Volkswagen Workshop Service and Repair Manuals

I    

II    

III    

Part I

• Toothed belt guard - upper part
• 40 Nm + 1/4turn (90 °) further
• Console
• 10 Nm
• Front toothed belt guard
• 20 Nm
• 20 Nm
• Lifting eye
• Rear toothed belt guard
• Coolant pump
• O-Ring
• ◆ Renew
• Idler roller

• 20 Nm
• Crankshaft toothed belt sprocket
• ◆ Note position when installing toothed belt
  
• Tensioner
• ◆ Checking => Page 13-17
• ◆ Tensioning toothed belts
  => Page 13-12
• 20 Nm
• Toothed belt
• ◆ Mark D.O.R. before removing
• ◆ Check for wear
• ◆ Do not kink
• ◆ Toothed belt routing => Fig. 1
• ◆ Removing and installing
  => Page 13-12
• Toothed belt guard - lower part

• Belt pulley
• ◆ When installing note fixing arrangement
• ◆ Removing and installing
  => Page 13-12 ; Removing, installing and tensioning toothed belt
• ◆ Removing and installing ribbed belt => Page 13-10
• 90 Nm + 1/4 turn (90 °) further
• ◆ Renew
• ◆ Oil threads
• ◆ The turning further can be done in several stages
• ◆ The turning further angle can be checked with a commercial protractor e.g. Hazet 6690

Part II

• Cylinder head cover
• ◆ Before fitting gasket coat transition between bearing cap/cylinder head and the half moon shaped recesses with D 454 300 A3
• 10 Nm
• ◆ Tighten from centre outwards
• HT cable cover
• Retainer
• ◆ For HT cable cover
• Cylinder head bolt
• ◆ Renew
• ◆ Note installation instructions and sequence when loosening and tightening
  => Page 15-4

• Cylinder head
• ◆ Removing and installing
  => Page 15-4
• ◆ If replaced renew the complete
  coolant
• Cylinder head gasket
• ◆ Renew
• ◆ Metal gasket
• ◆ If replaced renew the complete
  coolant

Part III

Note:

Servicing the clutch:

=> 5-Speed manual gearbox 085; Repair group 30; Servicing clutch

• Cylinder block
• ◆ Dismantling and assembling cylinder block, crankshaft and flywheel
  => Page 13-21
• ◆ Dismantling and assembling pistons and conrods
  => Page 13-31
• 45 Nm
• ◆ Tightening sequence:
  Upper right bolt first, then lower right bolt, and bolts on left last (as seen from direction of travel)

• Oil filter
• ◆ Loosen on hexagon
• ◆ Tighten by hand
• ◆ Note instructions on filter when installing
• 20 Nm + 1/4 turn (90 °) further
• ◆ Renew
• 15 Nm
• ◆ Loosen and tighten the flywheel end bolts only with socket insert 3249
• Sump
• ◆ Removing and installing
  => Page 17-14
• Sealing ring
• ◆ Renew
• Oil drain plug, 30 Nm
• Bracket
• ◆ For vane pump and alternator

• 45 Nm
• Washer
• Tensioning roller
• Tensioning element

→ Fig. 1     Toothed belt routing