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Diesel engine

The spare parts supply only the new intermediate shaft pulley, so when you install it on the engine before the release of January 1984 is necessary to provide a gap between the pulley and the bracket pump 0.5 mm, as shown.

If necessary, a file can be sawdust flare arm at the location of pulley. On engines found two variants of caps camshaft drive, and the camshaft drive belt is closed completely or partially.

Details of the camshaft drive

PERFORMANCE ORDER

1. Loosen the alternator mounting bolts. Turn the generator to the engine block and remove the belt 2 (see. Fig. Details camshaft drive) drive of the generator. 2. Remove the bolts 9 and remove the top cover 10. 3. Remove the cylinder head cover. 4. Install the new cylinder piston at TDC compression stroke. To do this, remove the plastic cap on top of the clutch housing and rotate the crankshaft to the TDC mark on the flywheel coincided with the tide on the clutch housing, as shown in the figure. This camshaft cams of 1st cylinder, starting from the camshaft drive should be facing upwards. The slit on the rear end of the camshaft to be arranged horizontally. A warning The crankshaft can be rotated only bolt crankshaft gear. 5. Lock the camshaft (2) special tool (1) as shown in the figure. To do this, insert the projection device into the slot in the end of the camshaft. Rotate the camshaft so that one end of the device was based on the cylinder head. Measure probe gap between the other end of the device and a head block. Insert the probe into the gap thickness equal to half of the measured gap. Rotate the camshaft so that the end of the tool was based on the probe, on the other hand to insert the probe of the same thickness between the end device and the head unit. Do not remove the device, since the camshaft drive assembly must be stalled. 6. Lock the gear (2) high pressure fuel pump, a special screwed rod (1) into the threaded hole of the gear, as shown in Figure (3 - front bracket pump). 7. Remove bolts 4 (see. Fig. Details camshaft drive) and to remove a pulley 3 of the crankshaft. 8. Remove the bottom cover 1 camshaft drive. 9. Loosen the nut 8 and the special wrench to turn the tensioner 7 to the left to loosen the tension of the belt 6. 10. Remove camshaft drive belt 6. 11. Unscrew the nut and remove the tensioner 8 7. 12. Remove bolt securing camshaft gear and inciting gear with a rubber hammer, remove it from the camshaft. If the engine is fitted cap completely covering the camshaft drive, then to remove the camshaft gear, it is necessary to insert into the hole cover 21 rod diameter of 6 mm and a hammer to knock off this rod gear. 13. Remove the bolt 5 and remove the gear 18 of the crankshaft. 14. Remove the bolt 17 and to remove a pulley 16, an intermediate shaft. Remove the key from the recesses of the intermediate shaft. 15. Special stripper to remove the gear 15 of the fuel pump. Remove the key. 16. To remove the back cover 21, it is necessary to remove the fuel pump and the front bracket 14 mounting the fuel pump.

Assembly

PERFORMANCE ORDER

1. If you have removed the back cover 21, you need to install the cover bracket 14 and the fuel pump 13. 2. Install the key into the recess of the shaft of the fuel pump, set the gear 15, to turn the nut gear, tighten to 45 Nm (4.5 kgf-m). 3. Fit the key into the recess of the intermediate shaft, set the pulley 16 of the intermediate shaft, screw the bolt 17 with a washer and tighten to 45 Nm (4.5 kgf-m). 4. Set the gear 18 so that the wheel lug into the groove on the crankshaft. Tighten the bolt 5 and tighten to 180 N ?� m (18.0 kgf ?� m) when the bolt has a hexagonal head. Since March 1988 set the twelve point head bolts with a torque of 90 Nm (9.0 kgf ?� m), then tighten half turn (180 ?�). Bolts with head dodecahedral reuse prohibited. Before wrapping applied to the bolt threads glue ?�D6?� Screwing. 5. Set the tensioner 7, tighten the nut and washer 8. The nut 8 is not delayed. 6. Install the camshaft gear, wrap, without tightening, the wheel bolt and washer. 7. Check the TDC coincidence of labels on a flywheel and clutch housing. 8. Turn gear fuel pump so that the mark coincided cogwheel and a bracket of the fuel pump as shown in Fig. 9. Lock the gear (2) high pressure fuel pump, a special screwed rod (1) into the threaded hole of the gear, as shown in Figure (3 - front bracket pump). 10. Attach the strap 6 (see. Fig. Details camshaft drive) on the camshaft gears, crankshaft, injection pump and pulleys of the intermediate shaft and the tensioner. 11. Tighten the camshaft gear to 45 Nm (4.5 kgf-m). 12. Remove the locking rod gear fuel pump. 13. Replace the belt 6 VW control device 210 to check belt tension after setting its value 12-13 scale units. The device is set midway between the camshaft gears and fuel pump. Turn tensioner special key 7 until the white line on the steel tongue device is aligned with the edge of the housing accommodation. While holding the tensioner in this position 7, 8, tighten the nut to 45 Nm (4.5 kgf-m). 14. Rotate the crankshaft by two turns and check the belt tension Timing. If the device shows the tension other than 12-13 units., Repeat the tensioning procedure. 15. Install the lower one and an upper cover 10. 16. To establish a pulley 3 of the crankshaft, tighten the screws 4 and tighten to 20 Nm (2.0 kgf-m). 17. Attach the belt 2 drives the generator and tighten it.