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
      - 2.2.3. Diesel engine
         2.2.3.1. Camshaft drive
         2.2.3.2. Removal and installation of a head of the block of cylinders
         2.2.3.3. Dismantling of a head of the block of cylinders
         2.2.3.4. Check and repair of a head of the block and its details
         2.2.3.5. Assembly of a head of the block of cylinders
         2.2.3.6. Adjustment of gaps between cams of a cam-shaft and levers of valves
         2.2.3.7. Technical condition of hydropushers of valves
         2.2.3.8. Intermediate shaft
         2.2.3.9. Flywheel
         2.2.3.10. Epiploons of a cranked shaft
         2.2.3.11. Oil case
         2.2.3.12. Oil pump
         2.2.3.13. Shatunno-porshnevaya group
         2.2.3.14. Cranked shaft
         2.2.3.15. Check of the block of cylinders
   + 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

indigo lake

2.2.3. Diesel engine

2.2.3.1. Camshaft drive

GENERAL INFORMATION

In January, 1984 the design of covers of a drive of a cam-shaft changed. The pulley of an intermediate shaft and a forward arm of the fuel pump of a high pressure (TNVD) in this regard changed. The pulley of an intermediate shaft began to settle down closer to the block of cylinders therefore on a new arm of TNVD there is a dredging in the location of a pulley of an intermediate shaft.

Gap between a pulley of an intermediate shaft and an arm of the fuel pump of a high pressure

In spare parts deliver only a new pulley of an intermediate shaft therefore at installation it on the release engine till January, 1984 it is necessary to provide a gap between a pulley and an arm of TNVD of 0,5 mm, as is shown in drawing.

If it is necessary, it is possible to saw round a file an arm otbortovka in the pulley location. On engines two options of covers of a drive of a cam-shaft, thus a belt of a drive of a cam-shaft meet is closed in whole or in part.

Details of a drive of a camshaft

1–bottom cover of a drive of a cam-shaft;
2–belt of a drive of the generator;
3–pulley of a cranked shaft;
4–bolt of fastening of a pulley;
5–bolt of fastening of a cogwheel of the crankshaft;
6–belt of a drive of a cam-shaft;
7–natyazhitel;
8–nut of fastening of a natyazhitel;
9–bolt of fastening of the top cover;
10-top cover of a drive of a cam-shaft;
11-back cover of a drive of a cam-shaft;

12-back arm of fastening of the fuel pump;
13-fuel pump of a high pressure;
14-forward arm of fastening of the fuel pump;
15-cogwheel of the fuel pump;
16-pulley of an intermediate shaft;
17-bolt of fastening of a pulley;
18-cogwheel of a cranked shaft;
19-the bottom cover of a drive of a cam-shaft (option of completely closed drive);
20-the top cover of a drive of a cam-shaft (option of completely closed drive);
21-a back cover of a drive of a cam-shaft (option of completely closed drive)
Dismantling

PERFORMANCE ORDER
1. To weaken an inhaling of bolts of fastening of the generator. To turn the generator to the block of cylinders and to remove a belt 2 (see fig. Details of a drive of a camshaft) generator drive.
2. To unscrew bolts 9 and to remove the top cover 10.
3. To uncover heads of the block of cylinders.
4. To establish the piston of the new cylinder in VMT of a step of compression. For this purpose to take out a plastic stopper from above a case of coupling and to turn a cranked shaft so that VMT label on a flywheel coincided with inflow on a coupling case, as is shown in drawing.
Thus cams of a cam-shaft of the 1st cylinder, considering from a cam-shaft drive, should be directed up. The cut on the back end of a cam-shaft should be located horizontally.

Prevention

The cranked shaft can be turned only for a bolt of fastening of a cogwheel of the crankshaft.


5. To stop a camshaft (2) special adaptation (1), as is shown in drawing. For this purpose it is necessary to insert an adaptation ledge into a cut in a cam-shaft end face. To turn a cam-shaft so that one end of the adaptation leaned on a block head. To measure shchupy a gap between other end of the adaptation and a block head. To insert into a gap щуп in the thickness, an equal half of the measured gap.
To turn a cam-shaft so that the end of the adaptation leaned on щуп, on the other hand to insert щуп the same thickness between the end of the adaptation and a block head. Not to remove the adaptation as at drive assembly the cam-shaft should be stopped.
6. To stop a cogwheel (2) fuel pumps of a high pressure, having screwed a special core (1) in a carving opening of a cogwheel, as is shown in drawing (3 – a forward arm of fastening of TNVD).
7. To unscrew bolts 4 (see fig. Details of a drive of a camshaft) and to remove a pulley 3 cranked shaft.
8. To remove the bottom cover of 1 drive of a cam-shaft.
9. To weaken an inhaling of a nut 8 and a special key to turn a natyazhitel 7 to the left, to weaken a belt 6 tension.
10. To remove a belt 6 of a drive of a cam-shaft.
11. To unscrew a nut 8 and to remove a natyazhitel 7.
12. To unscrew a bolt of fastening of a cogwheel of a cam-shaft and, lining a cogwheel with a rubber hammer, to remove it from a cam-shaft. If on the engine the covers which are completely closing a drive of a cam-shaft, are established to remove a cam-shaft cogwheel, it is necessary to insert 21 cores in diameter of 6 mm into an opening of a cover and a hammer to bring down by means of this core a cogwheel.
13. To turn out a bolt 5 and to remove a cogwheel of the 18th crankshaft.
14. To turn out a bolt 17 and to remove a pulley 16 intermediate shaft. To take out a shponka from dredging of an intermediate shaft.
15. A special stripper to remove a cogwheel 15 fuel pumps. To take out a shponka.
16. To remove a back cover 21, it is necessary to remove the fuel pump of a high pressure and a forward arm of the 14th fastening of the fuel pump.

Assembly

PERFORMANCE ORDER
1. If the back cover 21 was removed, it is necessary to establish a cover, an arm 14 and the fuel pump 13.
2. To establish a shponka in dredging of a shaft of the fuel pump, to establish a cogwheel 15, to wrap a nut of fastening of a cogwheel, to tighten the moment of 45 N · m (4,5 kgfs · м).
3. To establish a shponka in dredging of an intermediate shaft, to establish a pulley 16 intermediate shaft, to screw a bolt 17 with a washer and to tighten the moment of 45 N · m (4,5 kgfs · м).
4. To establish a cogwheel 18 so that the ledge of a wheel entered into a groove on cranked to a shaft. To wrap a bolt 5 and to tighten the moment of 180 N · m (18,0 kgfs · м), if the bolt has a six-sided head. Since March, 1988 establish bolts with a dvenadtsatigranny head, the moment of an inhaling of 90 N · to m (9,0 kgfs · м), then to tighten on a half of turn (180 °). With a dvenadtsatigranny head it is forbidden to reuse bolts. Before a wraparound to put on a bolt carving D6 glue for carving connections.
5. To establish a natyazhitel 7, to wrap a nut 8 with a washer. A nut 8 not to tighten.
6. To establish a cam-shaft cogwheel, to turn, without tightening, a bolt of fastening of a wheel with a washer.
7. To check coincidence of labels of VMT on a flywheel and a coupling case.
8. To turn a cogwheel of the fuel pump so that labels on a cogwheel and an arm of the fuel pump, as is shown in drawing coincided.
9. To stop a cogwheel (2) fuel pumps of a high pressure, having screwed a special core (1) in a carving opening of a cogwheel, as is shown in drawing (3 – a forward arm of fastening of TNVD).
10. To put on a belt 6 (see fig. Details of a drive of a camshaft) on cogwheels of a cam-shaft, the crankshaft, the fuel pump and pulleys of an intermediate shaft and a natyazhitel.
11. To tighten a bolt of fastening of a cogwheel of a cam-shaft the moment of 45 N · m (4,5 kgfs · м).
12. To take out stopping core from a cogwheel of the fuel pump.
13. To establish on a belt 6 the control VW 210 adaptation for check of a tension of a belt, previously having established on its scale value of 12-13 units. The adaptation establish in the middle between cogwheels of a cam-shaft and the fuel pump. To turn a special key a natyazhitel 7 until the white strip on a steel uvula of the adaptation will not be combined with edge of the case of the adaptation. Holding in this situation a natyazhitel 7, to tighten a nut the 8th moment of 45 N · m (4,5 kgfs · м).
14. To turn a cranked shaft on two turns and to check a tension of a belt of a drive of a cam-shaft. If the adaptation shows tension size excellent from 12-13 a unit, to repeat adjustment of a tension of a belt.
15. To establish bottom 1 and top the 10th covers.
16. To establish a pulley 3 crankshafts, to wrap bolts 4 and to tighten the moment of 20 N · m (2,0 kgfs · м).
17. To put on a belt 2 drives of the generator and to pull it.