Accessory drive belt — appearance 1. V-ribbed accessory drive belt 2. Guide roller for V-ribbed belt 3. Pulley on the crankshaft (with vibration damper, observe correct assembly position) 4. Mounting bolt - 10 Nm + turn an additional 90° (¼ turn) 5....
Accessory drive belt — removal and installation Removing 1. Remove the soundproofing cover on the assembly. 2. Remove the fender liner of the right front wheel arch (for details, see the relevant section in chapter Body ) 3. Unscrew the fastening bolts (3, 4, 6),...
Crankshaft pulley — removal and installation Removing 1. Remove the accessory drive belt. 2. Unscrew the bolts securing the crankshaft pulley (arrows), holding the pulley from rotation by the center bolt with a socket wrench, as shown in the figure below. 3....
Accessory drive belt tensioner — removal and installation Removing 1. Remove the accessory drive belt. 2. Loosen the fastening clamps and disconnect the right inlet pipe of the intake system, as shown in the figure below. 3. Pressing with a finger and releasing the clip,...
Compression test Note. To perform the following work, it is necessary to use special devices, control and measuring devices, as well as auxiliary tools: Hinge wrench No. 10 (3220). Compression pressure gauge e.g (V.A.G 1763). Adapter...
Upper decorative engine cover — removal and installation Removing Attention. In case of improper removal, the holders of the decorative engine cover on the cylinder head cover may break off. Therefore, all the instructions below must be observed. 1. Release the decorative...
Engine assembly — removal and installation Removing Note. The engine is removed together with the gearbox downwards. All cable clamps (bandages), which were loosened or cut during the removal of the engine, must be reattached in the same place when reinstalling...
Tightening torques for threaded connections Engine support 1. Not installed on this type of engine. 2. 20 Nm + 90° (replace with a new one). 3. 30 Nm + 90° (replace with a new one). 4. 16 Nm. Gearbox support 1. 50 Nm + 90°- replace with a new one. 2. 40 m + 90°-...
Timing belt — removal and installation Removing Attention. For any assembly work, especially in the engine compartment due to the narrow assembly area, observe the following rules: If the toothed drive belt is replaced during the repair (except for the...
Cylinder head — appearance 1. Cylinder head assembly 2. Washer 3. Cylinder head bolt 4. Engine oil pressure sensor, tightening torque 20 Nm 5. Stud, installation torque 20 Nm 6. Eyelet for attaching special tools to the cylinder head 7. Glow...
Checking the flatness of the cylinder head Check the flatness of the cylinder head in several places using a straightedge and feeler gauges. Maximum allowable deflection: 0.1 mm. Note. Reworking of the cylinder head on diesel engines is not permitted.
Cylinder head gasket marking Part Number = (arrow 1) Control code = (arrow 2) (disregard) Holes = (arrow 3) Note. Depending on the size of the interference of the pistons, cylinder head gaskets of various thicknesses are installed above the...
Removal and installation of a head of the block of cylinders Removing Attention. The engine temperature must not exceed 35°C, as the cylinder head may warp when the screws are loosened. The pistons must not be at TDC. Attention. For any assembly work, especially in the engine...
Gas distribution mechanism — appearance 1. Valve 2. Cylinder head assembly 3. Oil seal 4. Valve spring 5. Valve spring retainer 6. Crackers for fixing the valve 7. Lid 8. O-ring 9. Exhaust camshaft 10. Fastening bolt, tightening torque 10 Nm 11. Camshaft...
Gas distribution mechanism — removal and installation Removing 1. Remove the timing belt from the timing belt pulley on the camshaft and from the timing belt pulley on the high pressure pump. 2. Remove the toothed drive belt pulley on the camshaft. 3. Loosen the screw (1)...
Measuring the axial clearance of the timing camshafts Note. Necessary special devices, control and measuring devices, as well as auxiliary means: Universal Dial Indicator Holder (MPZ-447 (VW 387)). Dial indicator, for example (VAS 6079). 1. Remove the camshaft support...
Replacing valve stem seals 1. Remove the glow plugs. 2. Remove camshafts (see relevant section in this chapter). 3. For proper installation, the attachment of the rocker arms to the hydraulic tappets should be marked. 4. Remove the rocker arms...
Cylinder block and crankshaft — appearance 1. Bolt of fastening of a cover of a radical support of a cranked shaft 2. Crankshaft main bearing caps 3. Crankshaft bearing shells 4. Crankshaft thrust rings 5. Needle bearing 6. Crankshaft assembly 7. Bearing shells...
Connecting rod and piston group — appearance 1. Retaining ring 2. Top compression ring 3. Bottom compression ring 4. Oil scraper ring 5. Connecting rod cap bolts, tightening torque 30 Nm + 90° 6. Connecting rod cap 7. Connecting rod bearing shells 8. Pressure...
Checking the thermal clearance of the piston ring Set the ring perpendicular from the top down to the bottom of the bore in the cylinder about 15mm from the edge of the cylinder as shown in the figure below. For installation, a piston without rings should be used.
Piston ring height check Before proceeding with the inspection, clean the grooves in the piston for the piston rings.
Piston check Measure at a distance of 10 mm from the bottom edge, perpendicular to the axis of the piston pin. Maximum deviation from the nominal size: 0.04 mm.
Checking the inner diameter of the cylinders Measure the cylinder crosswise in 3 places in the transverse direction (A) and in the longitudinal direction (IN), as shown in the figure below. Maximum deviation from the nominal size: 0.10 mm.
Oil nozzle and safety valve Assembly position: The guiding edge of the oil spray nozzle must be aligned with the area of the cylinder block. Note. Oil nozzles cannot be bent. Bent oil nozzles must be replaced. 1. Screw with relief valve 2. Oil...
Measurement of piston protrusion above the surface of the cylinder block 1. Attach the piston protrusion gauge (MP 1-107) on the cylinder block as shown in the figure below. 2. Piston protrusion must be done on each piston in two places. When assembling new pistons and the engine, it is...
Separation of the new connecting rod With new connecting rods, it may happen that the intended break point is not completely broken. If you cannot remove the connecting rod cover manually, then proceed as follows: Mark connecting rod to cylinder liner....