Contents - Volkspage

2A.2 Engine in-car repair procedures
Torque wrench settings Nm Ibf ft
Cylinder head bolts (engine cold):
Stage1 ................................................ 40 30
Stage2 ................................................ 60 44
Stage 3 (angle tighten) .................................... + one half-turn (180”), OR + two quarter-turns (2x90°)
Main bearing cap bolts ..................................... 65 48
Camshaft cover screws ..................................... 10 7
Camshaft sprocket bolt ..................................... 80 59
Inlet manifold nuts/bolts ..................................... 25 18
Exhaust manifold nuts/bolts .................................. 25 18
Flywheel bolts:
Stage1 ................................................ 60 44
Stage 2 (angle tighten) .................................... + 90°
Sump ................................................. 20 15
Oil drain plug ............................................. 30 22
Oil pressure switch ........................................ 25 18
Crankshaft sprocket bolt .................................... 80 59
Crankshaft oil seal housing bolts .............................. 10 7
Auxiliary drivebelt pulley bolts ................................ 20 15
Oil pump mounting bolts .................................... 20 15
Oil pump cover bolts ....................................... 10 7
Oil pickup tube screws ...................................... 10 7
1 General information
1 The engine is of four cylinders, in-line,
overhead camshaft type mounted
transversely at the front of the car, with the
gearbox on the left-hand side. The top of the
engine is inclined slightly forwards.
2 The crankshaft is of five bearing type, and
the centre main bearing incorporates
thrustwashers to control crankshaft endfloat.
3 The camshaft is driven by a toothed timing
belt from a sprocket on the front of the
crankshaft, and the timing belt also drives the
water pump. The valves are operated by
hydraulic tappets. The cylinder block is of
cast iron and the cylinder head of light alloy.
4 The geared oil pump is located on the front
of the cylinder block and driven by the
crankshaft via a chain. A positive crankcase
ventilation system is incorporated.
Major operations possible with
the engine in the car
5 The following operations can be carried out
without having to remove the engine from the
car:
a) Removal and servicing of the cylinder
head, camshaft, and timing belt’.
b) Removal of the flywheel and clutch (after
removing the gearbox).
c) Renewal of the crankshaft front and rear
oil seals.
d) Removal of the sump.
e) Removal of the oil pump.
f) Renewal of the engine mountings.
Major operations only possible
after removal of the engine from
the car
6 The following operations can only be
carried out after removal of the engine from
the car:
a) Renewal of the crankshaft main bearings.
b) Removal of the crankshaft.
c) Removal of the pistons/connecting rods.
*Cylinder head dismantling procedures are
detailed in Chapter 2B and contain details of
camshaft and hydraulic tappet removal.
Note: It is possible to remove the pistons and
connecting rods (after removing the cylinder
head and sump) without removing the engine
from the vehicle. However, this procedure is
not recommended. Work of this nature is more
easily and thorough/y completed with the
engine on the bench, as described in Chapter
2B.
General information
Note: This sub-section has been written with
the assumption that the distributor, HT leads
and timing belt are correctly fitted.
1 The camshaft sprocket is crankshaftdriven,
by means of a timing belt, Both
sprockets rotate in phase with each other and
this provides the correct valve timing as the
engine rotates. When the timing belt is
removed during servicing or repair, it is
possible for the cam and crankshafts to rotate
independently of each other and the correct
valve timing is then lost.
2 The design of the engines covered in this
Chapter is such that potentially damaging
piston-to-valve contact may occur if the
camshaft is rotated when a piston is
stationary at, or near, the top of its stroke.
3 For this reason, it is important that the
correct phasing between the camshaft and
crankshaft is preserved whilst the timing belt
is off the engine. This is achieved by setting
the engine in a reference condition (known as
Top Dead Centre or TDC) before the timing
belt is removed and then preventing the shafts
from rotating until the belt is refitted. Similarly,
if the engine has been dismantled for
overhaul, the engine can be set to TDC during
reassembly to ensure that the correct shaft
phasing is restored.
4 TDC is the highest position a piston
reaches within its respective cylinder - in a
four stroke engine, each piston reaches TDC
twice per cycle; once on the compression
stroke and once on the exhaust stroke. In
general, TDC normally refers to cylinder No 1
on the compression stroke. (Note that the
cylinders are numbered one to four from the
timing belt end of the engine).
5 The crankshaft sprocket is equipped with a
marking which, when aligned with a reference
marking on the timing belt cover, indicates
that cylinder No 1 (and hence also No 4) is at
TDC.
6 The camshaft sprocket is also equipped
with a timing mark - when this is similarly
aligned, the engine is correctly positioned and
the timing belt can then be refitted and
tensioned.
7 The following sub-Sections describe setting
the engine to TDC on cylinder No 1.
Setting engine to TDC on
cylinder No 1 - timing be/t fitted
8 Before starting work, disconnect the battery
negative cable to disable the fuel ignition and
ignition system and to remove the risk of
electrical short circuits. Prevent any vehicle
movement by putting the transmission in
neutral, applying the parking brake and
chocking the rear wheels.
9 On the distributor cap, note the position of
the No 1 cylinder HT terminal. On some
models, the manufacturer provides a marking