Volkswagen Workshop Service and Repair Manuals

Removing and installing crankshaft pulley

Special tools and workshop equipment required

t	Torque wrench -V.A.G 1601-

t	Counterhold tool -3415-

t	Pins -3415/2-

t	Locking pin -T10340-

t	Torque wrench (5 … 50 Nm) -V.A.G 1331-

Removing –  Remove poly V-belt → Chapter.

–  Loosen belt pulley securing bolt. Hold pulley with counterhold tools -3415- and -3415/2-. Installing

–  Remove securing bolts -1- and remove coolant pipe bracket -2-.   Note t  Note that all contact surfaces from the securing bolt to the crankshaft must be free of oil and grease. t  Always use a new bolt. –  Tighten belt pulley hand-tight using a new securing bolt.

–  Unscrew plug -arrow- from crankcase.   Note t  Use of locking pin is intended to prevent crankshaft from turning as well when tightening to specified torque. t  Otherwise, the torque setting might not be correct. –  Screw locking pin -T10340- to stop into crankcase.   Caution If locking pin -T10340- cannot be screwed in as far as stop, this indicates that crankshaft is not in the correct position! In this case, proceed as described below. –  Remove locking pin. –  Turn crankshaft 90° in normal direction of rotation. –  Screw locking pin -T10340- to stop into crankcase. –  Tighten locking pin -T10340- to 30 Nm. –  Turn crankshaft in normal direction of rotation until the stop.

Locking pin -T10340- locks crankshaft in direction of engine rotation.   Caution When tightening securing bolt, it is essential to use counterhold tool -3415- with -3415/2- to prevent damage to locking pin. Tightening torque: 150 Nm + turn 180° further Hold pulley with counterhold tools -3415- and -3415/2-.

–  Unscrew locking pin -T10340- from crankcase. –  Screw plug into crankcase.

Specified torque: 30 Nm

–  Install coolant pipe bracket -2- and tighten bolts -1-. Specified torque M6 bolt = 10 Nm M8 bolt = 20 Nm –  Install poly V-belt → Chapter. Further assembly is basically the reverse of the dismantling sequence.