Volkswagen Workshop Service and Repair Manuals

Removing Engine codes AGR, AHF, ALH, ASV –  Remove right headlight: → Rep. Gr.94 –  Remove connecting pipe between charge air cooler and intake manifold → Chapter. Continuation for all engine codes –  Unscrew coolant expansion tank and lay to side. –  Remove power assisted steering reservoir and place to one side. –  Remove upper toothed belt guard. –  Remove vacuum pump for brake servo. –  Remove noise insulation: → Rep. Gr.50. –  Remove poly V-belt → Chapter.

–  Turn crankshaft to TDC of cyl. no. 1 (on vehicles with manual gearbox). -A- Engine code AGP, AQM-B- Engine code AGR, AHF, ALH, ASV   Note To turn the engine over by hand, fit camber adjusting lever -3098- to power steering vane pump.

–  Turn crankshaft to TDC of cylinder no. 1 -arrow- (on automatic gearbox).   Note t  To turn the engine over by hand, fit camber adjusting lever -3098- to power steering vane pump. t  Engine removed: Vehicles with manual gearbox Engine codes AGR, AHF, ALH, ASV

–  Screw in adjustment bar 2068 A as shown. –  Set adjustment bar to 96 mm -arrow A-. The left-hand notch of the vernier scale is the reference point. –  Turn crankshaft until flywheel TDC marking aligns with point of setting device -arrow B-.

Engine codes AGP, AQM –  Screw in TDC adjustment bar -2068 A- as shown. –  Set adjustment bar to 5 mm -arrow A-. The left-hand notch of the vernier scale is the reference point. –  Turn crankshaft until flywheel TDC marking aligns with point of setting device -arrow B-.

Vehicles with automatic gearbox –  Screw in TDC adjustment bar -2068 A- as shown. –  Set adjustment bar to 30 mm -arrow A-. The left-hand notch of the vernier scale is the reference point. –  Turn crankshaft until TDC marking on drive plate aligns with point of setting device -arrow B-.

Continuation for all vehicles –  Screw dowel screws -1- onto stop by hand into cylinder head. –  Lock camshaft as shown using camshaft bar -T10098 A-.

–  Lock injection pump belt pulley using diesel injection pump locking pin -3359-. –  Loosen securing bolts -1- of injection pump belt pulley.   Note t  Unscrew securing bolts with milled neck and tapered end and replace. (Part number of injection pump pulley -038 130 111 A-). t  Securing bolts without milled neck and with flat end should not be renewed. (Part number of injection pump pulley -038 130 111 B -). t  On no account should nut -2- for the hub be loosened. Otherwise the injection pump basic setting may be altered and this cannot be reset with normal workshop equipment –  Loosening tensioning roller.

–  Fit engine support bracket -10-222A- with adapters -10-222A/1- and take up weight of engine in installation position.

–  Unscrew securing bolts from assembly mounting/engine bracket, assembly mounting/body and assembly mounting/body bracket -arrows- and remove assembly mounting complete.   Note t  The assembly mounting may only be removed if the engine is supported with support bracket -10-222A-! t  The engine bracket must be loosened only when the assembly mounting has been removed.

–  Unbolt engine bracket from cylinder block -arrows- and remove.   Note t  When loosening both upper engine bracket bolts the engine must be raised slightly with the support bracket. t  When loosening the lower engine bracket bolt the engine must be lowered slightly with the support bracket. –  Remove vibration damper/belt pulley. –  Remove toothed belt lower and centre guards. –  Mark direction of rotation of toothed belt. –  Remove toothed belt.