Volkswagen Workshop Service and Repair Manuals

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• Upper toothed belt guard
• ◆ ▸7/87 metal version
• ◆ 8/87 ▸ as ilustrated
• 10 Nm
• Toothed belt guard
• ◆ only with plastic upper toothed belt guard
• Toothed belt
• ◆ Installation
• Tensioner
• ◆ Turn to the right using special spanner, e.g.Matra -V 159-
• 45 Nm
• Rear toothed belt cover

• 20 Nm
• ◆ 30 Nm with metal toothed belt cover
• ◆ The metal version of toothed belt cover has an aditional Allen screw.Secure with -D6-and tighten to 30 Nm.
• V-belt
• ◆ Check tension with thumb pressure
• ◆ Adjusting alternator V-belt tension
• ◆ Deflection in mm:

• Vibration Dampener/V-belt Pulley
• ◆ Watch position when installing toothed belt
• ◆ Installation possible in one position only - holes are offsset
• 20 Nm
• Lower toothed belt guard
• ◆ Engines without fully-enclosed toothed belt guard are equiped with a lower sealing flange incorporating toothed belt cover
• Crankshaft toothed belt sprocket
• ◆ Engines whit code letters EG and groove for woodruff key

• Hexagon bolt (M 12 x1.5), 80 Nm
• ◆ Use washer!
• ◆ Secure with -D6-
• ◆ For tightening and loosening, use holding tool 3099

• Hexagon Bolt (M14 x 1.5) 180 Nm
• ◆ Use washer!
• ◆ Lubricate threads
• ◆ For tightening and loosening use holding tool 3099
• Twelve-point bolt, 90 Nm + 180°
• ◆ Renew
• ◆ Lubricate threads and shoulder
• ◆ Do not use washer
• ◆ For tightening and loosening use holding tool 3099
• ◆ The additional 180°turn can be performed in several stages

• Intermediate shaft sprocket
• ◆ Watch position when installing the toothed belt
• 80 Nm

Note:

Gaskets and sealing rings must always be renewed.

• Oil filler cap
• 10 Nm
• Reinforcing strip
• Cylinder head cover
• Oil deflector plate
• Cylinder head cover gaskets
• Cilinder head
• ◆ Observe installation instructions and tightening
• Camshaft sprocket
• ◆ Watch position when installing the toothed beld

• Plug
• Cylinder head
• ◆ Removal and installation
• ◆ If replaced: renew coolant
• Suspension eye
• ◆ At the rear of the toothed belt cover on engines with Engine Code Letters EG
• Alternator bracket
• ◆ On engines equipped with toothed rack for belt tension adjustment
  
• 20 Nm
• Cylinder head gasket
• ◆ Install in correct position
• ◆ The word "OBEN" should face towards the cylinder head
• ◆ If replaced: renew coolant

Notes:

• ◆ Always renew gaskets and seeling rings.
• ◆ Should metal particles in substantial quantity be found in the engine oil - for instance, as a result for abrasion associated with crankshaft or conecting rod bearing damage - the oil passages should be thoroughly cleaned and the oil cooler renewed to prevent further damage.

• Distributor
• ◆ Installation:

=> Repair Group 28

• 20 Nm
• Seal or O-ring
• Seal or O-ring
• Woodruff key

• Hammer-headed screw
• Water pump
• Oil pressure sensor, 25 Nm
• Oil filter mount
• ◆ Engine Code Letters: ▸ EG 015 152
• Oil filter
• ◆ Loosen with strap wrench
• ◆ Follow installation instructions on filter
• Cover
• Sump gasket
• Sump
• 35 Nm

• 15...25 Nm
• ◆ As the tightening torque has a direct influence on the function of the knock sensor, it is imperative that it be tightened according to specification
• Knock sensor -G61-
• ◆ Only engines with code letters: 2H
• Oil pressure switch, 25 Nm
• ◆ Engine Codes: DX, JH, JJ, KT, 2H
• Seal
• Oil filter bracket
• ◆ ▸7/84 See
• ◆ 8/84 ▸Engine Codes: DX, JH, KT, 2H

• Oil cooler
• ◆ ▸7/84 See
• ◆ 8/84 ▸Engine Codes: DX, JH, KT, 2H
• ◆ Coat flange contact surfaces outside the seal with AMV 188 100 02
• ◆ Ensure clearance to adjacent parts
• 25 Nm
• ◆ 8/84 ▸Engine Codes: DX, JH, KT, 2H