Volkswagen Front Wheel Drive 1974-1989 Repair Guide

Intermediate Shaft

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3

  1. Remove timing belt cover(s), timing belt and intermediate shaft drive sprocket.
  2.  
  3. On 8-valve gasoline engines, remove the distributor. On carbureted engines, remove the fuel pump.
  4.  
  5. Remove the mounting flange retaining bolts. Thread the sprocket bolt onto the shaft finger-tight, then remove the flange and shaft by pulling on the sprocket bolt.
  6.  



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Fig. Fig. 1: Remove the bolt securing the intermediate shaft sprocket, then remove the sprocket

  1. Remove flange from the intermediate shaft and install a new oil seal.
  2.  



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Fig. Fig. 2: The intermediate shaft seals can be replaced without removing the shaft. Remove the bolts securing the flange, then pull the flange from the engine block



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Fig. Fig. 3: Replace both the O-ring and the lip seal on the flange

To install:
  1. Lubricate the oil seal lips with oil. When installing the mounting flange, be sure the oil return hole is at the bottom. Tighten the flange mounting bolts to 18 ft. lbs. (25 Nm).
  2.  
  3. Install the sprocket. Tighten the bolt to 58 ft. lbs. (79 Nm) on 8-valve engines, 48 ft. lbs. (65 Nm) on 16-valve engines and 33 ft. lbs. (45 Nm) on diesel engines.
  4.  

 
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