Diesel engine AMF / BAY / ATD / AXR / ASZ with a displacement of 1.4- / 1.9 liters
Removing
Remove the engine top cover.
Remove connecting pipe between charge air cooler and intake manifold.
Remove poly V-belt.
Turn the tensioning element of the V-ribbed belt slightly clockwise, remove the retainer T10060 or the drill shank / Allen key from the tensioning element and unload the tensioning element.
Remove upper toothed belt cover.
Remove lower engine cover.
Engine with a displacement of 1.9 liters: remove the lining of the right front wheel arch.
Remove charge air pipe between charge air cooler and turbocharger. The inlet openings must be carefully sealed or plugged accordingly.
Remove the crankshaft pulley.
Remove the lower and middle toothed belt guards.
Using a lifting device, slightly raise the engine by the lifting eyes.
Unscrew fasteners -arrows- and remove engine mount.
Attention: Remove the support only when the engine is suspended from the eyelets.
Attention: Loosen bolts -arrows- for engine support only when engine support has been removed.
Unbolt engine bracket to cylinder block -arrows-.
Note: To loosen the upper bolts, lift the engine slightly with a lifting device (about 45 mm). To loosen the lower bolt, lower the engine slightly (about 35 mm). To remove the engine bracket, tilt it outward upwards. If necessary, loosen the pendulum support at the gearbox and move the engine slightly forward.
Turning the crankshaft to the position corresponding to TDC for cylinder 1:
Turn the crankshaft so that the mark on the crankshaft sprocket is at the top and the arrow 4Z on the rear toothed belt guard is in line with the projections on the sensor disk located on the hub -arrows-.
Note: For the 1.4l TDI engine, the TDC markings are in position -A-.
Turning the crankshaft can be done in several ways:
1. Raise the car from the side in front. Engage 5th gear, tighten the handbrake. Turn the raised front wheel by hand. In this case, the crankshaft of the engine will also rotate. An assistant is required to turn the wheel.
2. Put the car on a flat surface. Engage 5th gear and move the vehicle forward or backward.
3. Engage neutral gear, tighten the handbrake. Turn the crankshaft at the central bolt of the belt pulley.
Caution: Do not turn the crankshaft using the camshaft gear bolt. In this case, the toothed belt is subjected to very high tension.
Lock the camshaft sprocket hub with HAZET 2588-3. To do this, insert the retainer into the cylinder head through the free elongated hole on the left side.
Note: Instead of the HAZET tool, you can also use a regular pin with a diameter of 6 mm.
Lock the crankshaft gear with the HAZET 2588-1 special tool. To do this, insert a special tool from the end of the gear wheel into the grooves of the teeth so that the pin of the tool enters the sealing gasket flange.
Caution: The marks on the crankshaft sprocket and the special tool must be opposite each other. In this case, the stud of the tool must fit into the gasket flange. If a special tool is not available, mark the TDC on the gasket flange, see bottom view in Figure V-1099.
Mark the direction of movement of the toothed belt.
Loosen bolts -1- for camshaft sprocket until camshaft sprocket can turn within oblong holes.
Loosen the tension pulley nut. Use the HAZET 2587-1 wrench to turn the tensioner until it can be locked with a suitable lock, eg VW-T10115. After that, turn the wrench clockwise until it stops and tighten the nut by hand.
Starting with the coolant pump gear, remove the toothed belt.
Installation
Turn the camshaft gear counterclockwise until it stops.
Fit the toothed belt over the crankshaft sprocket, idler pulley and camshaft sprocket.
Check that the tensioner plate fits into the hole in the rear toothed belt guard.
Loosen the fastening nut, turn the tension roller clockwise until it stops and put the toothed belt on the gear wheel of the coolant pump.
Turn the tension roller counterclockwise with a HAZET 2587-1 wrench and remove the retainer.
Turn tensioning roller with a wrench until the arrow is in the middle of the slot in the carrier plate -arrow-.
While holding the tensioning roller in this position, tighten the fastening nut to a torque of 20 Nm and tighten it by 45° (⅛ turnover) in the direction of tightening.
Tighten the camshaft sprocket bolts to 25 Nm.
Remove the crankshaft retainer and special tool for locking the crankshaft.
Turn the crankshaft in the direction of rotation 2 turns and set again to TDC for cylinder 1. Shortly before reaching TDC on the second turn, insert the special tool to lock the crankshaft with a pin into the gasket flange. If the tool does not insert, turn the crankshaft 1/4 turn back and turn it back to TDC.
Caution: Do not insert the crankshaft locking tool when turning the crankshaft backwards. If there is no locking tool, check that the TDC marks made before removal match.
Lock the camshaft sprocket hub with HAZET 2588-3.
If the latch is not inserted, proceed as follows:
- Remove the crankshaft locking tool and turn the crankshaft until the lock locks the camshaft sprocket hub.
- Loosen the camshaft gear mounting bolts.
Turn engine crankshaft slightly against direction of rotation until stud of crankshaft locking tool 2588-1 is directly in front of seal flange bore -arrow-.
Now rotate the crankshaft in the direction of travel until the pin of the locking tool engages in the gasket flange.
Tighten the camshaft sprocket bolts to 25 Nm.
Remove retainer and crankshaft locking tool.
Rotate the crankshaft in the direction of rotation 2 turns and set again to TDC for cylinder 1. Shortly before reaching TDC on the second turn, insert the special tool to lock the crankshaft with a pin into the gasket flange. If the tool does not insert, turn the crankshaft 1/4 turn back and turn it back to TDC.
Caution: Do not insert the crankshaft locking tool when turning the crankshaft backwards. If there is no locking tool, check that the TDC marks made before removal match.
Lock the camshaft sprocket hub with HAZET 2588-3.
Remove retainer and crankshaft locking tool.
Attach the engine bracket to the cylinder block and tighten the mounting bolts to 45 Nm.
Fit the engine support with new bolts to the body and tighten them to 20 Nm. After that tighten the bolts by 90° (¼ turn) in the direction of tightening.
Tighten engine support to engine bracket to 30 Nm. After that tighten the bolts by 90° (¼ turn) in the direction of tightening.
Install the middle toothed belt guard.
Install the lower toothed belt cover.
Tighten the crankshaft pulley to 10 Nm. Then turn the bolts in the tightening direction by 90° (¼ turn).
Install poly V-belt.
Install the upper toothed belt cover.
Install the pipe between the charge air cooler and the turbocharger and the pipe between the charge air cooler and the intake manifold.
1.9 l engine: Install right front wheel arch trim.
Install the engine cover.
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