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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Golf IV (1997 release)

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Volkswagen Golf 4
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Golf 4
Instructions
Engine
Gasoline engines
Technical specifications
Removal and installation of the bottom mudguard of a motor compartment
Engine 1,6- / 1,8-I
The engine 1,4-I
Toothed belt
The cylinder head of the engine
Engine-I 2,3-VR5
Compression check in engine cylinders
Removing and installing V-ribbed belt
Engine oil recommendations
Circuit of motor oil
Checking oil pressure and oil pressure sensor
Removing and installing oil pan
Starting the engine after major repairs
Troubleshooting Engine
The basic malfunctions of system of greasing
Diesel engines
Cooling system
Fuel System
Exhaust system
Ventilation and heating system
Coupling
Transmission
Suspension brackets and power shafts
Steering
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The engine 1,4-I



Toothed belt engine 1,4-I

1 - the top casing of a gear belt;
2 - a bolt, 20 Nm;
3 - connecting belt tension roller;
4 - toothed belt connection.
Check the condition of the toothed belt. Before removing the toothed belt must be put on it the arrow indicating the direction of rotation of the toothed belt;
5 - a bolt, 20 Nm;
6 - the back casing of a gear belt;
7 - a bolt 10 Nm;
8 - a bolt 20 Nm;
9 - eyelet;
10 - a bolt of fastening of the guide roller 25 Nm;
11 - the guide roller;
12 - an arm;
13 - a bolt, 50 Nm;
14 - seal. If damaged, use a new gasket;
15 - the water pump;
16 - the main tension roller of a gear belt;

17 - the guide roller;
18 - a bolt, 50 Nm;
19 - a pulley of a gear belt of a cranked shaft;
20 - a bolt, 20 Nm;
21 - the main gear belt. Check the condition of the toothed belt. Before removing the toothed belt must be put on it the arrow indicating the direction of rotation of the toothed belt. Do not bend a gear belt;
22 - V-belt pulley. For proper installation of the pulley has a lock;
23 - a bolt, 90 Nm + tighten on a corner 90 ?�. When installing, use a new bolt. Before screwing bolts grease with a thin layer of engine oil bearing surface of the bolt head. Dovorachivanie bolt by 90 ?� can be carried out in several stages;
24 - V-belt. Before removing the belt must be put on it the arrow indicating the direction of rotation of the belt;
25 - the bottom casing of a gear belt;
26 - a bolt, 50 Nm;
27 - the holder of the engine

Location timing belts on the engine 1,4-I


A - toothed belt connecting the pulleys of camshafts;


B - basic timing belt

The drive camshaft operating intake valves, made toothed belt from the crankshaft pulley. Drive the camshaft operating final valves, made toothed belt pulley on the camshaft operating intake valves.


A warning

Common operations for replacing the timing belt on all motors are set out in Section 2.1.3.2. This section presents only the differences relating to the engine 1,4-I.


PERFORMANCE ORDER
1. Remove the four screws and remove the top casing of the engine.
2. Remove the air filter.
3. Remove the top casing of a gear belt.
4. Set the first cylinder to the top dead center in the compression stroke. In this position, the insertion holes (indicated by arrows) on the camshaft pulleys must be designed for each other and located on a line (shown mounting hole location on the engine 1,4-I). In this position, the insertion holes can be inserted mandrel or drill shank diameter of 8 mm.
5. When installing the piston of the first cylinder in the TDC mark on the crankshaft pulley must be aligned with the pointer.
6. Remove the right support of the power unit (see. Subsection 2.1.3).
7. Lower the right side of the engine so to expose the bolt crankshaft pulley.
8. Remove the auxiliary V-belt.
9. Hold the special tool on the crankshaft rotation, unscrew the central bolt and a toothed pulleys V-belts.
10. Remove the V-belt pulley from the crankshaft, and then with two thick washers screw bolt from the hand of the crankshaft pulley.
Cars with air conditioning
11. Remove the guide and tension roller belt.
12. Remove the lower part of the toothed belt.
13. If the toothed belts are reused, using chalk or paint, mark the direction of rotation of toothed belts.
14. Loosen the nut of a tension roller of the main toothed belt, whereby the roller will turn and loosen the belt tension. Remove the primary timing belt.
15. Loosen the screw (1) securing the tension roller and the auxiliary gear belt by turning the tensioner roller clockwise to loosen the belt tension. Secure camshaft pulleys special tool and remove the timing belt.

A warning

After removal of the timing belts do not turn the camshaft pulleys, as otherwise can be an impact of valves with pistons.


16. Installation of the timing belt is made in accordance with the previously made marks, marking the direction of rotation of the toothed belt. When viewed from the front of the engine, the motor pulley rotates clockwise.
17. Check that the cut tooth (arrow) on a pulley of a gear belt of a cranked shaft is aligned with the pointer on the front cover of the engine.
18. Install the coupling toothed belt first pulley toothed belt camshaft operating final valves, then on a pulley toothed belt camshaft operating intake valves. Relaxed belt is to be bottom-side tension roller.
19. Turn the tensioner roller (1) of the auxiliary gear belt so that the pointer (2) is aligned with the tab on the cylinder head.
20. Turn the tension wheel of the auxiliary gear belt to perform internal hexagon. Tighten the bolt tensioning pulley to 20 Nm.
21. Install the primary timing belt sequentially on the water pump pulley, tensioner roller, crankshaft pulley, the guide pulley and the pulley of the camshaft operating intake valves.
22. Check the installation position of the tension wheel main gear belt. Bolt (2) fixing must pass through a recess of the movable plate (1) video (3 - pointer).
23. Using the internal hex wrench, turn the main tension roller of a gear belt to align the pointer (3) with the notch on the movable plate. In this position, tighten the nut on the tensioning pulley to 20 Nm.
24. Check that the crankshaft pulley and the camshaft are in the mounting position of the piston of the first cylinder at top dead center.
25. Establish a casing of a gear belt.
26. Install the crankshaft pulley and secure it with a new bolt.
27. Before screwing the bolt lubricate the bottom of the bolt head with clean engine oil. Tighten the bolts to 90 Nm and then tighten it to the angle of 90 ?�.
28. Fix the support to the engine block, tightening the bolts to 50 Nm.
29. Using new bolts, secure the right support of the power unit.
30. Install popolnitelny tank of power steering.
31. Install the V-belt.




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