Volkswagen Workshop Service and Repair Manuals

Note:

If when repairing an engine, metal shavings or large quantities of small metal particles - caused, for example, by partial seizure of crankshaft and conrod bearings - are found in engine oil, to prevent consequential damage, apart from thoroughly cleaning oil passages, it is necessary to renew the oil cooler.

I    

II    

III    

Part I

• Tensioner
• 20 Nm
• Tensioning lever
• Dust cap
• 10 Nm
• Toothed belt guard - lower part
• Toothed belt guard - upper part
• 45 Nm
• Tensioning roller
• Toothed belt
• ◆ Mark D.O.R. before removing
• ◆ Check for wear
• ◆ Do not kink
• ◆ Removing, installing and tensioning
  

• Toothed belt guard
• ◆ Engine code: AAM, ABS, ADZ
• Rear toothed belt guard
• Intermediate shaft sprocket
• 80 Nm
• ◆ Counter-hold with 3036 to loosen and tighten
• Crankshaft toothed belt sprocket
• 90 Nm + 1/4 turn (90 °) further
• ◆ Counter-hold with 3099 to loosen and tighten
• ◆ Renew
• ◆ Oil threads and shoulder
• ◆ The quarter turn further can be done in several stages.

• Pulley
• ◆ For coolant pump
• ◆ Version for ribbed belt
• Ribbed belt
• ◆ Mark direction of rotation before removing
• ◆ Removing and installing
  => Page 13-15
• Belt pulley/vibration damper
• ◆ Can only be installed in one position. Holes are off-set
• ◆ Note position when installing toothed belt
  => Page 13-18 , removing, installing and tensioning toothed belt

• 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
• 25 Nm
• Belt pulley

Part II

• Pressure regulating valve
• ◆ For crankcase breather
• ◆ Only on engine codes: 2E, ADY, AGG
• Cap
• ◆ Renew seal if damaged
• 10 Nm
• Cylinder head cover
• ◆ On engine codes AAM, ABS and ADZ sheet steel cover with reinforcing strips
• Oil deflector
• Cylinder head bolt
• ◆ Note sequence when loosening and tightening
  => Page 15-5 , removing and installing cylinder head

• Cylinder head cover gasket
• ◆ Renew if damaged
• ◆ On engine codes AAM, ABS and ADZ: 3-part, always renew
• ◆ Before fitting gasket coat transition between bearing cap/cylinder head with "D2"
• Cylinder head
• ◆ Removing and installing
  => Page 15-1
• ◆ If replaced renew the complete
  coolant
• Cylinder head gasket
• ◆ Renew
• ◆ If replaced renew the complete
  coolant
• Lifting eye

• Camshaft sprocket
• ◆ Note position when installing toothed belt
  => Page 13-18 , removing, installing and tensioning toothed belt
• From the crankcase breather
• ◆  , Item 13
• ◆ On engine codes ABS and ADZ the crankcase breather is extended by a metal pipe

Part III

• Cylinder block
• ◆ Removing and installing sealing flange and flywheel/drive plate => Page 13-23
• ◆ Removing and installing crankshaft => Page 13-31
• ◆ Dismantling and assembling pistons and conrods
  => Page 13-35
• Woodruff key
• ◆ Check for tight fit
• O-ring
• ◆ Renew if damaged
• Engine earth connection
• 25 Nm

• Knock sensor
• ◆ Only on engine codes: 2E, ADY, AGG
• ◆ Checking:

=> Repair group 01; Injection and ignition system; Interrogating and erasing fault memory

• 20 Nm
• ◆ Tightening torque influences the function of the knock sensor
• Distributor
• ◆ Installing:

=> Repair group 28; Injection and ignition system; Installing distributor

• 25 Nm
• Clamp
• Gasket
• ◆ Renew

• Oil filter bracket
• ◆ Types , Item 11
• Crankcase breather
• ◆ On engine codes 2E, ADY, AGG: to pressure regulating valve on cylinder head cover
• ◆ On engine codes AAM, ABS, ADZ: to crankcase breather hose for cylinder head cover/intake elbow
• 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
• 30 Nm
• Bracket
• ◆ For ribbed belts without tensioner
• Turn 20 Nm + 1/4 turn (90 °)
  further
• ◆ Renew
• Sump
• ◆ Clean sealing surface before installing
• Hammer head bolt
• Coolant pump
• ◆ Dismantling and assembling => Page 19-9

• 20 Nm
• 10 Nm
• Tensioning element
• Bracket
• ◆ For ribbed belts with tensioner
• Sealing ring
• ◆ Renew if damaged
• Tensioning lever
• 20 Nm
• ◆ Only loosen and tighten the flywheel end bolts with:
       Socket head bolts: 3249
       Hexagon head bolts: 3185

• Bracket
• ◆ For vane pump
• Gasket
• ◆ Renew
• ◆ Before fitting gasket coat sump flange/cylinder block flange with "D2"