2.1.3. Dismantling and assembly of engines
Crankshaft and block of cylinders
Prevention
The block of cylinders in collecting (4-cylinder models)
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1. Bolts
2. Inserts of the 1, 2, 4 and 5 radical bearing are established in covers of the 1, 2 and 5 radical bearings without oil flute, and in a cover of the 4th bearing with a myaslyany flute 3. Laying is subject to obligatory replacement 4. Forward holder of an epiploon 5. Epiploon 6. 20 N. of m. 7. Ring laying at damage replace 8. 25 N. of m. 9. Epiploon take an epiploon from the case a stripper 10-203 before installation slightly grease working and external edges of an epiploon 10. Epiploon case 11. Intermediate shaft at first remove the ignition distributor |
12. Inserts of the 1, 2, 4 and 5 radical bearing are established in a bed of the block of cylinders with an oil flute 13. Insert of the 3rd radical bearing the persistent bearing is installed in a bed of the block of cylinders with an oil flute (the repair bearing has an assembly fillet) 14. A persistent half ring from the block of cylinders 15. Insert of the 3rd radical bearing 16. The directing bearing put lubricant on the basis of a molybdenum disulfide 17. Crankshaft 18. Persistent half ring you watch correctness of installation 19, 20. Covers of radical bearings pay attention to asymmetry of a bed of an insert and fixing inflows |
Crankshaft sizes (engine 1,6 liters)
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Diameter of conrod necks (mm)
| |
| Standard size |
45,96 – 45,98
|
| First repair size |
45,71 – 45,73
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| Second repair size |
45,46 – 45,48
|
| Third repair size |
45,21 – 45,23
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Crankshaft sizes (engine 1,8 liters)
|
Diameter of radical necks (mm)
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Diameter of conrod necks (mm)
| |
| Standard size |
53,96 – 53,98
|
47,76 – 47,78
|
| First repair size |
53,71 – 53,73
|
47,51 – 47,53
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| Second repair size |
53,46 – 53,48
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47,26 – 47,28
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| Third repair size |
53,21 – 53,23
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47,01 – 47,03
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Crankshaft sizes (engine 2,0 liters)
|
Diameter of radical necks (mm)
|
Diameter of conrod necks (mm)
| |
| Standard size |
54,022 – 54,042
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47,822 – 47,842
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| First repair size |
53,772 – 53,792
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47,572 – 47,592
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| Second repair size |
53,522 – 53,542
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47,322 – 47,342
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| Third repair size |
53,272 – 53,292
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47,072 – 47,092
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Three repair sizes of bearings with a step to 0,25 mm.
Cam-shaft drive belt, installation
Prevention
Gear belt of the drive in collecting (4-cylinder models)
| 1. 45 N. of m. 2. Top cover of a gear belt 3. 20 N. of m. 4. 10 N. of m. 5. Uspokoitel 6. Klinoremenny transfer 7. Klinoremenny transfer 8. Remote laying 9. Pulley 10. 20 N. of m. 11. Klinoremenny transfer 12. Pulley 13. 20 N. of m. 14. Lower cover of a gear belt 15. 10 N. of m. 16. Remote plug 17. Bolt of the leading gear wheel tighten with the moment 90 N. of m and tighten on 1/4 turns доворот it is possible to execute in stages replace a bolt at an inhaling or an otvorachivaniye of a bolt stop a gear wheel adaptation 3099 before installation slightly oil a bolt for the engine |
18. Leading gear wheel of a gear belt 19. Intermediate gear wheel of a gear belt when clothing a belt you monitor the provision of an adjusting tag 20. 80 N. of m. 21. 20 N. of m. 22. Back cover of a gear belt (lower) 23. 10 N. of m. 24. Back cover of a gear belt (lower) 25. Gear belt of the drive of a cam-shaft 26. Roller of a natyazhitel |
Prevention
if necessary establish adjusting laying 2
Drawing an adjusting tag of a corner of an advancing of ignition Extraction of the directing bearing 3) turn out an internal cartridge of a stripper of an epiploon of 2085 on two turns from external (the internal boss has to act approximately on 3,0 mm), and record the screw with a nakatka Gap in a joint: – new compression rings – 0,30–0,45 mm; The piston in collecting (4-cylinder models) limit gap – 0,15 mm the nominal admission – no more than 0,04 mm maximum deviation from nominal diameter – 0,08 mm
Size b = 19,3 mm Diameters of the piston and channel of the cylinder (engine 2,0 liters) Gear belt in collecting (5-cylinder models) 1. Oil фипьтр 3) stop an uspokoitel adaptation 2084 and tighten a bolt of an uspokoitel with m 350 N.' moment, using the extender 2079 and a face key 5) turn off bolts of fastening of the pump of cooling liquid (are specified by shooters); establish a belt cover install the power steering pump establish klinoremenny transfer of the generator Axial side play: – the new crankshaft – 0,07–0,23 mm – limit – 0,25 mm – the radial gap – is checked by the calibrated plastic wire – the new crankshaft – 0,018–0,058 mm – limit – 0,16 mm Conrod bearings – check Axial side play: – new bearings – 0,05–0,31 mm – limit – 0,4 mm Radial gap: – new bearings – 0,010–0,056 mm – limit – 0,12 mm The radial gap is checked by the calibrated plastic wire. – new compression rings – 0,20–0,40 mm – new oil scraper rings – 0,25–0,50 mm – a limit gap of worn-out rings – 1,0 mm Check of a gap of piston rings in a piston flute new oil scraper rings – 0,02–0,06 mm limit gap of worn-out rings – 0,15 mm
the nominal admission – no more than 0,04 mm maximum deviation from nominal diameter of 0,08 mm Identification sizes of the piston
Size b = 22,2 mm the nominal admission – no more than 0,04 mm Check of internal diameter of the cylinder 1 – in 10 mm from the upper edge of the cylinder 2 – in the middle of the cylinder 3 – in 10 mm from bottom edge of the cylinder measurements are carried out by a nutromer on the range of 50-100 mm in places 1, 2 and 3 repeat measurements in the same places, but in the direction perpendicular to previous maximum deviation from nominal diameter – 0,08 mm
Head of the block of cylinders assembled
1. Block head cover
2. Consolidation of a cover of a head of the block (forward)
3. The conducted cam-shaft gear wheel at installation of a belt you monitor the correct provision of a gear wheel
4. Head of the block of cylinders
5. 25 N. of m.
6. Laying of a head of the block of cylinders the party with marking of "OBEN" has to be turned towards a block head 7. Arm of a natyazhitel of the generator
8. Consolidation of a cover of a head of the block (back)
9. Cam-shaft cover
10. Intensifying laying
11. Bolts of fastening of a head of the block
12. 10 N. of m.
13. Stopper of a maslozalivny mouth
Engine case assembled
1. 20 N. of m
2. Arm of fastening of the generator
3. Pump of cooling liquid
4. A bolt with a molotoobrazny head
5. Oil pallet
6. Laying of the oil pallet
7. 20 N. of m.
8. Laying
9. Laying
before assembly grease with structure
AMV 1881 100 02
10. Oil filter
turn off by means of a special key
before installation study the instruction
on the filter case
12. Oil cooler
13. Sensor of emergency pressure of oil of 25 Nanometers.
14. 20 N. of m.
15. Sensor of emergency pressure of oil
16. Flange of the case of an oil filter
17. Inlet branch pipe of a shirt of cooling of the block of cylinders
18. 20 N. of m
19. Sealing ring
20. 25 N. of m.
21. Plate of fastening of the distributor
22. Ignition distributor
Flywheel assembled
1. Tighten with the moment 30 N. of m and
tighten on 1/4 turn (on 90 °)
Tighten a dynamometer key
with the arrow indicator. At
tightening by a key "graggers"
breakage is possible, to tighten on 90 °
it is possible in two stages on 45 °
replace bolts
grease a carving of new bolts with the structure fixing from an otvorachivaniye
2. 10 N. of m.
3. Holder of a back epiploon
4. Laying
5. Intermediate plate
6. Back epiploon
remove adaptation 1O-221
before installation do not grease as on an epiploon from a remkomplekt lubricant is already available
establish by means of adaptation which is a part of a remkomplekt
7. Flywheel
8. Frictional clutch plate
at installation it is aligned by a mandrel 3176
9. An inhaling on diagonal with m 25 N.' moment.
10. Press clutch plate
Crankshaft / flywheel assembled
1. 65 N. of m.
2. Cover of radical bearings
the cover of the 1st bearing settles down from a crankshaft pulley storna
pay attention to the displaced bed arrangement under an insert of the bearing and inflows of bolts of fastening
3. Oil receiver tube
4. 10 N. of m.
5. Lock plate
is subject to obligatory replacement
6. Laying
is subject to obligatory replacement
7. 10 N. of m.
8. Persistent half rings of covers of radical bearings
pay attention to orientation of rings
at installation
9. Top inserts of radical bearings
establish together with persistent half rings
10. Lower inserts of 1, 2, 3 and 5 radical bearings
are not interchangeable
11. Persistent half rings of the block of cylinders
12. Crankshaft
13. The directing bearing
14. Tighten with the moment 350 N. of m and
tighten on 1/4 turns (90o)
15. Flywheel
before removal put orientation
tags in relation to the crankshaft 16. Lock rings
17. Epiploon
press off with the help
devices 320 3
before installation slightly grease working and external edges
establish by means of mandrels from a set 2080 A
press against the stop a mandrel from a set 2080 A
18. 10 N. of m.
19. 10 N. of m.
20. Oil pump
at installation you monitor the correct landing to the crankshaft
21. Laying
is subject to obligatory replacement
22. Laying
is subject to obligatory replacement
23. Holder of a back epiploon
24. Epiploon
remove by means of adaptation 2086
at installation do not grease as from a remkomplekt lubricant is applied on an epiploon in advance
establish by means of adaptation which is a part of a remkomplekt
remove adaptation and press a mandrel 2003/1 against the stop
25. 20 N. of m.
Flywheel, installation
the facet on a washer 1 has to be turned towards the plane of installation of a clutch plate
tighten bolts with 30 N.' moment of m and tighten on 1/4 turns (on 90 °)
Prevention
replace bolts. Carvings of new bolts are in advance greased by the structure fixing from an otvorachivaniye
Size and = 30,5–32,1 mm
The size and = 14 mm (it is measured on an arch).
Prevention
Removal / installation of the flywheel / hydrotransformer
Installation of the directing bearing by means of a shock stripper of VW 207 or 3176
the bearing facet with marking has to be turned from the engine aside
Landing depth
Size and = 1,5 mm
Forward epiploon of the crankshaft from a gear belt
Vypressovka and press fitting
PERFORMANCE ORDER
1) take off a gear belt
2) remove a gear wheel of a gear belt (turn off bolts by means of a key 3099)
4) for the correct orientation of a stripper, screw a cylindrical bolt from adaptation 3083 in the crankshaft against the stop
5) grease a carving head of a stripper of an epiploon, establish a stripper and with the maximum effort push into an epiploon
6) unscrew the screw with a nakatka, and rotate an internal cartridge of a stripper to an epiploon exit
7) clamp a stripper in a vice and get an epiploon flat-nose pliers
8) slightly grease working and external edges of a new epiploon
9) dress on a shaft the directing plug from adaptation 3083 and push an epiploon on the directing plug
10) press an epiploon against the stop
11) measure a gap in a joint of piston rings; insert a ring into the cylinder so that the plane of a ring settled down at an angle 90 ° to a cylinder axis, on distance of 15 mm from the lower edge of the cylinder
– new oil scraper rings – 0,25–0,45 mm;
– a limit gap – 1,0 mm.
1. Piston rings
place joints at an angle 120o
the tag of "top" on a ring is turned aside
piston bottoms
establish at the pressed-out rings in special pincers
2. Piston finger
establish and press off with
help of VW 222 A adaptation
3. Lock ring of a piston finger
4. Rod cover bolt
5. Block of cylinders
6. Connecting rod
we do not interchange
ledges have to coincide completely with dredging in a conrod cover limit
axial side play of 0,37 mm
check a radial gap by means of a calibration plastic wire a limit gap of 0,12 mm
7. Oil nozzle
8. 10 N. of m.
establish on AMV 1888 100.02 lubricant
9. Tighten with the moment 30 N. of m and tighten strictly on 1/4 turns (on 90 °)
grease contact surfaces
10. Rod cover
Tags "And" – number of the cylinder
tags "In" have to be turned towards a driving belt
11. Rod
replacement only of all set is allowed
12. Piston
put tags of installation of the piston and
numbers of the cylinder
the arrow on the piston is turned towards a gear belt
Check of a gap of piston rings in a piston flute
gap of new rings – 0,02–0,05 mm
Check of the sizes of the piston
measure diameter at distance about 10,0 mm from bottom edge of a skirt of the piston, at an angle 90 ° to a piston axis
Check of diameter of the cylinder
execute measurements by a nutromer on the range of 50-100 mm in three places, in the directions A (cross) and In (longitudinal)
Prevention
Identification of the piston
Size and = 4,6 mm
Diameters of the piston and channel of the cylinder (liter engine 1,6 and 1,8)
1. 350 N. of m.
2. Ремнь generator drive
3. Uspokoitel
4. 10 N. of m.
5. Lower cover of a belt of the drive of a cam-shaft
6. 10 N. of m.
7. Top cover of a belt of the drive of a cam-shaft
8. Gear belt of the drive of a cam-shaft
9. 80 N.m.
10. The conducted cam-shaft gear wheel
at installation of a belt of the drive you monitor the correct orientation of the conducted gear wheel 11. Remote plugs
12. Cover of a driving belt (back)
13. 10 N. of m.
14. 20 N. of m.
15. 20 N. of m.
16. Leading gear wheel of a cam-shaft
17. Pump of cooling liquid
the turn of a pump housing regulates a tension of a gear belt
18. Sealing ring
is subject to obligatory replacement
Prevention
Head of the block of cylinders in collecting (5-cylinder models)
The oil pallet in collecting (5-cylinder models)
1. Intensifying porkladka
2. Stopper of a maslozalivny mouth
3. Consolidation of a cover of a head of the block
4. Segment spline
5. Head of the block of cylinders 6. Laying of a head of the block of cylinders
7. Consolidation of a cover of a head of the block
8. Bolts of fastening of a head of the block
9. Block head cover
10. 10 N. of m.
turn off a special key study the instruction on the case
2. Block of cylinders
3. Laying
4. Lock plate
is subject to obligatory replacement
5. 10 N. of m.
6. Oil pallet
7. Oil receiver
8. 40 N. of m.
9. Uplotnitepny ring
is subject to obligatory replacement
10. 25 N. of m. 11. Lower cover of a case of coupling
12. 20 N. of m.
13. 10 N. of m.
14. 25 N. of m.
turn with use of adaptation 10-201
tighten in stages on diagonal
15. Press clutch plate
before removal put an orientation tag
16. The conducted clutch plate
it is aligned by means of a mandrel 3176
Uspokoitel, removal and installation
PERFORMANCE ORDER
1) apply anticorrosive structure of AVM 188 001 02 on surfaces of a carving and a bolt
2) put on on the crankshaft with the established uspokoitel a belt and a gear wheel
Gear belt, installation
Prevention
PERFORMANCE ORDER
1) installation of the moment of opening of valves
2) combine a tag on a cam-shaft gear wheel with edge of laying of a head of the block of cylinders (it is specified by an arrow)
3) turn the crankshaft in VMT;
after installation of the engine combine a tag of BMT "O" with the cast arrow on a coupling case (it is specified by an arrow in the drawing)
4) on the removed engine combine dredging on a pulley with a tag on the case of the oil pump (it is specified by an arrow)
establish a drive belt;
adjust a belt tension turn of the pump in the direction counterclockwise (it is specified by an arrow);
tighten bolts of fastening of the pump
Check of a tension of a belt
The tension of a belt is considered adjusted if the belt can be overwound on 90 ° big and index fingers in the middle between the conducted gear wheel of a cam-shaft and the pump of cooling liquid.
repeatedly check a belt tension
Prevention
Removal and installation of the crankshaft
PERFORMANCE ORDER
1) for removal: put a tag of provision of a flywheel concerning the crankshaft
2) for installation: tighten fastening bolts with 350 N.' moment of m and tighten on 1/4 turns (90 °)
3) it is possible to tighten on 90 ° in two stages on 45 °
4) replace bolts; carvings of new bolts are in advance greased by the structure fixing from an otvorachivaniye
Vypressovka of the directing bearing
press off the needle directing bearing a stripper
The crankshaft – the sizes
Measurement of a gap in a joint of piston rings
insert a ring into the cylinder so that the plane of a ring settled down at an angle 90 ° to a cylinder axis, at distance of 15 mm from the lower edge of the cylinder
Gap in a joint:
gap of new compression rings – 0,02–0,07 mm
Piston / rod assembled
1. Piston finger
at dense landing heat
the piston up to the temperature of 60 °C
establish and press off
by means of VW 207C adaptation
2. Stolorny ring of a piston finger
3. Rod cover bolt
4. Connecting rod
pay attention to correctness of installation
we do not interchange
ledges have to correspond completely to dredging in
to conrod cover
5. Block of cylinders
check of internal diameter of cylinders
6. An oil nozzle for
coolings of the piston
7. 10 N. of m.
establish on lubricant
AMV 188 100.028. Tighten with the moment 30 N. of m and tighten on
1/4 turns (on 90 °)
grease contact surfaces
for measurement of a radial gap of bearings, tighten with the moment 30 N. of m.
9. Rod
replacement only of all set is allowed
in the place "And" number tags are put
tags to be turned "Into" dolzhnea towards a driving belt
10. Lock ring of a piston finger
11. Piston
put tags of position of the piston in the cylinder and numbers of the cylinder
the arrow on the piston is turned towards a driving belt
identification of the piston
12. Piston rings
place joints at an angle 120 °
check of a gap in joints of rings ilpyustrirutsya check of height of a ring
the tag of "top" on a ring is turned towards the piston bottom
Check of diameter of the piston
measure diameter at distance about 10 mm from bottom edge of a skirt of the piston, at an angle 90 ° to a piston axis
Check of diameter of the cylinder
carry out measurements by a nutromer on the range of 50-100 mm in three places, in the directions A (cross) and In (longitudinal)
Size and = 4,4 mm
Prevention
Diameters of the cylinder and piston
Arrangement of components of a gear belt (Coupet's model)
1. Moment of an inhaling of 10 N. of m.
2. Cover of a gear belt (top)
3. Gear belt of the drive of a cam-shaft
4. Plugs
5. Moment of an inhaling of 65 N. of m.
tighten and turn off VW 544 key
6. Leading gear wheel of a cam-shaft
7. Cover of a gear belt (internal)
8. Moment of an inhaling of 350 N. of m.
tighten and turn off special keys of 2079 and 2084
9. Moment of an inhaling of 20 N. of m. 10. Uspokoitel
11. Moment of an inhaling of 10 N. of m.
12. Cover of a gear belt (lower)
13. Leading gear wheel of a gear belt
14. Roller of a natyazhitel
moment of an inhaling of 10 N. of m.
15. Moment of an inhaling of a bolt of 20 N. of m.
16. Pump of cooling liquid
17. Ring laying
at repair of engines of earlier release it is recommended to clear a laying prileganiye surface, and to replace ring laying
Prevention
Arrangement of components (Coupet's model)
1. Stopper of a maslozalivny mouth
2. Gas distribution mechanism cover
3. Block head bolt
4. Head of the block of cylinders
5. 65 N. of m.
6. The conducted cam-shaft gear wheel
at installation of a gear belt you watch correctness of provision of a gear wheel
7. Laying of a head of cylinders
8. Laying of a cover of the gas-distributing mechanism
9. Laying
10. The soaking-up collector
Engine components in collecting (Coupet's model)
1. Moment of an inhaling of 10 N. of m.
2. Oil receiver tube
at first fastens to the oil pump
3. Lock plate
is subject to obligatory replacement
4. Laying
5. Moment of an inhaling of 65 N. of m.
6. Covers of radical bearings
N1 cover, is from a crankshaft pulley
dredging under radical bearings at installation has to settle down one after another and to be turned towards a pulley
pay attention to the displaced arrangement of beds under radical inserts
7. Inserts of the 1, 2, 3, 5 and 6 radical bearings
in covers of bearings the lubricant flute is absent
this flute is available in beds of inserts of the block of cylinders
mutual replacement of the fulfilled inserts is not allowed
assembly ledges on inserts have to coincide with dredging in covers of bearings
8. The directing bearing
9. A persistent half ring of the inserts established in covers
these half rings differ in an arrangement of landing tooth10. Insert of the 4th radical bearing
in covers of bearings the lubricant flute is absent
this flute is available in beds of inserts of the block of cylinders
11. A persistent half ring of the inserts installed in the block of cylinders
these half rings differ in an arrangement of landing tooth
12. Crankshaft
13. Tighten with the moment 30 N. of m and tighten on 1/4 turns
to tighten on 1/4 turns, it is possible in two stages on 45 °
replace bolts
carvings of new bolts are in advance greased by the structure fixing from an otvorachivaniye
14. Flywheel
at removal and installation press the reperny probe of installation of the moment of ignition in a flywheel
press adaptation 10-201
15. Back epiploon of the crankshaft
16. Holder of an epiploon of the crankshaft
17. Oil pump
at installation be convinced that the shaft of the pump entered gearing with the crankshaft
18. Forward epiploon of the crankshaft
19. Moment of an inhaling of 10 N. of m.
20. Lock rings
Prevention
Diameters of necks
Piston / rod in collecting (Coupet's model)
1. Piston rings
2. Piston
3. Rod
it is processed together with a cover of the conrod bearing
we do not interchange
4. Cover of the conrod bearing
it is processed together with a rod
it is not interchangeable
5. Tighten with the moment 30 N. of m and tighten on 1/4 turns (90 °)
before an inhaling grease contact surfaces
6. Lock ring 7. Piston finger
at dense landing heat the piston to 60 °C
establish by means of a prisposbleniye of 2070
8. Rod cover bolt
9. Block of cylinders
10. Connecting rod
11. An oil nozzle for cooling of the piston
12. Moment of an inhaling of 10 N. of m.
before a wraparound grease with the fixing structure of AMV 188 001 02
13. Pay attention to an arrangement of tags at assembly
Removal lock ring of a piston finger
hook and take out a ring as shown in the drawing
Check of the sizes of pistons
diameter of the piston is measured at distance about 12 mm from bottom edge of a skirt of the piston, at an angle 90 ° to a piston axis
Diameters of the cylinder and piston
Places of measurement: