REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Transporter, Caravelle (1990 release)

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Volkswagen
	Transporter / Caravelle
		Instructions
		Engine
			General Data Engine
			Removing and installing engine
			Removing radiator
			Removal and installation of a mudguard of the engine
			Toothed belt
				Adjusting the timing belt
				Removing and installing toothed belt
					4-cylinder petrol engine
					4-cylinder diesel engine
					5-cylinder petrol engine
					5-cylinder diesel engine
			Cylinder Head
			Removing and installing the camshaft
			Hydraulic bucket tappets
			Replacing valve stem seals
			Valve
			Compression Test
			Belt
			Troubleshooting Engine
			Ignition system
			Lubrication system
			Engine cooling system
			The power supply system of the engine
			Fuel injection
			Exhaust system
		Coupling
		Transmission
		Suspension
		A steering
		Brakes
		Wheels and tires
		Body
		Electrical

printable version

5-cylinder diesel engine

Withdrawal

PERFORMANCE ORDER

1. To establish the car on props.
2. Remove the bottom casing of the engine compartment.
3. Fold the front radiator and support of the castle.
4. Remove the V-belt of the generator and the power steering pump (see. Subsection 2.12.1 and subsection 2.12.2).
5. Fold the generator all the way up and tighten the screws securely.
6. Unscrew the cylinder head cover, remove the seal and the Belleville washers.
7. Unscrew the rear fence drive pump on the cylinder head.
8. Loosen the hose clamps and remove the air hose between the air filter and the intake manifold.
9. Open the latches and pull out the front fence camshaft drive.
10. Apply using a pen or pencil on the fat toothed belt an arrow indicating the direction of its movement. The direction of rotation of the engine when viewed from the side of the toothed belt, right, clockwise.
11. Set the crankshaft in the TDC position for cylinder 1.
12. The crankshaft is set to TDC for cylinder 1, if the label flywheel-clutch coincide.

13. At the same time should match marks on the gear pump and the console (indicated by arrows). If the labels do not match, rotate the crankshaft one turn in the direction of its rotation.
	14. jammed gear pump suitable spine, VW-2064 or spine, as shown in the figure.
	15. Hold injection pump drive gear first pass VW-3036. Unscrew the bolt, remove the drive pinion and the toothed belt pump.
	16. jammed camshaft mounting line VW-2065-A. If you do not have special tools to make the line, as shown in Figure Adjusting ruler and a mandrel for checking the camshaft. The mounting line has a recess, which prevents possible scrolling camshaft.
17. To remove the car from the backup.
	18. Unscrew the central bolt of crankshaft vibration damper. This requires a counterstop VW-3248. Due to the high torque at unscrewing bolts car should stand on wheels.
19. To establish the car on props.
20. To unscrew a bolt of vibration damper M8.
21. Remove the vibration damper.
22. Loosen the bolts of the water pump and loosen the timing belt.
23. Unscrew the bottom casing of a gear belt.
24. Remove the timing belt to the crankshaft gear.
A warning Toothed belt must not be cut. Belt with cuts should always be replaced, because during operation it may break, leading to severe engine damage. If the camshaft will rotate at the removed gear belt, no one piston should be at TDC. Otherwise not avoid severe damage pistons or valves. If you need to turn the shaft, the pre-set all pistons at the same height. To put it on top of the belt pulley of the crankshaft chalk mark (prerequisite: the crankshaft is at TDC for cylinder one) and then rotate the crankshaft pulley 1/4 turn left or right. Chalk mark should now look to the left or right.

Setting

PERFORMANCE ORDER

1. Through the inspection window in the gearbox to verify that the TDC mark on the flywheel with the corresponding label.
2. jammed camshaft adjusting ruler.
3. Balance the mounting line: it jammed, turn camshaft so that one end of the mounting line lay on the cylinder head. Under the other end of the ruler to measure the gap formed petal probe. The probe is equal to half the size measurement, re-enter between the end line and the head unit. Rotate the camshaft so that the end of the line down to the probe. The second petal probe enter the same size for the other end of the line - between the ruler and the head unit.
4. Loosen 1/2 turn bolt camshaft drive gear.
5. Shoot down a cone of a cam drive gear on the camshaft hammer spike inserted into the 6 mm hole toothed belt.
6. Push the toothed belt camshaft.
A warning If the old belt to be used, be sure to pay attention to the direction of its movement. Installing the belt in the opposite direction may cause it to break and damage the engine. Therefore, always install the belt so that the stamped arrow indicates the direction of rotation (as viewed from the toothed belt, then clockwise).
7. Install the bottom casing of a gear belt.
8. Tighten the timing belt.
9. Tighten the bottom casing of a gear belt.
10. Check whether the crankshaft to TDC for cylinder 1, if necessary, install it.
11. Tighten the camshaft gear drive torque 85 Nm.
12. Remove the installation line.
13. Attach vibration damper and tighten 4 bolts M8 to 20 Nm.
14. To remove the machine from the backup.
15. Install the center bolt damper. The pre-applied to the threads and head contact surface sealant AMV18800102.
16. Tighten the central bolt torque of 460 Nm.
A warning Due to the high torque of the machine should stand on wheels.
17. Remove the counterstop VW-3248.
	18. Install the drive pinion and the toothed belt pump.
19. Tighten the screw drive gear torque 50 Nm, then loosen 1/2 turn. Drive pinion should rotate by hand.
20. Check the tension of the rear toothed belt monitoring device VW-210. Required value: 12 ... 13 of the scale of the instrument.
	21. If necessary, adjust the tension of the toothed belt back. To do this, loosen the bolts (arrows) and move the console to pump up or down.
22. Tighten the screws on the console to 50 Nm.
23. Take out the thorn from gear pump.
24. Check and adjust the start of the fuel supply pump (see. Subsection 2.17.7.6).
25. Screw the pump casing of the drive.
26. Check the gasket cylinder head cover and replace if necessary. Check the sealing cone on the pin if necessary to install. Install gasket set cylinder head cover, push on the upper sealing washer and dished washer on the stud. Tighten the two nuts to 10 Nm, to put the sealing caps.
27. Install the front top casing of a gear belt.
28. Fit and tighten the V-belt (see. Subsection 2.12.1).
29. Install an air hose between the air filter and intake tube and secure the two clamps.
30. Install the radiator with the support of the castle.
31. To establish the car on props.
32. Establish the bottom casing of the engine compartment.
33. To remove the car from the backups.

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