Contents - Volkspage

2A.8 Engine in-car repair procedures
9.3Oa Lay a new head gasket on the
cylinder block, engaging it with the
locating dowels
9.30b The gasket part number
should face upwards
10.6 Hydraulic tappet operation check
31 With the help of an assistant, place the
cylinder head and manifolds centrally on the
cylinder block, ensuring that the locating
dowels engage with the recesses in the
cylinder head. Check that the head gasket is
correctly seated before allowing the full
weight of the cylinder head to rest upon it.
32 Apply a smear of grease to the threads,
and to the underside of the heads, of the
cylinder head bolts; use a good-quality highmelting
point grease.
33 Carefully enter each bolt into its relevant
hole (do not drop them in) and screw in, by
hand only, until finger-tight.
34 Working progressively and in the
sequence shown, tighten the cylinder head
bolts to their Stage 1 torque setting, using a
torque wrench and suitable socket (refer to
illustration 9.18). Repeat the exercise in the
same sequence for the Stage 2 torque setting.
35 Once all the bolts have been tightened to
their Stage 2 settings, working again in the
given sequence, angle-tighten the bolts
through the specified Stage 3 angle, using a
socket and extension bar. It is recommended
that an angle-measuring gauge is used during
this stage of the tightening, to ensure
accuracy. If a gauge is not available, use white
paint to make alignment marks between the
bolt head and cylinder head prior to
tightening; the marks can then be used to
check that the bolt has been rotated through
the correct angle during tightening. Repeat
the exercise for the Stage 4 setting.
36 Refit the coolant pump with reference to
Chapter 3.
37 Refit the timing belt inner cover, tightening
the retaining screws securely. Refer to
Section 5 and refit the camshaft sprocket.
38 Refer to Section 2 and follow the
procedure for setting the engine to TDC on
No 1 cylinder with the timing belt removed. On
completion, refer to Section 4 and refit the
camshaft timing belt.
39 The remainder of refitting is a reversal of
the removal procedure, as follows:
a) Bolt the engine dipstick tube bracket to
the timing belt cover, where applicable.
b) Refer to Chapter 4C and reconnect the
exhaust downpipe to the exhaust manifold.
c) On multipoint fuel-injected systems, refer
to Chapter 4B and refit the fuel injectors,
fuel rail and the throttle body.
d) On single point fuel-injected models, refer
to Chapter 4A and refit the throttle body
and air box. Reconnect the in/et manifold
pre-heater wiring.
e) Refer to Chapter 5B and refit the
distributor and the ignition HT leads.
f) Refer to Section 6 and refit the camshaft
cover.
g) Reconnect the radiator, expansion tank
and heater coo/ant hoses, referring to
Chapter 3 for guidance. Reconnect the
coo/ant temperature sensor wiring.
h) Refer to Chapter 7 and refit the auxiliary
drivebelt(s)
i) Restore the battery connection.
j) Refer to Chapter 11 and refit the bonnet.
40 On completion, refer to Chapter 1 and
carry out the following:
a) Refill the engine cooling system with the
correct quantity of new coolant.
b) Refill the engine lubrication system with
the correct grade and quantity of oil.
3 Run the engine until it reaches its normal
operating temperature. Switch off the engine,
then refer to Section 6 and remove the
camshaft cover.
4 Rotate the camshaft by turning the
crankshaft with a socket and wrench, until the
first cam lobe over cylinder No 1 is pointing
upwards.
5 Using a feeler blade, measure the clearance
between the base of the cam lobe and the top
of the tappet. If the clearance is greater than
0.1 mm, then the tappet is defective and must
be renewed.
6 If the clearance is less than 0.1 mm, press
down on the top of the tappet, until it is felt to
contact the top of the valve stem (see
illustration). Use a wooden or plastic
implement that will not damage the surface of
the tappet.
7 If the tappet travels more than 0.1 mm
before making contact, then it is defective and
must be renewed.
8 Hydraulic tappet removal and refitting is
described as part of the cylinder head
overhaul sequence - see Chapter 2C for
details.
A
Warning:
!
After fitting hydraulic
tappets, wait a minimum of 30
minutes before starting the
engine to allow the tappets time
to settle, otherwise the increased stroke
may cause the pistons to strike the valve
heads.
Removal
1 Disconnect the battery negative cable and
position it away from the terminal.
2 Carry out the following operations:
a) Support the engine and remove the
transmission as described in Chapter 7.
b) Remove the clutch assembly as described
in Chapter 6.
3 Mark the relationship between the flywheel
and the end of the crankshaft with a dab of
paint, to aid refitting later.
4 Hold the flywheel stationary, by means of a
lever or angle iron engaged with the starter
ring gear (refer to Chapter 5A for details of
starter motor removal).
5 Unscrew the bolts progressively and lift the
flywheel from the crankshaft.
Caution: The flywheel is a heavy, bulky
component - enlist the help of an assistant
if possible. Wear gloves to protect your
hands from the ring gear teeth. Discard
the flywheel bolts - new items must be
used on refitting.