Volkswagen Golf ll, Jetta II

1983-1992 of release

Repair and car operation



Volkswagen Golf 2 / Jett 2
+ 1.1. Short technical characteristics of diesel engines
- 2. Engine
   2.1. Removal and engine installation
   - 2.2. Dismantling and engine assembly
      - 2.2.1. Engines in volume of 1,1 and 1,3 l
         2.2.1.1. Removal and installation of a head of the block of cylinders
         2.2.1.2. Dismantling of a head of the block of cylinders
         2.2.1.3. Survey, check and repair of a head of the block of cylinders
         2.2.1.4. Assembly of a head of the block of cylinders
         2.2.1.5. Adjustment of gaps between cams of a cam-shaft and levers of valves
         2.2.1.6. Technical condition of hydropushers of valves
         2.2.1.7. Camshaft drive
         2.2.1.8. Flywheel
         2.2.1.9. Epiploons of a cranked shaft
         2.2.1.10. Oil case
         2.2.1.11. Oil pump
         2.2.1.12. Shatunno-porshnevaya group
         2.2.1.13. Cranked shaft
         2.2.1.14. Check of the block of cylinders
      + 2.2.2. Engines in volume of 1,6 and 1,8 l
      + 2.2.3. Diesel engine
   + 2.3. System of greasing of the engine
   + 2.4. System of cooling of the engine
   + 2.5. System of production of the fulfilled gases
+ 3. Power supply system
+ 4. Coupling
+ 5. Transmission
+ 6. Transmission
+ 7. Forward drive
+ 8. Steering
+ 9. Suspension brackets
+ 10. Brake system
+ 11. Body
+ 12. Electric equipment




2.2.1.12. Shatunno-porshnevaya group

GENERAL INFORMATION

Cranked shaft and details of shatunno-piston group

1–cranked shaft;

2–loose leaf of the shatunny bearing;

3–bolt of fastening of a cover of a rod;

4–finger;

5–maslosjemny ring;

6–kompressionny ring;

7–piston;

8–lock ring;

9–plug of a head of a rod;

10-rod;

11-rod cover

Removal and dismantling

PERFORMANCE ORDER
1. To remove a block head, an oil case and the oil pump.
2. To mark each rod and a cover with cylinder number.
3. To turn a cranked shaft so that the piston of the first cylinder rose in situation NMT.
4. To unscrew nuts and to uncover the 11th rod (see fig. Cranked shaft and details of shatunno-piston group). To take out from a cover the 11th loose leaf 2 bearings, having noted previously its situation in a cover.
5. To take out the piston with a rod from the cylinder. In the same way to take out other pistons with rods.
6. To take out loose leaves of 2 bearings from the bottom heads of rods, having marked previously their situation.
7. To remove lock rings 8 and, having heated up the piston in hot water (about 60 ° C), by means of an opravka вытолкнуть fingers 4.
8. A stripper of piston rings to remove rings 5 and 6 from pistons.

Survey, check and repair of details of shatunno-piston group

Measurement of a lateral gap of a piston ring


Opilivaniye of the ends of piston rings

All details of shatunno-piston group after dismantling to clear and wash out gasoline. To examine pistons. If on them there are wear tracks, deep scratches, traces прогара, pistons to replace. By a micrometer to measure diameter of a skirt of the piston at distance of 10 mm from bottom edge of a skirt, perpendicular to an axis of a piston finger. If the measured diameter differs from nominal on 0,04 mm, it is necessary to replace the piston. To measure a lateral gap between piston rings and flutes on the piston, as is shown in fig. Measurement of a lateral gap of a piston ring. If the gap exceeds 0,15 mm, to replace rings or pistons. To measure a gap in the lock of a piston ring. For this purpose to insert a ring into the cylinder from a case and to advance the piston, as an opravka, on distance of 15 mm from the cylinder basis. By Shchup to measure a gap in the lock. If the gap exceeds 1,0 mm, a ring to replace. If the gap in the lock is less, than 0,3 mm, for kompressionny rings and 0,25 mm – for maslosjemny, it is possible to file the ends of rings by means of a file clamped in a vice, as is shown in Opilivaniye's fig. of the ends of piston rings.

To check landing of a piston finger in a rod. For this purpose to establish a rod horizontally and to insert a finger into a rod head. The finger should not be put forward from a head under the influence of a body weight. If the finger is put forward or drops out, it is necessary to replace a finger and the plug of a head of a rod. Выпрессовать old and to press the new plug in a rod head after that to drill in the plug an opening for an oil supply through an opening in a rod head. Then to develop development an opening under the size of a new finger, having sustained an assembly gap within 0,004–0,01 mm. The rod should rotate freely on a finger. Otherwise to press through a finger via the plug and in those places where on a finger there were prints, it is careful прошлифовать the plug. After that again to check ease of rotation of a rod on a finger. To check on a razmetochny plate coaxiality of openings of the top and bottom heads of a rod and if it is necessary, to correct a rod.

Scheme of measurement of diameter of the cylinder

And, In – the directions of measurements;

1, 2, 3 – belts of measurements

To check a gap between the piston and the cylinder. If it exceeds 0,12 mm, to chisel and отхонинговать cylinders under the repair size. It is necessary to chisel all four cylinders, even if a gap more specified only in one. After boring in cylinders establish pistons of the repair size. A gap between the piston and the cylinder calculate as a difference between diameter of the cylinder and diameter of the piston. Measurement of diameter of the piston is described above in same парагафе. Diameter of the cylinder measure by a nutromer in six points, in 10 mm from bottom edge of the cylinder, in 10 mm from the upper edge and in the middle in two perpendicular directions, as is shown in fig. Scheme of measurement of diameter of the cylinder. If wear of cylinders from the nominal size exceeds 0,04 mm, cylinders need to be chiseled also under the repair size.

Assembly

The amount of dredging in a piston head

and = 16,1 mm;
and = 56,6 mm – the engine with vsprysky;
and = 14,7 mm;
and = 16,6 mm;
and = 16,5 mm;
b= 55,7 mm – fashions. HZ;
b= 56,6 mm – fashions. MH, 2G, NU;
b= 56,6 mm – fashions. HK

Label on a head of the piston and inflow on a rod and a rod cover


Piston installation in the cylinder

1–a collar compressing piston rings;

2–hammer handle;

3–piston

Pistons of different models of engines differ in the amount of dredging in a piston head. The amount of dredging is shown on fig. The amount of dredging in a piston head. Besides, at the engines which are let out since September, 1985, openings under cylinders in laying of a head of the block are reduced. On a head of the piston there is a facet for prevention of blow of the piston about laying edge. Before assembly to replace shatunny bolts.

PERFORMANCE ORDER
1. To heat up the piston 7 (see fig. A cranked shaft and details of shatunno-piston group), having lowered it for some minutes in water with temperature 60 ° Page.
2. Into the hot piston to insert a rod 10 so that the shooter on a head of the piston and inflow on a rod, shown by shooters on fig. A label on a head of the piston and inflow on a rod and a rod cover, were directed to one party. To insert a finger 4 by means of an opravka.
3. To insert into place lock rings 8. To check ease of turn of the piston on a rod.
4. A stripper of piston rings to establish rings 5 and 6 on the piston. Before installation of new rings to measure a gap in the lock of each ring (see above). On rings the word of "TORAHS" is engraved, rings to establish this word to a piston head. Locks of piston rings to arrange evenly at an angle 120 ° to each other.
5. To turn a cranked shaft in situation at which the crank of the first cylinder would be below.
6. To grease pistons and piston rings with engine oil. On shatunny bolts to dress short pieces of a rubber hose casually not to damage a cylinder mirror.
7. To put on piston rings a collar 1 (see fig. Piston installation in the cylinder), to compress it, having inserted a rod with the piston into the cylinder, and in easy blows the handle 2 hammers to push the piston in the cylinder, thus a collar 1 should be pressed to the block, differently it is possible to break piston rings.
8. Pistons with rods need to be inserted into cylinders so that the shooter on a head of the piston and inflow on a rod, shown on fig. A label on a head of the piston and inflow on a rod and a rod cover, were directed towards a belt of a drive of a cam-shaft. After the piston is inserted into the cylinder, it cannot be turned.
9. To remove from shatunny bolts scraps of rubber hoses.
10. To insert according to the labels made at dismantling, into the bottom head of a rod the loose leaf 2 (see fig. The cranked shaft and details of shatunno-piston group) so that a fixing ledge of the loose leaf entered into dredging of a head of a rod. Plentifully to grease the loose leaf with engine oil. To advance the piston down so that the bottom head of a rod sat down on a neck of a crank of a cranked shaft.
11. To insert the loose leaf 2 into a cover of the 11th rod according to the labels made at dismantling. Thus fixing ledge of the loose leaf should enter into cover dredging. Plentifully to grease loose leaves with engine oil.
12. To establish a rod cover on shatunny bolts according to the labels put at dismantling. Inflow on a cover, shown on fig. A label on a head of the piston and inflow on a rod and a rod cover, should be from a belt of a drive of a cam-shaft as well as on a rod.
13. To oil places of a prileganiye of nuts on covers, to wrap nuts of shatunny bolts and evenly to tighten in two stages:
 – 1 stage – the moment of 30 N · m (3,0 kgfs · м);
 – The 2nd stage – to tighten on a turn quarter (90 °).
14. To turn a cranked shaft, to be convinced that it easily rotates.
15. To measure shchupy an axial gap of a rod between the bottom head of a rod and a cheek of a cranked shaft. It should be within 0,05–0,31 mm. Maximum permissible gap of 0,37 mm.
16. In the same way to establish other pistons with rods.