Dismantling and assembling the engine — VW

BFS
Note:

If when repairing an engine, metal shavings or large amounts of small metal particles are found in the engine oil, caused for example by partial seizure of crankshaft or conrod bearings. Perform the following work sequences to prevent consequential damage once repairs are complete:

Thoroughly clean oil passages
Renew oil spray jets
Renew oil cooler
Renew oil filter

I
=>page
13-2

II
=>page
13-6

Part I

45 Nm
Engine bracket
25 Nm
Retainer
various designs

Toothed belt guard, upper part
Removing and installing
=> page
15-7

Toothed belt guard, centre section
100 Nm
Use counterhold tool 3415 to loosen and tighten

Camshaft sprocket
Hexagon combi-bolt
10Nm

Rear toothed belt guard

Hexagon socket head bolt
15 Nm

O-ring
Renew

Coolant pump
15 Nm
Toothed belt
Mark direction of rotation before removing
Check for wear
Do not kink
Removing, installing and tensioning
=> page
15-7

Tensioning element for ribbed belt
Turn with open jaw spanner to slacken ribbed belt => page
13-10

Washer
20 Nm
Crankshaft toothed belt sprocket
90 Nm + 1/4 turn (90 °) further
Renew
Threads and shoulder must be free of oil and grease
Use counterhold tool 3415 to loosen and tighten

Toothed belt guard, lower part
10 Nm
Belt pulley
For power assisted steering pump

Poly V-belt
Mark direction of rotation before removing
Removing and installing
=> page
13-10

Belt pulley/vibration damper
Can only be installed in one position. Holes are offset
Note position when installing toothed belt
=>page
15-7
, Removing, installing and tensioning toothed belt

Tensioning roller
Checking semi-automatic toothed belt tensioning roller
=> page
13-12

Part II

Knock sensor 1 (G61)
Checking:

=> Repair group 01; Fault memory; Interrogating and erasing engine control unit fault memory
4-Cyl. Injection Engine (2 Valve, Roller Rocker Finger), Mechanics
Fault memory
Interrogating and erasing engine control unit fault memory

20 Nm
Torque setting influences the function of knock sensor

Coolant pipe
Dipstick
The oil level must not exceed the max. mark!
Markings
=>page
17-10
, fig.
1

Retainer
For ignition coil

10 Nm
6 Nm

20 Nm
Retainer
Oil filter bracket with attached parts
Dismantling and assembling => page
17-7

15 Nm + 1/4 turn (90 °) further
Seal
Renew

10 Nm
Engine speed sender
Checking:

=> Repair group 01; Fault memory; Interrogating and erasing engine control unit fault memory
4-Cyl. Injection Engine (2 Valve, Roller Rocker Finger), Mechanics
Fault memory
Interrogating and erasing engine control unit fault memory

Union
15 Nm

Seal
Renew if damaged

Seal
Renew

Coolant thermostat
Checking: Heat up thermostat in water
Starts to open at approx. 86 °C
Opening stroke min. 7 mm

45 Nm
Renew
Checking:

=> Repair group 87; Air conditioning system with manual controls; Removing and installing air conditioner compressor bracket
4-Cyl. Injection Engine (2 Valve, Roller Rocker Finger), Mechanics
Air conditioning system with manual controls
Removing and installing air conditioner compressor bracket

Compact bracket
For poly V-belt tensioning roller, alternator, power assisted steering vane pump and air conditioner compressor
Removing and installing:

=> Repair group 87; Air conditioning system with manual controls; Removing and installing air conditioner compressor bracket
4-Cyl. Injection Engine (2 Valve, Roller Rocker Finger), Mechanics
Air conditioning system with manual controls
Removing and installing air conditioner compressor bracket

Cylinder block
Removing and installing sealing flange and pressure plate/drive plate => page
13-14
Removing and installing crankshaft => page
13-29
Dismantling and assembling piston and conrod
=> page
13-35