Overhaul

Engine, disassembling and assembling





Notes:
^ When repairing the engine it should be secured to the engine frame with engine and transmission bracket VW 540 and supplementary set VW 54011B.
^ If large amounts of swath or wear are discovered during engine repair work, this can originate from damage to the crankshaft or connecting rod bearings. 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
^ To loosen ribbed belt, turn with open-end wrench, Removing and installing ribbed belts
3-Toothed belt guard-upper part
4-Toothed belt guard-center section
5-27 Nm
6-Idler wheel
7-Tensioning roller
^ Removing, installing and tensioning toothed belt
8-Toothed belt
^ Mark direction of rotation before removing
^ Check for wear
^ Do not kink
^ Removing, installing and tensioning
9-Coolant pump
^ Check for ease of movement
^ If damaged or leaking replace complete
^ Removing and installing
10-O-Ring
^ Always replace
11-15 Nm
12-Tensioning device for toothed belt
^ Removing, installing and tensioning toothed belt
13-Crankshaft toothed belt sprocket
14-15 Nm
15-20 Nm
16-9O Nm 1/4 turn (90°) further
^ Always replace
^ Counter-hold with 3415 to loosen and tighten
^ Threads and shoulder must be free of oil and grease
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
^ Check for wear
^ Do not kink
22-25 Nm
23-Belt pulley/vibration damper
^ Can only be installed in one position. Holes are offset
^ Note position when installing toothed belt, Removing, installing and tensioning toothed belt

Part II





1-Knock sensor 1 (G61)
2-20 Nm
^ Tightening torque influences the function of the knock sensor
3-Knock sensor 2 (G66)
^ Checking.
4-Dipstick
^ The 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
^ Disassembling and assembling.
10-15 Nm + 1/4 turn (90°) further
^ Always replace

11-Oil cooler
^ Coat contact area to flange, outside the seal, with AMV 188 100 02
^ Make sure 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
^ Removing and installing
^ Observe installation position, Removing and installing thermostat
^ Checking: heat-up thermostat in water
^ Opening commences approx. 86°C
^ Opening lift min. 7 mm
21-45 Nm
22-Compact bracket
^ For generator, air conditioner compressor and vane pump for power assisted steering
23-Right engine bracket