (RPM) sensor Ohm 1000 Injector Ohm 15-17 Service checks and adjustments Valve clearance -INLET mm Hydraulic Valve clearance -EXHAUST mm Hydraulic Compression pressure bar 9-13 Oil pressure bar/rpm 2,0/2000 Radiator cap bar 1,2-1,5 Thermostat opens C 87 Lubricants and capacities Preferred engine oil Ambient temperature range All temperatures Engine oil grade SAE 5W/30, 5W/40 Engine oil classification OEM VW 500.00 Engine oil options Engine with filter(s) litres 4,5 Other lubricants and capacities Manual gearbox oil grade SAE 75W/90 Synthetic Manual gearbox litres 2,7 Automatic transmission fluid Type Dexron II Automatic transmission (drain & refill) litres 2,7 Differential front/at litres 0,7 (AT) Differential oil grade - rear SAE 75W/90 Synthetic Differential rear litres 1,7 Cooling system litres 9,0 Brake fluid Type DOT 4 Brake fluid litres 1,0-1,5 Power steering fluid Type VW G 002 000 171 Power steering fluid litres 1,0 Tightening torques Cylinder head instructions Cylinder head Renew bolts Yes Stage 1 Tighten 40 Nm Stage 2 Tighten 60 Nm Stage 3 Tighten 180 Other engine tightening torques Main bearings Renew bolts/nuts No Main bearings Stage 1 35 Nm Main bearings Stage 2 65 Nm Big end bearings Renew bolts/nuts No Big end bearings Stage 1 30 Nm Big end bearings Stage 2 90 Oil pump to cylinder block 20 Nm 109 Sump bolts Sump drain bolt 30 Nm 54 Flywheel/driveplate Clutch to flywheel 25 Nm 62 Crankshaft pulley/damper centre bolt 150 Nm+180 Camshaft sprocket/gear 65 Nm Camshaft carrier/cap 15 Nm
Camshaft/rocker cover 10 Nm Inlet manifold to cylinder head 25 Nm 62 Exhaust manifold to cylinder head 25 Nm Spark plugs 30 Nm Lambda sensor (Oxygen) 50 Nm Knock sensor (KS) 20 Nm Chassis tightening torques 22 Front hub 22 Rear hub Steering track rod end 50 Nm Brake caliper to carrier Front 25 Nm 106 Brake caliper carrier to hub Front 125 Nm 62 Brake caliper to carrier Rear 35 Nm Brake caliper carrier to hub Rear 65 Nm Road wheels 120 Nm Starting and charging Battery V/RC(Ah) 12/110 (63) Starter motor Make Bosch Starter motor Type 0 001 108 101 Maximum cranking amps A 170-208 Brake disc and drum dimensions 78 Minimum disc thickness - ventilated Front 23 mm 105 Minimum disc thickness Rear 8 mm Minimum pad thickness Front 2 mm Minimum pad thickness Rear 2 mm Air conditioning 84 Air conditioning refrigerant Type R12 85 Air conditioning refrigerant quantity grams 1100±50 89 Air conditioning oil Type Dens Oil 6 88 Air conditioning oil quantity cm³ 300±20 Autodata Note 38 CO level Check CO level at sample pipe. Not adjustable. Autodata Note 171 Power steering fluid SLS = 2,5 litres. Autodata Note 109 Sump bolts M6 = 10 Nm M8 = 20 Nm. Autodata Note 54 Flywheel bolts Use new bolts. Tighten to 40 Nm + 180. Autodata Note 62 Use new bolts/nuts.
Autodata Note 22 Front/rear hub 190 Nm + 180 (use new bolt). Autodata Note 106 Brake caliper carrier to hub - front Twin piston caliper = 250 Nm. Autodata Note 78 Minimum disc thickness Twin piston caliper = 28 mm. Autodata Note 105 Minimum disc thickness Ventilated disc = 18 mm. Autodata Note 84 Refrigerant type 10.92 = R134a. Autodata Note 85 Refrigerant quantity 10.92 = 750-800 grams. Autodata Note 89 Oil type 10.92 Zexel = G052 154 A2 10.92 Denso = G052 300 A2. Autodata Note 88 Oil quantity 10.92 = 250-300 cm³.
Cylinder layout Timing mark Tightening sequence