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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Golf II, Jetta (from 1983 to 1992, the year of issue)

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Volkswagen Golf 2 / Jetta
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Volkswagen
Golf 2 / Jetta
General Information
Engine
Removing and installing engine
Disassembly and assembly of the engine
Engines in volume of 1,1 and 1,3 l
Engines in volume of 1,6 and 1,8 l
Camshaft drive
Removal and installation of the cylinder head
Dismantling the cylinder head
Assembling the cylinder head
Adjustment of backlashes between cams of a cam-shaft and levers of valves
Countershaft
Flywheel
Crankshaft Seals
Oil pump
The connecting rod-piston group
Crankshaft
Checking cylinder
Diesel engine
Engine lubrication system
Engine cooling system
Exhaust
The power supply system
Coupling
Transmission
Transmission
Front-wheel Drive
A steering
Suspension
Brakes
Body
Electrical
 


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Engines in volume of 1,6 and 1,8 l



Details of the camshaft drive

1 - the water pump pulley;
2 - a bolt of fastening of a pulley of the water pump;
3 - the bolt of the crankshaft pulley;
4 - the crankshaft pulley;
5 - alternator drive belt;
6 - caps;
7 - Timing cover lower;
8 - Cover Timing top;
9 - Timing belt;
10 - a cover of the rear camshaft drive;
11 - a cogwheel of an intermediate shaft;
12 - a bolt of fastening of an intermediate shaft gear;
13 - a cogwheel of a cranked shaft;
14 - bolt crankshaft gear;
15 - Timing belt tensioner;
16 - the nut tensioner

Position marks on the camshaft gear when the piston of the first cylinder at TDC

1 - cylinder head;

2 - a cogwheel of a camshaft;

3 - head cover;

A - TDC cogwheel

Dismantling

PERFORMANCE ORDER
1. Loosen the bolts fastening of an adjusting lath of the generator to the cylinder head and the generator - to the bracket and the adjusting plate. Turn the generator to the power to ease the tension of the belt 5 (see. Fig. Details camshaft drive) of the generator and remove the belt.
2. Remove the four screws and remove the 2 1 water pump pulley.
3. Remove the top cover 8 Timing.
4. Disconnect the hose from the crankcase ventilation head cover.
5. Remove the head cover together with the seal cover and the pressure plate.
6. Unscrew the four screws 3 and remove the crankshaft pulley 4.
7. Remove the bottom cover 7 Timing.
8. Loosen the bolts securing camshaft gear, crankshaft and intermediate shaft.
9. Set the piston of the first cylinder in the compression stroke TDC. To do this, temporarily install the crankshaft pulley in place by screwing it with one screw. Rotate the crankshaft so that the mark on the crankshaft pulley coincided with a label on a cogwheel of an intermediate shaft as shown in the figure.
If the label on the camshaft gear must coincide with the upper face of the cylinder head cover, as shown in Fig. The position of the label on the gear wheel of the camshaft at the position of the piston of the first cylinder at TDC. Both valves of the first cylinder, starting from the camshaft drive belt, closed and camshaft cams pointing upwards. Remove the crankshaft pulley.
10. Loosen the nuts 16 and 15 to turn the key tensioner anti-clockwise to loosen the belt tension 9.
11. Remove the belt 9 with the gears of the distribution, the crankshaft 13 and the intermediate shaft 11 and tensioner pulley 15.
12. Unscrew the nut 16 and remove the tensioner 15.
12 13. Remove the bolt and remove the gear 11 of the intermediate shaft, remove the key.
14 14. Remove the bolt and remove the gear 13 to the crankshaft, remove the key.
15. Remove the bolt and remove the gear from the intermediate shaft, remove the key.
16. Loosen the screws and remove the rear cover 10 Timing.

Assembly

Adjustment and check belt camshaft drive

1 - drive belt tensioner camshaft;

2, 3 - wrenches;

4 - a cogwheel of a cam;

5 - Timing belt;

6 - pinion countershaft

PERFORMANCE ORDER
1. Install the rear cover 10 (see. Fig. Details camshaft drive) camshaft drive and tighten bolts of its fastening.
2. Insert the key into the slot on the crankshaft gear set 13. Coat the thread of the bolt 14 adhesive for threaded connections ?�D6?�, tighten the bolt with a washer and tighten to 200 N ?� m (20.0 kgf ?� m) (on cars Release from March 1988 established the twelve point bolt head, tightening torque 90 Nm).
3. Insert the key into the slot on the cam shaft, set the gear, to turn a bolt with a washer and tighten to 80 Nm (8.0 kgf-m). The label on a cogwheel should coincide with the upper plane of the cylinder head cover (see Fig. Position of mark on the camshaft gear with the position of the piston of the first cylinder in VMT). If you want to rotate the camshaft, the first turn around the crankshaft by 90 ?� so that none of the piston was at TDC.
4. Insert the key into the slot on the intermediate shaft, set the gear 11, wrap a bolt 12 with a washer and tighten to 80 Nm (8.0 kgf-m).
5. Set the tensioner 15, wrapped, without tightening the nut 16.
6. Temporarily install the crankshaft pulley 4 on the gear 13. The label on a pulley 4 should coincide with a label on a cogwheel 11.
7. Put on the belt 9 on the camshaft gears, crankshaft and intermediate shaft and pulley tensioner. Check that the label
TDC has not budged.
8. Tighten the belt 9. To do this, turn the key 3 (see. Fig. Adjustment and check belt camshaft drive) 1 tensioner clockwise to pre-tension the belt. Check that TDC has not budged. Turn the tensioner 1 further clockwise, pulling the belt 5 so that it can be deployed for no more than 90 ?�, holding his two fingers in the middle between the distribution and intermediate shafts. While holding this position, the tensioner 1 3 key, tighten the nut on the tensioner key 2. Turn the crankshaft two turns and check whether the TDC. 4 Remove the pulley (see. Fig. Details camshaft drive).
9. Install the bottom cover 7 Timing.
10. To establish a pulley 4, tighten the screws 3 and tighten to 20 Nm (2.0 kgf-m).
11. To establish a cover 8 Timing.
12. To establish a pulley of the water pump 1, tighten screws 2 and tighten to 20 Nm (2.0 kgf-m).
13. Attach the belt 5.
14. Tighten the belt 5, pressing the generator of the cylinder so that it caved in to 5 mm (for a new belt 2 mm), if you press it with your finger in the middle between the crankshaft and alternator pulleys. Tighten the bolt of the generator to an adjusting lath, then bolt the generator to an arm.




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