2.5.2.4. 5-cylinder diesel engine

Removal

PERFORMANCE ORDER
1. To install the car on props.
2. To remove the lower casing of a motor compartment.
3. To cast away forward a radiator and a support of the lock.
4. To take off maple belts of the generator and pump of the power steering (see subsection 2.12.1 and subsection 2.12.2).
5. To cast away the generator against the stop up and to tighten reliably bolts.
6. To unscrew a cover of a head of the block of cylinders, to remove sealing and dish-shaped washers.
7. To unscrew a back protection of the TNVD drive from a head of the block of cylinders.
8. To weaken collars and to remove an air hose between the air filter and an inlet collector.
9. To open locks and to take out a forward protection of the drive of a cam-shaft.
10. To apply by means of a felt-tip pen or a fatty pencil on a gear belt to the shooter, specifying the direction of its movement. The direction of rotation of the engine if to take a detached view a gear belt, right, clockwise.
11. To install the crankshaft in the provision of VMT for 1 cylinder.
12. The crankshaft costs in the provision of VMT for 1 cylinder if tags a flywheel case of coupling coincide.
13. At the same time tags on a gear wheel of TNVD and the console have to coincide (are specified by shooters). If tags do not coincide, to turn the crankshaft on one turnover of the direction of its rotation.
14. To jam TNVD gear wheel a suitable thorn, VW-2064 or a thorn, as shown in the drawing.
15. To hold a driving gear wheel of TNVD VW-3036 counteremphasis. To unscrew a fastening bolt, to remove a driving gear wheel and the TNVD gear belt.
16. To jam a cam-shaft the adjusting range VW-2065-A. If near at hand there is no special tool, to make a ruler, as shown in the drawing the Adjusting ruler and a mandrel for check of a cam-shaft. The adjusting ruler has dredging which interferes with possible scrolling of a cam-shaft.
17. To remove the car from a prop.
18. To unscrew the central bolt of a vibroquencher of the crankshaft. VW-3248 counteremphasis is for this purpose necessary. Owing to big torque at a bolt vyvinchivaniye the car has to stand on wheels.
19. To install the car on props.
20. To unscrew M8 bolt from a vibroquencher.
21. To remove a vibroquencher.
22. To weaken bolts of a water pomp and to weaken a gear belt.
23. To unscrew the lower casing of a gear belt.
24. To take off a gear belt from a crankshaft gear wheel.
Prevention

The gear belt should not have cuts. The belt with cuts has to be replaced surely as during operation it can tear that will lead to heavy breakages of the engine.

If the cam-shaft is turned at the taken-off gear belt, then any piston should not be in VMT. Otherwise not to avoid heavy breakages of pistons or valves.

If it is required to turn a shaft, then to install previously all pistons at identical height. For this purpose to put from above on a belt pulley of the crankshaft a cretaceous tag (a preliminary condition: the crankshaft is in the provision of VMT for 1 cylinder), then to turn a belt pulley of the crankshaft on 1/4 turns to the left or to the right. The cretaceous tag has to look to the left or to the right now.

Installation

PERFORMANCE ORDER
1. Through an observation port in the transmission to check coincidence of a tag of VMT on a flywheel with the tag corresponding to it.
2. To jam a cam-shaft an adjusting ruler.
3. To balance an adjusting ruler: for this purpose to turn the jammed cam-shaft so that one end of an adjusting ruler laid down on a head of the block of cylinders. Under other end of a ruler to measure by the petal probe the formed gap. The probe equal to a half of the measured size to enter between the end of a ruler and a head of the block again. To turn a cam-shaft so that the end of a ruler fell by the probe. To enter the second petal probe of the same size under other end of a ruler – between a ruler and a head of the block.
4. To weaken a bolt of fastening of a driving gear wheel of a cam-shaft on 1/2 turns.
5. To bring down from a cam-shaft cone a driving gear wheel of a cam-shaft blow of the hammer to the thorn inserted into 6 mm an opening of a casing of a gear belt.
6. To put on a gear belt of a cam-shaft.
Prevention

If the old belt is used, by all means to pay attention to the direction of its movement. Installation of a belt in the opposite direction can lead to its rupture and breakages of the engine. Therefore to establish a belt always so that the put arrow specified the direction of rotation of the engine (if to take a detached view a gear belt, then clockwise).
7. To establish the lower casing of a gear belt.
8. To pull a gear belt.
9. To tighten the lower casing of a gear belt.
10. To check whether there is a crankshaft in the provision of VMT for 1 cylinder, if necessary to establish.
11. To tighten a bolt of fastening of a driving gear wheel of a cam-shaft the moment of 85 N · m.
12. To remove an adjusting ruler.
13. To put on a vibroquencher and to tighten 4 bolts of M8 the moment of 20 N · m.
14. To remove the car from a prop.
15. To establish the central bolt of a vibroquencher. Previously to apply AMV18800102 sealant on a carving and a surface of a prileganiye of a head.
16. To tighten the central bolt the moment of 460 N · m.
Prevention

Because of the big moment of an inhaling the car has to stand on wheels.
17. To remove VW-3248 counteremphasis.
18. To establish a driving gear wheel and the TNVD gear belt.
19. To tighten a bolt of a driving gear wheel the moment about 50 N · m, then to weaken on 1/2 turns. The driving gear wheel has to rotate by hand.
20. To check a tension of a back gear belt the control VW-210 device. The required value: 12... 13th scales of the device.
21. If necessary to adjust a tension of a back gear belt. For this purpose to weaken bolts of fastening (arrow) and to shift the console with TNVD down or up.
22. To tighten bolts on the console the moment of 50 N · m.
23. To take out a thorn from TNVD gear wheel.
24. To check and adjust the beginning of supply of TNVD fuel (see subsection 2.17.7.6).
25. To screw a TNVD drive casing.
26. To check laying of a cover of a head of the block of cylinders, if necessary to replace. To check existence of a sealing cone for a hairpin, if necessary to establish. To establish laying, to establish a cover of a head of the block of cylinders, to get the top sealing washer and a dish-shaped washer on a hairpin. To tighten two nuts the moment of 10 N · m, to put on sealing caps.
27. To establish in front the top casing of a gear belt.
28. To put on and pull maple a belt (see subsection 2.12.1).
29. To establish an air hose between the air filter and an inlet pipe and to fix by two collars.
30. To establish a radiator with a lock support.
31. To install the car on props.
32. To establish the lower casing of a motor compartment.
33. To remove the car from props.