Contents - Volkspage

2A.6 Engine in-car repair procedures
12 Restore the ignition system by
reconnecting the distributor multiway wiring
plug.
1 Disconnect the battery negative cable and
position from the terminal.
2 Refer to Chapter 1 and remove the auxiliary
drivebelt(
3 With reference to Sections 2 and 4 of this
Chapter, remove the auxiliary belt pulley and
timing belt cover, then set the engine to TDC
on cylinder No 1 and remove the timing belt
and camshaft sprocket.
4 Note that the inner timing belt cover shares
mounting bolts with the coolant pump - refer
to Chapter 3 and remove the coolant pump.
After removing the retaining screws, lift the
inner timing belt cover away from the engine
block - this will expose the camshaft oil seal.
5 Drill two small holes into the existing oil
seal, diagonally opposite each other. Thread
two self tapping screws into the holes and
using two pairs of pliers, pull on the heads of
the screws to extract oil seal. Take great care
to avoid drilling through into the seal housing
or camshaft sealing surface.
6 Clean out the seal housing and sealing
surface of the camshaft by wiping it with a
lint-free cloth - avoid using solvents that may
enter the cylinder head and affect component
lubrication. Remove any swarf or burrs that
may cause the seal to leak.
8.13a Withdraw the rear oil seal housing
from the dowels on the cylinder block. . .
7 Lubricate the lip of the new oil seal with
clean engine oil and push it over the camshaft
until it is positioned above its housing.
8 Using a hammer and a socket of suitable
diameter, drive the seal squarely into its
housing. Note: Select a socket that beats only
on the hard outer surface of the seal, not the
inner lip which can easily be damaged.
9 With reference to Sections 2 and 4 of this
Chapter, refit the inner timing belt cover,
timing sprockets, then refit and tension the
timing belt. On completion, refit the timing belt
outer cover.
10 With reference to Chapter 1, refit and
tension the auxiliary drivebelt(
Crankshaft front oil seal
1 Remove the crankshaft timing belt
sprocket, with reference to Section 5.
2 If available use VW tool 2085 to remove the
oil seal from the oil pump. Alternatively, drill
two small holes into the existing oil seal,
diagonally opposite each other. Thread two
self tapping screws into the holes and using
two pairs of pliers, pull on the heads of the
screws to extract oil seal. Take great care to
avoid drilling through into the seal housing or
crankshaft sealing surface.
3 Clean out the seal housing and sealing
surface of the crankshaft by wiping it with a
lint-free cloth - avoid using solvents that may
8.13b . . . and recover the gasket
enter the oil pump and affect component
lubrication. Remove any swarf or burrs that
may cause the seal to leak.
4 Lubricate the lip of the new oil seal with
clean engine oil and push it over the crankshaft
until it is positioned above its housing.
5 Using a hammer and a socket of suitable
diameter, drive the seal squarely into its
housing. Note: Select a socket that bears only
on the hard outer surface of the seal, not the
inner lip which can easily be damaged.
6 Refit the crankshaft sprocket with reference
to Section 5.
Crankshaft rear oil seal
7 Remove the flywheel (see Section 11).
Method 1
8 Drill two diagonally opposite holes in the oil
seal, insert two self-tapping screws, and pull
out the seal with grips.
9 Clean out the seal housing and sealing
surface of the crankshaft by wiping it with a
lint-free cloth - avoid using solvents that may
enter the crankcase and affect component
lubrication. Remove any swarf or burrs that
may cause the seal to leak.
10 Using the plastic fitting tool supplied with
the new oil seal, tap the seal into the housing
using a suitable metal tube. Note: Do not
lubricate the seal to ease fitting - it is supplied
with a friction-reducing coating.
11 Refit the flywheel (see Section 11).
Method 2
12 Remove the sump (see Section 13).
13 Unscrew the bolts and withdraw the seal
housing from the dowels on the cylinder
block. Remove the gasket (see illustrations).
14 Support the housing on blocks of wood
and drive out the oil seal (see illustration)
15 Clean out the seal housing by wiping it
with a lint-free cloth - avoid using solvents
that may enter the crankcase and affect
component lubrication. Remove any swarf or
burrs that may cause the seal to leak.
16 Using the plastic fitting tool supplied with
the new oil seal, tap the seal squarely into the
housing using a block of wood (see
illustration). Note: Do not lubricate the seal to
ease fitting - it is supplied with a frictionreducing
coating.
17 Clean the mating faces then refit the
housing, together with a new gasket, and
tighten the bolts evenly in diagonal sequence
to the specified torque.
18 Refit the sump and flywheel as described
in Sections 13 and 11 respectively.
8.14 Removing the seal from its housing 6.16 Driving the new oil seal
into its housing
Removal
1 Select a solid, level surface to park the
vehicle upon. Give yourself enough space to
move around it easily.