Engine: Locations

Assembly overview

Note:
^ If large quantities of metal particles or other deposits (caused, for example, by partial seizure of the crankshaft or connecting rod bearings) are found in the engine oil when performing repairs, clean the oil passages thoroughly and replace the oil spray jets, the oil cooler and the oil filter in order to prevent further damage from occurring later.
^ When working on the engine, it should be secured to the holding fixture VW 540 with spacers VW 540/1 B and to the assembly stand.





I -
II -

Part I





1 - 25 Nm
2 - Tensioning element for ribbed belt
^ Turn with open end wrench to relieve tension on ribbed belt.

3 - Toothed belt guard - upper part

4 - Toothed belt guard - middle part

5 - 27 Nm

6 - Idler roller

7 - Tensioning roller

8 - Toothed belt
^ Mark direction of rotation before removing.
^ Check for wear
^ Do not kink.

9 - Coolant pump

10 - O-ring
^ Always replace

11 - 15 Nm

12 - Tensioning element for toothed belt

13 - Crankshaft toothed belt pulley

14 - 15 Nm

15 - 20 Nm

16 - 90 Nm plus 1/4 turn (90°)
^ Replace
^ Use counterhold 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 - Belt pulley
^ For power 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.

Part II





1 - Knock Sensor (KS) 1 -G61-

2 - 20 Nm
^ Tightening torque influences function of knock sensor

3 - Knock Sensor(KS) 2 -G66-

4 - Dipstick
^ Oil level must not be above max. mark!
^ Markings

5 - Guide
^ For dipstick

6 - O-ring
^ Always replace

7 - Coolant pipe

8 - 20 Nm

9 - Oil filter bracket

10 - 15 Nm plus 1/4 turn (90°)
^ Replace

11 - Oil cooler
^ Coat contact area to oil filter bracket, outside seal, with AMV 188 100 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 - Seal
^ Replace

15 - 10 Nm

16 - Engine speed (RPM) sensor -G28-

17 - Hose union

18 - 15 Nm

19 - O-ring
^ Always replace

20 - Thermostat
^ Checking: Heat-up thermostat in water
- Opening begins: approx. 86° C
- Opening lift: min. 7 mm

21 - 45 Nm

22 - Compact bracket
^ For ribbed belt tensioning roller, Generator, power steering pump and air conditioning compressor

23 - Engine bracket - right