Instructions: If, during engine repair, large quantities of metal shavings and wear products are found in the engine oil - the source of which is increased wear, for example, due to damage to the connecting rod bearing - then in order to avoid subsequent damage, in addition to thoroughly cleaning the lubrication channels, it is necessary to replace the oil filter. Lubricate all bearing and working surfaces before installation work. For installation work, the engine must be mounted on the engine and gearbox bracket -VAS 6095-.
Belt drive
- 1 - 40 Nm and turn 90° further. To loosen and tighten the mounting bolt, hold the compressor shaft with a 16 mm wrench, replace
- 2 - Compressor belt pulley
- 3 - 23 Nm
- 4 - Tensioner for the compressor poly V-belt, loosen with a 16 mm wrench, secure with a locking pin -T10060 A-
- 5 - 8 Nm
- 6 - Cooling system pump with electromagnetic clutch of compressor "N421"
- 7 - 23 Nm
- 8 - Tensioner of the poly V-belt, loosen with a 16 mm wrench "T10241" and secure with a locking pin -T10060 A-. On vehicles with a manual transmission, an overrunning roller is installed instead of the tensioner. Tightening torque of the fastening bolt: 40 Nm
- 9 - 23 Nm
- 10 - Generator
- 11 - Crankshaft pulley. There should be no oil or grease on the mating surfaces
- 12 - Fastening bolt, replace. There should be no oil and/or grease on the bolt clamping surface. Insert, having lubricated the thread with oil, fix the belt pulley from turning with the help of the counter support "3415", the final tightening can be performed in several stages. The angle of the final tightening can be measured with the help of a regular angle measuring disc
- 13 - 40 Nm and turn 90° further. Removal and installation with the vehicle raised, replace
- 14 - Air conditioning compressor
- 15 - 25 Nm
- 16 - Tensioner element of the poly V-belt, loosen with a wrench, secure with a 4 mm Allen key
- 17 - Poly V-belt, mark the direction of travel before removing. When installing the poly V-belt, pay attention to the direction of travel and the correct fit on the pulleys and tension elements
- 18 - Compressor poly V-belt, mark the direction of travel before removing. When installing the poly V-belt, pay attention to the direction of travel and the correct fit on the pulleys and tension elements
(The information is posted on this website: VWmanual.ru)
Cylinder block
- 1 - Cylinder head with camshaft housing, it is prohibited to process the adjacent surface. With built-in camshaft bearings. Remove the remains of the old sealant, when installing, insert from above vertically with the mounting pins into the holes of the cylinder head
- 2 - Cylinder block
- 3 - Bracket for additional units for tension element and air conditioning compressor
- 4 - Overlay
- 5 - Sprocket for driving the oil pump and timing chain. There should be no oil or grease on the mating surfaces
- 6 - 20 Nm and turn 90°, replace
- 7 - Sprocket. Secure the sprocket using the support -T10172
- 8 - Drive chain, mark the direction of movement before removing (installation position)
- 9 - 25 Nm
- 10 - 15 Nm
- 11 - Chain tensioner with bar for driving the oil pump
- 12 - Pressure plate
- 13 - Oil pan, clean the seating surface before installation, apply silicone sealant during installation -D 176 404 A2-
- 14 - 15 Nm
- 15 - Piston for drive chain tensioner
- 16 - Pressure spring
- 17 - Chain tensioner
- 18 - 9 Nm
- 19 - Timing gear housing, when installing additionally use silicone sealant -D 176 501A1-, To facilitate installation, screw 2 M6x80 mounting pins into the camshaft housing and cylinder block. To facilitate insertion of the timing gear housing, screw the oil pan with two bolts
- 20 - 10 Nm
- 21 - Belt pulley, observe tightening method. There should be no oil or grease on the mating surfaces. Secure the belt pulley from turning using counter support "341522". Replace the fastening bolt. There should be no oil and/or grease on the clamping surface of the bolt, insert after lubricating the thread with oil. Secure the belt pulley from turning using counter support "3415". The angle of additional tightening can be measured using a standard angle measuring disc
- 23 - Support bushing. There should be no oil or grease on the mating surfaces
- 24 - O-ring, replace
- 25 - 50 Nm
- 26 - Gasket
- 27 - 40 Nm and turn 90° further. Fix the sprockets using the counter support "T10172". Bolt with left-hand thread, replace
- 28 - 50 Nm and turn 90°, replace
- 29 - Tensioner bar
- 30 - Valve timing adjuster, do not disassemble
- 31 - Timing chain
- 32 - Sprocket for exhaust camshaft, secure sprockets using counter support "T10172"
- 33 - Timing chain guide rail
- 34 - Guide pins, tightening torque: 20 Nm
- 35 - Support bushing
Removal and installation a poly V-belt
Instructions: To remove the poly V-belt, loosen the 2 tension elements.
Drain the coolant by removing hose "2".
Ignore position "1". Unlock the clamp and remove the right-hand connecting nipple from the radiator in the direction of travel. Depending on the vehicle configuration, remove the sound insulation or underride guard. Mark the direction of travel of the poly V-belt. To loosen the poly V-belt, turn the tensioner from above using a 16 mm wrench "T10241" in the "direction of the arrow".
Secure the tensioner with the locking pin -T10060 A-. To loosen the poly V-belt, turn the tensioner from below with a 16 mm spanner in the "direction of the arrow",
Secure the tensioner with a 4 mm Allen key "1". Remove the poly V-belt "2".
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