Volkswagen Workshop Service and Repair Manuals

Notes:

• ◆ When the engine is stripped and assembled, it should be secured to the assembly stand with engine and gearbox support VW 540.
• ◆ If during repair work, metal shavings or larger quantities of small metal particles are found in the engine oil - caused, for example, by partial seizure of the crankshaft and conrod bearings - then, in addition to thoroughly cleaning out the oil passages, it is necessary to renew the oil cooler.
• ◆ Defective injectors can cause violent knocking noises in the engine which sound like defective bearings. When this occurs, run engine at idling speed and slacken off injector pipe unions one after the other. If knocking stops when a union is loosened, this indicates that the injector concerned is defective.

Servicing injectors:

Engine code AEF

=> Repair group 23; Servicing fuel injection system; Servicing injectors

▸ 09.99 (Engine codes AGD, AHG, AKU):

=> Repair group 23; Servicing diesel direct injection system; Servicing injectors

Servicing injectors:

10.99 ▸(Engine codes AGD, AKU, ASX):

=> Repair group 23; Servicing diesel direct injection system; Servicing injectors

I    

II    

Part I

• 45 Nm
• Cover cap
• Engine bracket
• Toothed belt guard - upper part
• Toothed belt
• ◆ Mark D.O.R. before removing
• ◆ Check for wear
• ◆ Do not kink
• ◆ Removing, installing and tensioning
  
• 20 Nm
• Tensioning roller
• ◆ Checking semi-automatic toothed belt tensioning roller => Page 13-14
• ◆ Tensioning toothed belt
  => Page 15-11 , Removing, installing and tensioning toothed belt

• 45 Nm
• Camshaft sprocket
• ◆ Drive from camshaft taper using hammer and drift through hole in rear toothed belt guard => Page 15-11 , Removing, installing and tensioning toothed belt
• 25 Nm
• ◆ Renew belt pulley/vibration damper bolts and tighten to 10 Nm + 1/4 turn (90 °) further
• Idler wheel
• ◆ Only engine codes AGD, AHG, AKU, ASX
• 10 Nm
• Rear toothed belt guard
• Clip
• ◆ Check securely seated

• Injection pump sprocket
• ◆ Engine codes AGD, AHG, AKU, ASX
• ◆ Single part
• ◆ Removing
• Injection pump sprocket
• ◆ Engine code AEF
• ◆ Two part
• 25 Nm
• ◆ Engine code AEF
• 55 Nm
• ◆ Engine codes AGD, AHG, AKU, ASX
• Injection pump
• ◆ Removing and installing for engine code AEF:

=> Repair group 23; Servicing fuel injection system; Removing and installing injection pump

• ◆ Removing and installing for engine codes AGD, AHG, AKU, ASX:

=> Repair group 23; Servicing diesel direct injection system; Removing and installing injection pump

• Bracket
• ◆ Only engine codes AGD, AHG, AKU, ASX
• Console
• 25 Nm
• ◆ Only tighten when injection pump is bolted tightly to the console
• Intermediate shaft sprocket
• Crankshaft toothed belt sprocket
• 90 Nm + 1/4 turn (90 °) further
• ◆ Counter-hold with 3099 to loosen and tighten
• ◆ Renew
• ◆ Threads and shoulder must be free of oil and grease
• ◆ The quarter turn further can be done in several stages.

• Tensioning lever
• ◆ Grease with G 000 100
• Tensioner
• Washer
• 20 Nm
• ◆ Left-hand thread
• Ribbed belt
• ◆ Mark direction of rotation before removing
• ◆ Check for wear
• ◆ Do not kink
• ◆ Removing and installing
  => Page 13-13
• Pulley
• ◆ For coolant pump
• ◆ Removing and installing coolant pump and compact bracket => Page 19-9

• Belt pulley/vibration damper
• ◆ Can only be installed in one position. Holes are off-set
• Toothed belt guard - lower part
• Spreader clip

Part II

• Cylinder block
• ◆ Removing and installing sealing flange and flywheel
  => Page 13-18
• ◆ Removing and installing crankshaft => Page 13-26
• ◆ Dismantling and assembling pistons and conrods
  => Page 13-31
• O-ring
• ◆ Renew if damaged
• Vacuum pump
• Clamp
• 20 Nm
• Gasket
• ◆ Renew
• Oil filter bracket

• 25 Nm
• Oil cooler
• ◆ Engine codes AEF, AGD and ASX
• ◆ Coat surface contacting oil filter bracket outside the seal with AMV 188 100 02
• ◆ Ensure clearance to adjacent components
• ◆ See note
  => Page 13-1
• Oil filter
• ◆ Loosen with strap wrench
• ◆ Tighten by hand
• ◆ Note instructions on filter when installing
• Cap
• 10 Nm

• Engine speed sender (G28)
• ◆ Only engine codes AGD, AHG, AKU, ASX
• ◆ Checking:

=> Repair Group 01; Self-diagnosis; Interrogating fault memory

• 25 Nm
• ◆ Note tightening sequence
  Page => 19-11 , Fig. 1
• Tensioning element
• Sealing ring
• ◆ Renew if damaged
• Compact bracket
• ◆ For coolant pump, coolant thermostat, ribbed belt tensioning roller, alternator and P.A.S. vane pump
• ◆ Removing and installing
  => Page 19-9

• Tensioning lever
• ◆ Grease with G 000 100
• 20 Nm
• ◆ Remove and install both rear bolts gearbox end with jointed spanner 3185
• Sump
• ◆ Clean sealing surface before installing
• Baffle plate
• ◆ With gasket
• ◆ Renew gasket if damaged
• ◆ Before fitting gasket coat sump flange/cylinder block flange with "D2"
• ◆ Engine codes AGD, AHG, AKU, ASX only renew gasket