Check for revised parts

Check for crankshaft bolt modification – 1.5L diesel engine

  • Visually check —1.057
    That the old style front crankshaft bolt and washer have been replaced with the new style bolt and washer.
    -new style bolt has shoulder
    -new style washer has collar
  • If not:
    Remove old style bolt and washer.
    Visually check the crankshaft sprocket, key way and key for signs of wear or damage.
  • If not damaged:
    Replace old style bolt and washer with new style bolt and washer.
    Torque new style bolt to 150Nm (108 ft. lbs.)
  • If damaged:
    Remove crankshaft sprocket.
    If sprocket, key or key way are damaged, replace parts as necessary.

 

 

Cars with dealer-installed A/C1.058

When installing the new style crankshaft bolt on cars with dealer-installed A/C
-Remove old spacer (with shoulder) and
-Replace with new Spacer ZVW 455 218(flat)

 

 

 

 

 

1980 Rabbit diesel with factory air conditioning

 

When checking for the new style crankshaft bolt and washer
or
when installing the new style crankshaft bolt and washer on 1.5L diesels with factory air-conditioning:

  • Loosen alternator belt.
  • Remove pulley with cast center bolt by removing the 4 pulley nuts.
  • Remove A/C pulley halves and shims.
  • Access to crankshaft and bolt is now possible thru hub assembly.
  • Install new style crankshaft bolt and collared washer if necessary.
  • Torque new style bolt to 150 Nm (108 ft./lbs.).

1.059

 

 

 

Check air filter

1.060

Visually check air filter.
Replace if dirty and check to see that Breather Hose Kit was installed (1977 – 1979 cars, 1980 cars to engine # CK 513 210)