Volkswagen Workshop Service and Repair Manuals

Engine codes ABD, ABU

Engine code AEA, AEE, AEX, APQ

I    

II    

III    

Part I

• Toothed belt guard - upper part
• Toothed belt
• ◆ Mark D.O.R. before removing
• ◆ Check for wear
• ◆ Do not kink
• ◆ Removing, installing and tensioning
  => Page 13-20
• 80 Nm
• Camshaft sprocket
• ◆ Note position when installing toothed belt
  => Page 13-20
• Bracket
• ◆ Engine code letters ABD
• ◆ For fuel pipes
• 10 Nm
• ◆ Install with D6
• Rear toothed belt guard

• 10 Nm
• Coolant pump
• ◆ To tension toothed belt loosen slightly and turn with screwdriver => Page 13-20
• O-ring
• ◆ Renew if damaged
• Bolt M6: 10 Nm
  Bolt M8: 20 Nm
• ◆ Install with D6
• Crankshaft toothed belt sprocket
• Toothed belt guard - lower part
• Belt pulley
• ◆ When installing note fixing arrangement
• ◆ Note position when installing toothed belt
  => Page 13-20

• Ribbed belt
• ◆ Mark direction of rotation before removing
• ◆ Removing and installing
  => Page 13-19
• 20 Nm
• 90 Nm + 1/3 turn (120 °) further
• ◆ Renew
• ◆ Oil threads
• ◆ The turning further can be done in several stages
• ◆ The turning further angle can be checked with a commercial protractor e.g. Hazet 6690

Part II

• 10 Nm
• Sealing washer
• ◆ Renew
• Cylinder head cover
• Cap
• ◆ Renew seal if damaged
• Oil deflector
• Cylinder head cover gasket
• ◆ Renew if damaged
• ◆ Before fitting gasket coat transition between bearing cap/cylinder head with D 454 300 A3
• Cylinder head bolt
• ◆ Note installation instructions and sequence when loosening and tightening
  => Page 15-8

• Cylinder head
• ◆ Removing and installing
  => Page 15-8
• ◆ If replaced renew the complete
  coolant
• Cylinder head gasket
• ◆ Renew
• ◆ If replaced renew the complete
  coolant

Part III

Note:

Servicing the clutch:

=> 4-Speed manual gearbox 084; Repair group 30; Servicing clutch

=> 5-Speed manual gearbox 085; Repair group 30; Servicing clutch

• Cylinder block
• ◆ Dismantling and assembling cylinder block, crankshaft and flywheel
  => Page 13-26
• ◆ Dismantling and assembling pistons and conrods
  => Page 13-37
• Oil filter
• ◆ Loosen with strap wrench
• ◆ Tighten by hand
• ◆ Note instructions on filter when installing

• Gasket
• ◆ Not on engines with liquid gasket
• ◆ Renew
• ◆ Before fitting gasket coat sump flange/cylinder block flange with "D2"
• Sump
• ◆ Removing and installing engines with liquid gasket
  => Page 17-16
• 15 Nm
• ◆ Loosen and tighten the bolts flywheel end only with:
       Socket head bolts:
       3249
       Hexagon head bolts: 3185
• Sealing ring
• ◆ Renew
• Oil drain plug, 30 Nm

• 45 Nm
• ◆ Tightening sequence:
  Upper right bolt first, then lower right bolt, and bolts on left last (as seen from direction of travel)
• Bracket
• ◆ For vane pump and alternator
• Tensioning element
• 20 Nm
• Washer
• Tensioning roller

Engine code AEA, AEE, AEX, APQ

I    

II    

III    

Part I

• Toothed belt guard - upper part
• Toothed belt
• ◆ Mark D.O.R. before removing
• ◆ Check for wear
• ◆ Do not kink
• ◆ Removing, installing and tensioning
  => Page 13-20
• 20 Nm + 1/4 turn (90 °) further
• ◆ Renew
• Camshaft sprocket
• ◆ Note position when installing toothed belt
  => Page 13-20
• 10 Nm
• ◆ Install with D6
• Rear toothed belt guard
• 10 Nm

• O-ring
• ◆ Renew
• Coolant pump
• 20 Nm
• Tensioner
• ◆ Checking => Page 13-25
• ◆ Tensioning toothed belts
  => Page 13-20
• 20 Nm
• Crankshaft toothed belt sprocket
• ◆ Note position when installing toothed belt
  => Page 13-20
• Belt pulley
• ◆ When installing note fixing arrangement
• 20 Nm

• Ribbed belt
• ◆ Mark direction of rotation before removing
• ◆ Removing and installing
  => Page 13-19
• Hexagon bolt: 90 Nm + 1/3 turn
  (120 °) further
  Multi-point screw: 90 Nm + 1/4 turn (90 °) further
• ◆ Renew
• ◆ Oil threads
• ◆ The turning further can be done in several stages
• ◆ The turning further angle can be checked with a commercial protractor e.g. Hazet 6690
• Toothed belt guard - lower part

Part II

• 10 Nm
• ◆ Renew
• Sealing washer
• ◆ Renew
• Cylinder head cover
• Cap
• ◆ Renew seal if damaged
• Cylinder head cover gasket
• ◆ Renew if damaged
• ◆ Before fitting gasket coat transition between bearing cap/cylinder head with D 454 300 A3
• Cylinder head bolt
• ◆ Renew
• ◆ Note installation instructions and sequence when loosening and tightening
  => Page 15-8

• Cylinder head
• ◆ Removing and installing
  => Page 15-8
• ◆ If replaced renew the complete
  coolant
• Cylinder head gasket
• ◆ Renew
• ◆ Metal gasket
• ◆ If replaced renew the complete
  coolant

Part III

Note:

Servicing the clutch:

=> 5-Speed manual gearbox 020; Repair group 30; Servicing clutch

• Cylinder block
• ◆ Dismantling and assembling cylinder block, crankshaft and flywheel
  => Page 13-26
• ◆ Dismantling and assembling pistons and conrods
  => Page 13-37
• 45 Nm
• ◆ Tightening sequence:
  Upper right bolt first, then lower right bolt, and bolts on left last (as seen from direction of travel)

• Oil filter
• ◆ Loosen with strap wrench
• ◆ Tighten by hand
• ◆ Note instructions on filter when installing
• 20 Nm + 1/4 turn (90 °) further
• ◆ Renew
• Gasket
• ◆ Not on engines with liquid gasket
• ◆ Metal gasket
• ◆ Renew
• ◆ Before fitting gasket coat sump flange/cylinder block flange with "D2"
• 15 Nm
• ◆ Loosen and tighten the flywheel end bolts only with socket insert 3249
• Sump
• ◆ Aluminium sump

• Sealing ring
• ◆ Renew
• Oil drain plug, 20 Nm
• Bracket
• ◆ For vane pump and alternator
• 45 Nm
• Washer
• Tensioning roller
• Tensioning element