ASY diesel engine with a displacement of 1.9 liters and a power of 47 kW (64 hp)
Removal
Remove the top engine cover.
Remove the poly V-belt.
Remove the upper timing belt cover.
Remove the brake booster vacuum pump.
Remove the lower engine compartment cover.
Using a lifting device, lift the engine slightly to relieve its support. Remove the engine support by first unscrewing the fastener at the engine bracket, and then at the body of the "arrow".
Note: The engine mount is attached to the body with four bolts, only 2 bolts are visible in the picture.
Remove the middle timing belt cover.
Loosen the engine bracket fastening to the cylinder block.
Turn the engine crankshaft to the position corresponding to TDC for cylinder 1. To do this, turn the crankshaft in the direction of rotation until the mark on the flywheel "1" coincides with the mark on the gearbox "2".
Note: To check, look vertically from the side of the milled surface -A- of the gearbox at the mark on the flywheel.
Using the VW-T10098 adjusting ruler, lock the camshaft in the TDC position. To do this, screw the centering bolts "1" into the cylinder head by hand until they stop.
Note: With the cylinder head cover removed, you can also insert the VW-3418 adjusting ruler into the camshaft groove and use two feeler gauges to align it with the top surface of the cylinder head.
Lock the fuel injection pump gear using the VW-3359 or HAZET 2588-3 locking device. Alternatively, you can use a 6 mm diameter pin.
Loosen the fuel injection pump gear mounting bolts, but do not unscrew them.
Remove the lower timing belt cover.
Loosen the crankshaft belt pulley fastening.
Mark the direction of rotation of the toothed belt.
Loosen the tension roller mounting nut.
Remove the timing belt.
Installation
Check if the TDC mark on the flywheel matches the timing mark.
Loosen the camshaft gear mounting bolt by 1 turn. To do this, remove the cylinder head cover and hold the camshaft by the flats with an open-end wrench.
Caution: Never use the camshaft adjustment ruler as a holder.
Remove the timing gear from the camshaft using a standard puller.
Unscrew the mounting bolt and remove the gear wheel.
Keeping the same direction of movement, place the timing belt first on the crankshaft gear, then on the guide roller, coolant pump gear and tension roller.
Align the fuel injection pump gear wheel in the center of the elongated hole.
Place the camshaft gear with the toothed belt on and secure with the mounting bolt. Do not tighten the mounting bolt; the camshaft gear should still be able to turn.
Turn the tension roller to the right with a double-set wrench, such as the HAZET 2587. until the cutout and protrusion of the tension roller match the "arrows".
Caution: If the tensioner pulley has been overtightened, it must be completely loosened again and then tightened again. Never overtighten the tensioner pulley by turning it too far.
Tighten the tension roller mounting nut to a torque of 25 Nm.
Check the installation position of the tension roller: the locking plate "arrow" must fit into the recess on the cylinder head, otherwise the holder must be turned accordingly.
Check again that the TDC marks on the flywheel match.
Tighten the central bolt securing the camshaft gear to a torque of 45 Nm.
Caution: Hold the camshaft by the flats with an open-end wrench. Under no circumstances should a camshaft adjuster that is still installed be used as a holder.
Tighten the fuel injection pump gear mounting bolts to a torque of 25 Nm.
Remove the camshaft adjustment ruler.
Turn the crankshaft 2 revolutions and set it to the TDC position of the combustion process for cylinder 1. Check again that the TDC marks on the flywheel match. Check whether the camshaft adjusting ruler and the fuel injection pump gear lock are inserted.
Check the tension of the toothed belt. If the notch and the projection or the notch and the arrow do not match, tighten the tension roller and tighten the fastening nut to 25 Nm.
Turn the crankshaft 2 revolutions and repeat the check operations.
Tighten the engine bracket mounting bolts to the cylinder block to a torque of 45 Nm.
Install the engine support with new mounting bolts.
Tightening torques:
- engine mount to body: 20 Nm + 90° (¼ turn) in tightening direction;
- engine support to engine bracket: 30 Nm + 90° (¼ turn) in tightening direction.
Install the vacuum pump.
Install the lower timing belt cover.
Tighten the crankshaft belt pulley fastening to a torque of 10 Nm. Then turn the bolts in the tightening direction by 90° (¼ turn).
Note: Installation is only possible in one position.
Install the poly V-belt.
Install the lower engine compartment cover.
Install the upper timing belt cover.
Install the top engine cover.
Check the start of fuel supply dynamically (at a service station).
Adjusting ruler of the camshaft VW-3418:
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