Engine, Disassembling and Assembling

Engine, disassembling and assembling

Note:
^ When working on the engine it should be secured to assembly stand VW 313 using engine bracket 3269 or VW 540 and supplementary set 540/1 B.
^ If when repairing an engine, metal shavings or large amounts of small metal particles are found in the engine oil, caused by partial seizure of crankshaft or Connecting rod bearings, perform the following work sequences to prevent consequential damage once repairs are complete:
- Thoroughly clean oil passages
- Replace oil spray jets
- Replace oil cooler
- Replace oil filter
- Replace oil non-return valve





Part I





1. Control housing
^ Lubricate contact surfaces of oil seal when installing
^ Removing and installing, Refer to Camshaft, Engine, Service and Repair
^ Disassembling and assembling, Refer to Cylinder Head, Service and Repair, Valve Gear Servicing, See Fig. 6
^ Check screen of control housing for soiling before installing
2. 8 Nm
^ Replace
3. Camshaft roller chain
^ Mark direction of rotation before removing (installation position)
^ Installing, Refer to Timing Components, Adjustments
4. Exhaust camshaft timing adjuster
^ Marking: 32A
^ Turn engine over only when camshaft timing adjuster is installed
^ Check camshaft timing adjustment, Refer to Camshaft, Engine, Adjustments
^ Installing, Refer to Timing Components, Adjustments
5. Intermediate shaft
6. Thrust washer
7. 8 Nm
^ Insert with locking compound D 000 600 A2
8. Tensioning plate
^ For camshaft roller chain item 3
9. Mounting stud, 10 Nm
^ For tensioning plate item 8
10. Chain tensioner, 40 Nm
^ For camshaft roller chain item 3
^ Turn engine over only when chain tensioner is installed
11. Seal
^ Replace if damaged or leaking
12. Chain sprocket
^ For roller chain item 17
13. Chain sprocket
^ For camshaft roller chain item 3
14. 60 Nm plus additional 1/4 turn (90°) further
^ Replace
^ Use counter support T10069 to loosen and tighten
15. Chain tensioner with tensioning rail
^ For roller chain item 17
^ Before installation release the locking device in the chain tensioner with a small screwdriver and press the tensioning plate against the chain tensioner
^ Turn engine over only when chain tensioner is installed
16. Drive sprocket
^ Integral part of crankshaft
^ Ground down tooth aligned with main bearing joint = TDC cyl.1
17. Roller chain
^ Mark direction of rotation before removing (installation position), Refer to Fig. 1
18. Guide rail
19. Stud without collar, 10 Nm
^ For guide rail item 18
20. 10 Nm
^ For guide rail item 24
21. 23 Nm
^ For guide rail item 24
22. Intake camshaft timing adjuster
^ Marking: 24E
^ Turn engine over only when camshaft timing adjuster is installed
23. 60 Nm plus additional 1/4 turn (90°) further
^ Replace
^ Contact surface of sensor wheel on bolt head must be dry for assembly
^ To remove and install, use a 32 mm open jaw spanner on camshaft to counter support
24. Guide rail
^ For camshaft roller chain item 3
25. Camshaft adjustment valve 2 (exhaust) - N318
^ Mark connector and component before pulling connector off
^ Checking activation:
Refer to Powertrain Management
26. Valve 1 for camshaft adjustment -N205
^ For intake camshaft
^ Check camshaft timing adjustment
^ Mark connector and component before pulling connector off Engine Code(s): BDF
27. Guide rail
^ For camshaft roller chain item 3
^ Clipped into control housing





Fig. 1 Marking roller chains
- Mark roller chains before removing (e.g. with paint arrow pointing in direction of rotation).

Note: Do not mark chain with a punched mark, notch or similar!





Part II
1. 45 Nm
2. Engine bracket
3. 8 Nm
^ Secured to intake manifold
4. Dipstick
^ The oil level must not exceed the max. mark!
^ Markings, Refer to Engine Lubrication, Lubrication System Components, Servicing
5. Guide tube
^ For dipstick
^ Secured by a bolt to intake manifold
6. Cylinder block
^ Removing and installing sealing flange and dual-mass flywheel, Refer to Transmission and Drivetrain, Manual Transmission/Transaxle, Flywheel
^ Removing and installing crankshaft, Refer to Crankshaft, Engine, Service and Repair
^ Disassembling and assembling piston and Connecting rod, Refer to Piston, Engine, Service and Repair
7. Knock sensor (KS) 1 -G61
^ 3-pin
^ Installation location: Between cyl. 1 and cyl. 3
^ The contact surfaces between knock sensor and cylinder block must be free of corrosion, dirt and grease.
^ Checking:
Refer to Powertrain Management
8. 20 Nm
^ Torque setting influences the function of knock sensor
9. 10 Nm
10. Oil pump drive cover
11. O-ring
^ Replace
^ Lubricate before installing
12. Oil pump drive
13. Oil non-return valve, 5 Nm
^ Observe installation position
^ Clean if badly soiled
14. Intermediate shaft
15. Thrust washer
16. 10 Nm
^ Install with locking compound "D6"
17. Drive shaft
^ For oil pump drive
18. Oil pump
^ Coat oil pressure pipe at cylinder block and oil pump housing with sealing compound AMV188001 02
19. 23 Nm
20. 8 Nm
^ Insert with locking compound D 000 600 A2
21. Oil drain plug, 30 Nm
^ Replace if leaking
22. Oil pan
23. 12 Nm
24. Oil filter housing
25. Vibration damper
26. 100 Nm plus additional 1/4 turn (90°) further
^ Replace
^ Use counter support T10069 to loosen and tighten, Refer to Fig 1
^ Tighten using torque wrench VAG 1601
27. Knock sensor (KS) 2-G66
^ 2-pin
^ Installation location: Between cyl. 4 and cyl. 6
^ The contact surfaces between knock sensor and cylinder block must be free of corrosion, dirt and grease.
^ Checking:
Refer to Powertrain Management
28. Engine speed (RPM) sensor -G28-
^ Checking:
Refer to Powertrain Management





Fig. 1 To loosen and tighten securing bolt, hold vibration damper with counter support T10069

Note:
^ Vibration damper securing bolt must be replaced.
^ Tighten securing bolt with torque wrench VAG 1601.