VOLKSWAGEN AYC — 2.5L Engine
2.5L · 102 hp
Engine overview
Manufacturer
VOLKSWAGEN
Displacement
2.5 L
Power
102 hp
Production years
2001-2003
Fuel type
Diesel
Vehicles with this engine
7D
Torque figures by job
From the step-by-step procedures for this engine — each figure sits in the step that uses it.
- 24 Nm (18 lb-ft) — Tighten new securing bolts (1) to
- 90 Nm (66 lb-ft) — Tighten securing nut to
- 20 Nm (15 lb-ft) — Tighten securing nut (2) to
- 15 Nm (11 lb-ft) — Tighten securing bolt to
- 160 Nm (118 lb-ft) — Tighten injection pump drive pulley securing nut to
- 12 Nm (8.9 lb-ft) — Insert intermediate plate (1) and tighten locking bolt to
- 20 Nm (15 lb-ft) — Tighten coolant pump securing bolts to
- 85 Nm (63 lb-ft) — Tighten camshaft pulley securing bolt with counterhold tool3036, note mark on head of…
- 460 Nm (339 lb-ft) — Insert counterhold tool T10025 and tighten central bolt for vibration damper/crankshaft…
- 20 Nm (15 lb-ft) — Tighten the four M8 securing bolts for vibration damper/crankshaft toothed belt pulley to
- 50 Nm (37 lb-ft) — Hold injection pump drive pulley in position with counterhold tool3036 and pre-tighten to
- 100 Nm (74 lb-ft) — Following adjustment for the second time, hold injection pump drive pulley with…
- 30 Nm (22 lb-ft) — Tighten locking bolt to
- 20 Nm (15 lb-ft) — Tighten securing nut (2) to
- 15 Nm (11 lb-ft) — Tighten securing bolt to
- 160 Nm (118 lb-ft) — Tighten injection pump drive pulley securing nut to
- 12 Nm (8.9 lb-ft) — Insert intermediate plate (1) and tighten locking bolt to
- 85 Nm (63 lb-ft) — Tighten camshaft pulley securing bolt
- 20 Nm (15 lb-ft) — Tighten securing nut (2) to
- 15 Nm (11 lb-ft) — Tighten securing bolt to
- 160 Nm (118 lb-ft) — Tighten injection pump drive pulley securing nut to
- 12 Nm (8.9 lb-ft) — Insert intermediate plate (1) and tighten locking bolt to
- 25 Nm (18 lb-ft) — Tighten securing bolts for lock carrier plate (2) to
- 20 Nm (15 lb-ft) — Tighten belt tensioner securing bolt to
- 85 Nm (63 lb-ft) — Tighten camshaft pulley securing bolt with counterhold tool3036, note mark on head of…
- 160 Nm (118 lb-ft) — Install counterhold tool T10025 and tighten central bolt for vibration damper/crankshaft…
- 20 Nm (15 lb-ft) — Tighten four M8 securing bolts for vibration damper/crankshaft toothed belt pulley to
Notes on removing
- 20 Nm (15 lb-ft) — Screw engine support3227 to cylinder block to approx
- 45 Nm (33 lb-ft) — Coat thread and head contact surface of securing bolt and securing nuts between exhaust…
- 25 Nm (18 lb-ft) — Position manifold on turbocharger and tighten to
- 30 Nm (22 lb-ft) — Position oil return line with new seal and tighten to
- 25 Nm (18 lb-ft) — Position oil supply line with new oil seals and tighten cap nut to
- 25 Nm (18 lb-ft) — Position intake manifold with guard plate and new seal (coating or bead of seal points to…
- 50 Nm (37 lb-ft) — Hold injection pump drive pulley in position with counterhold tool3036 and pre-tighten to
- 100 Nm (74 lb-ft) — Following adjustment for the second time, hold injection pump drive pulley with…
Removing and installing tensioner for poly V-belt
- 20 Nm (15 lb-ft) — Screw engine support3227 to cylinder block to approx
Dynamically checking and adjusting commencement of injection
- 20 Nm (15 lb-ft) — Tighten securing nut (2) to
- 25 Nm (18 lb-ft) — Tighten securing bolts for lock carrier plate (2) to
- 10 Nm (7.4 lb-ft) — Tighten securing bolts to
Factory specifications
Values from the manufacturer documentation for this engine.
Engine (general)
| Engine code | AYC |
| Capacity | 2459 cc |
| Idle speed | 755 - 880 rpm |
| Normal | 25 - 31 bar |
| Minimum | 24 bar |
| Differential limit between cylinders | 5 bar |
| Oil pressure | 2.0 / 2000 bar/rpm |
Engine (diesel)
| Injection pump (make and type) | Bosch VE 5 |
| Number of cylinders | 5 |
| Injector firing order | 1 - 2 - 4 - 5 - 3 |
| Injector pressure | 220 - 230 bar |
| Minimum | 200 bar |
| Exhaust gas analysis test method/probe (Germany only) | B / 1 |
| Oil temperature during test | 80 °C |
| Exhaust gas analysis | 2.01 m-1 |
| Min. no-load governed speed | 4500 rpm |
| Max. no-load governed speed | 4900 rpm |
| Idle speed, minimum | 755 rpm |
| Idle speed, maximum | 880 rpm |
| Test time | 0.5 s |
Cooling system
| Cap pressure | 1.3 - 1.5 bar |
| Thermostat opens at | 87 °C |
| Thermostat fully open at | 102 °C |
| Stage 1/Fan 1 | 84 - 89 °C |
| Stage 2/Fan 2 | 90 - 95 °C |
Electrical
| Battery | 72/92 (>1999) 74/80/88 (1999>) Ah |
| Alternator | 90/120 A |
Capacities
| Engine sump, incl. filter | 5.5 l |
| Manual transmission | 02G |
| Gearbox refill | 2.3 2.7 l |
| Automatic transmission | 01P |
| Gearbox refill | 3.0 - 3.5 l |
| Differential | 1.15 0.75 (01/1996>) l |
| Cooling system | 9.0 l |
| Air-conditioner refrigerant | 950 + 50 g |
| Air-conditioner refrigerant | 1000 + 50 g |
| Air-conditioner refrigerant | 1350 + 50 g |
| Air-conditioner refrigerant | 1400 + 50 (5/1993 >) 1350 + 50 (7/1997 >) g |
| Air-conditioner refrigerant | 700 +50 g |
| Air-conditioner compressor oil | 135 ml |
| Air-conditioner compressor oil | 240 ml |
Torque settings
| Cylinder head bolts — Stage 1 | 40 Nm |
| Cylinder head bolts — Stage 2 | 60 Nm |
| Cylinder head bolts — Stage 3 | 90 ° |
| Cylinder head bolts — Stage 4 | 90 ° |
| Flywheel | 60 Nm + 90° Nm |
| Big-end bearing cap | 30 Nm + 90° Nm |
| Main bearing cap | 65 Nm |
| Oil plug | 30 Nm |
| Injector nozzle | 25 Nm |
| Glow plugs | 15 Nm |
| Front hub | 200 Nm |
| Rear hub | 200 Nm |
| Wheel nuts | 160 Nm |
Emissions
| Emission code | 70/220*1996/69 |
| Emission standard | Euro 2 (10/1997 ->) |
| CO2 average | 208 - 221 g/km |
| CO | 0.288 - 0.399 g/km |
| HC NOx | 0.800 - 0.863 g/km |
| Particles | 0.083 - 0.086 g/km |
| Emission code | 70/220*1999/102A |
| Emission standard | Euro 3 (08/2000 ->) |
| CO2 average | 208 - 213 g/km |
| CO | 0.242 g/km |
| NOx | 0.682 g/km |
| HC NOx | 0.730 g/km |
| Particles | 0.083 g/km |
| Emission standard | Euro 2 |
| CO2 average | 265 g/km |
| CO | 0.162 g/km |
| HC NOx | 1.196 g/km |
| Particles | 0.156 g/km |
| Emission standard | Euro 2 (07/1998 ->) |
| CO2 average | 230 - 235 g/km |
| CO | 0.171 - 0.362 g/km |
| NOx | 0.609 g/km |
| HC NOx | 0.702 - 0.811 g/km |
| Particles | 0.082 - 0.084 g/km |
| Emission standard | Euro 3 (02/2001 ->) |
| CO | 0.362 g/km |
| HC NOx | 0.702 g/km |
| Particles | 0.082 g/km |
| Emission standard | Euro 3 |
| CO2 average | 219 g/km |
Engine codes in the same family
The same code prefix usually means the same block with a different output, fuel or model year. Procedures are often shared — check the code on the engine plate.
Workshop procedures for this engine
Step-by-step procedures from the workshop database, carrying 72 torque figures.
- Removing and installing camshaft · 15 torque figures
- Removing and installing injection pump · 14 torque figures
- Removing and installing injectors · 6 torque figures
- Checking timing · 7 torque figures
- Removing, installing and tensioning camshaft toothed belt (▸ 01.95) · 6 torque figures
- Removing, installing and tensioning injection pump toothed belt (engine codes ACV, AHY, AJT, AUF, AXG, AXL, AYC, AYY) · 5 torque figures
- Removing, installing and tensioning camshaft toothed belt (02.95 ▸) · 4 torque figures
- Removing and installing fuel tank
- Removing, installing and tensioning injection pump toothed belt (engine codes AAB, AJA) · 2 torque figures
- Adjusting commencement of injection · 3 torque figures
- Checking air mass meter G70
- Securing engine to assembly stand · 3 torque figures
- Checking charge pressure control solenoid valve N75
- Adjusting V-belt tension for alternator · 3 torque figures
- Checking exhaust gas recirculation valve N18
- Checking exhaust gas recirculation
- Removing and installing tensioner for poly V-belt · 1 torque figures
- Renewing engine control unit
- Checking glow plugs · 2 torque figures
- Checking exhaust gas recirculation and air mass meter function
- Checking intake manifold pressure sender G71
- Checking accelerator position sender G79
- Draining and filling with coolant · 1 torque figures
- Checking voltage supply for diesel direct injection system
- Checking brake light switchF and brake pedal switch F47
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TorqFix was built by a mechanic — after a 2,700 km drive with five roadside repairs that no diagnostic tool could explain.
The figures on this page come from manufacturer workshop documentation and are shown as they are. The page is assembled automatically from that data — it is not written by an AI. The AI works in the chat, where it answers for your specific car. It writes nothing here.
Variants of the same model differ. Cross-check torque against the factory manual for your engine before final tightening.
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The story behind TorqFix →Workshop data on this page last updated 22 Aug 2026.