Volkswagen Workshop Service and Repair Manuals

I    

II    

Part I

• Toothed belt guard - upper part
• 20 Nm
• Coupling drive tensioning roller
• ◆ Checking
• ◆ Tensioning toothed belts
  => Page 13-14
• Coupling drive toothed belt
• ◆ Mark D.O.R. before removing
• ◆ Check for wear
• ◆ Do not kink
• ◆ Toothed belt routing => Fig. 1
• ◆ Removing, installing and tensioning
  => Page 13-14
• 20 Nm
• Rear toothed belt guard
• 12 Nm

• 20 Nm
• Lifting eye
• 25 Nm
• Idler roller
• Bracket
• 50 Nm
• Coolant pump
• ◆ Removing and installing
  => Page 19-20
• Main drive tensioning roller
• ◆ Checking => Page 13-25
• ◆ Tensioning toothed belts
  => Page 13-14

• Main drive toothed belt idler roller
• 50 Nm
• Crankshaft toothed belt sprocket
• ◆ Note position when installing toothed belt
  => Page 13-14
• 20 Nm
• Main drive toothed belt
• ◆ Mark D.O.R. before removing
• ◆ Check for wear
• ◆ Do not kink
• ◆ Toothed belt routing => Fig. 1
• ◆ Removing, installing and tensioning
  => Page 13-14

• Belt pulley
• ◆ When installing note fixing arrangement
• ◆ Removing and installing
  => Page 13-14 ; Removing, installing and tensioning toothed belt
• ◆ Removing and installing ribbed belt => Page 13-11
• 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

• Ribbed belt
• ◆ Mark direction of rotation before removing
• ◆ Removing and installing
  => Page 13-11
• ◆ Ribbed belt routing
  => Page 13-12
• ◆ Vehicles with air conditioning system have an additional idler roller
• Toothed belt guard - lower part
• 50 Nm
• Console

Part II

Note:

Servicing the clutch:

=> 5-Speed manual gearbox 02K; Repair group 30; Servicing clutch; Removing and installing clutch

• Cylinder block
• ◆ Dismantling and assembling pistons and conrods
  => Page 13-53
• 50 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 at hexagon bolt head
• ◆ Tighten by hand
• ◆ Note instructions on filter when installing
• M8: 20 Nm + 1/4 turn (90 °) further,
  M10: 45 Nm
• Compact bracket
• ◆ For vane pump and alternator
• ◆ For vehicles without air conditioning system
• ◆ Removing and installing compact bracket on vehicles with air conditioning system:

=> Heating, air conditioning; Repair group 87; Air conditioner with manual control; Removing and installing air conditioner compressor bracket

• 13 Nm
• ◆ Loosen and tighten only bolts on flywheel end with socket insert T10058
• Sump
• ◆ Removing and installing
  => Page 17-8
• Sealing ring
• ◆ Renew
• Oil drain plug, 30 Nm
• 45 Nm
• Washer
• Tensioning roller
• Tensioning element

→ Fig. 1     Toothed belt routing

A - Coupling drive toothed belt

B - Main drive toothed belt