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A4/NB TDI Engine Tools for 1999.5 Golf/Jetta and all New Beetle TDI timing belt replacement: 1. Injector pump alignment pin (3359) 2. Cam gear puller (4001) 3. Alignment guide plate (3418) 4. Cam gear holding bar (3036) 5. Toothed belt tensioning tool (T1020) 6. Stubby 5mm Driver (1/4” drive) Note paper towels stuffed into the intake to prevent “Murphy’s Law” from kicking in.This keeps you from dropping that flying spring clamp into an intake duct!! Raise up the power steering reservoir and pull the coolant reservoir hose under and to the front of the car. Cover the fender and let the coolant reservoir hang on the front of the car.upper timing belt cover and the flex line coming from the air filter going to the engine. I strongly suggest stuffing some paper towel in both holes to prevent you from dropping something into the turbo inlet. Using a 5mm 3/8” drive allen socket, remove all the front and driver side rear allen bolts except for the two by the oil filler cap. For those use the special cut-off 1/4″ drive socket that you made to remove them. Believe me when I say this, I have tried EVERY possible way to do this and I have stripped out a few heads in the process and this by far is the only true easy way to do it. Also disconnect hose to the valve cover, plug and and secure it.

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Due to known issues with the VW and Audi high pressure fuel pump system, it is mandatory that the fuel injection ECU of your vehicle be scanned before installation of the A.W.E. Tuning fuel pump parts. If any of the following fault codes are present, STOP, and do not install the A.W.E. Tuning fuel pump parts. The following codes are related to the wear issues as outlined in the factory Technical Ser- vice Bulletin 150702 and installation of pump parts will void the A.W.E. Tuning warranty: P2293 P0087 P1093 P3089 – – – – Fuel pressure regulator malfunction Fuel rail / system pressure too low Fuel trim 2 bank 1 malfunction Signal line for fuel pump electronics: electrical malfunction If upon removal of the factory pump and inspection of the camshaft and follower reveals con- ditions similar to those in the following TSB, STOP, and do not install the A.W.E. Tuning fuel pump parts. The images in the following factory TSB represent wear issues and installation of pump parts will void the A.W.E. Tuning warranty.

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Note: With a used vehicle, we suggest a penetrating spray lubricant to be applied liberally to all exhaust fasteners and allowing a significant period of time for the chemical to lubricate the threads before attempting to disassemble. 1. The OE exhaust cannot be removed without cutting the pipe above the rear-axel area. Cut pipe as indicated using a metal-cutting blade (Figure 1). Support the muffler as needed while cutting. 2. Loosen the (2) clamp bolts as shown (13mm) and slide clamp towards front of vehicle. (Figure.2) 3. Using a muffler stand or an additional person to hold the muffler assem- bly up into position, slide the (2) hangars out of the rubber isolators and remove the front muffler assembly. Keep the hardware for use during the installation of your new exhaust system. (Figure 3) 4. Slide the (2) hangars out of the rubber isolators and remove the rear muf- fler assembly. Warning: Use extreme caution during installation. Torque all fasteners according to manufacturer’s torque values and tightening sequence. DO NOT use air impact tools to tighten fasteners on Borla Performance Exhaust Systems. Use of such tools may result in bent flanges or gasket contact areas leading to exhaust leaks. TITLE: 2009-2010 Volkswagen Jetta TDI Sedan and Sport Wagon TDI Installation Instructions (pn-140317)

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2 – Filter element 3 – Seal 4 – Mass Air Flow (MAF) sensor -G70-* 5 – Air duct 6 – 6 Nm 7 – Air filter, upper portion 8 – Cooling body Not for engine code AWM 9 – Rubber ring Not for engine code AWM 10 – Wire For EVAP canister system 11 – 10 Nm 12 – Heat shield 13 – Rubber grommet 14 – Spacer sleeve 15 – Base plate 16 – Air filter, lower portion

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Turbocharging Components, System Overview NOTE: – Boost pressure control is switched off during partial throttle operation by the EGR part throttle switch -Fl66- and the two-way valve for EGR -N161- – Check and adjust EGR part throttle switch – Check two-way valve for EGR 1 – Exhaust manifold 2 – 25 Nm (18 ft lb) 3 – Hose – To Diesel injection pump 4 – Gasket – Replace – Coated side toward intake manifold 5 – Intake manifold 6 – 45 Nm (33 ft lb) – Replace – Coat threads and bolt head sealing surfaces with high temperature (2000 °F) anti-sieze compound 7 – Gasket – Replace – Note installation position 8 – To Positive Crankcase Ventilation valve 9 – From Air Cleaner 10 – Turbocharger – Boost pressure checking, refer to “Turbocharger, Checking”. See: Testing and Inspection 11 – Wastegate – Integral part of turbocharger cannot be replaced – Hose/pipe connections, refer to “Turbocharger Hoses and Lines, Connecting”. See: Vacuum and Vapor Hose Diagrams 12 – Oil return line – To cylinder block 13 – Sealing rings Page 3 1996 Volkswagen Passat Sedan L4-1.9L DSL Turbo (AAZ) Copyright © 2008, ALLDATA 9.70 Page 2 – Replace 14 – Banjo bolt – 30 Nm (22 ft lb) 15 – 30 Nm (22 ft Ib) 16 – Front exhaust pipe 17 – Oil supply pipe – From oil filter bracket 18 – Air hose 19 – Mounting bracket – Between exhaust pipe and exhaust manifold