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3-2-snyatie-i-ustanovka-dvigatelya.html
3.2. Removal and engine installationRecommendations about engine removal
Before the work beginning attentively familiarise with the given section.
If the engine remove for repair, it is necessary to choose a place for work, to provide space for service and storage of spare parts. Repair is recommended to be spent on a car repair shop or in garage with an equal horizontal floor with a pure firm covering.
Before removal clear of pollution and wash up the engine and a motor compartment. For engine removal use the load-lifting mechanism allowing safely to lift the power unit.
If you remove the engine for the first time, it is necessary to invite the skilled expert. Some works should be carried out with the assistant.
All clips and collars which at engine removal will be damaged or cut, at engine assemblage replace new.
The engine acts in film forward without a transmission.
The merged cooling liquid is necessary for collecting and utilising.
Before a detachment of the storage battery find out, whether there is at you a code of inclusion of a radio receiver.
Removal
Switch off ignition and disconnect a wire of "weight" from the storage battery.
Uncover a broad tank.
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Fig. 3.1–1. An arrangement of clamps of fastening of the bottom mudguard of a motor compartment
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Release the clamps shown by arrows on fig. 3.1–1, and remove the bottom mudguard of a motor compartment.
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Fig. 3.1–2. An arrangement of bolts of fastening of an arm of the bottom mudguard of a motor compartment
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Turn away two bolts and remove an arm of the bottom mudguard of a motor compartment (fig. 3.1–2)
Establish under the engine the pallet for gathering of a cooling liquid.
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Fig. 3.1–3. An arrangement of an air line (1) and collars (2 and 3) fastenings of hoses of system of cooling
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Loosen the a collar 3 (fig. 3.1–3), remove a hose and merge cooling liquid in the pallet.
Loosen the a collar 2, remove a hose, move it downwards and merge cooling liquid from a radiator.
Disconnect fastening of an air line 1 from the generator.
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Fig. 3.1–4. An arrangement of the oil filter and the oil heat exchanger: 1 – a hose; 2 – the oil filter; 3 – the oil heat exchanger
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Disconnect an additional hose of system of cooling in the bottom part of the oil heat exchanger and merge cooling liquid in the pallet. On fig. by 3.1-4 arrow the collar of fastening of an additional hose of system of cooling to the oil heat exchanger is shown.
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Fig. 3.1–5. An arrangement of a stopper plum of a cooling liquid from the block of cylinders of the engine
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Turn out from the block of cylinders of the engine a carving stopper plum of the cooling liquid, 3.1–5 arrow shown on fig.
At stopper installation it is necessary to use a new sealing ring.
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Fig. 3.1–41. An arrangement of screws of fastening of a casing of the engine
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Turn out four screws and remove an engine casing (fig. 3.1–41 see).
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Fig. 3.1–42. An arrangement of collars of fastening of an air branch pipe of a flowmeter of air and the soaking up pipeline: 1 – the pipeline of giving of fuel; 2 – a hose of giving of fuel
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Loosen the collars also remove the air branch pipe which is connecting a measuring instrument of the expense of air and soaking up the pipeline (fig. 3.1–42 see).
The prevention
The fuel system is under pressure. Before separation of elements of fuel system it is necessary to remove pressure in system. For this purpose close a place of separation of fuel system pure rags and, being careful, smoothly unscrew a connecting nut.
Unscrew nuts and disconnect a hose топливоподачи from the pipeline (fig. 3.1–42 see).
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Fig. 3.1–6. An arrangement of hoses in the top part of the engine: 1 – a ventilation hose картера; 2, 4, 6, 7 – vacuum hoses; 3 – the valve for switching of the soaking up pipeline; 5 – connection of a vacuum hose with the vacuum amplifier of brakes; 8 – screws of fastening of an air branch pipe of throttle knot
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Disconnect a hose of system of ventilation картера from the right cover of a head of the block of cylinders (fig. 3.1–6).
Turn out the valve 3 for switching of the soaking up pipeline and take him together with the pipeline aside.
Being careful, remove a vacuum hose 6.
Turn out screws 8 and remove an air branch pipe from the case of throttle knot.
Disconnect a hose of system of ventilation картера from the left cover of a head of the block of cylinders.
Remove a hose of the vacuum amplifier of brakes from a connector and take a connector from an arm.
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Fig. 3.1–7. An arrangement of protective casings (1–4) in a back part of a motor compartment
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Remove protective casings 1–4 in a back part of a motor compartment (fig. 3.1–7).
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Fig. 3.1–8. An arrangement of screws and a direction of removal (1) casings of the block of management
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Turn the left casing closing the block of management, in a direction specified by an arrow (1, fig. 3.1–8), and turn out the back right screw.
Turn out the remained screws of fastening shown by arrows on fig. 3.1–8.
Remove a casing of the block of management.
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Fig. 3.1–9. An arrangement of the block of engine management (1), the block of management of a drive (2) and electric sockets (3) on a partition of a motor compartment
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Disconnect electric sockets from the block of engine management 1 (fig. 3.1–9) and the block of management of a drive 2, and also all electric sockets on a partition of a motor compartment. Arrows specify an arrangement of screws of fastening of the case of safety locks.
Disconnect an electric socket from the block of management GRA.
Take the sealing plate located between a motor compartment and a tank of a radiator.
Release from clips electroconducting in a motor compartment.
Turn away the plug of fastening of electroconducting to a partition of a motor compartment and move electroconducting aside.
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Fig. 3.1–10. An arrangement of an air branch pipe (1) and an air inlet (2) about a forward cross-beam of the engine
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Separate an air inlet 2 (fig. 3.1–10) from a forward cross-beam and remove it together with an air branch pipe 1.
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Fig. 3.1–11. An arrangement of screws of fastening of the top part of the case of the air filter
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Turn out four screws shown by arrows on fig. 3.1–11, fastenings of the top part of the case of the air filter, thus disconnect electric sockets 1–3 and take them aside.
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Fig. 3.1–12. An arrangement of a connecting nut of fastening of the delivery pipeline of the hydraulic pump
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Unscrew a connecting nut and disconnect the delivery pipeline of the hydraulic pump (fig. 3.1–12).
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Fig. 3.1–13. An arrangement of a collar of fastening of a vacuum hose to the AKF-valve
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Loosen the a collar also disconnect a vacuum hose from the AKF-valve (fig. 3.1–13).
Cars with GRA
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Fig. 3.1–14. An arrangement of draught of management (1), nuts of fastening (2) vacuum blocks and a vacuum hose (3)
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Disconnect draught of management 1 (fig. 3.1–14) from the vacuum block.
Remove from the vacuum block a vacuum hose 3.
Unscrew a nut 2 and remove the vacuum block.
All cars
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Fig. 3.1–15. Places of fastening of a cable of an accelerator to throttle заслонке and covers of a cable of an accelerator to an arm
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Disconnect a cable of an accelerator from throttle заслонки, a cable cover take from an arm (fig. 3.1–15).
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Fig. 3.1–16. An arrangement of collars of fastening of hoses of system of cooling to a broad tank (arrows on the right) and to heater unions (arrows at the left) on a partition of a motor compartment
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Loosen the collars also disconnect the hoses connecting an average pipe of system of cooling and a broad tank (arrows on the right on fig. 3.1–16).
Loosen the collars (arrows at the left) also disconnect hoses of system the coolings going to a heater.
Move hoses to the right bottom part of a motor compartment.
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Fig. 3.1–17. A direction of moving of a clamp of an electric socket
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Disconnect all electric sockets on a forward wall for what move a clamp in an arrow direction (fig. 3.1–17).
Disconnect electric sockets of ljambda-gauges and take from clamps the wires going to ljambda-gauges.
Release from clamps all electric conducting of the engine.
Cars with a mechanical transmission
Disconnect an electric socket from the speedometer gauge (the marksman And on fig. 3.1–18).
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Fig. 3.1–18. An arrangement of electric sockets of the gauge of a speedometer () and the backing switch ()
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Disconnect an electric socket from the backing switch – the multipurpose gauge (marksman).
All cars
Unscrew nuts of fastening of a final collector accessible from above and a reception exhaust pipe.
Turn out, but not completely, the top bolts of fastening of a transmission to the engine.
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Fig. 3.1–19. Elements of fastening of an average pipe of system of cooling: 1, 3 – collars; 2, 5 – bolts; 4 – a hose
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Remove an average pipe of system of cooling for what loosen the collars 1 and 3 (fig. 3.1–19), turn out bolts of fastening 2 and 5 and disconnect from it a hose 4.
Cars with the electric fan of a radiator
Turn out screws, remove the electric fan of a radiator and take him together with the connected wires aside.
Cars with the fan of a radiator with вязкостной муфтой
Unscrew a casing of the fan and remove it.
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Fig. 3.1–40. A reversing of a bolt of fastening of the fan of a radiator
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Keeping a pulley of the fan of a radiator from проворачивания a special key 3212, a usual key unscrew a bolt of fastening of a pulley. As the bolt has the left carving, for unscrewing it is necessary to rotate it clockwise (fig. 3.1–40 see).
Lift upwards the fan of a radiator and remove it from the car.
All cars
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Fig. 3.1–43. An arrangement of screws of fastening of a casing semi wedge a belt
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Turn out screws and remove a casing semi wedge a belt (fig. 3.1–43 see).
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Fig. 3.1–20. Installation of the special adaptation (1) for fastening of a hose of giving of fuel to the hydraulic pump
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Using the special adaptation (fig. 3.1–20), attach a hose of giving of fuel to the hydraulic pump. In the left bottom part of a motor compartment loosen the a collar also turn out a bolt of fastening of an arm of a hose of giving of fuel.
Move downwards the special adaptation between a casing of a gear belt and a head of the block of cylinders or the block of cylinders.
Enclose pure rags under the hydraulic pump for gathering of following oil.
Cars with a mechanical transmission
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Fig. 3.1–21. Elements of fastening of wires and sockets: 1 – a bolt of fastening of a wire of "weight"; 2 – a nut of fastening of a wire; 3 – an electric socket; 4 – a collar
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Release a clamp and disconnect an electric socket 3 (fig. 3.1–21).
Remove a casing closing electric connections.
Turn away a bolt of 1 fastening of a wire of "weight".
Turn away a nut of 2 fastenings of wires.
Turn away a collar of 4 fastenings of electric wires and take wires aside.
Cars with the conditioner and / or an automatic transmission
The prevention
Chalk, marker or paint note a rotation direction semi wedge a belt. If at installation полиwedge the belt rotates in other party, it will lead to its destruction.
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Fig. 3.1–44. Tension easing semi wedge a belt: 1, 2 – installation sites of pins for fixing of the mechanism of a tension. By an arrow the rotation direction шестигранного a key for tension reduction semi wedge a belt is shown
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Using face шестигранный a key on 10 mm, loosen the a tension semi wedge a belt for what turn the tension mechanism clockwise before combination of apertures (an arrow 1 and 2, fig. 3.1–44) see.
Fix the tension mechanism in this position, having inserted into apertures a steel core in diameter of 5 mm.
Remove полиwedge a belt from pulleys.
Cars with the conditioner
For oil gathering establish the pallet under a motor compartment.
Merge engine oil, having unscrewed a stopper маслосливного apertures and if necessary pressing it that oil did not follow prematurely.
Loosen the a collar also remove a back hose from the oil heat exchanger.
Remove the oil heat exchanger.
The prevention
Contour of cooling of a central air not to open.
Take electric wires of the compressor of the conditioner from fastenings.
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Fig. 3.1–22. An arrangement of bolts of fastening of an arm of the compressor of the conditioner
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Turn away four bolts of fastening of an arm of the compressor of the conditioner, shown by arrows on fig. 3.1–22.
Take aside the conditioner compressor together with the wires attached to it and tubes.
Cars with an automatic transmission
Disconnect from the generator electric wires.
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Fig. 3.1–23. Elements of fastening of the generator: 1 – a nut; 2 – a bolt
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Turn out the bottom bolt 2 (fig. 3.1–23) generator fastenings.
Keeping a key the top bolt from проворачивания, unscrew a nut 1.
Take the top bolt of fastening of the generator and remove the generator.
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Fig. 3.1–24. An arrangement of bolts of fastening of a starter: 1 – a nut; 2 – an electric socket
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Disconnect from a starter an electric socket 2 (fig. 3.1–24), unscrew a nut 1 and disconnect from a starter power (плюсовый) a wire.
Turn out two bolts (arrows on fig. 3.1–24) fastenings of a starter and, being careful, remove a starter.
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Fig. 3.1–25. An arrangement of a bolt of fastening of the hydrotransformer
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Through the aperture which has opened after removal of a starter, turn out three bolts of fastening of the hydrotransformer (fig. 3.1–25). For access to each subsequent bolt it is necessary to turn a cranked shaft of the engine in a direction of its working rotation on 1/3 turns. For проворачивания a cranked shaft it is necessary to use the central bolt of fastening of a pulley of a cranked shaft.
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Fig. 3.1–26. An arrangement of bolts of fastening of the arms supporting pipelines, to an automatic transmission
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Turn away two bolts (fig. 3.1–26) fastenings of arms for support of pipelines to an automatic transmission.
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Fig. 3.1–27. An arrangement of the gauge of frequency of rotation of the engine (1), an electric socket (2), the gauge of a speedometer and a bolt (3) fastenings of the pipeline of an automatic transmission
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Turn on at its presence the gauge of 1 frequency of rotation of engine G28. The gauge 1 (fig. 3.1–27) is located in a forward left part of a transmission.
The note
Observe cleanliness at work with an automatic transmission.
If necessary remove an automatic transmission and drive shaft.
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Fig. 3.1–28. An arrangement of nuts of fastening of a reception exhaust pipe to the forward muffler
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From below the car unscrew nuts of fastening of a reception exhaust pipe to the forward muffler (fig. 3.1–28).
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Fig. 3.1–29. An arrangement of nuts of fastening connecting муфт systems of release of the fulfilled gases
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Unscrew the nuts specified by arrows on fig. 3.1–29, крепящие connecting муфты.
Being careful, remove a forward exhaust pipe with catalytic neutralizer and ljambda-gauges. Thus do not damage the wires going to ljambda-gauges.
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Fig. 3.1–30. An arrangement of a support of the jack of a twisting moment of the engine: 1 – a support; 2 – the terminator
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Turn out bolts of fastening of a support 1 (fig. 3.1–30) the jack of a twisting moment of the engine and, moving a support, remove it.
From below the car turn out accessible bolts of fastening of a transmission to the engine.
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Fig. 3.1–31. An arrangement of bolts of fastening of the engine to the bottom frame
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Turn out the bottom bolts (fig. 3.1–31) engine fastenings to the bottom frame.
Prepare the left adapter 10–222А/4 and the load-lifting device 10–222А with captures for transmission support.
From the back party on the top platform of an adapter 10–222А/4 drill an aperture in diameter of 10,2 mm and cut carving М12.
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Fig. 3.1–32. Installation of adaptations for transmission support: 1 – the left adapter 10-222А/4; 2 - the load-lifting device 10-222А; 3 – the complete set of captures 2024 А/2, 2024 А/1 and 3147
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Establish an adapter 10–222А/4 and the load-lifting device 10–222А on racks and connect them together, using a carving aperture (fig. 3.1–32).
The lifting screw should settle down from the back party of the load-lifting device.
Fix capture of the load-lifting device on a transmission.
Rotating the screw of the elevating device, pull capture so that the transmission weight was perceived by the elevating device. Completely turn out the bottom bolts of fastening of a transmission to the engine.
Disconnect from a cowl of a rack of support of a cowl. Establish a cowl vertically and fix it in this position.
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Fig. 3.1–33. Engine fastening by load-lifting capture 3033: 1 – capture
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Suspend on таль load-lifting capture 3033 (fig. 3.1–33) and fix it on the engine.
Turn out the top bolts of fastening of a transmission to the engine.
Be convinced that all electric wires, hoses, branch pipes and pipelines are disconnected from the engine.
Cars with an automatic transmission
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Fig. 3.1–34. Use of mount for hydrotransformer pressing to the engine at engine removal
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Before engine removal press mount the hydrotransformer to the engine (fig. 3.1–34).
Being careful, raise the engine, then take away it from a transmission and take upwards from a motor compartment.
Cars with an automatic transmission
Fix the hydrotransformer on the engine.
Installation
Engine installation is spent to sequences, return to removal, taking into account the following.
Replace on new self-locking nuts and bolts which tightened доворачиванием on a certain corner, and also sealing rings and linings.
Check up presence of the aligning plugs defining relative position of the engine and a transmission.
At connection of the engine with a transmission be careful not to damage the gauge of frequency of rotation of the engine.
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Fig. 3.1–35. Use of special tool VW 540 (1) at engine installation on the stand
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If it is necessary to repair the engine, fix it at the stand by means of special tool VW 540 (fig. 3.1–35).
Cars with a mechanical transmission
Clear Slots a shaft of a drive and at a reuse of a disk of coupling remove from it corrosion traces. Grease Slots a drive shaft with a thin layer of greasing G 000 100.
Check up a condition of the bearing of deenergizing of coupling and if necessary replace it.
Using the mandrel, check up a centering of a disk of coupling.
Check up a condition of the needle bearing in an end face of a cranked shaft from outside a flywheel. If necessary replace the bearing.
Cars with an automatic transmission
For hydrotransformer fastening to a leading disk it is necessary to use bolts of an original design.
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Fig. 3.1–36. Distance measurement between a basic surface for bolts of fastening of the hydrotransformer and a basic surface картера
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Check up correctness of installation of the hydrotransformer. If the distance between a basic surface for bolts of fastening of the hydrotransformer and a surface картера makes 19 mm, means, the hydrotransformer is established correctly. At incorrectly established hydrotransformer this distance makes 14 mm (fig. 3.1–36). Wrong installation of the hydrotransformer leads to destruction of a leading part of the hydrotransformer and the pump of an automatic transmission.
Establish the engine into place and, having shaken it here and there, provide a correct arrangement on support.
Establish полиwedge a belt.
Check up correctness of installation of a support of the jack of a twisting moment of the engine.
If the flywheel at engine installation take aside the gauge of frequency of rotation of the engine acted in film.
Check up adjustment of a cable of an accelerator.
Fill in in cooling system cooling liquid. The reuse of a cooling liquid is not supposed in case the head of the block of cylinders acted in film or the block of cylinders was replaced.
Fill in oil in system of the amplifier of a steering and remove from it air.
Be convinced that elements of systems of release of the fulfilled gases are correctly established on suspension brackets and bodies do not concern at rocking.
Check up correctness of connection of electric sockets.
Connect "a weight" wire to the storage battery.
Include a radio receiver and enter into it a code.
Lift glasses electric glass lifts upwards against the stop. Then press all switches стеклоподъемника once again, at least for 1 second, in position of closing for activation of the block of management glass lifts.
Establish time for hours.
Before engine start-up check up presence and oil level in the engine.
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Fig. 3.1–37. An arrangement and numbering of bolts of fastening of a mechanical transmission to the engine: And – an installation site of the aligning plug
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Fig. 3.1–38. An arrangement and numbering of bolts of fastening of an automatic transmission to the engine: And, In – installation sites of aligning plugs
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Fig. 3.1–39. The units put in action поликлиновым by a belt: 1 – гаситель fluctuations; 2 – a bolt, 22 Нм; 3 – полиwedge a belt; 4 – a bolt, 22 Нм; 5 – the generator; 6 – a bolt, 45 Нм; 7 – a bolt, 22 Нм; 8 – a generator arm; 9 – a bolt, 45 Нм; 10 – распорная the plug; 11 – a bolt, 55 Нм; 12 – a bolt, 22 Нм; 13 – a pulley of the pump of the amplifier of a steering; 14 – the delivery pipeline of the amplifier of a steering; 15 – a hollow bolt, 40 Нм; 16 – sealing rings; 17 – a bolt, 22 Нм; 18 – the pump of the amplifier of a steering with an arm; 19 – a bolt, 22 Нм; 20 – the tension mechanism semi wedge a belt; 21 – a bolt, 25 Нм; 22 – the conditioner compressor; 23 – a special nut, 25 Нм; 24 – a pulley semi wedge a belt
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