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





2.2.4.5. Removal and installation of a head of the block of cylinders
GENERAL INFORMATION

Head of the block of cylinders of the diesel engine
1–top part of a casing of a gear belt;
2–gear belt. Check a condition of a gear belt. Before removal of a gear belt it is necessary to put on it to the shooter specifying the direction of rotation of a gear belt. Do not bend a gear belt;
3–nut, 20 Nanometers;
4–bolt, 20 Nanometers;
5–bolt, 45 Nanometers;
6–pulley of a gear belt. Removal of a pulley of a gear belt of a camshaft from an adjusting cone of a camshaft is made with use of the drift passed through an opening in a back casing of a gear belt;
7–tension roller;
8–a directing roller;
9–back casing of a gear belt;
10-bolt, 10 Nanometers;
11-eye;
12-bolt of fastening of a head of the block
cylinders. At installation it is necessary to use new bolts;
13-oil guard;
14-cover of a head of the block of cylinders. Consolidation of a cover of a head of the block of cylinders privulkanizirovano to a cover therefore at damage of consolidation it is necessary to replace a cover of a head of the block of cylinders;		 15-a condensing cuff. At damage it is necessary to use a new condensing cuff;
16-cover;
17-a ventilating pipe to an air inlet;
18-collar;
19-reduktsionny valve. For system of ventilation of a case;
20-consolidation. At damage it is necessary to use new consolidation;
21-bolt, 5 Nanometers;
22-топливопроводы high pressure, 25 Nanometers. Replacement топливопроводов a high pressure is necessary for making in a set. It is not authorized to bend pipelines;
23-vacuum pump. For the vacuum amplifier of brakes;
24-consolidation. At installation it is necessary to use new consolidation;
25-fuel nozzle;
26-glow plug, 15 Nanometers;
27-laying of a head of the block of cylinders. At installation it is necessary to use new laying and to fill in in cooling system fresh cooling liquid

Marking of laying of a cover of a head of the block of cylinders of the diesel engine

1–number of the spare part;

2–code;

3–laying characteristic

The head of the block of cylinders is necessary for removing on the cold engine. Removal of a head of the block of cylinders is made together with an inlet and final collector.

The burned-through or defective laying of a head of the block of cylinders is determined by the following signs:

 – engine capacity reduction;
 – reduction of level of cooling liquid. Thus the exhaust pipe leaves white steam;
 – reduction of level of engine oil;
 – existence in engine oil of cooling liquid, thus level of oil increases. At existence in engine oil of cooling liquid engine oil gains gray color and has foam vials;
 – availability of engine oil in cooling liquid;
 – intensive allocation of bubbles from cooling liquid;
 – compression reduction in two next cylinders of the engine.

Removal

PERFORMANCE ORDER
1. Check that the engine cold. Otherwise give time for engine cooling.
2. Switch off ignition and remove a weight wire from the accumulator.
SDI engine
3. Remove an inlet collector.
TDI engine
4. Remove a pipe connecting a radiator of nadduvayemy air and an inlet collector.
5. Merge cooling liquid from cooling system.
6. Disconnect from a lobby and the left side of a head of the block of cylinders hoses of system of cooling and move them aside.
7. Disconnect the electric socket from the sensor of pressure of oil 0,3 a bar.
8. Unscrew the tire of giving of tension from incandescence candles. Unscrew glow plugs. Clear places of connection of pipelines to fuel nozzles and the fuel pump of a high pressure. Unscrew connecting nuts and remove топливопроводы. Close openings suitable jams.
9. Unscrew from a head of the block of cylinders fuel nozzles.
10. Weaken or cut a collar and remove a hose of ventilation of a case from the inlet pipeline. Release fixing bracket and remove a hose of ventilation of a case from the block of cylinders. Remove a sealing ring.
11. Lift the car.
12. Unscrew a reception exhaust pipe from a final collector or a turbonagnetatel. Using a soft wire, suspend a reception exhaust pipe to a body.
13. Remove the top casing of a gear belt.
14. Weaken a tension of a gear belt and remove it from a camshaft pulley.
15. Weaken a bolt of fastening of a pulley of a camshaft on a turn half. Remove a pulley of a gear belt of a camshaft from an adjusting cone of a camshaft, using a drift passed through openings in a back casing of a gear belt. Unscrew a bolt and remove a camshaft pulley.
16. Unscrew bolts of fastening of a back casing of a gear belt.
17. In the sequence shown in drawing, unscrew bolts of fastening of a head of the block of cylinders on a turn half, and then in the same sequence unscrew bolts.
18. Check that all pipelines, hoses and electric sockets are disconnected from a head of the block of cylinders.
19. Remove a head of the block of cylinders from the engine and establish it on two wooden whetstones. At removal of a head wring out a back casing of a gear belt.
Prevention

Do not turn a camshaft on the removed head of the block of cylinders. If the camshaft is established in position of the piston of the first cylinder in the top dead point in a compression step, cams of a camshaft of the first cylinder should be directed up. In this situation it is possible to establish the tool for blocking in a groove in a camshaft end face.
20. Remove laying of a head of the block of cylinders.

Installation

PERFORMANCE ORDER
1. Interfaced surfaces of a head and the block of cylinders should be absolutely pure. For their cleaning use a firm plastic or wooden scraper. When cleaning be careful, as the aluminum alloy is very easy for damaging.
2. Check, that the deposit did not get to oil and water canals. It is especially important for greasing system as the deposit can block supply of oil to engine components. If necessary clear channels.
3. Clear openings under bolts in the block of cylinders. Bolt screwing up in the opening filled with oil can break off the block because of hydraulic pressure.
4. Using a metal ruler and щуп, check planeness of interfaced surfaces.
5. The deviation from planeness should be no more than 0,1 mm.
6. If on the engine new pistons are established, it is necessary to measure a vystupaniye of pistons from the block of cylinders and on the basis of size of a vystupaniye of pistons to choose thickness of new laying of a head of the block of cylinders (see fig. Marking of laying of a cover of a head of the block of cylinders of the diesel engine).
7. At installation of a head of the block of cylinders it is necessary to use new laying. Take laying from tight packing directly ahead of installation on the block of cylinders.
8. For the correct installation of a head of the block of cylinders and laying of a head of the block of cylinders screw in in extreme openings of the block of the cylinders, the fastenings of a head of the block of the cylinders intended for bolts, directing pins of VW 3070. In the absence of directing pins they can be made independently for what it is necessary to use two old bolts of fastening of a head of the block of cylinders. Cut off from bolts of a head and instead of them cut through a groove for a screw-driver. After installation of a head of the block of cylinders, using a screw-driver, unscrew directing pins.
9. Using paint, note the adjusting provision of a pulley of a cranked shaft. Then turn a cranked shaft of the engine on 1/4 turns in order that any of pistons was not in the top dead point. Before installation of a gear belt it is necessary to establish a cranked shaft in situation at which the piston of the first cylinder will be in VMT in a compression step.
10. Being careful, establish a head of the block of cylinders.
11. For fastening of a head of the block of cylinders use only new bolts. Screw in bolts of fastening of a head of the block of cylinders by hand.
12. A screw-driver unscrew two directing pins and on their place screw in two bolts of fastening of a head of the block of cylinders.
13. Gradually in the sequence shown in drawing, tighten in some stages bolts of fastening of a head of the block of cylinders. Stage of 1-40 Nanometer. Stage of 2-60 Nanometers. The stage 3 – to tighten on a corner 90 °. The stage 4 – to tighten on a corner 90 °.
14. Further pulling up of a head of the block of cylinders is not required.
15. Turn a cranked shaft of the engine on 1/4 turns so that the piston of the first cylinder was established in VMT in a compression step. Check that the camshaft is established in the situation corresponding to installation of the piston of the first cylinder in VMT in a step of compression. Grease working surfaces of a pusher and camshaft cams with pure engine oil.
16. Screw in bolts of fastening of a back casing of a gear belt.
17. Establish a gear belt.
Prevention

Do not forget to take fixing tool of a pulley of the fuel pump of a high pressure.
18. Establish a cover of a head of the block of cylinders and tighten nuts of fastening of a cover the moment of 10 Nanometers.
19. Establish the top casing of a gear belt.
20. Connect a reception exhaust pipe to a final collector or a turbonagnetatel.
21. Lower the car.
SDI engine
22. Establish an inlet pipe.
TDI engine
23. Establish a pipe between a radiator of nadduvayemy air and an inlet pipe and fix it collars.
24. Connect hoses to a head of the block of cylinders.
25. Fill in in system of cooling of the engine fresh cooling liquid.
26. Screw in glow plugs.
27. Screw in fuel nozzles.
28. Connect a weight wire to the accumulator.
29. Check oil level in the engine and if necessary finish it to norm.
30. Start the engine and warm up it to normal working temperature.
31. Check a condition and tightness of system of cooling.
32. Check the moment of injection of the fuel pump of a high pressure.