volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

Seal lid - replace > < Poly-V belt travel
Engine - assembly and disassembly
Engine - assembly and disassembly
  Note
t  To carry out assembly works, fasten the engine on the assembly stand, using the Support for VW 643 or VW 643/1 -VW 313- or Rotary stand for engine and gearbox -VAS 6095-.
t  It is necessary to carefully clean the oil ducts and to replace the oil filter if, when servicing the engine, significant amounts of metal particles and detached particles are found in the oil, due to abrasion or wear resulting from seizing (for instance, from the conrods or bearing shells). This procedure prevents any consequential damage.
t  Lubricate all supporting and sliding surfaces prior assembly.
  WARNING
Always replace self-locking nuts and screws subject to angular torque
   

I → Anchor
II → Anchor
Part I
   
1 - Upper cover to mechanical distributor
2 - Toothed belt
q   Mark rotation direction before removal.
q   Check for wear.
q   Do not bend.
q   Removal, installation and adjustment → Chapter.
3 - 20 Nm + 90°
q   Replace after each removal.
q   To loosen and tighten, immobilize the camshaft gear with the Pin wrench -3036-.
4 - Camshaft gear
q   Check the fastening during installation.
q   Check the installation position of toothed belt → Chapter.
5 - 10 Nm
q   Install with Liquid sealant -D000 600 A2-.
6 - Front cover of the mechanical distribution
7 - Water pump
q   With integrated sealing gasket.
q   The sealing gasket must not be separated from the water pump.
q   In case of damages and leaks, replace the entire pump together with the sealing.
q   Check if it turns smoothly.
q   Removal and installation → Rep. gr. 19 „Cooling system“.
8 - Toothed belt tensioning roller
q   Check → Chapter.
q   Toothed belt: removal, installation and adjustment → Chapter.
9 - 20 Nm
10 - 20 Nm
11 - Engine support
12 - Crankshaft sprocket
q   Check installation position of toothed belt → Chapter.
13 - 50 Nm
14 - 10 Nm
15 - Crankshaft pulley
q   Check the fastening during installation.
q   Removal and installation → Chapter.
q   Remove and install of Poly-V belt → Chapter.
16 - 20 Nm
17 - Poly-V belt
q   Mark the spinning direction before the removal.
q   Remove and install of Poly-V belt → Chapter.
q   Poly-V belt routing → Chapter.
18 - 90 Nm + 90°
q   Replace after each removal.
q   To loosen and tighten, use Wrench -3415-.
q   Tightening continuation can be carried out in several steps.
q   Tightening angle can be measured with a common protractor, for example, Hazet 6690.
19 - Lower cover to the mechanical distributor

Part II
  Note
Clutch repairs: → Automatic/manual gearbox; Rep. gr.30.
   
1 - Cylinder block
q   Remove and install crankshaft → Chapter.
q   Remove and install pistons and conrods → Chapter.
q   Of cast iron.
2 - 50 Nm
q   Tightening sequence: first tighten the upper right screw, then the lower right screw, and finally the left screw (front view, in the direction the vehicle moves).
3 - Oil filter
q   Release → Chapter
q   Hand tighten.
q   Follow the oil filter installation instructions.
4 - M 8: Tighten to 20 Nm + 90°, M 10: 45 Nm
q   Replace after each removal.
5 - 10 Nm + 90°
q   Replace after each removal.
q   Loosen fastening screws from crankcase to cylinder block, on the pulley side (4 units), from inner side of the the crankcase.
6 - Crankcase
q   Two parts.
q   Clean sealing surface thoroughly before installation.
q   Install with Silicone sealant for engine -D  176  404  A2 ou A3-.
q   To remove and install, remove oil sump from crankcase.
q   Removal and installation → Chapter.
7 - Oil draining plug, 30 Nm
q   With integrated sealing ring.
q   Replace.
8 - Compact support
q   For Generator (Alternator) -C-, air conditioner compressor, power steering oil pump and Poly-V belt fastening element.
q   Remove and install the compact support in vehicles with air conditioning: → Ventilation system; Rep. gr.87.
9 - Tensioning roller
q   To Poly-V belt.
q   Not applied to the (elastic) Poly-V belt.
q   Vehicles with air conditioning and/or power steering only.
q   To loosen Poly-V belt, turn with 16-mm wrench.
q   Remove and install of Poly-V belt → Chapter.
10 - Support
q   For snap-in connectors.
11 - 40 Nm.

   

Seal lid - replace > < Poly-V belt travel