Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling cylinder block and crankshaft

Note:

Short engines are supplied with a needle bearing in the crankshaft.

Before being installed in vehicles with automatic gearbox the needle bearing should be removed.

• 65 Nm
• Bearing cap
• ◆ Bearing cap 1 - pulley end
• ◆ Retaining tabs of shells must be above one another
• Bearing shells 1, 2, 4 and 5
• ◆ With no oil groove for caps 1, 2 and 5
• ◆ With oil groove for cap 4 and cylinder block
• ◆ Do not interchange used shells

• Thrust washer
• ◆ For cap
• ◆ Note location
• Bearing shell 3
• ◆ Fitting bearing
• ◆ For cap without oil groove
• ◆ For cylinder block with oil groove
• Thrust washer
• ◆ For cylinder block
• Crankshaft
• ◆ Axial clearance
  New: 0.07...0.17 mm
  Wear limit: 0.25 mm
• ◆ Check radial clearance with Plastigage
  New: 0.03...0.08 mm
  Wear limit: 0.17 mm
• ◆ Do not turn the crackshaft when measuring the radial clearance
• ◆ Crankshaft dimensions => page13-25
• 25 Nm

• Oil seal
• ◆ Take sealing flange off to remove
• ◆ Install with 10-203
• ◆ Slightly lubricate sealing lip and outer edge prior to installation
• Sealing flange
• O-ring
• ◆ Renew if damaged
• Intermediate shaft
• ◆ Remove distributor and fuel pump first
• ◆ Axial play max. 0.25 mm
• Oil seal
• ◆ Renew
• 20 Nm
• 10 Nm
• Front sealing flange
• ◆ With additional toothed belt cover => Fig. 1
• Gasket
• ◆ Renew

Removing and installing pressure plate and sealing flange

Note:

Clutch repairs

=> Repair Group 30

• Gasket
• ◆ Renew
• Bolt
• ◆ M6 = 10 Nm
  M8 = 20 Nm
• Oil seal
• ◆ ä07.90
• ‒ Remove with 10-221
• ‒ Slightly lubricate sealing lip and outer edge before installing
• ‒ Position using fitting sleeve 2003/2A
• ‒ Insert as far as stop with 2003/1
• ◆ 08.90 ä
• ‒ Completely renew sealing flange with oil seal

• Intermediate plate
• ◆ Must fit on dowel sleeves
• Pressure plate
• ◆ Removing and installing => Fig. 2
• ◆ Installing drive plate for automatic gearbox
• 60 Nm + 1/4 turn (90°) further
• ◆ Renew
• ◆ Turning on by 90° can be done in several steps
• Release plate
• ◆ Ensure that retaining lugs are fitted properly
• Retaining ring
• ◆ Lever out with screwdriver
• ◆ Watch location => Figs. 4, 5 and 6
• Clutch plate
• ◆ Centre with VW 547

• Flywheel
• ◆ Can be renewed with engine in situ after taking gearbox out
• ◆ Removing and installing =>Fig. 3
• ◆ Subsequent machining of ignition timing notch =>page13-29
• 20 Nm

→ Fig.1     Front sealing flange with toothed belt cover

01.76 ä up to introduction of fully enclosed toothed belt guard 02.79 äthe front sealing flange was installed with an additional belt cover to prevent belt jumping under unfavourable conditions.

→ Fig.2     Removing and installing pressure plate

→ Fig.3     Removing and installing flywheel

→ Fig.4     Installing retaining ring for the release plate, version A

Pay attention to wire ends -arrow-.

→ Fig.5     Installing retaining ring for the release plate, version B

Pay attention to wire ends -arrows-.

→ Fig.6     Installing retaining ring for the release plate, version C

Pay attention to wire ends -arrow-.