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
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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
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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;
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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. |
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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.
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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. |
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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. |
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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. |
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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. |
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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. |
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