Volkswagen Golf 2004 Workshop Manual page 71

– Turn crankshaft slightly against engine direction of rotation
until the pin of the crankshaft stop is positioned just before the
hole in the sealing flange -arrow-.
– Now turn crankshaft in engine direction of rotation until crank‐
shaft stop pin engages in sealing flange whilst turning.
– Apply counterhold -T10172- as shown. Press counterhold -
T10172- in direction of arrow keeping camshaft pulley under
tension.
– In this position, tighten camshaft pulley securing bolts
-arrows- to 25 Nm.
– Remove locking pins -3359- and crankshaft stop -T10050
bzw. T10100- .
– Turn crankshaft at least two rotations in engine direction of
rotation and set again to just before TDC No. 1 cylinder.
– Repeat check.
– Install centre and lower parts of toothed belt guard.
– Install belt pulley vibration damper: specified torque 10 Nm +
90° (1/4 turn) further.
– Install lower part of toothed belt guard.
– Install poly V-belt tensioning element: specified torque 25 Nm.
– Install poly V-belt ⇒ page 16
Further assembly is basically the reverse of the dismantling se‐
quence. In the process, note the following:
♦ Ensure that fuel hose connections are tight.
♦ Do not interchange supply and return lines (return line blue or
with blue markings, supply line black).
♦ When installing charge air pipes, ensure that locking lugs en‐
gage correctly.
– Install wheel housing liner.
– Install noise insulation tray. ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body - front; Assembly overview - noise insula‐
tion .
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011
.
65
1. Cylinder head