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
      - 2.2.2. Engines in volume of 1,6 and 1,8 l
         2.2.2.1. Camshaft drive
         2.2.2.2. Removal and installation of a head of the block of cylinders
         2.2.2.3. Dismantling of a head of the block of cylinders
         2.2.2.4. Assembly of a head of the block of cylinders
         2.2.2.5. Adjustment of gaps between cams of a cam-shaft and levers of valves
         2.2.2.6. Intermediate shaft
         2.2.2.7. Flywheel
         2.2.2.8. Epiploons of a cranked shaft
         2.2.2.9. Oil pump
         2.2.2.10. Shatunno-porshnevaya group
         2.2.2.11. Cranked shaft
         2.2.2.12. Check of the block of cylinders
      + 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




2.2.2.3. Dismantling of a head of the block of cylinders

GENERAL INFORMATION

Head of the block of cylinders, camshaft and drive of valves

1–final valve;
2–inlet valve;
3–laying;
4–valve spring the internal;
5–valve spring the external;
6–plate of springs of the valve;
7–valve pusher;
8–adjusting washer;
9–camshaft;
10-cover of the bearing,
11-shponka;
12-cam-shaft cogwheel;
13-washer;
14-bolt of fastening of a cogwheel;
15-valve crackers;
16-maslosjemny cap;
17-washer basic valve springs;
18-the plug directing the valve;
19-head of the block of cylinders;
20-cam-shaft epiploon

PERFORMANCE ORDER
1. To remove an inlet pipe and a final collector if they were not removed earlier at removal of a head of the block from the engine.
2. To unscrew a bolt 14 (see fig. The head of the block of cylinders, a camshaft and a drive of valves) to remove a cogwheel 12 and to take out a shponka 11.
3. To unscrew nuts of fastening of covers of 10 bearings No. 5, 1 and 3, considering from a belt of a drive of a cam-shaft. Covers of bearings are numbered, but it is possible to put on them labels if numbers are not visible. To remove covers of bearings.
4. To weaken and evenly, on a diagonal, to unscrew nuts of covers of bearings No. 2 and 4. To remove covers of bearings.
5. To take out a camshaft 9.
6. To remove an epiploon 20.
7. To take out pushers of 7 valves, previously having marked them in order that at assembly to establish on the place. On engines of the EZ and GU models since January, 1985 hydropushers of valves are established. From above in dredging of a pusher 7 the adjusting washer 8 is established. It is impossible to interchange the position of adjusting washers, each washer should remain on the place.
8. The special adaptation to compress springs 5 and 4 valves and to take out crackers 15.
9. Weakening pressing the adaptation lever, to release valve springs. To remove the adaptation.
10. To remove a plate 6 and to take out springs 4 and 5.
11. To remove a maslosjemny cap 16 and a basic washer 17, having enclosed previously something in the combustion chamber to prevent valve loss.
12. To take out the valve from the combustion chamber, having marked it that at assembly to establish on the same place. In the same way to take out other valves.

Check and repair of a head of the block and its details

Check and repair of a head of the block and its details are similar to check and repair of a head of engines in working volume of 1,1 and 1,3 l (see subsection 2.2.1.3).

Different data are provided below.

Height of a head of the block of cylinders

Height of a head of the block of cylinders – 132,6 mm.

Distance between a torets of a core of the valve and the top plane of a head of the block of cylinders

Size "a":

for inlet valves – 33,8 mm;

for final valves – 34,1 mm.

Sizes of saddles of valves

and – external diameter of a saddle of the valve;

b–distance from a surface of a head of the block till external diameter of a saddle;

with – width of a working facet of a saddle;

z–bottom plane of a head of the block of cylinders

EZ and GU engines
Inlet valve
Final valve
and = 37,2
and = 32,4
with = 2,0
with = 2,4
b= 9,2
b= 9,2
Engines in capacity of 112 h.p.
Inlet valve
Final valve
and = 39,2
and = 32,4
with = 2,0
with = 2,4
b= 9,2
b= 9,6
Engines with hydropushers of valves
Inlet valve
Final valve
and = 34,8
and = 27,8
with = 2,2
with = 2,2
b= 9,2
b= 9,6

Sizes of valves

and – diameter of a plate of the valve;

b–diameter of a core;

with – length of the valve

EZ and GU engines
Inlet valve
Final valve
and = 38,0
and = 33,0
with = 7,97
with = 7,95
b= 98,7
b= 98,5
Engines in capacity of 112 h.p.
Inlet valve
Final valve
and = 40,0
and =33,0
with = 7,97
with = 7,95
b= 98,7
b= 98,5
Engines with hydropushers of valves
Inlet valve
Final valve
and = 38,0
and = 33,0
with = 7,97
with = 7,95
b= 91,0
b= 90,8

Diameter of necks of a camshaft of 26 mm. Maximum admissible wear of necks of 0,25 mm.

Cam-shafts mark as follows:

 – the engine in working volume of 1,6 l – a label yellow paint between cams of the 1st cylinder;
 – the engine in working volume of 1,8 l – a cast lug on the first cam and a label dark blue paint between cams of the 1st cylinder;
 – the EZ engine with hydropushers of valves – the inscription which has been beaten out between cams of the 1st cylinder, I-BII-026;
 – the GU engine with hydropushers of valves – the inscription which has been beaten out between cams of the first cylinder, I-AII-026.

The cam-shaft of the repair size with necks in diameter of 25,75 mm is marked by yellow paint on "VW Audi" inscription.

The admissible palpation of a cam-shaft measured on an average neck, – 0,1 mm.