Volkswagen Workshop Service and Repair Manuals

Special tools, testers and auxiliary items

• ◆ Counter-hold tool 3036
• ◆ V.A.G 1331 Torque wrench (5...50 Nm)
• ◆ V.A.G 1332 Torque wrench (40...200 Nm)
• ◆ Sealing compound AMV 174 004 01

Removing

Engine codes ABD, ABU

• ‒ Remove toothed belt guard upper part and cylinder head cover.
• ‒ Loosen camshaft sprocket (counter-hold with 3036).
• ‒ Loosen coolant pump and remove toothed belt.
• ‒ Pull off camshaft sprocket.
• ‒ Unbolt rear toothed belt guard from cylinder head.
• ‒ Remove distributor.

• ‒ → First remove bearing caps 5, 1 and 3.
• ‒ Slacken off bearing caps 2 and 4 alternately and diagonally.

Engine code AEA, AEE, AEX, APQ

• ‒ Remove ribbed belt .
• ‒ Remove vibration damper and toothed belt guard upper and lower parts.
• ‒ Loosen camshaft sprocket (counter-hold with 3036).
• ‒ Release tensioner and take off toothed belt.
• ‒ Pull off camshaft sprocket.
• ‒ Unbolt rear toothed belt guard from cylinder head.
• ‒ Remove cylinder head cover.
• ‒ Remove distributor.

• ‒ → First remove bearing caps 5, 1 and 3.
• ‒ Slacken off bearing caps 2 and 4 alternately and diagonally.

Installing

• ● The pistons must not be positioned at TDC.

Note:

Note fitting position of bearing cap: Wider cast lug -arrow A- to intake side and the bearing cap number -arrow B- readable from the exhaust side.

• ‒ Oil camshaft running surfaces.
• ‒ Tighten bearing caps 2 and 4 alternately and
  diagonally to
       6 Nm.
• ‒ Coat bearing cap 1 and 5 contact surfaces lightly with sealant AMV 174 004 01.
• ‒ Install bearing caps 3, 1 and 5 and tighten to
       6 Nm.
  When doing this insert distributor for centralizing bearing cap 5.
• ‒ Turn all nuts by 1/4 turn (90 °) further.
• ‒ Insert bolts for bearing cap 5 and tighten to
       10 Nm.

The rest of the assembly is basically a reverse of the dismantling sequence.

Installing toothed belt and adjusting timing => Page 13-20 .

Note:

When new tappets have been installed the engine must not be started for about 30 minutes. Hydraulic compensation elements must settle (otherwise valves will strike pistons).