2003 Volkswagen Transporter Box Van engine fastener tightening specifications

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Condition	Value

expand_moreAir intake system

expand_moreInduction-pipe flap control unit


2.8 VR6 with gasoline vr-6 2.8 L 201 HP at 6200 RPM, 270 N⋅m at 3200 RPM engine (2000.6–2003.4)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreIntake manifold

expand_moreAll Volkswagen gasoline straight-4 2.0 Liters AAC engines


M6	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
M8	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m


All Volkswagen gasoline vr-6 2.8 Liters AMV engines	7.38–11.06 lbf⋅ft7.38–11.06 lbf⋅ft10–15 N⋅m
All other modifications	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAuxiliary assemblies


Auxiliary drive belt deflection pulley	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreAuxiliary drive belt tensioner


1.9 TD with diesel straight-4 1.9 L 67 HP engine (1992.10–2003.4)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_more2.0 with gasoline straight-4 2.0 L 83 HP engine (1990.7–2003.4)


With 120-A generator	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
With fan belt	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m


2.5 TDI Syncro with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
2.5 TDI Syncro with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
2.5 TDI with diesel straight-5 2.5 L 149 HP engine (2000.9–2003.4)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
2.8 VR6 with gasoline vr-6 2.8 L 201 HP at 6200 RPM, 270 N⋅m at 3200 RPM engine (2000.6–2003.4)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAll other modifications


M6	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
M8	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreAuxiliary drive belt tensioner

expand_more2.0 with gasoline straight-4 2.0 L 83 HP engine (1990.7–2003.4)


With 120-A generator	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m


All other modifications	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreAir-conditioning compressor

expand_more2.0 with gasoline straight-4 2.0 L 83 HP engine (1990.7–2003.4)


M10	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
M8	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m


2.5 TDI Syncro with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
2.5 TDI Syncro with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m

expand_more2.8 VR6 with gasoline vr-6 2.8 L 201 HP at 6200 RPM, 270 N⋅m at 3200 RPM engine (2000.6–2003.4)


M10 × 112 screws	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
M8 × 25 screws	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAll other modifications


M10	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
M8	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreAir-conditioning compressor bracket


2.4 D with diesel straight-5 2.4 L 74 HP engine (1997.8–2003.4)	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m

expand_more2.5 TDI Syncro with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)


M10	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
M8	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m


2.8 VR6 with gasoline vr-6 2.8 L 201 HP at 6200 RPM, 270 N⋅m at 3200 RPM engine (2000.6–2003.4)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAll other modifications


M10	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
M8	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m


Air-conditioning compressor pressure line	5.16 lbf⋅ft5.16 lbf⋅ft7 N⋅m

expand_moreAlternator

expand_more1.9 TD with diesel straight-4 1.9 L 67 HP engine (1992.10–2003.4)


M10	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
M8	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_more2.0 with gasoline straight-4 2.0 L 83 HP engine (1990.7–2003.4)


With fan belt	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
With ribbed V-belt	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m


2.5 TDI Syncro with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
2.5 TDI Syncro with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
2.8 VR6 with gasoline vr-6 2.8 L 201 HP at 6200 RPM, 270 N⋅m at 3200 RPM engine (2000.6–2003.4)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAll other modifications


With air-conditioning	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Without air-conditioning system	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m

expand_moreAlternator pulley


2.5 TDI Syncro with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
2.8 VR6 with gasoline vr-6 2.8 L 201 HP at 6200 RPM, 270 N⋅m at 3200 RPM engine (2000.6–2003.4)	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m

expand_moreGenerator bracket

expand_more1.9 TD with diesel straight-4 1.9 L 67 HP engine (1992.10–2003.4)

expand_moreWith fan belt


M8 × 65 screws	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
M8 × 70 screws	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m


With ribbed V-belt	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_more2.0 with gasoline straight-4 2.0 L 83 HP engine (1990.7–2003.4)


With air-conditioning	24.34 lbf⋅ft24.34 lbf⋅ft33 N⋅m
Nuts must be replaced.
Without air-conditioning	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m


2.5 TDI Syncro with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
2.5 TDI Syncro with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
2.8 VR6 with gasoline vr-6 2.8 L 201 HP at 6200 RPM, 270 N⋅m at 3200 RPM engine (2000.6–2003.4)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All other modifications	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m

expand_morePower steering pump bracket


All Volkswagen gasoline straight-4 2.0 Liters AAC engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreAll Volkswagen diesel straight-4 1.9 Liters ABL engines


M10 × 98 screws	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
M12 × 50 screws	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Nuts	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Tensioning screws	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m


All other modifications	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m

expand_moreServo pump pulley


All other modifications	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreServo steering pump


2.5 TDI Syncro with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
All other modifications	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m


Vacuum pump	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreCarburetion


Injection pump drive wheel	73.76 lbf⋅ft73.76 lbf⋅ft100 N⋅m

expand_moreExhaust gas return valve


All Volkswagen diesel straight-5 2.5 Liters AJT engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
All Volkswagen diesel straight-5 2.5 Liters AYY engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

expand_moreExhaust recirculation pipe


Nuts	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Sealing rings must be replaced.
Screws	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Sealing rings must be replaced.

expand_moreFuel-distributing pipe


2.8 VR6 with gasoline vr-6 2.8 L 201 HP at 6200 RPM, 270 N⋅m at 3200 RPM engine (2000.6–2003.4)	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m


Injection hoses	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreInjection nozzle (injector)

expand_more2.5 TDI Syncro with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)


Vehicles manufactured in and after 05.1999	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m


2.5 TDI with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
2.5 TDI with diesel straight-5 2.5 L 149 HP engine (2000.9–2003.4)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_more2.5 TDI with diesel straight-5 2.5 L 87 HP engine (1998.12–2003.4)


Vehicles manufactured in and after 05.1999	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m


All other modifications	51.63 lbf⋅ft51.63 lbf⋅ft70 N⋅m

expand_moreInjection pump


2.4 D with diesel straight-5 2.4 L 74 HP engine (1997.8–2003.4)	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
All other modifications	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreInjection pump pulley

expand_moreAll Volkswagen diesel straight-4 1.9 Liters ABL engines


One-part injection pump pulley	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Two-part injection pump pulley	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m


All Volkswagen diesel straight-5 2.4 Liters AJA engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
All Volkswagen diesel straight-5 2.4 Liters AJA engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
All Volkswagen diesel straight-5 2.4 Liters AAB engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
All other modifications	66.38 lbf⋅ft66.38 lbf⋅ft90 N⋅m

expand_moreInjection pump lockup screws


With spacer	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
Otherwise	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreCharging


Turbo charger	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Screws and nuts must be replaced.

expand_moreTurbocharger oil feed line


At the turbocharger	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Sealing rings must be replaced.
On the engine block	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Sealing rings must be replaced.

expand_moreTurbocharger oil return line


At the turbocharger	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Sealing rings must be replaced.
On the engine block	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m

expand_moreCooling system

expand_moreCoolant drain plug


2.8 VR6 with gasoline vr-6 2.8 L 201 HP at 6200 RPM, 270 N⋅m at 3200 RPM engine (2000.6–2003.4)	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreCoolant pump


1.9 TD with diesel straight-4 1.9 L 67 HP engine (1992.10–2003.4)	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
All other modifications	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreCoolant pump pulley

expand_moreAll Volkswagen gasoline straight-4 2.0 Liters AAC engines


Collar screws	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Otherwise	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m


All Volkswagen diesel straight-4 1.9 Liters ABL engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Volkswagen gasoline vr-6 2.8 Liters AMV engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreFan wheel


2.8 VR6 with gasoline vr-6 2.8 L 201 HP at 6200 RPM, 270 N⋅m at 3200 RPM engine (2000.6–2003.4)	2.95–4.43 lbf⋅ft2.95–4.43 lbf⋅ft4–6 N⋅m

expand_moreRadiator mounting


2.8 VR6 with gasoline vr-6 2.8 L 201 HP at 6200 RPM, 270 N⋅m at 3200 RPM engine (2000.6–2003.4)	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreCylinder head

expand_moreCamshaft bearing

expand_moreAll Volkswagen gasoline vr-6 2.8 Liters AMV engines


First stage	3.69 lbf⋅ft3.69 lbf⋅ft5 N⋅m
Second stage	45°45°45°


All other modifications	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
First tighten bearing covers 2 and 4 alternately and in steps

expand_moreCylinder head screws


Third stage	90°90°90°
Fourth stage	90°90°90°

expand_moreAll Volkswagen gasoline vr-6 2.8 Liters AMV engines

Figure 1. Cylinder head, Cylinder head screws, Volkswagen gasoline vr-6 2.8 Liters AMV.


First stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Screws must be replaced. See figure 1.
Second stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m

expand_moreAll other modifications

Figure 2. Cylinder head, Cylinder head screws, All other modifications.


First stage	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Screws must be replaced. See figure 2.
Second stage	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m


Cylinder head screws shank length (new)	4.53 in4.53 in115 mm
Valve cover	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreEngine block

expand_moreConnecting rod bearing


First stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Screws must be replaced. Lightly oil the screws.
Second stage	90°90°90°

expand_moreCrankshaft central screws

expand_more1.9 TD with diesel straight-4 1.9 L 67 HP engine (1992.10–2003.4)


First stage	66.38 lbf⋅ft66.38 lbf⋅ft90 N⋅m
Screws must be replaced. Lightly oil the screws.
Second stage	90°90°90°

expand_more2.0 with gasoline straight-4 2.0 L 83 HP engine (1990.7–2003.4)


First stage	66.38 lbf⋅ft66.38 lbf⋅ft90 N⋅m
Screws must be replaced. Lightly oil the screws.
Second stage	90°90°90°

expand_more2.8 VR6 with gasoline vr-6 2.8 L 201 HP at 6200 RPM, 270 N⋅m at 3200 RPM engine (2000.6–2003.4)


First stage	73.76 lbf⋅ft73.76 lbf⋅ft100 N⋅m
Screws must be replaced.
Second stage	90°90°90°

expand_moreAll other modifications


65 mm screws	339.28 lbf⋅ft339.28 lbf⋅ft460 N⋅m

expand_more110 mm screws


First stage	118.01 lbf⋅ft118.01 lbf⋅ft160 N⋅m
Second stage	180°180°180°

expand_moreCrankshaft pulley


1.9 TD with diesel straight-4 1.9 L 67 HP engine (1992.10–2003.4)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_more2.0 with gasoline straight-4 2.0 L 83 HP engine (1990.7–2003.4)


Collar screws	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Otherwise	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_more2.4 D with diesel straight-5 2.4 L 74 HP engine (1997.8–2003.4)

expand_moreVehicles manufactured in and after 02.1995


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Second stage	90°90°90°

expand_moreAll other modifications


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Second stage	90°90°90°

expand_moreDrive plate


First stage	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
Screws must be replaced.
Second stage	90°90°90°

expand_moreFlywheel


First stage	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
Screws must be replaced.
Second stage	90°90°90°


Flywheel cover	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreMain bearing

expand_moreAll Volkswagen gasoline straight-4 2.0 Liters AAC engines

expand_moreWith continuous thread


First stage	47.94 lbf⋅ft47.94 lbf⋅ft65 N⋅m
Second stage	90°90°90°


Otherwise	47.94 lbf⋅ft47.94 lbf⋅ft65 N⋅m

expand_moreAll Volkswagen diesel straight-4 1.9 Liters ABL engines


First stage	47.94 lbf⋅ft47.94 lbf⋅ft65 N⋅m
Screws must be replaced.
Second stage	90°90°90°

expand_moreAll Volkswagen gasoline vr-6 2.8 Liters AMV engines


First stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Screws must be replaced.
Second stage	180°180°180°


All other modifications	47.94 lbf⋅ft47.94 lbf⋅ft65 N⋅m

expand_moreVibration damper


1.9 TD with diesel straight-4 1.9 L 67 HP engine (1992.10–2003.4)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_more2.0 with gasoline straight-4 2.0 L 83 HP engine (1990.7–2003.4)


Collar screws	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Screws	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_more2.4 D with diesel straight-5 2.4 L 74 HP engine (1997.8–2003.4)

expand_moreVehicles manufactured in and after 02.1995

expand_moreCentral screws


First stage	118.01 lbf⋅ft118.01 lbf⋅ft160 N⋅m
Bolts must be replaced.
Second stage	180°180°180°

expand_moreM8


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Second stage	90°90°90°

expand_more2.5 TDI Syncro with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Second stage	90°90°90°

expand_more2.5 TDI with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)

expand_moreVehicles manufactured in and after 02.1995

expand_moreCentral screws


First stage	118.01 lbf⋅ft118.01 lbf⋅ft160 N⋅m
Bolt must be replaced.
Second stage	180°180°180°

expand_moreM8


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Second stage	90°90°90°

expand_more2.5 TDI with diesel straight-5 2.5 L 149 HP engine (2000.9–2003.4)

expand_moreVehicles manufactured in and after 02.1995

expand_moreCentral screws


First stage	118.01 lbf⋅ft118.01 lbf⋅ft160 N⋅m
Bolt must be replaced.
Second stage	180°180°180°

expand_moreM8


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Second stage	90°90°90°

expand_more2.5 TDI with diesel straight-5 2.5 L 87 HP engine (1998.12–2003.4)


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Second stage	90°90°90°

expand_moreAll other modifications

expand_moreWith ribbed V-belt


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Second stage	90°90°90°


Otherwise	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreEngine control

expand_moreCamshaft drive belt deflection pulley


2.5 TDI with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
2.5 TDI with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
2.5 TDI with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
2.5 TDI with diesel straight-5 2.5 L 149 HP engine (2000.9–2003.4)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All other modifications	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreCamshaft timing gear


All Volkswagen gasoline straight-4 2.0 Liters AAC engines	59 lbf⋅ft59 lbf⋅ft80 N⋅m
All Volkswagen diesel straight-4 1.9 Liters ABL engines	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m

expand_moreAll Volkswagen gasoline vr-6 2.8 Liters AMV engines


First stage	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
Screws must be replaced.
Second stage	90°90°90°

expand_moreAll other modifications


Class 8.8 screws	62.69 lbf⋅ft62.69 lbf⋅ft85 N⋅m
Class 10.9	73.76 lbf⋅ft73.76 lbf⋅ft100 N⋅m

expand_moreChain tensioner


2.8 VR6 with gasoline vr-6 2.8 L 201 HP at 6200 RPM, 270 N⋅m at 3200 RPM engine (2000.6–2003.4)	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m


Injection pump drive belt tensioning roller	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

expand_moreTiming case cover


2.8 VR6 with gasoline vr-6 2.8 L 201 HP at 6200 RPM, 270 N⋅m at 3200 RPM engine (2000.6–2003.4)	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Screws must be replaced. Tighten new screws crosswise.

expand_moreToothed belt guard

expand_more2.4 D with diesel straight-5 2.4 L 74 HP engine (1997.8–2003.4)


M6	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
M8	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_more2.5 TDI with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)


M6	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Toothed belt guard, rear
M8	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Toothed belt guard, rear

expand_more2.5 TDI with diesel straight-5 2.5 L 149 HP engine (2000.9–2003.4)


M6	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
M8	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m


All other modifications	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Toothed belt guard, rear

expand_moreToothed belt guard at the bottom


2.5 TDI Syncro with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
2.5 TDI Syncro with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
2.5 TDI with diesel straight-5 2.5 L 149 HP engine (2000.9–2003.4)	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
2.5 TDI with diesel straight-5 2.5 L 87 HP engine (1998.12–2003.4)	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
2.5 TDI with diesel straight-5 2.5 L 87 HP engine (1998.12–2003.4)	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreAll other modifications


M6	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
M8	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreToothed belt tensioning roller

expand_more1.9 TD with diesel straight-4 1.9 L 67 HP engine (1992.10–2003.4)


With automatic tensioner	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Otherwise	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m


2.0 with gasoline straight-4 2.0 L 83 HP engine (1990.7–2003.4)	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
2.4 D with diesel straight-5 2.4 L 74 HP engine (1997.8–2003.4)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
2.5 TDI Syncro with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
2.5 TDI Syncro with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
2.5 TDI with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
2.5 TDI with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
2.5 TDI with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
2.5 TDI with diesel straight-5 2.5 L 149 HP engine (2000.9–2003.4)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
2.5 TDI with diesel straight-5 2.5 L 87 HP engine (1998.12–2003.4)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
2.5 TDI with diesel straight-5 2.5 L 87 HP engine (1998.12–2003.4)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreAll other modifications


Nuts	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Screws	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreEngine lubrication

expand_moreOil cooler


2.5 TDI with diesel straight-5 2.5 L 87 HP engine (1998.12–2003.4)	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
2.5 TDI with diesel straight-5 2.5 L 87 HP engine (1998.12–2003.4)	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
All other modifications	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreOil drain plug


All Volkswagen gasoline straight-4 2.0 Liters AAC engines	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
All Volkswagen diesel straight-4 1.9 Liters ABL engines	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
All Volkswagen gasoline vr-6 2.8 Liters AMV engines	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
All other modifications	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m

expand_moreOil filter


All Volkswagen diesel straight-5 2.5 Liters AJT engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAll Volkswagen gasoline vr-6 2.8 Liters AMV engines


Oil filter cover	14.75–18.44 lbf⋅ft14.75–18.44 lbf⋅ft20–25 N⋅m
Slightly oil sealing lips.
Oil filter drain plug	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m


All Volkswagen diesel straight-5 2.5 Liters AYY engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreOil filter housing


All Volkswagen diesel straight-5 2.5 Liters AJT engines	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
All Volkswagen gasoline vr-6 2.8 Liters AMV engines	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
All Volkswagen diesel straight-5 2.5 Liters AYY engines	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreOil pressure sensor


All Volkswagen diesel straight-5 2.5 Liters AJT engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Volkswagen gasoline vr-6 2.8 Liters AMV engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Volkswagen diesel straight-5 2.5 Liters AYY engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreOil pump


All Volkswagen diesel straight-5 2.5 Liters AJT engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Volkswagen gasoline vr-6 2.8 Liters AMV engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Volkswagen diesel straight-5 2.5 Liters AYY engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreOil sump


All Volkswagen gasoline straight-4 2.0 Liters AAC engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Volkswagen diesel straight-4 1.9 Liters ABL engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Volkswagen gasoline vr-6 2.8 Liters AMV engines	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m

expand_moreAll other modifications


M6	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
M8	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreEngine management

expand_moreCamshaft sensor


2.8 VR6 with gasoline vr-6 2.8 L 201 HP at 6200 RPM, 270 N⋅m at 3200 RPM engine (2000.6–2003.4)	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreCrankshaft sensor


All Volkswagen gasoline vr-6 2.8 Liters AMV engines	2.95–8.85 lbf⋅ft2.95–8.85 lbf⋅ft4–12 N⋅m
All Volkswagen diesel straight-5 2.5 Liters AXG engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreGlow plugs


1.9 TD with diesel straight-4 1.9 L 67 HP engine (1992.10–2003.4)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
2.4 D with diesel straight-5 2.4 L 74 HP engine (1997.8–2003.4)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All other modifications	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m


Knock sensor	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Lambda sensor	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m

expand_moreEngine mounting

expand_moreEngine bracket

expand_moreAll Volkswagen gasoline straight-4 2.0 Liters AAC engines

expand_moreOn the engine block


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Second stage	90°90°90°

expand_moreAll Volkswagen diesel straight-4 1.9 Liters ABL engines

expand_moreOn the engine block


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Second stage	90°90°90°

expand_moreAll Volkswagen diesel straight-5 2.5 Liters AJT engines

expand_moreOn the engine block


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Second stage	90°90°90°

expand_moreAll Volkswagen gasoline vr-6 2.8 Liters AMV engines

expand_moreOn the engine block


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Second stage	90°90°90°

expand_moreAll other modifications


At the cylinder head	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
On the engine block	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m

expand_moreEngine mounting


Central screws	47.94 lbf⋅ft47.94 lbf⋅ft65 N⋅m
Nuts	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m

expand_moreExhaust system

expand_moreCatalytic converter


All Volkswagen diesel straight-5 2.5 Liters AJT engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAll Volkswagen gasoline vr-6 2.8 Liters AMV engines


M10	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Screws and nuts must be replaced.
M8	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Screws and nuts must be replaced.


All Volkswagen diesel straight-5 2.5 Liters AYY engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreCatalytic converter bracket


All Volkswagen diesel straight-5 2.5 Liters AJT engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Volkswagen gasoline vr-6 2.8 Liters AMV engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Volkswagen diesel straight-5 2.5 Liters AYY engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreExhaust manifold


Vehicles manufactured in and after 05.1999	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreExhaust manifold heat shields


All Volkswagen diesel straight-5 2.5 Liters AJT engines	8.85–10.33 lbf⋅ft8.85–10.33 lbf⋅ft12–14 N⋅m
All Volkswagen gasoline vr-6 2.8 Liters AMV engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
All Volkswagen diesel straight-5 2.5 Liters AYY engines	8.85–10.33 lbf⋅ft8.85–10.33 lbf⋅ft12–14 N⋅m

expand_moreExhaust pipe

expand_moreAll Volkswagen gasoline straight-4 2.0 Liters AAC engines


M6	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
M8	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
M10	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m


All Volkswagen diesel straight-5 2.5 Liters ACV engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Volkswagen diesel straight-5 2.5 Liters AJT engines	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
All Volkswagen gasoline vr-6 2.8 Liters AMV engines	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
All Volkswagen diesel straight-5 2.5 Liters AXG engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAll other modifications


Vehicles manufactured in and after 05.1999	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m

expand_moreExhaust pipe bracket


2.5 TDI with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
2.5 TDI with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
2.5 TDI with diesel straight-5 2.5 L 101 HP engine (1995.9–2003.4)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
2.5 TDI with diesel straight-5 2.5 L 149 HP engine (2000.9–2003.4)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
2.5 TDI with diesel straight-5 2.5 L 87 HP engine (1998.12–2003.4)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
2.5 TDI with diesel straight-5 2.5 L 87 HP engine (1998.12–2003.4)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
2.8 VR6 with gasoline vr-6 2.8 L 201 HP at 6200 RPM, 270 N⋅m at 3200 RPM engine (2000.6–2003.4)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAll other modifications


M6	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
M8	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
M10	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m


Exhaust pipe rear	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m

expand_moreExhaust system middle heat protection plate


2.8 VR6 with gasoline vr-6 2.8 L 201 HP at 6200 RPM, 270 N⋅m at 3200 RPM engine (2000.6–2003.4)	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreFuel supply


Fuel filter bracket	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreIgnition system

expand_moreSpark plugs


All Volkswagen gasoline vr-6 2.8 Liters AMV engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All other modifications	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreStart system

expand_moreStarter


M8	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
M10	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
M12	59 lbf⋅ft59 lbf⋅ft80 N⋅m

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2003 Volkswagen Transporter Box Van user's manual. Keep in mind that all information here is provided “as is” without any warranty of any kind.

Before doing any DIY service please check your insurance policy and Volkswagen warranty policy for your region. In some regions DIY service may invalidate your warranty.

Maintenance Items

Chassis and Body Fastener Tightening Specifications
Engine Fastener Tightening Specifications
Front Suspension Fastener Tightening Specifications
Rear Suspension Fastener Tightening Specifications
Transmission Fastener Tightening Specifications

Service Intervals

Conquer your fears and never give up!

DIY car service is not as difficult as it looks like and it might save you thousands of dollars per year. It might be even fun and a good thing to do with your kids on a weekend to teach them how basic machinery works. It's really hard to screw something up and damage your car permanently if you use right tools, follow Volkswagen Transporter Box Van service manual and use right parts and fluids in prescribed amounts. Even modern cars stuffed with electronics can be serviced in your garage or even in your driveway. Changing engine oil, brake fluid, ATF, replacing brake pads, and etc. It's all may be done by yourself in a mater of a couple of hours.

Doing basic service for your 2003 Volkswagen Transporter Box Van you're not only saving money, but also also improving your technical skills and learning something new.

2003 Volkswagen Transporter Box Van generations

In 2003 Volkswagen offered 2 generations of the Transporter Box Van. Engine fastener tightening specifications may vary in different generations. Be sure that you are looking at the rigt modification.

T5

Type 7HA, Type 7HH, Type 7EA, Type 7EH

2003 Volkswagen Transporter Box Van T4 GP (T4 facelift) Engine Fastener Tightening Specifications

Table of Contents

Conquer your fears and never give up!

2003 Volkswagen Transporter Box Van generations

T5

Volkswagen Transporter Box Van T4 GP (T4 facelift) model years

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