Volkswagen Workshop Service and Repair Manuals

Notes:

• ◆ Short engines are delivered with needle roller bearing in the crankshaft.Before installation in vehicles with automatic gearbox this needle bearing must be removed.
• ◆ When checking radial clearance, do not rotate crankshaft.

• Seal
• ◆ Removal and installation
• Front seal flange
• Gasket
• ◆ Renew

• Bearing shells 1, 2, 4 and 5
• ◆ With oil groove
• ◆ Do not interchange used bearing shells
• Crankshaft
• ◆ Axial clearance new: 0.07...0.17 mm Wear limit: 0.25 mm
• ◆ Use Plastigage to measure radial clearance. New: 0.03...0.08 mm Wear limit: 0.17 mm
• Bearing shells 1, 2, 4 and 5
• ◆ For caps 1, 2 and 5 without oil groove
• ◆ For cap 4 with oil groove
• ◆ Do not interchange used bearing shells.
• 65 Nm

• Bearing cap
• ◆ No. 1 bearing cap - pulley end
• ◆ Bearing shell retaining grooves must align
• Thrust washer
• ◆ For cap
• ◆ Position correctly
• No. 3 bearing shell
• ◆ Fitted bearing
• ◆ Without oil groove
• Needle bearing
• ◆ Not present
• 25 Nm
• Oil seal
• ◆ Remove seal flange to remove
• ◆ Install with 10-203
• ◆ Lighty oil sealing lip and outer edge before installation

• Seeling flange
• Intermediate shaft
• ◆ Remove distributor first
• ◆ Axial clearance: max. 0.25 mm
• Thrust washer
• ◆ For cylinder block
• No. 3 Main bearing shell
• ◆ Fitted bearing
• ◆ With oil groove

Note:

Repair work on the clutch:

=> 4 and 5-Speed manual gearbox 020; Repair group 30

• Gasket
• ◆ Renew
• M6 = 10 Nm
  M8 = 20 Nm
• Seal
• ◆ Remove with 10-221
• ◆ Lightly oil sealing lip and outer edge before installation
• ◆ Start with special tool 2003/1
• Intermediate plate
• ◆ Must vest on the fitting sleeves

• Preassure plate
• ◆ Removal and installation =>fig.2
• ◆ Install drive plate for automatic gearbox
• 100 Nm
• ◆ Renew
• ◆ Secure with -D6- locking fluid
• Release plate
• ◆ Position retaining tabs properly
• Retaining ring
• ◆ Lever out with screwdriver
• ◆ Watch installation position
• Clutch disc
• ◆ Align with VW 547

• Flywheel
• ◆ Can be replaced with engine installed by removing gearbox
• ◆ Removal and installation =>fig.1
• ◆ Making mark for ignition timing => page 13-33
• 20 Nm

→ Fig.1     Removing and installing flywheel

→ Fig.2     Removing and installing pressure plate