Replacing the intermediate shaft (VW Golf 2)

The intermediate shaft can only be replaced with the engine removed from the vehicle. The method for fastening the shaft is shown in Figure 211. To dismantle the shaft, first remove the high-pressure fuel pump (HPFP) and all units and parts connected to the camshaft. The cylinder head can remain on the engine. The intermediate shaft seal flange has a channel for supplying lubricant and is installed only in a certain position. The flange determines the axial clearance of the shaft and is subject to replacement when the clearance exceeds 0.25 mm. The flange seal is an O-ring. The ring must be replaced after each flange removal.

The shaft is installed as follows:

Insert the shaft, having previously installed a new oil seal on it in the same way as the front crankshaft oil seal. Tighten the oil seal holder mounting bolt to a torque of 25 Nm.

Place the tensioner roller on the intermediate shaft so that its projection fits into the groove. This will ensure that the roller is in the correct position. If you have to replace the roller, remember that only rollers for the drive of the design changed in 1984 are applicable, i.e. for an engine with a different toothed belt casing. When installing a new roller on an old type of engine with a casing covering the toothed belt, you need to measure the gap "A" (figure 211) between the roller and the pump bracket. This gap should be at least 0.5 mm (this also applies to the modified engine). If necessary, remove the bracket and use a file to remove excess metal in the indicated area.





Insert the bolts with washers and tighten them to a torque of 45 Nm with the locking mechanism (for example with a rod), inserted into the hole of the roller and resting against the wall of the flywheel housing.

The remaining actions are performed in the reverse order of dismantling.

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