Service Repair Manual |
| Year | 2002-2006 |
|
| Engine code | BMD |
|
| Engine size | 1198ccm |
|
| Power | 40kw |
|
| Idle speed | 600-800rpm |
|
| Compression | 15.0bar |
|
| Minimum compression | 11.0bar |
|
| Fuel system | Simos 3PG |
|
| Firing order | 1-2-3 |
|
| Spark plug | NGK ZFR5P-G |
|
| Electrode gap | 0.9mm |
|
| Lambda | 0.97-1.03 |
|
| Radiator cap | 1.4-1.6bar |
|
| Thermostat opens | 87℃ |
|
| Battery | 44Ah |
|
| Alternator | 70A |
|
| Cylinder head tightening sequence | |
 |
|
| Cylinder head tightening torque 1 | 30Nm |
|
| Cylinder head tightening torque 2 | 90° |
|
| Cylinder head tightening torque 3 | 90° |
|
| Spark plug Tightening torque | 20-30Nm |
|
| Engine oil with filter | 3.0l |
|
| Cooling system | 5.1l |
|
| Gearbox oil |
1.9l |
|
| Engine oil grade | VW 501.01 SAE 5W-30 |
| VW 501.01 SAE 5W-40 |
| VW 502.00 SAE 5W-30 |
| VW 502.00 SAE 5W-40 |
| VW 502.00 SAE 10W-30 |
| VW 502.00 SAE 10W-40 |
|
| Gearbox oil grade | API GL-4 SAE 75W-90 |
|
| Brake fluid | DOT 4 |
|
 |
| Tire dimension (x/y R z) | 155/80 R13 |
| 165/70 R14 |
| 185/60 R14 |
|
| Front wheel presure | 2.3 / 2.1 / 2.2bar |
|
| Rear wheel presure | 2.2 / 2.0 / 2.0bar |
|
| Wheel bolt tightening torque (B) | 120Nm |
|
 |
| Minimal front brake disk thickness (R) | 15.0 / 19.0mm |
|
| Minimal front pad thickness without backing plate (P2) | 2.0mm |
|
| Rear drum diameter (D) | 200.0mm |
|
| Minimal rear shoe thickness (S) | 2.2mm |
|
