Assembly overview - part II, chain drive, engine codes AZQ, BME, BZG — VW

Assembly overview - part II, chain drive, engine codes AZQ, BME, BZG
Caution
The crankshaft must not be removed. Just loosening the main bearing caps will cause deformation of the cylinder block bearing pedestals. This deformation will cause a reduction of the bearing clearance. Even if the bearing shells are not renewed bearing damage could occur due to a different bearing clearance.
If the bearing cap bolts are loosened, the cylinder block must be renewed complete with the crankshaft.
Measuring the main bearing clearance is not possible with normal workshop equipment.
The pistons must not be removed.
Cylinder head with camshaft housing
Sealing surface must not be reworked.
With integrated camshaft bearings.
Removing and installing
Chapter
Remove sealant residue.
Coat with D 154 103 A1 before fitting.
When installing, lower vertically from above so that dowel pins fit into holes in cylinder head.
Cylinder block
2 parts
Bolts must not be loosened.
Note
The pistons must not be removed.
Balancer shaft
Gear wheel
For balancer shaft.
The securing bolt must not be loosened!!!
Oil pump
Renew complete only.
Guide pins
Specified torque: 20 Nm
Guide rail
For timing chain
Item
Chain sprocket
For crankshaft.
Chain sprocket
For oil pump drive.
Drive chain for oil pump
Before removing, mark direction of rotation (installation position).
Chain sprocket
For oil pump.
Adjusting valve timing
Chapter
.
Oil sump
Remove and install on engines with liquid gasket
Chapter
.
Clean sealing surface before fitting.
Install with silicone sealant D 176 404 A2.
15 Nm
8 Nm
Cover
20 Nm +
1
/
4
turn (90°) further
Renew.
Bearing bush
With O-ring.
Note
Always renew O-ring after removal.
Belt pulley
Do not cant when installing.
Removing and installing poly V-belt
Chapter
.
90 Nm +
1
/
4
turn (90°) further
Renew.
Oil before installing.
Lock with
counterhold
3415
.
When tightening, lock crankshaft using
locking pins
T10121
.
The turning further angle can be measured with a commercial protractor.
25 Nm
45 Nm
10 Nm
To intake manifold.
10 Nm
Oil separator
With vacuum valve.
O-ring
Renew if damaged.
Valve timing housing
Install with silicone sealant D 174 003 A2.
When fitting, install two
M6x75
studs into cylinder head and cylinder block as a guide.
To guide valve timing housing, secure oil sump in position with two bolts.
Cover
O-ring
Renew if damaged.
50 Nm +
1
/
4
turn (90°) further
Renew.
Tensioning plate
Chain tensioner
9 Nm
Timing chain
Chain sprocket
For camshaft.
15 Nm
Was only fitted on engine code AZQ.
Guide rail
Was only fitted on engine code AZQ.
Note
The guide rail has been discontinued, also as replacement part.
In case of repair the guide rail need not be installed.
Washer
Was only fitted on engine code AZQ.