ENGINE: EXPLODED VIEW Engine 13 .0 116 V engine 23456 1 #18 1 :171615 1413 2 1211109 8 7 420m. 12, Timing belt lower cover. 2 Timing belt cover attachment, 10 Nm. 18, Poly belt 3. Timing belt upper cover. Remove and refusing too! U-40010. ‘4 Tension roller fixing nut. 46 Ne Mark the deocton of rotation before removing it ‘5. Timing bett tension roller. 14, Pulley for Poty-V belt. 6 Timing belt 418. Vibration dampener. Before disassembling, mark the direction of rotation Note the mounting positon. Do not bend. 46, Vibot. 1. inner cover. 17. Pulley for V belt. &. Intermediate shaft dive pinion. 48, Pulley. 9. Crankshaft pinion. 18, Poly bet tensioningEngine 13 Crankshaft assembly: 2.01 16 V engine ENGINE: EXPLODED VIEW [38078] 1. Fixing bolt. 20 Nm. 8. Bracket fixing bolt 45 Nm. 2 Manifold intake, top. 3. Gasket. 10. Camshatt drive Replace, Note the poston when assembing te timing bk 4. Oylinder head cover. Remove an ref ving he tol Usena02 5. Gylinder head cover gasket. 11, Gylinder head Replace f damaged Ferremoval and reiting, ake no acount he proper 6. Cylinder head. seuence (eter to Grup 19) Disassembly and reassembly (ler to Group 15), 12. Gpnder ead cover fing 10 7. Gylinder head gasket. (12.96)ENGINE: EXPLODED VIEW 12345 32 14 B8se 27262425 Engine 13 Crankshaft assembly: 2.0 | 16 V engine 6783491011 24 2322218 201918 1 yfinder block. 2. Cooling iid pump thing bolts. Yr. Engine spood transmitter Sonn» 3B, Sdpport ngs ace 18 Suppor 2. Pinking sensor 20. Fang bot 45 3 Pking sensor xing bot Bi; Tenson device fing Bot. 10 Nm. ‘The tgttonng torque affecs the sensor operation. B 5. Oring. 23. Support fing nuts. 20 Nm. Replace. 2A, Offseat 6. Ph. Fepsace Ht damaged. 7, bitsctment Ranges. 25. Support & Fang Dot 25 Nm 25. Tendionng pally Ovi. 27. Hammer ad bot tx the cooting auld pum. pace, 28. Cooling tad pure. 10. Gasket. ae ressambly (eter to Group 19, ‘Replace damaged ~. o4 14, Cramtahaft sump vont. 32. Ol sum feng bot. 25 Nn. 12. Girtter support ‘Remove the bot 0 te ye! 13, Ol cooler ‘zpanner one Ropar Grou 17 16 23m 1. Vane pump suppor” 3 Oummee 32. Ol sump gasket ease sing the to! U-40078 othe universal itor remo Bo not sk he gasket, note the mounting poston. "ighton by han (12.96)Engine 13 Crankshaft assembly: 2.0 1 16 V engine DISTRIBUTION TIMING BELT DRIVE Removal and refitting ‘The following operations can be carried out with the engine fitted into the vehicle or with the engine at tached to a rotary trestle. {tthe disassembly is carried out inthe vehicle, discon- ‘ect the negative terminal on the battery and partially remove the air fiter/nlet tube assembly, for which the following items must be removed! 1. Junction clip between inlet tube and inlet manifold. 2. Suction take-off from its fixing to the inlet air ther- mo-regulator. 3. Inlet air temperature transmitter connector. ‘4. Sump gasses ventilation tube from is fixing to the pressure regulating valve, 5. Idling stabiizer valve tube from its fixing to the valve, 6. Hot air tube from its fixing to the exhaust manifold heat shield 7. ‘Air intake muffer bushing from its housing to the air fiter assembly, Remove the O-rings which connect the air fiter as- ‘sembly to the bodywork and remove the fer. Romove the upper cover after removing the fixing bolts. 108005 IN VEHICLE Remove the Poly-V belt using the appropriate tool: — Models with tensioning roller u-40010, — Models without tensioning rolier ‘u-40050, When removing the belt, mark the turning direction: this mark should be taken into account’ when re assembling, 4 (12.96)198002 IN VEHICLE (models wth Poly-V and tensioning roller) Remove the bot fixing the Poly-V bet tension roller, to hold the nut, the roller rear cover must be removed by prying with a screwdriver. raatos Remove the upper bolts or nuts which hold the lower Engine 13 Crankshaft assembly: 2.0 | 16 V engine 488016 IN VEHICLE Raise the vehicle and remove the lower engine pro- tection. Remove the power steering drive pulley by loosening the fixing Bolt 1 and the bolt ofthe tensioning nut. Remove the Poly-V belt IN VEHICLE Remove the crankshaft drive pulley together with the vibration damper. necessary to remove the lower guard, remove the ‘cooling liquid pump pulley. To cary out this operation, too! U-40011 must be used. (12.96)Engine 13 Crankshaft assembly: 2.0 1 16 V engine Remove the remaining bolts fixing the lower quard and remove the lower guard, ‘Align the mark on the distributor drive shaft pinion with the arrow on the cylinder head cover. Ifthe cylinder head cover has been removed, the mark fon the back of the distributor drive shaft pinion must be flush with the cylinder head, 136107 Loosen the timing belt by loosening the tension roller fixing nut and turning the roller counterclockwise us~ ing tool U-30008, Remove the timing belt and mark the direction of movement if the belt is to be reused. Remove the camshaft and the intermediate shat drive gears using too! U-20002/1 Remove the crankshaft pinion. To remove the fixing bolt, the crankshaft must be prevented from turning. 6 (12.96)(ON THE WORK BENCH With the engine attached to a rotary trestle, lock the ‘flywheel using the too! U-30035 to prevent the crank shaft from 18106 ON THE VEHICLE With the engine installed in the vehicle, use the 'U-30027 spanner to prevent the engine from turning by fixing i to the pinion using suitable bolts. ‘The power-assisted steering tension support must be romaved in order fo fit the spanner. Reassembly ‘To reassemble, reverse the above operations taking the following into account: Refit the crankshaft pinion and tighten the bolt to the specified torque. Engine 13 Crankshaft assembly: 2.0 1 16 V engine Refit the camshaft and intermediate shaft drive pin- ions. To prevent the above shafts from turning, use tool U-20002/1 Fit the timing belt on the crankshaft pinion and on the. intermediate shaft gear Fit the lower cover ofthe toothed bet, 128076 Place the crankshalt drive pulley together with the vi- bration damper. The mark on the vibration damper must align with the mark on the lower cover of the: toothed belt 198073 ‘Align the mark on the distributor drive shaft pinion with ‘the arrow on the eylinder head cover. It the cylinder head cover has been removed, the mark ‘on the back of the distributor drive shaft pinion must be flush with the eylinder head.Engine 13 Crankshaft assembly: 2.0 1 16 V engine CCheck that the engine flywheel mark matches withthe mark on the clutch housing, 136107 After the distribution marks are matched, fit the timing belt and tighten the belt to the proper tension, by turn- ing the tension roller clockwise using tool U-30009 {the toothed bet must only be tensioned with the en= ‘ine cold), 8 (12.96) Check that the tautness of the gear-tooth belt is, ‘correct matching the marks on the tension roller. It not, loosen the tension roller nut and, using the tool 1U-30008, turn the roller anticlockwise as far as it wil {90, then turn the roller anticlockwise unti the marks ‘match, Tighten the tension roller withthe fastening nut. Tum the crankshaft two tums, until the marks are again on TOC and recheck the adjustment, Fit the plug into the clutch housing, Place the upper cover, the Poly-V belt tensioning pul- ley and the belt. Pay attention to the direction indicat ing mark on the Poly-V bolt. Fit and tighten the power steering drive bett (Running ‘gear, Group 48)TIMING BELT Tightening 08113 If tensioning is carried out in the vehicle, disconnect the negative cable of the battery and partially remove the air fterinlt tube assembly, for which the follow. ing iterss must be removed: +1. Junction clip between inlet tube and inlet manifold 2. Suction take-off from its fxing to the inlet air ther- ‘mo-reguiator. 2. Inlet air temperature transmitter connector. 4, Sump gasses ventilation tube from its fixing to the pressure regulating valve. 5. Idling stablizer valve tube from its fixing to the valve. 6. Hot air tube from its fixing to the exhaust manifold heat shield 7. Air intake mutter bushing from its housing to the air filter assembly Remove the O-rings which connect the air fiter as- ‘sembly to the bodywork and remove the fier. Engine 13 Crankshaft assembly: 2.0 I 16 V engine saAN02 Remove the upper cover after removing the fixing bolts. Match the distributor marks and, when they are in the ‘TDC position, check the tautness of the gear-tooth belt (tis can only be tensioned with the engine cold}. 98023 CCheok that the marks on the tension roller match. if rot, loosen the tension roller nut and, using the too! 1U-30009, turn the tension roller anticlockwise as far as it will go and then turn the roller clockwise unt the marks match. Tighten the tension roller withthe fastening nut. ‘Turn the crankshaft two tums, until the marks are again on TDC and recheck the adjustment. ‘Strongy press the timing belt with the index finger; the marks on the tensioner should move apart. Release the pressure on the belt the tensioner roller should re- turn to its original position (the marks on the tensioner should realign}. (12.96) 8POLY-V BELT Removal and refitting Removal If the bet isto be reused, the direction of rotation must be marked before removing the belt; the mark must be taken into account when refitting, 08005 VERSION WITH POLY-V BELT AND TENSIONING ROLLER, Detach the Poly-V belt from the alternator pulley using too! U-40010. 278026 VERSION WITH POLY:V BELT, WITHOUT TENSION ING ROLLER Remove the Poly-V bet. Remove the belt by loosening the bolts holding the al= temnator bracket. 10 (12.96) Engine 13 Crankshaft assembly: 2.0 1 16 V engine Place the U-40050 tool as shown in the photograph and use a spanner to move the tool until the tension- ing spring is overcome. ‘Once detensioned, remove the Poly-V belt from its fx ing to the engine (the cooling liquid pump pulley should be removed fist. 86016 Raise the vehicle and remove the power steering drive bolt. To do this, the fixing bolt 1 and the tensioning nut bolt must be icosened Remove the Poly-V bett Refitting To reassemble, reverse the above operations taking the following into account: When reiting the Poly-V bett (ony i itis being reused), take into account the direction of rotation mark 11 models with a Poly-V belt without tensioning roller, ‘once the belt is refitted and before the alternator se~ Curing bolts are tightened, the engine must be run at idling speed (approx. 10 seconds); the alternator fixing bolts must then be tightened (starting with the lower bolt. Fit and tighten the power steering drive belt (Running gear, Group 48)Engine 13 Crankshaft assembly: 2.0 1 16 V engine CYLINDER BLOCK, SEALS AND ENGINE FLYWHEEL: EXPLODED VIEW 123456 | | 1514131012 511109 87 1aa022) 1. Intermediate shaft Can be removed with the engine fitted into the Forove ving the tol 010000 and ret using the oo! vehi by renovg the gearbox. ‘dese contact area must be free from 2. Crankshat ol spoovens oo eaoe Remove wing ton U-10000 an refusing oot - 20019, ‘Check that tho Isa propor seat on the centering 3. Cover fixing bolt. 25 Nem. bushings. 4 Front cover, 410, Cover fixing bolt. 10 Nm. 5 Gasket 11, Rear cover with seal. Replace. Removal and replacarnent 6. Cynder block. 2. Check the cyindor bores. Removal and reiting, Check the axial ply. 7. Engine theo! fxing bot. 60 Nem 13. Oning. Foose he ecationalbohening by 9" canbecaried * Raplate damaged. ‘ut in several stages. 14, Oi seal holding cover. 45. Intermediate shaft ol! seal holder fixing bolt. 8. Engine Use the U-20035 retainer too! to remove and install (12.96) "CRANKSHAFT OIL. SEAL, FLYWHEEL SIDE Replacement To replace the oll seal, it is necessary to remove first the gearbox-differential assembly. Remove the pressure assembly fixing bolts; block ro tation with the U-30035 too! Remove the pressure assembly together with the ‘clutch plate. raanio Remove the bolts fixing the engine flywheel and re- move the flywheel 2 « Engine 13 Crankshaft assembly: 2.0 1 16 V engine 128013 Remove the intermediate plate fixing bolts and re- ‘move the intermediate plate. Push out the oil seal using the percussion tool U-10080. (Operate on different ofthe oil seal until pushing it out ‘Be very careful throughout the operation. 2.96)Engine 13 Crankshaft assembly: 2.0 | 16 V engine 136021 ‘The spare oil seal i fitted with a bushing to make the {iting easier and to alow the oll seal ip side over the ‘crankshaft without getting damaged. Place the bushing on the crankshaft and slide the re- tainer onto it) 138090 Fully insert the retainer with the U-40052 tool. 128010 I necessary, replace the entire cover and seal assem- bly and tighten the bolts to the specified torque. To refit, reverse the above operations taking the fol- lowing into account ‘The engine flywheel bolts must be replaced and fitted with a sealant; tighten the bolts crosswise tothe spec led torque: aati Centre the clutch plate using the U-10050 tool and the U-10050/F adaptor; cross-lighten the pressure as- sembly fixing bolts to the specified torque. (12.96) 13Engine 13 Crankshaft assembly: 2.01 16 V engine (CRANKSHAFT ASSEMBLY: EXPLODED VIEW [13023] ‘4. Contra haf bearing EN ‘Te cylinder Block sie half bearing with lubrication groove. ‘The cap side half bearing without hubvication groove. Forrnumber S erankshaft cap. Note the mounting positon 6.1% n Forthe engine speed transmitter. 17. Bolt fixing ‘crown. 10. Nm + 90" 8 Cran(CRANKSHAFT OIL SEAL, DISTRIBUTION SIDE Replacement To replace the crankshaft oil seal, proceed as follows: Remove the crankshaft pinion; the procedure is ke the one described for the operation “timing belt drive, removal and refitting” but removing the camshaft and intermediate shaft drive pinions is not required. Remove the power-assisted steering tension bracket. Remove the cover and seal and use a punch to re- ‘move the seal (Once the seal has been removed, re-fit the cover to the block (12.96) Engine 13 Crankshaft assembly: 2.0 | 16 V engine lace the centring part of the tool U-40062 on the crankshaft and slide the ol seal over the centring part Lightly ol the ol seal ip and outer edge before fitting, Place the pusher of the too! U-40062 and acting on the pinion fixing bolt insert the ol seal uni it stops. ‘After fiting the oll seal, proceed with the reassembly by reversing the procedure for disassembiing,INTERMEDIATE SHAFT OIL SEAL Replacement To replace the intermediate shaft oll seal, proceed as folows: Remove the intermediate shaft pinion; the procedure is lke the one described for the operation “timing belt drive, removal and refiting” but removing the ‘camshaft and crankshaft drive pinions is not required 136081 Disassemble the intermediate shaft drive pinion using the tool U-20002/1 saAns Remove the oil seal holding cover and push the seal ut of the cover using a drive head. ‘Once the seal has been removed, refit the cover to the block. 16 (12.96) Engine 13 Crankshaft assembly: 2.0 | 16 V engine Lightly oil the ol seal ip and outer edge. Fit the oil seal on the centring ring of tool U-30002. Insert the ol seal using the too! pusher; for pushing, a ‘proper bolt must be used. Ater fitting the oil seal, proceed with the reassembly by reversing the procedure for disassembling,Engine 13 2.0 116 V engine INTERMEDIATE SHAFT ‘To reassemble, reverse the above operations taking Removal and replacement the following into account: Removal Rafe tered sf andro theo Sl ol To replace the oll seal the engine must be removed from the vehicle. Remove the timing belt. Ifthe seal has been replaced, lightly ol the sealing lip and its outer edge. Fit the oil seal on the centring ring of tool U-90002. Insert the oil seal using the tool pusher; to push the the toot U-20002/ tool, a proper bolt must be used. Before refiting the intermediate shaft drive pinion, ‘check using a dial gauge that the shaft axial play does not exceed 0.25 mm, raants Remove the oil seal holding cover and, ifthe oil seal is. to be replaced, remove the oll seal from the cover. Remove the intermediate shaft (12.96) W(CRANKSHAFT: Dimensions (mm) ‘Main bearing Dimensions | crankshaft, for grinding pins mm = 0.022 Basic $400 dimension 0.042 ~ 0.022 Class 53.75 ~ 0.042 = 0.022 Class 53.50 0.042 = ~ 0.022 Class 53.25 47.05, 0.042 0.042 Crankshaft bearing cap fiting and tightening cys: i vom Poa Fit the caps with the corresponding half bearings, ac- ‘cording to the order marked on them, Cap No. 1 is fited on the distribution side, FRelif the caps taking into account that the half bearing Projections must be superimposed. Tighten the bolts to a torque of 65 Nm. 18 Engine 13 Crankshaft assembly: 2.0116 V engine CRANKSHAFT RADIAL PLAY Checking ana To check the radial play with the engine assembled, Use Plastigage and proceed as follows: ‘Remove the crankshaft bearing cap. Carefully clean the half bearing and the crankshaft journal Place a Plastigage strip in axial direction over the crankshaft journal Refit the cap and tighten to a torque 65 Nm. Note Do not turn the crankshaft while checking the radial lay, Romove the cap and check the width ofthe Plastigage strip with the measurement scale, The value measured must be within the following range: New engine 0.02 t0 0.06 mm. Maximum allowable wear 0.17 mm. (12.96)Engine 13 .0 116 V engine CRANKSHAFT AXIAL PLAY Ckecking CCheck the bearing number 3 (adjustment bearing) ax ial play using a fester gauge. ‘The axial play measurement must be: Now engine 0,07 to 0,47 mm. Maximum allowable wear 0,25 mm. ‘AXIAL HALF BEARINGS. Reassembiy 13a ‘Note the mounting position; the grooves on one of the half bearing sides must be directed towards the crank shat (12.96) 19ODOZZA 1993 BET COMDOBA Engine 13 Crankshaft assembly: 2.0 1 16 V engine CONNECTING ROD, PISTONS AND PISTON PINS: EXPLODED VIEW + 12 oo uy 10 4. Piston rings. Remove and refit using special tweezers Stagger the piston ring ends By 120" (Ghook the play. ‘Tho mark “TOP” must be rected towards the piston head, 2. Piston, Cheek ‘Mark the mounting position and the cylinder to which it belongs. 3. Connecting rod. includes a dling to lubricate the piston pin Replace as complete sats only. ‘Mark the eorespondence withthe cylinder “B” ‘Tho marks "A" must be directed towards the distbution side. ‘4. Connecting rod cap. ‘The marks "A" must be directed towards the distribution side, ‘5. Connecting rod cap fixing mut. 30 Nm + 90°. (ithe contact suraces, 6 Prossre valve 27 Nm. pening pressure: 25 * 3.2 bar 7. Olt injector. £8. Connecting rod big end half bearing. includes a dling to lubricate the piston pin. Note the mounting poston. Do not interchange used half bearings. Make sure that the retaining projections are properly seated, 8. Cylinder block. Check the cyinder bores. 410. Connecting rod bolt 11, Girclip. 42. Piston pin, Remove and refit using the too! U-20008, Iracessary to faciate reascembly, heat the piston 10.60°C. 20 (12.96)PISTON-PISTON PIN-CONNECTING ROD ‘ASSEMBLY Disassembly, checking and reassembly Disassembly saan2s Hold the connecting rod-piston pin-piston assembly ‘on a bench vise using guards on the jaws. Remove the piston rings using special tweezers. Remove the circips and remove the piston pin by ‘pushing it out using the tool U-20008. Mark the mounting position and the cylinder to which it belongs. Engine 13 Crankshaft assembly: 2.0 1 16 V engine If the condition on the parts is good, the parts may be reused. ‘The connecting rods must be replaced by complete sets only, Mark the correspondence between the assemblies and the cylinders and note mounting position. Checking the pistons aa07 ‘Take the measurements at about 10 mm from the lower edge and at 90" with the piston pin axis. The maximum allowable tolerance with regard to the rated dimension is 0.04 mm. Note Whenever a repair is carried out, only pistons and pis- ton rings of the same class will Be fitted as well as on- ly pistons of the same weight, (12.96) aPISTON-PISTON PIN-CONNECTING ROD ‘ASSEMBLY Disassembly, checking and reassembly Disassembly Hold the connecting rod-piston pin-piston assembly fon a bench vise using guards on the jaws. Remove the piston rings using special tweezers. Remove the cirlips and remove the piston pin by pushing it out using the tool U-20008. ‘Mark the mounting position and the cylinder to which it belongs, Engine 13 Crankshaft assembly: 2.01 16 V engine 124006 If the condition on the parts is good, the parts may be reused. ‘The connecting rods must be replaced by complete sats only Mark the correspondence between the assemblies and the cylinders and note mounting position. Checking the pistons 9037 ‘Take the measurements at about 10 mm from the lower edge and at 90° with the piston pin axis. The maximum allowable tolerance with regard to the rated dimension is 0.04 mm. Note Whenever a repair is carried out, only pistons and pis ton rings of the same class will be fited as well as on- Iy pistons of the same weight. (12.96) aChecking the cylinder bore H 1 Using a precission inside caliper (50-100 mm), mea ‘sure at three different points both crosswise A and legthwise B ‘Maximum allowable difference with regard to the rat ed dimension: 0.08 mm. Piston and cylinder bore dimensions Values (in mm) Measurement |g piston [0 cylinder bore Basic dimension | 2.485 we lose | cone | e78 Class 82.995 301 For greater values, the cylinder bore must be ground. Up 10 the allowable oversize in accordance with the scale for oversized pistons. ‘After grinding, wash and dry the cylinder bores and ‘clean any paricle from the walls using a viscous oil Note ‘The calibration must not be carried out with the cylin- der block attached to the rotary trestle, as due to the stresses the measurements could be incorrect. Engine 13 Crankshaft assembly: 2.0 1 16 V engine Reassembly Before refiting the connecting rod-piston pin-piston assembly carty out all the measurements and check- ings required. Hold the connecting rod on a bench vise using proper ‘guards on the jaws, Refit the piston-piston pin-connecting rod assembly. \Note the mounting position of the connecting rod with regard to the piston; the arrow engraved on the piston. hheadmust be pointing to the cast pegs on the con- ‘necting rod small end: (Check that the connecting rod and the piston belong to the same cylinder. aad Fit the piston pin using too! U-20008, It the piston pin is difficult to insert, heat the piston to ‘about 60°. Fit the cccips. (12.98) 23a Fit the piston rings on the piston using special tweez- ers for piston rings. Position the piston ring ends staggered by 120° and taking into account that the mark "TOP" must be di- rected towards the piston head, When refiting the connecting rod-piston pin-piston assembly into the cylinder block, make sure that the humbers of the assemblies match those of the cylin ders, Before refting, lubricate the contact and fiction sur- faces using engine oi. ‘The arrows engraved on the pistons must be pointing to the distribution side. For refiting, use an adjustable clamp. Engine 13 2.0116 V engine CONNECTING ROD RADIAL PLAY CHECKING 120045 With the engine assembled, the play checking can be carried out using Plastigage. Remove the connecting rod cap. Clean thoroughly the half bearing and the crankshaft bin Place either on the crankshaft pin or on the half bear- ing a Piastigage strip in axial drection, Refit the connecting rod cap and tighten the bolts toa {torque of 30 Nm: do not turn the crankshaft during the measurement, Remove the connecting rod cap. Check the Plastigage strip width using the measure- ment scale. The radial play must be: New . sone 0.04 0 0.06 mn. Maximum allowable wear .- 042 mm. After checking the play, refit the connecting rod caps {and tighten the botts to the specified torque. 24 (12.96)Engine 13 Crankshaft assembly: 2.0 | 16 V engine CONNECTING ROD AXIAL PLAY CHECKING COMPRESSION RATIO ‘Test conditions — Engine oil temperature: minimum 30 °C. —Thoottle valve fully open. —Engine speed transmitter connector (next to the central connector, disconnected. — Battery in good condition, — Spark plugs removed. Checking Measure with a feeler gauge, ‘The axial play must be: New 0.05 to. 0.31 mm. ‘Maximum aliowabie wear (0.37 mm. 138109 Fir the VAG 1381 or VAG 1763 pressure meter into the spark plug hole. Operate the starter motor until the pressure recorder does not show any further increase in pressure. ‘The compression ratio must be within the following ranges: in New | Maximum allowable| Engine (bars) wear (bars) ABE 10+13 78 The maximum allowable difference between any two cylinders must not exceed 3 bar (12.96) 25