Volkswagen Golf Workshop Service and Repair Manuals

Note:

• ◆ Always renew gaskets and oil seals.
• ◆ If large amounts of metal burr as well as abrasion are found while repairing the engine and this is caused by seizure (e.g. bearings), the oil cooler must be renewed in addition to cleaning the oil ducts thoroughly in order to avoid follow-up damage.

•      I      => Part I
• ◆ page 13-2
•      II      => Part II
• ◆ page 13-5
•      III      => Part III
• ◆ page 13-7

Part I

• Upper toothed belt guard
• ◆ 04.88 ä as illustrated ä03.88 made of metal
• 10 Nm
• Toothed beld guard
• ◆ Only with plastic upper toothed belt guard
• Toothed belt
• ◆ Mark direction of rotation before removing
• ◆ Check for wear
• ◆ Do not kink
• ◆ Installing
• Tensioning roller
• ◆ Turn to the right to tension: Installing toothed belt => page 13-9
• 45 Nm
• Rear toothed belt guard

• 20 Nm
• ◆ 30 Nm with metal toothed belt cover
• ◆ Additionally secure hexagon bolt with D6 in the case of metal toothed belt cover
• V belt
• ◆ Check tension with thumb pressure
• ◆ Max. deflection:
  New V belt approx. 2 mm
  Use V belt approx. 5 mm
• ◆ Adjusting tension with tensioning nut => page 13-12
• Pulley
• ◆ Watch position when fitting toothed belt => page 13-9
• ◆ Watch location when fitting pulley
• 20 Nm
• Lower toothed belt guard
• Crankshaft sprocket

• Double-hexagon bolt, 90 Nm + 1/4 turn (90º) further
• ◆ Renew
• ◆ Do not use washer
• ◆ Lubricate thread and collar
• ◆ Counterhold with 3099 when loosening and tightening
• ◆ Turning further 90° can be done in serveral steps
• Hexagon bolt (M 12 x 1.5), 80 Nm
• ◆ User washer
• ◆ Secure with D6
• ◆ Counterhold with 3099 when loosening and tightening
• Hexagon bolt (M 14 x 1.5), 180 Nm
• ◆ Use washer
• ◆ Lubricate thread
• ◆ Counterhold with 3099 when loosening and tightening
• Intermediate shaft sprocket
• ◆ Watch position when fitting toothed belt => page 13-9
• 80 Nm

Part II

• Cap
• 10 Nm
• Reinforcement strip
• Cylinder head cover
• Oil deflector
• ◆ Only with hydraulic bucket tappets
  ä 02.87
• Gaskets for cylinder head cover
• ◆ Renew
• Cylinder head bolt
• ◆ Installation instructions and sequence when loosening and tightening => page 15-6
• Camshaft sprocket
• ◆ Watch position when installing toothed belt => page 13-9

• Plug
• Cyliner head
• ◆ Removing and installing => page 15-1
• ◆ After renewing, remplace entire coolant
• ◆ With hydraulic bucket tappets
  ä 02.87 has no camshaft bearing Nº. 4
• Suspension eye
• Clamping bracket for alternator
• ◆ 04.85 ä with rack for adjusting V belt tension => page 13-12
• 25 Nm
• Cylinder head gasket
• ◆ Renew
• ◆ Watch position:
  Marking "oben" must be towards cylinder head
• ◆ After renewing, replace entire coolant

Part III

• Distributor
• ◆ Installing

=> Repair Group 28

• 20 Nm
• Gasket
• ◆ Renew
• O-ring
• ◆ Renew
• Woodruff key
• Hammerhead bolt
• Coolant pump
• ◆ Check for smooth running
• Fuel pump
• Oil filter bracket

• Oil filter
• ◆ Loosen with strap wrench,
• ◆ Tighten by hand
• ◆ Pay attention to installation instructions on oil filter
• Intermediate flange
• Gasket
• ◆ For oil sump
• ◆ Renew
• ◆ Do not bond on
• ◆ Watch correct position
• Oil sump
• 35 Nm