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.
• ◆ All bearing and running surfaces must be oiled before assembling.

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
  
• 20 Nm + 1/8 turn (45 °) further
• Tensioning roller
• 100 Nm
• 25 Nm
• Camshaft sprocket

• Hub
• ◆ With sender wheel
• ◆ Counter-hold with T10051 to loosen and tighten
• ◆ To remove, use puller T10052
• ◆ Removing and installing => Page 15-47, Removing and installing camshaft
• 10 Nm
• Rear toothed belt guard
• Sealing grommet
• ◆ Renew if damaged
• Toothed belt tensioner
• Idler wheel
• Coolant pump
• ◆ Removing and installing
  => Page 19-18
• Crankshaft toothed belt sprocket

• 120 Nm + 1/4 turn (90 °) further
• ◆ Renew
• ◆ Counter-hold with 3415 to loosen and tighten
• ◆ Do not additionally oil or grease the threads and shoulder
• ◆ The quarter turn further can be done in several stages.
• 15 Nm
• 20 Nm
• Toothed belt guard - lower part
• Belt pulley/vibration damper
• ◆ Can only be installed in one position. Holes are off-set
• 10 Nm + 1/4 turn (90 °) further
• Toothed belt guard - centre part

Part II

• Cylinder head cover
• ◆ With oil filler neck
• ◆ Replace oil filler neck also if cylinder head cover is damaged
• ◆ Before fitting, thoroughly clean sealing surface of cylinder head with clean rag
• To turbocharger
• 10 Nm
• ◆ First hand tighten all bolts
• ◆ Then first tighten both top bolts and the rest from inside to outside diagonally to specified tightening torque

• Pressure regulating valve
• ◆ For crankcase breather
• Cap
• ◆ Renew seal if damaged
• Gasket
• ◆ Renew if damaged
• Oil filler neck
• ◆ Renew
• Bracket
• ◆ With fuel pipe
• Cylinder head cover gasket
• ◆ Renew if damaged
• 20 Nm
• Lifting eye
• 10 Nm

• Central connector
• ◆ For unit injector
• From brake servo
• Tandem pump
• ◆ For fuel and vacuum supply
• ◆ Removing and installing
  => Page 20-36
• ◆ Checking => Page 20-32
• 25 Nm
• Supply hose
• ◆ From fuel filter
  => Page 20-8
• ◆ White or with white marking
• ◆ Check securely seated
• ◆ Secure with spring-type clips

• Return hose
• ◆ To fuel filter
  => Page 20-8
• ◆ Blue or with blue marking
• ◆ Check securely seated
• ◆ Secure with spring-type clips
• Gasket
• ◆ Renew
• Pin 10 Nm
• ◆ For engine cover
• Bracket
• Tapered hexagon nut

• Cylinder head gasket
• ◆ Renew
• ◆ Note identification
  
• ◆ If replaced renew the complete
  coolant
• Hall sender (G40)
• ◆ For camshaft position
• ◆ Unclip to remove sealing grommet from rear toothed belt guard
• ◆ Checking:

=> Repair group 23; Servicing diesel direct injection system; Checking Hall sender for camshaft position

• Cylinder head bolt
• ◆ Renew
• ◆ Note sequence when loosening and tightening
  => Page 15-21, removing and installing cylinder head
• ◆ Insert washers into cylinder head before installing => Page 15-30, item 4, Servicing valve gear
• Unit injector
• ◆ Removing and installing

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

Part III

• 45 Nm
• Engine bracket
• Cylinder block
• ◆ Removing and installing sealing flange and flywheel
  => Page 13-19
• ◆ Dismantling and assembling pistons and conrods
  => Page 13-46
• Connection, 40 Nm
• ◆ For oil return pipe from turbocharger
• ◆ Renew
• Spacer sleeve
• Rubber bush
• Bracket
• ◆ For connectors for Hall senders for camshaft position (G40) and engine speed (G28)

• 10 Nm
• Gasket
• ◆ Renew
• Oil filter bracket
• ◆ Dismantling and assembling => Page 17-9
• 15 Nm + 1/4 turn (90 °) further
• ◆ Renew
• ◆ First fit upper left and lower right bolt, then tighten the four bolts diagonally
• O-ring
• ◆ Renew
• 20 Nm
• Engine speed sender
• ◆ Checking:

=> Repair Group 01; Self-diagnosis; Interrogating and erasing fault memory

• Connection
• ◆ For thermostat
• 15 Nm
• Coolant thermostat
• ◆ Removing and installing
  => Page 19-21
• 45 Nm
• ◆ Note tightening sequence
  Page => 19-10, Fig. 1
• Compact bracket
• ◆ For alternator, air conditioning compressor PAS vane pump and ribbed belt tensioning element
• Tensioning element
• ◆ for ribbed belt
• 25 Nm

• Sump
• ◆ Clean sealing surface before installing
• ◆ Install with silicone sealant
  D 176 404 A2
  => Page 17-17
• ◆ To remove sump, gearbox must first be removed

=> 5-Speed manual gearbox 02J; Repair group 34; Removing and installing gearbox

• 15 Nm
• ◆ To remove the rear bolts near gearbox, the gearbox must be removed

=> 5-Speed manual gearbox 02J; Repair group 34; Removing and installing gearbox

• Cover
• ◆ With sealing tape
• ◆ Clean strainer if soiled

• Retaining frame
• ◆ Before installing, check that the fitting sleeves for centring on cylinder block are in place and that the O ring is inserted in the retaining frame
• ◆ Removing and installing =>13-33
• 40 Nm
• Protective cap
• ◆ For drive shaft