Removing the timing belt of a diesel engine 1.9 l
The drive device of the gas distribution system of the 1.9l engine of the Volkswagen Transporter T4 is shown in fig. 197.
Rice.
197 Camshaft drive device - 1.9 engine 1 - tensioning roller, 2 - bolt 20 Nm, 3 - tensioning lever, 4 - dust cap, 5 - nut, 45 Nm, 6 - tensioning roller, 7 - spacer clamp, 8 - toothed belt guard upper, 9 - bolt, 45 Nm 10 - camshaft gear, 11-bolt, 10 Nm, 12-nut 45Nm, 13 - rear toothed belt guard, 14 - injection pump, 15-nut, 45Nm, 16 - bracket, 17 - console, 18 - two-piece injection pump gear, 19 - injection pump gear, 20 - toothed belt, 21 - countershaft pulley, 22 - crankshaft gear, 23 - bolt, tightening torque 90Nm + 1/4 turn (90 '), 24 - lower toothed belt casing, 25 - V-belt / V-ribbed belt for driving the generator and coolant pump, 26 - V-belt for driving the power steering vane pump, 27 - vibration damper.
The camshaft located in the head of the block is driven by a toothed belt lying on the gear wheels of the camshaft, crankshaft and injection pump.
The intermediate shaft is driven by a polypin belt. Here you should pay attention to the fact that special tools are required to adjust the installation of the injection pump and the camshaft, since without them it is impossible to correctly adjust the installation of either the injection pump or the camshaft.
A special tool is also needed to adjust the tension of the V-ribbed belt. Do not proceed with the operations described below if you do not have the special tools required to perform them. If the toothed belt is not damaged during operation, it must be operated without accidents up to 100 thousand kilometers. The tension of the toothed belt is adjusted by means of a roller with an eccentric.
The toothed belt can be replaced in the engine installed in the car.
The following steps will deal with just such a case. ♦ Remove the upper toothed belt cover.
Loosen the alternator mounting, tilt it towards the engine and remove the V-belt. Remove the valve head cover. ♦ You now need the 2065A Special Tool.
This is the camshaft setting line. After installing the piston of the first cylinder at TDC, install a ruler on the upper seating surface of the block head from the flywheel side. To set the piston of the first cylinder to TDC, turn the crankshaft so that the TDC mark on the flywheel is opposite the pointer in the control window of the clutch housing (remove the plug in the upper part of the housing). The way of installation of a ruler and a cam-shaft is shown in fig.
198. For precise setting, proceed as follows: ♦ Turn the camshaft yak so that one end of the ruler rests on the surface of the block head.
Rice. 198 TDC setting ruler on the block head (upper part of the figure) - setting the TDC mark on the flywheel relative to the pointer in the control window (lower part of the figure)
♦ On the other hand, measure the width of the gap between the surface of the head and the ruler with a feeler gauge.
♦ Prepare two plates with a thickness equal to half the size of the gap and insert one between the ruler and the head of the block.
♦ Rotate the camshaft so that the ruler rests on the plate.
♦ Insert the second of the prepared plates into the gap formed on the other side.
♦ For the next operation, dowel pin 2064 is required (fig. 199). Insert it into the injection pump pulley to lock it.
Rice. 199 Blocking the toothed pulley of the injection pump with a pin 2064
♦ Loosen the nut securing the toothed belt tensioner and turn the tensioner to the left.
Loosen the bolt and remove the crankshaft pulley as well as the vibration damper and the coolant pump pulley. ♦ Remove the lower toothed belt cover.
♦ Remove the toothed belt from the timing belt pulleys.