New V-belt 2 mm
Used V-belt 5 mm
- TIghten securing bolts on vane pump.
Tightening torques
Component Nm
Vane pump to bracket 25
Removing and installing ribbed belt Removing
Note:
Mark the direction of rotation with chalk or felt pen before removing the ribbed belt. If the belt rotates in the wrong direction when it is refitted, it may break.
- Remove V-belt=>Page 13-9.
- Detach cover cap -Item 6-, Page 13-3, from tensioning roller.
-
Õ To slacken ribbed belt tensioning roller, apply 17 mm socket with extension to central nut.
- To slacken ribbed belt, turn tensioning element in direction of arrow.
-
Õ Turn ribbed belt tensioning element in direction of arrow. - Fit ribbed belt over alternator pulley last. Release tensioning element.
Note:
Ensure that the ribbed belt is properly seated in the pulleys when installing.
- Install V-belt=>Page 13-9. - Routing of belts=>Page 13-13
- Press on cover cap -Item 6-, Page 13-3, for tensioning roller. - Start engine and check that belts run properly.
Installing
Routing of belts
-
Õ Routing of ribbed belt on vehicles without air conditioner.
-
Toothed belt drive Note:
Mark the direction of rotation with chalk or felt pen before removing the toothed belt. If a used belt rotates in the wrong direction when refitted, this can result in breakage.
1 - Toothed belt guard - top
When installing, engage carefully in bottom toothed belt guard 2 - Toothed belt
Mark direction of rotation with chalk or felt pen before removing Check for wear
Removing=>Page 13-20 Installing=>Page 13-26
3 - 20 Nm
4 - Tensioning roller
Checking semi-automatic toothed belt tensioning roller
=> Page 13-30 Position
=>Fig.1, Page 13-18 5 - 45 Nm
Counter-hold with 3036 to loosen and tighten
6 - Camshaft sprocket
Release from camshaft taper by tapping with a hammer (using a drift through toothed belt guard opening) 7 - 25 Nm
8 - Idler roller 9 - 10 Nm
11 - 10 Nm 12 - 25 Nm
13 - Woodruff key
Check proper seating 14 - Injection pump sprocket
Removing injection pump sprocket =>Fig. 3, Page 13-19
Check that Woodruff key is fitted correctly
15 - Intermediate shaft sprocket Installation position
=>Fig. 2, Page 13-18
Check that Woodruff key is fitted correctly
16 - Crankshaft sprocket
Contact surface between sprocket and crankshaft must be free of oil. Can only be installed in one position.
17 - 90 Nm + 1/4 turn (90 °) further Renew
Do not use oil
Use counter-hold tool 3099 or 3415 to loosen and tighten
Bolting on counter-hold tool 3099 => Page 13-39
18 - 45 Nm
Use counter-hold tool 3036 to loosen and tighten
19 - 45 Nm 20 - 10 Nm
21 - Toothed belt guard - bottom To remove, unbolt vibration damper
900058 Type
4A Type description ÕFig.1Position of semi-automatic tensioning roller1Z CUT
The retaining lug must fit in the opening in the rear toothed belt guard.
ÕFig.2Installation position of intermediate shaft sprocket The wider rim -arrows- of the intermediate shaft sprocket is at the front.
900058 Type
4A Type description ÕFig.3Removing injection pump sprocket1Z CUT z Toothed belt removed => Page 13-20 - Unscrew nut for injection pump sprocket. - Release arms of puller 3032 and apply puller.
- Align arms of puller with holes in injection pump sprocket and secure.
- Apply tension to injection pump sprocket by tightening puller. - Release injection pump sprocket from taper of injection pump by lightly tapping spindle of puller (hold sprocket while doing this so it does not fall out).
Removing and installing toothed belt Special tools and workshop equipment required
Mandrel 2064 Setting bar 2065 A Retainer 3036
900058 Type
4A Type description
-
Õ Remove engine cover panel -arrows-. - Remove V-belt=>Page 13-9.
- Remove ribbed belt => Page 13-11.
-
Õ Unbolt pulley with vibration damper. Removing
-
900058 Type
4A Type description
-
Õ Turn crankshaft to TDC No. 1 cylinder -arrow- (vehicles with manual gearbox).
-
Õ Turn crankshaft to TDC No. 1 cylinder -arrow- (vehicles with automatic gearbox).
Note:
Turning crankshaft to TDC No. 1 cylinder with engine removed=> page 13-31.
900058 Type
4A Type description
-
Õ Lock camshaft using setting bar 2065 A.
-
Õ Centralize setting bar as follows:
With setting bar in position, turn camshaft so that one end of setting bar contacts cylinder head. Using feeler gauge, measure gap at other end of setting bar. Insert a feeler gauge corresponding to half the measured gap between setting bar and cylinder head. Now turn camshaft until setting bar contacts feeler gauge. Place a 2nd feeler gauge, of the same thickness, at the other end between setting bar and cylinder head.
-
Õ Lock injection pump sprocket with pin 2064.
- Mark direction of rotation of toothed belt with chalk or felt pen. - Loosen tensioning roller.
- Remove idler wheel. - Take off toothed belt.
Installing (adjusting valve timing)
z Camshaft locked in position with setting bar. z Injection pump locked in position with pin 2064. Notes:
The position of the toothed belt must be set as described below, even after repairs in which the belt is only taken off the camshaft sprocket.
The crankshaft must not be at TDC at any cylinder when the camshaft is turned. Otherwise there is a risk of damage to valves and piston crowns.
Never use the setting bar to hold the camshaft when loosening and tightening the bolt securing the camshaft sprocket. Counter-hold with 3036.
-
Õ Loosen camshaft sprocket securing bolt 1/2 turn. Release camshaft sprocket from camshaft taper by tapping with a hammer (using a drift through rear toothed belt guard opening). - Check again whether TDC mark on flywheel and reference mark are aligned.
- Fit toothed belt (check direction of rotation) on crankshaft sprocket, intermediate shaft sprocket, injection pump sprocket and tensioning roller.
- Fit camshaft sprocket together with toothed belt and locate with securing bolt (camshaft sprocket can still turn).
-
Õ Using a suitable wrench (e.g. Matra V/159), turn eccentric mounting on tensioning roller clockwise until notch aligns with raised portion (arrows).
Note:
If the eccentric mounting is turned too far to the right (by mistake) , slacken completely before re-tensioning.
- Tighten lock nut on tensioning roller to 20 Nm.
- Check again whether TDC mark on flywheel and reference mark are aligned.
- Tighten bolt securing camshaft sprocket to 45 Nm.
Note:
On no account use the setting bar to hold the camshaft when loosening and tightening the bolt securing the camshaft sprocket. Counter-hold with 3036.
- Remove setting bar. - Remove pin 2064.
- Turn crankshaft two full revolutions in normal direction of rotation and set again to TDC No. 1 cylinder.
-
Õ Check tension of toothed belt.
- Markings -arrows- should be in line. - Re-tension toothed belt if necessary.
- Check whether injection pump sprocket can be locked with pin 2064.
- Check position of camshaft with setting bar. Note:
If the setting bar or pin do not fit in place, repeat adjustment procedure.
- Remove setting bar. - Remove pin 2064.
- Install ribbed belt =>Page 13-12. - Install V-belt=>Page 13-9.
- Check injection pump commencement of delivery (dynamic) => Diesel direct injection and glow plug system (4-cylinder TDI); => Repair group 23; Servicing diesel direct injection system;=> => Dynamically checking and adjusting commencement of injection
Tightening torques
Component Nm
Toothed belt sprocket to camshaft 45
Idler wheel to console 25
Semi-automatic tensioning roller to cylinder block
20 Bottom section of toothed belt guard to cylinder block
10
Vibration damper with 8.8 25
Checking semi-automatic toothed belt tensioning roller Test requirements
z Toothed belt in position and tensioned. Test sequence
-
Õ Tension toothed belt with firm thumb pressure. Notch and raised portion -arrows- must move apart.
- Release thumb pressure on toothed belt. The tensioning roller should move back to its initial position.
- Markings -arrows- should be in line.
Turning crankshaft to TDC with engine removed Special tools and workshop equipment required Adjustment bar 2068 A for top dead centre Vehicles with manual gearbox
z Oil filter removed.
-
Õ Fit TDC adjuster gauge 2068 A with screw as illustrated. - Set adjuster gauge to 107 mm (the reference point is the left notch of the vernier -arrow-).
- Turn crankshaft until TDC marking "0" on flywheel coincides with end of adjuster gauge.
Vehicles with automatic gearbox z Oil filter removed.
-
Õ Fit TDC adjuster gauge 2068 A with screw as illustrated. - Set adjuster gauge to 99 mm -arrow- (the reference point is the left notch of the vernier -arrow-).
- Turn crankshaft until TDC marking "0" on drive plate coincides with end of adjuster gauge.
Note:
TDC marking "0" is stamped into the cylinder block side of the drive plate.
Removing and installing sealing flanges and flywheel/drive plate Note:
For repairs to the clutch:
=> 5-Speed manual gearbox 012/01W, Front-wheel drive; Repair group 30; Servicing clutch=>
1 - Oil seal
To remove, remove sealing flange -Item 27-
Install with 10-203 Lightly oil sealing lip
2 - Intermediate shaft sprocket Installation position
=>Fig. 1, Page 13-38
Check position of Woodruff key -Item 25-
3 - 45 Nm
Use counter-hold 3036 to loosen and tighten
4 - 25 Nm 5 - Oil seal
Renewing => Page 13-39 Lightly oil sealing lip of oil seal 6 - 10 Nm
7 - Front sealing flange
Before fitting sump, apply a small amount of sealant
"AMV 174 004 01"to sealing points between sealing flange and cylinder block
8 - Gasket Renew
900058 Type
4A Type description MY
9 - Cylinder block
Removing and installing crankshaft => Page 13-48
Dismantling and assembling pistons and conrods
=> Page 13-57 10 - Vacuum pump For brake servo 11 - O ring Renew 12 - Cover 13 - 10 Nm 14 - 20 Nm 15 - Bracket For exhauster 16 - O ring Renew
900058 Type
4A Type description MY
17 - Oil seal Renew 18 - 10 Nm
19 - Rear sealing flange With oil seal
Only renew complete
Lightly oil sealing lip of oil seal Before fitting sump, apply a small amount of sealant
"AMV 174 004 01"to sealing points between sealing flange and cylinder block
20 - Gasket
Only install gasket if sealing flange has no sealing lip on cylinder block side
21 - Flywheel/drive plate
Removing and installing flywheel => Page 13-44
Removing and installing drive plate =>Page 13-45
900058 Type
4A Type description MY
22 - 60 Nm + 1/4turn (90 °) further Renewing
23 - Intermediate plate
Must be located on dowel sleeves Do not damage orbend when assembling
24 - Intermediate shaft
Axial clearance max. 0.25 mm 25 - Woodruff key
Check that Woodruff key is fitted correctly
26 - O ring Renew
27 - Sealing flange for intermediate shaft
900058 Type
4A Type description ÕFig.1Installation position of intermediate shaft sprocket1Z CUT The wider rim -arrows- of the intermediate shaft sprocket is at the front.
Renewing crankshaft oil seal - pulley end -
Special tools and workshop equipment required
Oil seal extractor 2085 Oil seal fitting tool 3083
4A
- Remove ribbed belt => Page 13-11. - Remove toothed belt => Page 13-20. -
Õ Remove crankshaft toothed belt sprocket. To do this counter -hold sprocket with 3099.
Note:
Special tool 3415 can be used instead.
-
Õ Screw cheese-head bolt from 3083 five or six turns into crankshaft before applying oil seal extractor.
- Unscrew inner part of the oil seal extractor 2085 two turns (approx. 3 mm) out of the outer part and lock with knurled screw.
Removing
z Engine in vehicle
900058 Type
4A Type description
-
Õ Lubricate threaded head of oil seal extractor, place it in position and, exerting firm pressure, screw it as far as possible into oil seal.
- Loosen knurled screw and turn inner part against crankshaft until the oil seal is pulled out.
- Clamp flats of oil seal extractor in vice. Remove oil seal with pliers.
- Clean contact surface and sealing surface. Installing
- Lightly oil sealing lip of oil seal.
-
Õ Place guide sleeve from 3083 onto crankshaft journal. - Slide oil seal over guide sleeve.
4A
-
Õ Press oil seal in onto stop using press sleeve and bolt from 3083.
- Renew bolt for toothed belt sprocket.
- Install crankshaft sprocket and lock in position with retainer 3099.
Notes:
Contact surface between toothed belt sprocket and crankshaft must be free of oil.
Do not grease bolt for toothed belt sprocket.
- Install toothed belt (adjust valve timing) => Page 13-26. - Allow stop for torque reaction support to rest on rubber buffer for torque reaction support under its own weight, and tighten bolts.
- Install ribbed belt =>Page 13-12. - Install V-belt=>Page 13-9.
Tightening torques
Component Nm
Toothed belt sprocket to crankshaft 90 + 90°1)2)
Torque reaction support M8 20
M10 40
1)Renew bolt
Removing and installing flywheel/ drive plate Flywheel
Special tools and workshop equipment required Counter-hold tool 10-201
Work sequence
-
Õ Reverse position of retainer 10-201 for loosening/tightening bolts.
- Mark position of flywheel relative to engine. - Renew bolts.
Tightening torque
Component Nm
Flywheel to crankshaft 60 + 90°1)
900058 Type
4A Type description
Counter-hold tool VW 558
Hexagon bolt M8 x 45 and two M10 hexagon nuts Depth gauge
Removing
-
Õ Secure counter-hold tool VW 558 to the drive plate with a hexagon bolt M8x45. Place two M10 hexagon nuts -1- between counter-hold tool and drive plate.
- Mark position of drive plate relative to engine. - Loosen securing bolts on drive plate.
Drive plate
900058 Type
4A Type description
-
Õ Locate drive plate with shim -2- and packing plate -1- .The lug -arrow- must face towards torque converter.
- Insert at least 3 old securing bolts and tighten to 30 Nm.
-
Õ Measure distance -a- at three points and calculate average value.
- Specified distance: 26 ... 28 mm If the specification is exceeded: Installing
900058 Type
4A Type description
-
Õ Remove drive plate again and install without shim -2-. Tighten bolts to 30 Nm again.
- Measure distance again. If the specification is attained: - Fit new bolts and tighten.
Tightening torque
Component Nm
Drive plate to crankshaft 60 + 90°1)
Removing and installing crankshaft Note:
Secure engine to engine bracket VW 540 on assembly stand when dismantling/assembling engine. 1 - Thrust washers
For bearing 3
Different versions for cylinder block and bearing cap
Note fixing arrangement 2 - Bearing shell
Bearing shell with oil groove for cylinder block
Do not interchange used bearing shells (mark with waterproof pen)
3 - Crankshaft
Axial clearance new: 0.07...0.17 mm
Wear limit: 0.37 mm
Check radial clearance with Plastigage
New: 0.03...0.08 mm Wear limit: 0.17 mm
Do not rotate the crankshaft when checking the radial clearance Crankshaft dimensions => Page 13-56
4 - Bearing shell
Bearing shell without oil groove for bearing cap
Do not interchange used bearing shells (mark with waterproof pen) 5 - Thrust washers
For bearing 3 bearing cap Different versions for cylinder block and bearing cap
6 - 65 Nm + 1/4turn (90 °) further Renewing
When measuring radial clearance of crankshaft, tighten to 65 Nm but do not turn further
7 - Bearing cap
Bearing cap 1: Pulley end Bearing cap 3 with recesses for thrust washers
Bearing shell retaining lugs
(cylinder block/bearing cap) must be on the same side
8 - 10 Nm + 1/4 turn (90 °) further Renew
Always renew sender wheel if bolts have been unscrewed =>Fig.1, Page 13-52
9 - Needle bearing
Pulling out and driving in => Page 13-53
10 - Sender wheel
For engine speed sender (G28) Can only be installed in one position. Holes are off-set Always renew sender wheel if securing bolts have been unscrewed
Removing and installing =>Fig. 1, Page 13-52 11 - Fitted pin
Checking projection from crankshaft=>Fig. 2, Page 13-52
4A ÕFig.1Removing and installing sender wheel1Z CUT
- Always renew sender wheel -2- if securing bolts -1- have been unscrewed.
Notes:
If the securing bolts are tightened a second time, the seats for the countersunk bolt heads in the sender wheel will be distorted to such an extent that the bolt heads will come into direct contact with the crankshaft -3- (-arrows-) and the sender wheel will only fit loosely under the bolts.
The mounting holes are asymmetrically spaced, so it is only possible to install the sender wheel in one position.
Tightening torque
Component Nm
Sender wheel to crankshaft 10 + 90° 1)2)
1)Renew bolts
2)90° is a quarter turn
ÕFig. 2Checking dowel pin projection out of crankshaft
Dowel pin projection -3- out of crankshaft a =2.5...3.0 mm
Removing and installing needle bearing in crankshaft
Special tools and workshop equipment required
Drift VW 207 C
Special tool Kukko 21/1 (Item 1) and Kukko 22/1 (Item 4) Notes:
A needle bearing must be fitted in the crankshaft on vehicles with manual gearbox. Install needle bearing if necessary. The needle bearing must not be fitted in the crankshaft on vehicles with automatic gearbox. Remove needle bearing if necessary.
900058 Type
4A Type description
-
Õ Pull out needle bearing using Kukko 21/1 and Kukko 22/1.
Installing
-
Õ Knock in with drift VW 207 C or centring mandrel 3176. - Lettering on needle bearing must be visible when installed. Removing
4A ÕInstallation depth for needle bearing1Z Distance a = 1.5 mm
Crankshaft dimensions (in mm)
Honing dimension Main journal dia. Conrod journal
dia. -0.022 -0.022 Basic dimension 54.00 47.80 -0.042 -0.042 -0.022 -0.022 1st undersize 53.75 47.55 -0.042 -0.042 -0.022 -0.022 2nd undersize 53.50 47.30 -0.042 -0.042 -0.022 -0.022 3rd undersize 53.25 47.05 -0.042 -0.042
Dismantling and assembling pistons and conrods
Note:
Vehicles can be fitted with two different types of conrods:
Conrods with fitted pin -item 8-: use conrod bolts without centring location. Conrods without fitted pin: use conrod bolts with centring location(fitted bolts). 1 - 7 Nm
Version fitted>06.96
Apply sealant AMV 188 001 02 when installing
2 - Oil spray jet For piston cooling Version fitted>06.96 With pressure relief valve (opens at 1.3 ... 1.6 bar)
3 - Pressure relief valve, 27 Nm Version fitted 07.96>(phased in) opens at:
1.3 ... 1.6 bar
Do not apply locking fluid 4 - Oil spray jet
For piston cooling
Version fitted 07.96>(phased in) 5 - Bearing shell
Note installation position
Do not interchange used bearing shells (mark with waterproof pen) Ensure retaining lugs fit tightly in recesses
Axial clearance Wear limit: 0.37 mm
Check radial clearance with Plastigage:
Wear limit: 0.08 mm
Do not rotate crankshaft when checking radial clearance
6 - Cylinder block
Checking cylinder bores =>Fig. 4, Page 13-64
Piston and cylinder dimensions =>Page 13-68
7 - Bearing shell
Note installation position
Do not interchange used bearing shells (mark with waterproof pen) Ensure retaining lugs fit tightly in recesses
Axial clearance Wear limit: 0.37 mm
Check radial clearance with Plastigage:
Wear limit: 0.08 mm
Do not rotate crankshaft when checking radial clearance
8 - Fitted pin See note =>Page 13-57
The fitted pin must seat securely in the conrod, not in the bearing cap 9 - Conrod
See note =>Page 13-57 Only renew as a set Mark cylinder number -A- Installation position:
Marking -B- faces towards pulley end
10 - Circlip 11 - Piston pin
If difficult to move, heat piston to approx. 60 °C
12 - Piston
With combustion chamber Checking=>Fig. 3, Page 13-64 Mark installation position/cylinder number=> Fig.5, Page 13-65
Renew piston if there are cracks in piston skirt
Arrow on piston crown points to pulley end
Install using piston ring clamp Checking piston projection at TDC =>Page 13-66
Piston and cylinder dimensions =>Page 13-68
13 - Piston ring
Offset gaps by 120 °
Remove and install with piston ring pliers
"TOP" must face towards piston crown
Checking ring gap =>Fig. 1, Page 13-63
Checking ring-to-groove clearance =>Fig. 2, Page 13-63
14 - Conrod bearing cap Mark cylinder number -A- Installation position:
Marking -B- faces towards pulley end
15 - Conrod bolt, 30 Nm + 1/4 turn (90 °) further
See note =>Page 13-57 Renew
Oil threads and contact surface To measure radial clearance use old bolts
4A ÕFig. 1Checking piston ring gap1Z
- Push ring squarely from above down to approx. 15 mm from bottom end of cylinder.
Piston ring New Wear limit
Dimensions in mm
1st compression ring 0.20...0.40 1.0
2nd compression ring 0.20...0.40 1.0
Oil scraper ring 0.25...0.50 1.0
ÕFig. 2Checking ring to groove clearance - Clean groove before checking clearance.
Piston ring New Wear limit
Dimensions in mm
1st compression ring 0.06...0.09 0.25
2nd compression ring 0.05...0.08 0.25
4A ÕFig. 3Checking piston
- Measure pistons approx. 10 mm from lower edge of skirt, at 90° to the piston pin axis.
- Deviation from nominal dimension not more than 0.04 mm
4A ÕFig. 4Checking cylinder bores1Z
Special tools and workshop equipment required Internal dial gauge 50...100 mm
- Take measurements at 3 positions in both lateral -A- and longitudinal -B- directions.
- Deviation from nominal dimension not more than 0.10 mm
4A ÕFig.5Piston installation position and piston/cylinder 1Z CUT