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



2.2.3.2. Removal and installation of a head of the block of cylinders

GENERAL INFORMATION

Order of an inhaling of bolts of fastening of a head of the block of cylinders


Laying of a head of the block of cylinders

The red arrow indicates detail number, dark blue – on the cuts specifying thickness of laying.
Size of a vystupaniye of the piston
Thickness of laying, mm
Number of cuts
Engine in capacity of 45 h.p.
0,67-0,82
1,4
1
0,83-0,92
1,5
2
0,93-1,02
1,6
3
Engine in capacity of 70 h.p.
0,81-0,86
1,5
2
0,91-1,02
1,6
3
Engines with hydropushers of valves (from 09.1985 g)
0,66-0,86
1,4
1
0,87-0,90
1,5
2
0,91-1,02
1,6
3

The engine is removed from the car

PERFORMANCE ORDER
1. To remove a belt of a drive of the generator and the top cover of a drive of a cam-shaft (see subsection 2.2.3.1).
2. To uncover heads of the block of cylinders.
3. To disconnect the current carrying tire from candles of an incandescence and to turn out candles.
4. To clear gasoline топливоприводы in fastening places to the fuel pump of a high pressure and to nozzles and to remove them. Toplivoprivoda it is impossible to bend or change their form.
5. To turn out nozzles.
6. To remove an inlet pipe and an exhaust collector.
7. To establish the piston of the first cylinder in situation VMT (see subsection 2.2.3.1).
8. To weaken a tension of a belt of a drive of a cam-shaft and to remove a belt from a cam-shaft cogwheel (see subsection 2.2.3.1).
Prevention

After the belt of a drive of a cam-shaft was removed, it is impossible to turn cranked, distributive and intermediate shaft.


9. If on the engine the covers which are completely closing a drive of a cam-shaft are established, it is necessary to remove a cogwheel 15 (see fig. Details of a drive of a camshaft) fuel pump, pump 13, pump 14 arm, cogwheel of a cam-shaft and back cover 21.
10. A special key to unscrew bolts of fastening of a head of the block of cylinders. Bolts to turn on evenly as it should be, the return specified fig. Order of an inhaling of bolts of fastening of a head of the block of cylinders.
11. To remove a head of the block of cylinders and laying of a head of the block. If the head of the block "became attached" to the block, it is impossible to hammer between a head and the block of a screw-driver or any tool as it is possible to damage a head surface. It is necessary to knock slightly with a hammer through wooden laying on a block head.
12. After survey and replacement of the damaged and worn-out details installation of a head of the block make in return sequence. Thus it is necessary to replace laying of a head of the block and a cover of a head of the block, and also bolts of fastening of a head of the block. In spare parts deliver three laying of a head of the block, differing in the thickness. To distinguish laying, detail number is put on them, and also two are made one, or three cuts, as is shown in fig. Laying of a head of the block of cylinders. The thickness of laying which it is necessary to establish on the engine, is defined by a vystupaniye of pistons over the plane of the block of cylinders in VMT. It is necessary to establish laying of the same thickness, as well as at old laying. Since September, 1995 laying which has an additional opening in diameter of 16 mm between the 1st and 2nd cylinders is established.
13. If at measurement of a vystupaniye of pistons different sizes turn out, it is necessary to select laying for the biggest size of a vystupaniye of the piston.
14. For simplification of normal installation of a head of the block it is necessary to make directing pins of old bolts of fastening of a head of the block. At two bolts to chop off heads and to cut through shlitsa under a screw-driver. These pins to screw before head installation in extreme openings of the block from an inlet pipe.
15. To tighten bolts of fastening of a head of the block in the sequence specified fig. An order of an inhaling of bolts of fastening of a head of the block of cylinders, in three stages:
 – the 1st stage – 40 N · m (4,0 kgfs · м);
 – the 2nd stage – 60 N · m (6,0 kgfs · м);
 – the 3rd stage – to tighten further on a half-turn (180 °).
16. After assembly to start and warm up the engine (the temperature of oil is not lower 50 ° C). To tighten bolts of a head of the block on a turn quarter (90 °).
17. After run of 1000 km once again to tighten bolts of a head of the block on a turn quarter (90 °) (except engines of fashions. 1V).

The engine is established on the car

In need of replacement of laying of a head of the block of cylinders, grinding in of valves, deposit cleanings etc. it is possible to remove a block head, without removing the engine from the car. It is impossible to remove a head on the hot engine (temperature of cooling liquid higher 40 ° C).

PERFORMANCE ORDER
1. To disconnect a wire from the "minus" plug of the storage battery.
2. To merge liquid from system of cooling of the engine (see subsection 2.4.1).
3. To disconnect hoses of system of cooling from a head of the block of cylinders.
4. To remove an air line from the air filter to an inlet pipe or to a turbokompressor.
5. To disconnect a reception pipe of the exhaust silencer from a final collector.
6. To disconnect electric wires from the valve blocking supply of fuel, from candles of an incandescence, the sensor of pressure of oil and the sensor of temperature of cooling liquid.
7. To turn out glow plugs.
8. To clear and disconnect топливоприводы from nozzles and the pump of a high pressure.
9. To turn out nozzles. Further sequence same, as at the engine which has been removed from the car (see above).