VOLKSWAGEN GOLF IV

since 1997 of release

Repair and car operation



Foltsvagen Golf 4
+ 1. Maintenance instruction
- 2. Engine
   + 2.1. Petrol engines
   - 2.2. Diesel engines
      2.2.1. Technical characteristics
      2.2.2. Bottom mudguard of a motor compartment
      2.2.3. Removal and installation of the power unit
      - 2.2.4. Gear belt
         2.2.4.1. Removal
         2.2.4.2. Installation of the piston of the first cylinder in VMT
         2.2.4.3. Installation
         2.2.4.4. Check of a tension roller of a gear belt
         2.2.4.5. Removal and installation of a head of the block of cylinders
      2.2.5. Removal and installation of an inlet collector of the diesel SDI engine
      2.2.6. Compression check in engine cylinders
      2.2.7. Removal and installation of a poliklinovy belt
      2.2.8. Recommendations about engine oils
      2.2.9. Circulation of engine oil
      2.2.10. Check of pressure of oil and sensor of pressure of oil
      2.2.11. Removal and installation of the oil pallet
      2.2.12. Diagnostics of malfunctions of the diesel engine
      2.2.13. Main malfunctions of system of greasing
+ 3. Cooling system
+ 4. Fuel system
+ 5. Exhaust system
+ 6. Ventilation and heating system
+ 7. Coupling
+ 8. Transmission
+ 9. Suspension brackets and power shafts
+ 10. Steering
+ 11. Wheels and tires
+ 12. Brake system
+ 13. Body
+ 14. Electric equipment and electroschemes










2.2.4.2. Installation of the piston of the first cylinder in VMT

PERFORMANCE ORDER
1. Turn a cranked shaft of the engine so that the piston of the first cylinder was established in the top dead point.
2. To turn a cranked shaft of the engine it is possible the next ways:
      – lift a forward part of the car and fix on supports. Include the 5th transfer and tighten the hand brake. Holding one forward wheel from a provorachivaniye, manually turn the second forward wheel. Thus the cranked shaft of the engine will be turned;
      – establish the car on an equal horizontal platform, then include the 5th transfer and manually move the car forward or back;
      – establish a transmission in neutral situation and tighten the hand brake. Using a wrench, for a bolt of fastening of a pulley of a cranked shaft turn a cranked shaft of the engine.

Prevention

Do not turn a cranked shaft of the engine for a bolt of fastening of a pulley of a camshaft as in this case load of a gear belt is maximum.


Mechanical transmission
3. Remove a cap in a coupling case.
4. Turn a cranked shaft of the engine until the label "0" on a flywheel will not be combined with the index on a case of coupling (shooter). At combination of labels with indexes the piston of the first cylinder is in VMT in a compression step (And – the engine AGP, B – engines AGR, AHF, ALH).
Automatic transmission
5. Turn a cranked shaft of the engine until the label "0" will not appear at the left in a window of the hydrotransformer (shooter). In this case the piston of the first cylinder is in VMT in a compression step.
Diesel SDI engine
6. Remove an inlet collector.
7. Remove the top casing of a gear belt and a cover of a head of the block of cylinders.
8. If the gear belt is repeatedly established, using a marker or paint, note the direction of rotation of a gear belt. If to look from a forward part of the engine, pulleys of the engine rotate clockwise.
9. Unscrew bolts (the broad tank and a popolnitelny tank of the amplifier of a steering are specified by shooters), fixing and, without disconnecting from them hoses, move them aside.
10. Establish the tool for blocking 3418 in a groove in a camshaft end face.
11. With the instrument of blocking established in a camshaft, turn a camshaft (turning a cranked shaft clockwise) so that the instrument of blocking by one party nestled on a surface of a head of the block of cylinders. Using an edge щупа, measure a gap between the second end of the instrument of blocking and a head of the block of cylinders. Turn a camshaft slightly back and from two parties between the instrument of blocking and a head of the block of cylinders establish two щупа in the thickness, an equal half of earlier measured gap.
12. Block a pulley of the fuel pump a fixing pin of VW-3359. From a pulley of the fuel pump unscrew bolts (1) and on their place screw in new bolts, having tightened them at this stage by hand. Unscrewing of bolts is necessary for making in turn as sections of a pulley of the fuel pump can move. Do not unscrew the central nut (2) fastenings of a pulley of the fuel pump as thus the pulley can be displaced.
13. Because the right support of the power unit interferes with removal of a gear belt, it is necessary to support the engine the special VW 10-222A adaptation and to remove the right support of the power unit.
14. Support of the engine can be carried out from below a jack through wooden whetstone.
15. Holding from a provorachivaniye a pulley of a cranked shaft, unscrew four bolts, fixing a pulley to a cranked shaft. Remove a pulley of a cranked shaft.
16. Unscrew bolts (are specified by shooters), fixing the right support of the power unit to a body and the holder of the engine.
17. Unscrew bolts (are specified by shooters), fixing the holder of the right support of the power unit to the engine.
18. Unscrew a nut of fastening of a tension roller of a gear belt.
19. Remove a gear belt from engine pulleys.

Prevention

Do not bend sharply gear belt as in use the gear belt in a place of a sharp excess can become torn that will lead to engine damage.


20. After removal of a gear belt do not change the provision of pulleys of a gear belt.

Prevention

If after removal of a gear belt to turn a cranked shaft of the engine, there will be an impact of pistons to valves therefore they will be damaged and serious repair of the engine is required. Note the provision of a pulley of a cranked shaft for what with paint put labels on a pulley and the block of cylinders of the engine. If necessary it is possible to turn a cranked shaft of the engine on 90 ° on hour or counter-clockwise.

Check a gear belt on wear, stratification or a zamaslivaniye. If on a gear belt there are oil traces, before installation of a new belt find a source of leakage of oil and eliminate it.

Do not overwind and do not bend a gear belt. Exclude hit on a gear belt of the oil, cooling liquid or fuel.