Volkswagen Workshop Service and Repair Manuals

Notes:

• ◆ 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, apart from 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 codes 1Z, AHU, AEY, AFN, AVG, ALE

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

Engine codes 1Y, AAZ

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

I    

II    

III    

Part I

• Tensioner
• 20 Nm
• Tensioning lever
• ◆ Lubricate with G 000100
• Dust cap
• Spreader clip
• Toothed belt guard - upper part
• Toothed belt
• ◆ Mark D.O.R. before removing
• ◆ Check for wear
• ◆ Do not kink
• ◆ Removing, installing and tensioning
  
• 45 Nm
• ◆ 20 Nm for semi-automatic tensioning roller

• Eccentric
• ◆ For semi-automatic tensioning roller
• Tensioning roller
• ◆ The semi-automatic tensioning roller is illustrated
• ◆ Checking semi-automatic toothed belt tensioning roller
  => Page 13-31
• 45 Nm
• Camshaft sprocket
• ◆ Drive off camshaft taper using hammer and drift through toothed belt guard openings
• 25 Nm
• Idler wheel
• ◆ Engine codes: 1Z, AHU, AEY, AFN, AVG, ALE
• 10 Nm

• Rear toothed belt guard
• Injection pump sprocket
• ◆ Single part
• ◆ Engine codes: 1Z, AHU, AEY, AFN, AVG, ALE
• ◆ Engine codes:
  1Y, AAZ ▸ 09.94
• ◆ Removing
• Injection pump sprocket
• ◆ Two part
• ◆ Engine codes:
  1Y, AAZ ▸ 10.94
• Injection pump
• ◆ Removing and installing for engine codes 1Z, AHU, AEY, AFN, AVG, ALE

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

• ◆ Removing and installing for engine codes: 1Y, AAZ

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

• Bracket
• ◆ Engine codes: 1Z, AHU, AEY, AFN, AVG, ALE
• ◆ Engine codes
  1Y, AAZ ▸ 09.94
• 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.
• 55 Nm
• ◆ 45 Nm for engine codes: 1Y, AAZ
• Toothed belt guard - lower part

• Pulley
• ◆ For coolant pump
• ◆ Version for ribbed belt
• Ribbed belt
• ◆ Mark direction of rotation before removing
• ◆ Removing and installing
  => Page 13-16
• Belt pulley/vibration damper
• ◆ Can only be installed in one position. Holes are off-set
• V-belt
• ◆ Adjusting V-belt tension:

=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic pipes

• Pulley
• ◆ For coolant pump
• ◆ V-belt version
• Belt pulley

Part II

• Cylinder head cover
• Cap
• ◆ Renew seal if damaged
• Upper sealing washer
• Dished washer
• 10 Nm
• Cap
• To intake hose
• Retaining clip
• Pressure regulating valve
• ◆ For crankcase breather
• Gasket
• ◆ Renew if damaged

• Cylinder head cover gasket
• ◆ Renew if damaged
• Crankcase breather
• Cylinder head bolt
• ◆ Note sequence when loosening and tightening
  => Page 15-9 , removing and installing cylinder head
• Securing clip
• O-ring
• ◆ Renew
• Lower sealing cone
• Injector pipes
• ◆ Tighten to 25 Nm
• ◆ Remove with 3035
• ◆ Always remove pipework complete
• ◆ Do not alter shape

• Cylinder head
• ◆ Removing and installing
  => Page 15-1
• ◆ If replaced renew the complete
  coolant
• Cylinder head gasket
• ◆ Renew
• ◆ Note marking
  
• ◆ If replaced renew the complete
  coolant
• 20 Nm
• Lifting eye

Part III

• Cylinder block
• ◆ Removing and installing sealing flange and pressure plate/flywheel/drive plate
  => Page 13-33
• ◆ Removing and installing crankshaft => Page 13-42
• ◆ Dismantling and assembling pistons and conrods
  => Page 13-46
• O-ring
• ◆ Renew if damaged
• Turn 20 Nm + 1/4 turn (90 °)
  further
• ◆ Renew
• Vacuum pump
• Clamp
• 20 Nm
• Connection
• ◆ For crankcase breather

• Gasket
• ◆ Renew
• Banjo bolt, 25 Nm
• To turbo charger
• ◆ Engine codes
  1Z, AHU, AAZ, AFN, AVG, ALE
• Sealing ring
• ◆ Renew
• 25 Nm
• Oil filter bracket
• Oil cooler
• ◆ Coat contact area to flange, 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
• 10 Nm
• Engine speed sender
• 30 Nm
• Bracket
• ◆ For ribbed belts without tensioner
• Hammer head bolt
• Tensioning element
• Sealing ring
• ◆ Renew if damaged
• Bracket
• ◆ For ribbed belts with tensioner

• Tensioning lever
• ◆ Lubricate with G 000100
• Coolant pump
• ◆ Dismantling and assembling => Page 19-8
• Sump
• ◆ Clean sealing surface before installing
• ◆ Engine codes AEY, AFN, AVG with oil sump cover
• ◆ Removing and installing oil sump cover
• 20 Nm
• ◆ Remove and install both rear bolts gearbox end with jointed spanner 3185
• Bracket
• ◆ For vane pump

• Gasket
• ◆ Renew
• ◆ On engine codes 1Y, AAZ with baffle plate: Replace seal if damaged
• ◆ Before fitting gasket coat sump flange/cylinder block flange with "D2"
• Woodruff key
• ◆ Check for tight fit