GOLF II and Jetta II vehicles are equipped with four-stroke in-line diesel engines with prechamber and direct fuel injection. High pressure fuel pump (injection pump) works in conjunction with a fuel injection cut-off device and a hydraulic accumulator. Turbocharged engines are equipped with a device for regulating the turbocharging pressure.
The camshaft mounted in the cylinder head, cast from light alloy, is driven by a toothed belt. Dry cylinder liners are used; crankshaft - five-bearing. Late production engines use hydraulic valve lifters.
Turbocharged engines differ from conventional diesel engines in the following ways:
- The cylinder head, valve seats, valves and swirl chamber inserts are made of a special heat-resistant material and cannot be replaced with similar parts for a conventional diesel engine, although they do not differ in appearance.
- The head gasket is made from a different material.
- Special nozzles are installed in the cylinder block, through which oil is supplied to their bottoms to cool the pistons.
- The pistons have cutouts in the skirts for the nozzles.
- Starting with 1983 models, the front crankshaft nose was redesigned to allow a larger pulley bolt to be screwed in. This change affected the design and conventional diesel engines.
- The oil pump has large gears with a larger diameter.
- An oil cooler is installed between the oil filter and the filter flange.
- A modified injection pump was used.
- The design of the components of the exhaust gas system and the exhaust manifold has been changed so that the installation of a turbocharger becomes possible.
- The air filter is separated from the intake manifold.
All engines that use pressure oil lubrication are very sensitive to the presence of contaminants. Therefore, during any operation on the engine, special attention must be paid to ensure that dirt particles or foreign objects do not get into hoses, connecting holes, tubes, etc. It is best to seal the ends of fuel hoses and holes with adhesive tape. Before starting work, thoroughly wash the outside of the engine, plugging all openings with clean, lint-free materials.
The procedure for disassembling the engine will be described in detail below. All repairs that can be carried out both on the engine installed in the car and on the removed engine will be described. To avoid repetition, the previously described dismantling details will be omitted. If it becomes necessary to completely disassemble the engine, then it will be enough to perform all the described operations in turn. During removal, all mating components must be marked so that they can be reinstalled during assembly if they are to be reused. This is especially important for pistons, valve covers, bearings and liners. Removed components and parts must be kept in strict order. Bearing surfaces and seals must not be marked with a steel scriber or digital stamp. Many parts are made of light alloys and special care must be taken when working with them. If, for example, it is necessary to use a hammer to separate them, then this can only be a hammer with a rubber or plastic working part.
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