Engine, Disassembling and Assembling

Engine, disassembling and assembling





Note:
^ When stripping and assembling the engine it should be secured to the engine frame with engine and gearbox bracket VW 540 and supplementary set VW 540/1B.
^ If large amounts of material (as metallic particles and abrasive fragments) removed by a cutting or grinding tool or wear are discovered during engine repair work, this can be from damage to the crankshaft or connecting rod bearings due to partial seizure or oil loss. To prevent any further damage from occurring, carry out the following once the repair procedure is complete:
^ Thoroughly clean oil channels
^ Replace oil spray jets
^ Replace oil cooler
^ Replace oil filter





Part I
1. 25 Nm
2. Tensioning device for ribbed belt
^ Turn with open-end spanner to loosen ribbed belt
3. Toothed belt guard - upper part
4. Toothed belt guard - center section
5. 27 Nm
6. Idler wheel
7. Tensioning roller
8. Toothed belt
^ Mark direction of travel before removing
^ Check for wear
^ Do not kink
^ Removing, installing and tensioning, Refer to Timing Belt, Service and Repair
9. Coolant pump
10. O-Ring
^ Always replace if damaged
11. 15 Nm
12. Tensioner for toothed belt
13. Crankshaft toothed belt sprocket
14. 15 Nm
15. 20 Nm
16. 90 Nm +1/4 turn (90°) further
^ Always replace
^ Counter-hold with 3099 to loosen and tighten
^ When bolting on, place two washers between toothed belt pulley and counterhold
17. Toothed belt guard - lower part
18. 10 Nm
^ Insert with locking fluid D 000 600 A2
19. Pulley
^ For power assisted steering pump
20. 25 Nm
21. Ribbed belt
^ Mark direction of rotation before removing
^ Removing and installing, Refer to Timing Belt, Service and Repair
22. 25 Nm
23. Belt pulley/vibration damper
^ Can only be installed in one position (holes are offset)
^ Note position when installing toothed belt





Part II
1. Knock sensor 1 -G61
^ Checking:
2. 20 Nm
^ Tightening torque influences function of knock sensor
3. Knock sensor 2 -G66
^ Checking:
4. Dipstick
^ Oil level must not be above the max mark!
5. Guide
^ For dipstick
6. O-Ring
^ Always replace
7. Coolant pipe
8. 20 Nm
9. Oil filter bracket
10. 15 Nm +1/4 turn (90°) further
^ Always replace
11. Oil cooler
^ Coat contact area to flange, outside the seal, with AMV 1 88 100 02
^ Ensure clearance to adjacent components
12. 25 Nm
13. Oil filter
^ Loosen with strap wrench
^ Tighten by hand
^ Note instructions on filter when installing
14. Gasket
^ Always replace
15. 10 Nm
16. Engine speed sender
^ Checking:
17. Connection
18. 15 Nm
19. O-Ring
^ Always replace
20. Coolant thermostat
^ Checking: heat-up thermostat in water
^ Opening commences approximately 86°C
^ Opening lift min. 7 mm
^ Removing and installing, Refer to Thermostat, Engine Cooling, Service and Repair
^ Observe installation position, Refer to Thermostat, Service and Repair
^ Checking: heat-up thermostat in water
21. 45 Nm
22. Compact bracket
^ For ribbed belt tensioning roller, alternator, power steering pump and air conditioning compressor
23. Right engine bracket