Service Workshop Manual Inca 1995 > Inca 2000 > 4 cyl | engine (1,9 Itr.), Mechani Edition 04.03 Service Department. Technical InformationSs List of Workshop Manual Repair Groups Repair Group 00 - Technical data 10 - Removing and installing engine 13 - Crankshaft group 15 - Cylinder head, Valve gear 17 - Lubrication 19 - Cooling system 20 - Fuel supply system 26 - Exhaust system Service Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2015 Seat S.A SO1A1YX92204 cyl. diesel engine (1,9 ltr), Inca 1995 > , Inca 2000 > Ss Mechanics - Edition 04.03 “== 00 - Technical data 10 13 15 17 4 14 12 Removing and installing engine 4 4.1 Removing 12 Fitting 1.3 Tightening torques: 14 — Engine assembly brackets 4.5 Vehicles with air conditioning: additional instructions 1.6 Engine support rubber bearings: replacement Crankshaft group : 1 Engine: disassembly and assombly 44 Assembly diagram 1.2 Poly-V belt: removing and fiting 2 Block, crankshaft oil seal and engine flywheel/traction disk: ro and ‘assembly - 24 Crankshaft oil seal, pulley side: replacement - g . 22 Crankshaft cil seal, distribution side: removing end fting 23 Intermediate shaft seal: replacement . 24 Intermediate shaft: removing and fiting 3 Crankshaft: disassembly and assembly 3.1. Crankshaft dimensions 4 Piston and piston rod: disassembly and assembly 4.4 Piston and cylinder dimensions 4.2 Position ofthe piston in the TDC: verification Cylinder head, Valve gear 4 44 12 13 14 15 2 24 22 23 24 25 26 27 28 29 Contents Technical data Engine number Engine data Engine: removal and fitting Cylinder head: disassembly and assembly Assembly diagram Cylinder head: removal and installation Notched belt: removing and fitting, stressing ‘Semi automatic tensioning pulley for the notched belt: verification Compression: verification Accelerator control: disassembly and assembly Assembly diagram Hydraulic pushers: verification Hydraulic pushers: replacement . Valve seating: revision Camshaft: removing and fiting Oil seal for the camshaft: replacement Valve guides verification Valve guides: replacement \Valve rod seals: replacement 2.10 Turbulence chamber Lubrication 4 14 12 fisassembly and assembly Lubrication system: Assembly diagram Oil pressure and the oil pressure switch: verification Noo RONN 19 BRAG contents iSs Inca 1995 > , Inca 2000 > mewn" 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 19-Cooling system ...... 20- 26 - 1 14 12 13 14 15 16 17 1 14 12 13 14 15 16 2 1 14 12 13 14 2 24 22 23 24 Fuel supply system oo... 2... ee cee eee Exhaust system Cooling system: cisassembly and assembly Cooling system, bodywork side: disassembly and assembly Cooling system, engine side: disassembly and assembly Cooling system, pump side: disassembly and assembly Cooling liquid: evacuation and charging Radiator: removal and installation Refrigeration liquid pump: removing and fitting Cooling system air tight seal: verification Fuel supply system wee Fuel tank with accessories: disassembly and assembly Lubrication system: disassembly and assembly Safety precautions Rules for cleanliness ual level sender: removing and fitting Fuel tank: removing and fitting Accelerator control: disassembly and assembly Exhaust system Exhaust manifold, front exhaust pipe with catalytic converter and accessorie: and assembly Exhaust silencer with exhaust suppors: disassembly and assembly Exhaust system: positioning .. Exhaust system air tight seal; verfication Exhaust gas recirculation system Exhaust gas recirculation systom’ disassembly and assembly Exhaust gas recirculation valve N18 : verification Exhaust gas recirculation two-way valve N161 : verification Exhaust gas recirculation: verification isassembly 1 1 1 73 74 75 7 79 at 83 83 83 85 86 86 a7 88 94 93 93 93 95 96 96 7 97 98 98 99 ContentsSs Inca 1995 > , Inca 2000 > en 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 “== Technical data 1 Technical data 14 Engine number ‘The engine identification code consists of up to nine symbols (al- phanumeric). The first part (three distinct letters maximum) rep- Fesents the “engine identification letters” , the second part (six numbers) represents the “correlative number’ . If more than ‘999,989 engines with the same engine identification letters are produced, the first of the six numbers is replaced by a letter. ‘The distinct letters and the correlative number of the engine are engraved on the cylinder block between the injection pump and the vacuum pump. In addition, an adhesive label with the identification letters and the correlative number in the upper notched belt protection. The “engine identification letters” appear in the rear of the vehicle described in the client's Technical Assistance Plan and also in the rear of the vehicle, in the spare wheel compartment or the floor of the boot. 1.2 Engine data Identification letters Y Exhaust gas emissions according to = |Cylinder capacity Ltr. 1.9 Power iaimin 2714400, Torque Nenimin 724/2000...2000 Bore mm 735 [Stroke mm| 95.5 |Compression ratio 22.5:1 |Cetane number min. 45 Firing order 1-3-4-2 (Catalytic converter No Exhaust gas recirculation Yes 'Supercharging No Intercooler No. 1 Tocheical data 1semy_ Inca 1995 > , Inca 2000 > mewn" 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 10 1 Engine: removal and fitting moving and installi en ‘Special tools and workshop equipment required © Engine bracket - AR-22048- AR-22048, SAT 8010 mo, @ Torque spanner -SAT 8010- Pliers -120029- o“_ Attachment tool -720127- CMD # Workshop crane - VAG 12028- © Drip tray -V.AG 1306- 720028 e017 oa op VAG 1202 V.A.G 1308 “Th i @ Attachment tool -T20082- 2 ep. Gr. 10- Removing and installing engineSs Inca 1995 > , Inca 2000 > aleve 4 cyl. diesel engine (1,9 it.), Mechanics - Edition 04.03, “=n 14 Removing w Note! © Tocarry out this work it willbe necessary to disconnect battery earth strap. The vehicle should be checked for a fitted radio. ifnecessary, obtain the anti-theft code for the radio first. © The engine is removed along with the gearbox towards the front of the vehicle, + Allof the cable attachments that are opened or cut when re- ‘moving the engine must be replaced in exactly the same position for the installation. % The removed liquid refrigerant should be put into a clean re- ceptacle to be re-used or disposed of The removed liquid refrigerant should be put into @ clean re- ceptacle to be re-used or disposed of = Draining the liquid refrigerant = page 75 — Remove the battery: = Rep. Gr. 27 ; Battery ~ Remove the air fiter assembly. = Remove the accelerator cable from the injection pump = page 91. - Remove the fuel supply and return tubes from the injection pump: = Rep. Gr. 23 ; Direct injection diesel system (F) now + Once the tubes have been removed, put the bolts back into place fo aveid the penetration of dit. % Do not mix up the bolts during replacement, the screw is marked with the abbreviation ‘OUT Pull connectors off thermo-switch and radiator fan. = Remove the flexible tubes for the liquid refrigerant, the cylinder head and the radiator with the help of the pliers -T20029- — Remove the lock plate and the attached pieces: > Rep. Gr. 50 ; Bodywork, front — Pull vacuum and breather flexible hoses off the engine. ~ Remove the speedometer and the reverse light electrical con- nections. = Remove all ofthe electrical cables from the gearbox, alterna tor, starter motor and the engine leaving them separated = Release all the electrical connections necessary for the re- moval of the engin Release the power steering liquid tank and secure it above, = Remove the clutch cable: = Rep. Gr. 30 ; Clutch operation = Remove the gear stick from the gearbox: > Rep. Gr. 34 Clutch operation mechanism .. — Remove the hydraulic pump and secure it using wire without damaging or forcing the tubes: > Reo. Gr. 48; Hydraulic or electro-hydraulic pump, tank and hydraulic tubes . 1. Engine: removal and ting 3© inca 1995 nea 2000 mening cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 Remove the right hand side articulated semi axle from the ve- hicle and the left hand side articulated semi axle from the gearbox: = Rep. Gr. 40 ; Articulated semi axles = Remove the front exhaust tbe from the exhaust manifold = page 93 Vehicles with air conditioning — Follow the additional instructions and assembly work = page 7 Continued for all vehicles — Remove the power steering tubes from the engine assembly attachments. = Secure the attachment too! -T20127- to the engine and with the help of the workshop crane -V.A.G 12024. sight raise the engine. - Release the bolts that join the supports to the engine assem- bly. = Withdraw the engine assembly towards the front. (Has When the assembly is lifted out, it must be carefully guided to prevent damage to bodywork. In order to carry out assembly work, the engine should be attach- ed to the assembly stand using the engine bracket -AR-2204A. along with the attachment tool -T20082- - Free the gearbox. - With the help of the workshop crane -V.A.G 1202A- , place the engine in the bracket -AR-22044- — Attach the engine to the bracket -AR-2204A. using the attach- ‘ment tool -T20082- 12 Fitting For fitting, the operations are carried out in reverse order, taking the following into account: = Ensure that the sockets for centring of the engine assembly are in place on the engine block and, if not then fit them. V.A.G 1202 A 4p. ar. 10- Removing and insaing engineSs Inca 1995 > , Inca 2000 > aleve 4 cyl. diesel engine (1,9 it.), Mechanics - Edition 04.03, “=n Position the intermediate plate in the airtight seal and fitit in the adjustment sockets -arrows- = Verify, necessary the centring of the clutch converter drive plate. - Check clutch release bearing for wear, replace if necessary. Lightly grease clutch release bearing, release bearing guide sleeve and input shaft teeth, = When placing the drive train, take into account that there is sufficient play with respect to the articulated semi axies, — When placing the engine supports, ensure that the flange of the back right console and the rebate of the front console fit into the metal/rubber bearing guide -arrows- = Align the engine using a shaking movement so that the sup- ports are not under ariy tension. Position the bolts that attach the engine assembly to the gear- box and engine supports. = Remove the attachment fool -T20127- and the workshop crane. — Put the front exhaust tube on the exhaust manifold > page $3. = Position the articulated semiaxles: + Rep. Gr. 40; Articulated semi axles Vehicles with air conditioning ~ Position the air conditioning air compressor: > Rep. Gr. 87; Cooling agent circuit: repairs . Follow the additional instructions and assembly work = page 7 Continued for all vehicles = Position the power steering pump: = Rep. Gr. 48 ; Hydraulic or electro-hydraulic pump, tank and hydraulic tubes — Position the gear stick: + Rep. Gr. 34; Clutch operation mechanism. = Position the clutch cable: > Rep. Gr. 30 ; Clutch operation mechanism. = Position the lock carrier plate: + Rep. Gr. 60 ; Bodywork, front — If necessary, adjust the clutch cable: > Rep. Gr. 30; luteh ‘operation mechanism: repairs — Charging the liquid refrigerant = page 75 — Position the accelerator cable on the injection pump = page 81 = Connect the fuel supply and retum tubes to the injection pump: = Rep. Gr. 23 ; Direct injection diesel system — Make the electrical connections and position the cable laying: > Current flow diagrams, Electrical fault finding and Fitting lo- cations. — Carry outa test drive and interrogate fault memory: Gr. 04 ; Fault memory Rep. 1. Engine: removal and tingsemy_ Inca 1995 > , Inca 2000 > mewn" 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 13 Tightening torques [Serewing Tightening tor que Bolts, nuts M10 60 Nm M12 80 Nm [Articulated semi axlesianged axles 45m [Attachment bolts for engine block susports_| 25 Nm [Attachment bolts for metalirubber bearing 0 Nm supports Exhaust pipe to manifold 40 Nm Engine to bodywork supports 60 Nm 14 Engine assembly brackets Tightening torques: (Oiled bolts) Complete front support of the drive train. Tightening torque A: 55 Nm Tightening torque 8: 45 Nm Tightening torque C: 55 Nm Complete rear right support of the engine assembly. Tightening torque A: 25 Nm Tightening torque B: 60 Nm Tightening torque C: 30 Nm Complete rear left support of the drive train, Tightening torque A: 60 Nm Tightening torque B: 35 Nm Tightening torque C: 30 Nm 6 ep. ar. 10- Removing and installing engineSs Inca 1995 > , Inca 2000 > aleve 4 cyl. diesel engine (1,9 it.), Mechanics - Edition 04.03, “=n 1.5 Vehicles with air conditioning: additional instructions A Caution The air conditioning cooling agent circuit must not be opened. To prevent damage to condenser and cooling agent pipes/o- $28 ensure that pipes and hoses are not stretched, kinked or (a) Note! The cooling agent circuit should not be opened except in work shops with the qualified personne, tools and required equipment. In order to remove and fit the engine without having to open the cooling agent circuit: = Remove the lock carrier plate and the attached pieces: > Rep. Gr. 50 ; Bodywork, front - Remove the braces of the cooling agent tubes. — Remove the Poly-V ribbed belt = pace 16 — Remove the air conditioning compressor: = Rep. Gr. 87 ; Cooling agent circuit: repairs . = Unscrew the cooling agent tubes from their attachments on the crossbeam. — Put the air conditioning compressor to one side along with the lock carrier plate in such a way that the flexible tubes of the cooling agent -arrows- are not under any strain, ~ Place the attachment tool -T20127- and secure it with @ work- shop crane, Release the bolts that attach the engine assembly to the gear- box and engine supports. = Withdraw the engine assembly towards the front. (F) now Pay a maximum of attention and protect components in order to avoid any damage or strain on the bodywork or on any of the air conditioning installation components. 1.6 Engine support rubber bearings: replacement 1. Engine: removal and ing 7Ss semy_ Inca 1995 > , Inca 2000 > severing cyl, diesel engine (1,9 Itr.), Mechanics - Edition 04.03 ‘Special tools and workshop equipment required @ Torque spanners -SAT ‘SAT 9010 3010. ry oe ‘© Compression tool -T20080- © Attachment tool - Cy 2 ow U-s00256- # Pressure tool -U-40501- 6mm Operation sequence @ Note! To camy out this work it is necessary to disconnect battery earth strap. The vehicle should be checked for a fitted radio. ifneces- sary, obtain the anti-theft code for the radio first — Position the support device -U-30025E- . = Attach the shaft in the leftring of the cylinder head and slightly pre-stress the engine. = Remove the front support attachment from the engine assem- by. — Remove the sub frame beam from the vehicle, 8 ep. ar. 10- Removing and installing engineSs Inca 1995 > , Inca 2000 > en 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 “== - Use a lever to separate the washers from the separator sock- ets (replace damaged andior bent washers). — Remove the separator sockets and the rubber bearings. — Fit new rubber bearings and insert the separator sockets as far as possible. — Place the rubber bearing impregnated with soapy water into the pressure tool socket -U-40501-. ~ Position the pressure tool in the sub frame beam, as shown in the diagram, w@ Note! Take into account that the conical part of the expansion nut - 120090- must not be in contact with the socket. = Operate the nut-T20090- until the rubber bearing is in position. — Position the washers -1- and fit the nut T20090-, with the conical part facing the washer. — Operate the nut until the edge of the separator sockets is wid- ened, = Fitthe aub frame beam and tighten. Tightening torque: 60 Nm 1. Engine: removal and ingseny Inca 1995 > , Inca 2000 > mormin 4 cyl diesel engine (1,9 Itr.), Mechanics - Edition 04.03 4 Crankshaft grou, 1 Engine: disassembly and assembly (F) now © If during engine repairs, significant quantities of metal shav- ings and particles separated by abrasion or erosion due to Inction damage, for example base plate bearings or the piston red, are discovered in the oi, to avoid damage caused by this particularity, apart from a minute cleaning of the oil conduits, the oil radiator must be replaced. Defective injectors may result in a strong knocking noise from the engine and it may be assumed that there are damaged bearings. In case of @ complaint, heat the engine by ‘dling it and loosen one by one the injection tube connections. If the Sound disappears when @ connection is loosened, this means the corresponding injector is defective Repairing injectors: > Rep. Gr. 23 ; Direct injection diesel sys- tem 14 Assembly diagram 10 ep. ar. 13- crankshaft oroupInca 1995 > nce 2000> =, 4 cyl. diesel engine (1,9 it), Mechanics - Edition 04.03 “=~ I page = page 12 l- page = page 14 Il- page > page 15, 1. Engine: isassombly and assomty 141Ss seny_ Inca 1995 > , Inca 2000 > mln 4 oyl diesel engine (1,9 ir), Mechanics - Edition 04.03 1.1.1 Part | 1- Tension pulley 1D Only for vehicles fitted with air conditioning 2-20Nm 3- Tensioning rod 123 45 6 78 9 101112131415 1615 Lubricate using -¢ 000 4 = Dust protection cover 5 - Expansive clip 6 - Upper protection cover of the notched belt 7 = Notched belt Before removing this, mark the rotation direc- tion Check for wear Donot bend Removing and fitting, tightening = page 41 8-45Nm 20 'Nm with semi auto- ‘matic tensioning pulley 9- Off centre Q For semi automatic ten- sioning pulley 32.31 30 29 28 27 15 2615 13 2113 2019 10- Tension pulley Q Verification 11-45Nm 12 Cogwheel for timing belt 2 Remove the camshaft from the cone by tapping once with a hammer and punch through the opening in the protective cover for the notched belt 13-25Nm 14- Idler roller For other engine identification letters 15-10Nm 16 - Rear protection cover of the notched belt 17 Injection pump cogwheel 1 Single piece 18- Injection pump cogwheel O Two piece 19- Injection pump (2 Removing and fitting: = Rep. Gr. 23 ; Direct injection diese! system 12 Pop. 6x. 13- Crankshaft groupSs Inca 1995 > , Inca 2000 > aleve 4 cyl. diesel engine (1,9 it.), Mechanics - Edition 04.03, “=n 20 - Support 21 - Console 22- Intermed fe shatt pulley 23 - Notched belt wheel/crankshaft 24-90 Nm +! /4 turn (20°) 2 Replacement Stop the spin by griping and loosening using the -T20018A- tool 2 Retightening cannot be carried out in stages 25-45Nm 26 - Lower protection cover of the notched belt 27 - Liquid coolant pump pulley 2 Poly-V belt version 28 - Poly-V belt 2 Before removing this, mark the rotation direction 2 Removing and fitting = page 16 29 - Belt pulley/vibration damper 2 Attachment is only possible in one position, the openings are distributed asymmetrically 30 - Trapezoidal drive belt Adjustment of the trapezoidal drive belt tension= Rep. Gr. 48 ; Hydraulic pump, tank and hydraulic tubes 31 - Liquid coolant pump pulley Version for trapezoidal drive belt 32 - Crankshaft pulley 1. Engine: csassombly and assambly 13,E, inca 1995 > , nca 2000 > mln 4 oyl diesel engine (1,9 ir), Mechanics - Edition 04.03 1.1.2 Part Il 1- Cylinder head cover 2- Cover Replace the gasket ifit is deterioratec 123456789 3- Upper sealing washer 4- Washer 5-10 Nm 6-Cap 7 To the flexible suction tube 8- Clip 9 Pressure regulator valve Q Cylinder block breather 10- Gasket Replace if damaged 11 - Cylinder head cover gas- ket Replace if damaged 12- Cylinder block breather 13- Cylinder head bolt Replacement Follow the correct order for loosening, tightening and the tightening tor- que = page 38 14- Attachment clip 15- O-ring Replacement 16 - Lower sealing cone 17 - Injection tubes Tighten to 25 Nm Loosen and tighten using the -U-40072- tool Always remove the complete set of tubes Q Do not modify the curvature 18- Cylinder head O Disassembling and assembling = page 35 1 Hreplaced, renew all the coolant 19- Cylinder head gasket Replacement Observe the labelling = page 38 O Ifreplaced, renew all the coolant 20-20 Nm 21 - Ring 14 Pop. 6x 13- Crankshaft groupInca 1995 > nce 2000> =, 4 cyl. diesel engine (1,9 it), Mechanics - Edition 04.03 “=~ 1.1.3 Part Ill 1- Cylinder block 2 Block, crankshaft oll seal and engine fly- wheel!traction disk > page 19 Q Crankshaft = page 29 Piston and piston rod > page 31 2- O-ring Replace if damaged 3-20 Nm + 1 /4 turn (90°) 2 Replacement 12324 4- Vacuum pump 5 - Attachment part 6 -20Nm 7 = Connection union 2 Cylinder block breather 8 - Gasket 2 Replacement 9 - Seal bolt, 25 Nm 2 For other engine identi- fication letters 10-Tothe turbocompressor to the exhaust gases 2 For other engine identi- fication letters 44- O-ring 24 22 23 22 2116 6 20 19 18 17 16 a Replacement 42-25Nm 13 - Oil filter bracket 14. Oll cooler Grease using -AMV 188 100 02- the contact surface of the oil fter support, outside of the O-ring Ensure clearance to adjacent components, Observe the note = page 10 15 - Oil fiter Tighten by hand Follow the fitting instructions printed on the fiter Replace = page 65 46 -10Nm 17 - Engine transmission 18-30Nm 19 - Support For Poly-V belt without tensioning pulley 1. Engine:csassombly and assambly 15semy_ Inca 1995 > , Inca 2000 > mewn" 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 20- Hammer type bolt 21 - Tensioning element 22- O-ring Replace if damaged 23- Support For Poly-V belt with tensioning pulley 24- Tensioning rod 1D Lubricate using -G 000 100- 25- Coolant pump Removing and fitting = page 79 26 - Sump Clean sealing surface before instaling 27 -20Nm Extract the rear bolts towards the gearbox using the -U-40051A- tool 28 - Support For vane pump 29- Gasket Q Fitted to the anti-vibration plate Replace if damaged 30-Pin D Check if itis seated properly 12 Poly-V belt: removing and fitting ‘Special tools and workshop equipment required 4 Turning tool -U-40010- u-40010 @ Turning tool -U-40050- u-40050, 16 pep. ar.13- Crankshaft oroupSs Inca 1995 > , Inca 2000 > one 4 cyl. diesel engine (1,9 Itr.), Mechanics - Edition 04.03 “=i 1.24 Removing w Note! If the belt is to be reused, before removal, mark on it the rotation direction, this mark should be observed for fiting. Versions with tensioning pulley for Poly-V ~ Peston the -U-40010- tool on the Paly-V bel tensioning pu ley. — Release the belt tension by pressing on the tool -arrow- — Remove the Poly-V belt from its position on the alternator pul- ley, Versions without tensioning pulley and air conditioning — Unscrew at least by one full turn, the alternator attachment bolts. = Connect the -U-40050- tool, and with the help of a wrench, put pressure on the tool until the tensioning spring gives. = Once tension has been released, remove the Poly-V belt from its engine attachment (itis recommended to first seperate the belt from the pulley of the coolant pump). Continued for all vehicles ~ Removing the sound procting tay: = Rep. Gr. 50; Bodywork, ront = Remove the trapezoidal belt from the power steering hydraulic pump: > Rep. Gr. 48 ; Hydraulic or electro-hydraulic pump, tank and hydraulic tubes = Remove the Poly-V belt. 1.2.2 Fitting For fitting, the operations are carried out in reverse order, taking the following into account: — When attaching the Poly-V belt (ifit is being reused), observe the rotation direction mark. For versions with the Poly-V belt without the tensioning pulley, ‘once the belt is in place but before tightening the alternator at- tachment bolts, the engine should be rotated slowly (approxi- mately 10 seconds), then tighten the alternator attachment bolts (beginning by the lower bot), Tightening torque: 25 Nm = Fitting and tensioning the trapezoidal belt: = Rep. Gr. 48 : Hydraulic or electro-hycraulic pump, tank and hydraulic tubes 1. Engine: csassombly and assambly 17semy_ Inca 1995 > , Inca 2000 > mewn" 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 1.2.3. Poly-V belt or trapezoidal belt path Path of the belt without tensioning pulley and without air condi- tioning compressor. 1 Crankshaft pulley 2- Alternator pulley 3- Coolant pump 4- Power steering hydraulic pump i Path of the belt with tensioning pulley and with air conditioning compressor. 1+ Crankshaft pulley 2+ Tension pulley 3- Alternator pulley 4 Air conditioning compressor 5+ Coolant pump 6+ Power steering hydraulic pump 18 Rep. Gr. 13- Crankshaft oroupInca 1995 > nce 2000> =, 4 cyl. diesel engine (1,9 it), Mechanics - Edition 04.03 “=~ 2 Block, crankshaft oil seal and engine flywheel/traction disk: disassem- bly and assembly Clutch repairs: > Rep. Gr. 30; Clutch: disassembly and assern- ly 1 Intermediate shaft seal 2 Removing and fiting 2 page 24 2-Pin Check ifitis seated properly 3-25Nm 4- Crankshaft oil seal 2. Removing and fiting = page 22 5 - Gasket Replacement 6 - Cylinder block Crankshaft = page 29 2 Piston and piston rod page 31 7-60 Nm +" /g turn (90°) Replacement 13 8-Plate Note the fitting position 9- Clutch press 3 Removing and fiting page 2 10 - Engine flywheel To remove and fit, im- mobilise using the - 120075A- tool 11 - Intermediate plate Should siot into the ad- Justment sleeves Do not damagelbend when assembling 12- Crank shaft oil seal with seal Only renew complete A To remove, extract the clutch press = page 20 Lubricate carefully the lip of the seal 13-10.Nm 14 - Crankshaft bearing seal D Replace = page 20 15- Intermediate shaft 2 Removing and fing = page 26 16 - O-ring Replace if damaged 2. Block, crankshaft ol seal and engine lywhesitraction disk disassembly and assombly 19)Ss seny_ Inca 1995 > , Inca 2000 > mln 4 oyl diesel engine (1,9 ir), Mechanics - Edition 04.03 17 - Oil seal for the intermediate shaft To separate and fit the clutch press Removing — Secure the clutch press using the -U-40008- tool = Remove the bolts attaching the clutch press to the crankshaft. Fitting — Attach the clutch press to the crankshaft. Tightening torque: 60 Nm + 7/4 turn (90°) 24 Crankshaft oil seal, pulley side: replacement Special tools and workshop equipment required @ Torque spanners SAT SAT 8010 8010- @ Holding tool -7200184- # Guide sleeve -7200818- @ Extractor -720143- 2.1.1 Removing = Remove the Poly-V ribbed belt = page 16 — Remove the notched belt > page 41 20 ep. Gr. 13- Crankshaft eroupSs Inca 1995 > , Inca 2000 > aleve 4 cyl. diesel engine (1,9 it.), Mechanics - Edition 04.03, “=n - Remove the notched wheel from the crankshaft. To do this, immobilise it using the -T20018- tool. = Attach the oil seal-extractor -T20143/2- , 88 shown in the dia- ‘gram, inserting the end of the tool between the axle and the Seal and searching for the supporting point for the other end. Put force on the lever until the seal is freed, be careful not to damage the axle. 2.1.2 Fitting w Note! Progressive insertion of the PTFE seals (characteristics: no re- taining spring, larger sealing lig). The sealing lip of these seals cannot be olled or greased. A radial bearing seal for the axles of {he type used previously (retaining spring) may be replaced by @ PTFE seal, but not vice versa. Oil lightly the sealing lip of the new bearing seal (only if itis racial). = Connect the seal to the guide sleeve of the -T20081B/6- tool and fit the ensemble to the crankshaft pivot, Insert the seal using the guide sleeve -T20081/1- until the limit by using the centre Bott. 2. Block, crankshaft ol seal and engine fywhoaltracton disk: dsassambly and assmbly 21semy_ Inca 1995 > , Inca 2000 > mewn" 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 = Fitthe cogwhee! of the crankshaft, taking into account the as- sembly position. To do this, immobilise the cogwheel using the -T20018A- tool. Tightening torque: 120 Nm + "/4 turn (90°) ~ Fit the notched belt and adjust the distribution time = page 41 — Fit the Poly-V ribbed belt > page 16 2.2 Crankshaft oil seal, distribution side: re- moving and fitting Special tools and workshop equipment required @ Holding tool -7200184- @ Guide sleeve -7200818- 2.2.1 Removing = Remove the Poly-V ribbed belt = page 16 = Remove the notched belt = page 41 22 rep. Gr. 13- Crankshaft groupSs Inca 1995 > , Inca 2000 > aleve 4 cyl. diesel engine (1,9 it.), Mechanics - Edition 04.03, “=n - Remove the cogwheel from the crankshaft. To do this, immo- bilise it using the -T20018A. tool = Extract the bolts attaching the oll seal — Remove the oil seal. If necessary, remove it by tapping gently with a plastic mallet - Remove sealant residue on cylinder block with a flat scraper. = Cover the seal with a clean cloth = Remove sealant remains on Sealing flange with @ rotating plastic brush (wear protective goggles) — Clean sealing surface, must be free of oil and grease. 2.2.2 Fitting w Note! © Note the use by date of the sealant. The oil seal must be fitted within five minutes of the application of the silicon base sealant. 2. Block, crankshaft ol seal and engine ywhesltracton disk disassembly and assombly 23semy_ Inca 1995 > , Inca 2000 > mewn" 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 ~ Cut the tip of the tube at the highest mark (diameter of the nozzle: approximately 3 mm). = Proceeding in the manner indicated in the diagram, apply the silicon base sealant -D 176 404 A2- to the clean contact sur- face of the oil seal. Ribbon thickness -arrows- : 2... 3mm (Has © The ribbon of sealant should not be any thicker, iso, sealant ‘may enter into the ofl sump and could block up ithe fiter in the axle support cover and could leak onto the surface of the crankshaft ol seal © Before the application of sealant’, clean the contact surface of the seal using a clean cloth — Fit sealing flange immediately and lightly tighten all bolts. (0) ree Use guide sieeve -T200818/6- to fit sealing flange with the ofl seal already installed. — Tighten diagonally the bolts attaching the sealing flange. Tightening torque: 15 Nm = Clean off any excess sealant. — Fitthe crankshaft cogwheel, To do this, immobilise it using the -T20018A- tool. Tightening torque: 90 Nm + | /4 turn (20°) (8) ve Following the fitting ofthe oil sump, the sealant should be allowed to aly for approximately 30 minutes. After this period, the engine oil may be recharged. — Fitthe notched belt and adjust the distribution time = page 41 ~ Fit the Poly-V ribbed belt = page 16 23 Intermediate shaft seal: replacement ‘Special tools and workshop equipment required # Holding tool -T20018A- 24 Rep. Gr. 13- Crankshaft eroupSs Inca 1995 > , Inca 2000 > aleve 4 cyl. diesel engine (1,9 it.), Mechanics - Edition 04.03, “=n Guide sleeve -T200818- 7200818 2.3.1. Removing = Remove the Poly-V ribbed belt > page 16 = Remove the notched belt = page 41 Attach the intermediate shaft pulley using the -T20018A- tool extract the bolt -arrow- and remove the pulley = Extract the tio bolts -arrows- and remove the seal cover car- rier. = Remove the bearing seal from the seal cover carrier using a wedge hammer. 0 2.3.2 Fitting fr Note! Progressive insertion of the PTFE seals (characteristics: no ré- taining spring, larger sealing lig). The sealing lip of these seals cannot be olled or greased. A radial bearing seal for the axles of {he type used previously (retaining spring) may be replaced by @ PTFE seal, but not vice versa. — Fitthe seal cover carrier without the seal and attach it. Tight- ening torque: 25 Nm Lightly ol the lip ofthe fiting and the outer edge of the seal (only itis radial). 2. Block, crankshaft ol seal and engine ywhesitracton disk disassembly and assombly 2Dsemy_ Inca 1995 > , Inca 2000 > mewn" 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 ~ Connect the seal to the guide sleeve of the -T20081B/4- tool and fit the ensemble to the intermediate shaft = Insert the seal using the guide sleeve -T200816/1- until the T200816/4 lint by using the esntre Bot yenoai — Fitthe intermediate shaft pulley, attach it using the -T20018A- tool and secure with the bot arrow. Tightening toque: 45 im Fit the notched belt and adjust the distribution time = page 41 = Fit the Poly-V ribbed belt = page 16 24 Intermediate shaft: removing and fitting ‘Special tools and workshop equipment required @ Holding tool -T20018A- # Guide sleeve -7200818- 26 ep. Gr. 13- Crankshaft oroupSs Inca 1995 > , Inca 2000 > aleve 4 cyl. diesel engine (1,9 it.), Mechanics - Edition 04.03, “=n 2.4.1 Removing w Note! 9 remove the intermediate shaft, the engine must be removed from the vehicle > page 2. Extract the bolt -arrow B- and remove the vacuum pump. Remove the Poly-V ribbed belt = page 16 Remove the notched belt = page 41 = Secure the intermediate shaft pulley using the -T20018A- tool, extract the bolt -arrow- and remove the pulley. - Extract the two bolts -arrows- and remove the seal cover car- rier. = Remove the intermediate shaft 24.2 Fitting For fiting, the operations are carried out in reverse order, taking the following into account: = Fitthe intermediate shaft along with the seal cover carrier and secure it using the bolts -arrows- . Tightening torque: 25 Nm (Eno Before fiting the pulley of the intermediate shaft, ensure that the axia/ play of the shaft is no more than 0.25 mm. = Fit the sea! to the intermediate shaft = page 24 2. Block, crankshaft ol seal and engine fywhesltracton disk disassembly and assombly 27semy_ Inca 1995 > , Inca 2000 > mewn" 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 - Fitthe engine in the vehicle = pace 2 28 ep. Gr. 13- Crankshaft eroupSs Inca 1995 > , Ince 2000 > Jnr 4 cyl. diesel engine (1,9 it), Mechanics - Edition 04.03 “=~ 3 Crankshaft: disassembly and assembly ft) Note! Before carrying out assembly work, oil should be applied to the support and slide surfaces. 1-Half bearings 1, 2,4 and 5 Never interchange these Half bearing 4 with lubri- cation groove 2-65 Nm + '/4 turn (90°) 2 Replacement 2 To carry out the meas- ure of radial play, tighten to torque but do not tighten further 3 - Bearing caps Bearing cap 1: Pulley side 2 Bearing cap 3 with re- bates for the friction ‘washers 2 Cylinder block bearing shell rims and bearing cap must coincide 4- Bearing cap 3 For bearing cap without oil groove 2 For cylinder block with oil groove 5 - Thrust washer 2 For bearing cap 3 Note the fiting position 6 - Generator star 2 For other engine identi- 2 fication letters MSDS 7=10'Nm + 1/4 turn (90°) 2 For other engine identification letters 8 - Adjustment pin 2 For other engine identification letters 9 - Crankshaft Axial play, new: 0.07 ... 0.17 mm, Wear limit: 0.37 mm Check radial clearence with Plastigage. New: 0.03 ... 0.08 mm. Weer limit: 0.17 mm. Do not rotate the crankshaft when checking the radial clearance Crankshaft dimensions = page 29 ouuu 31 Crankshaft dimensions (Dimensions in mm) 8. Crankshaft: disassembly and assombty 29Ss semy_ Inca 1995 > , Inca 2000 > mewn" 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 Rectification meas- | Bed plate bearing | Piston rod bearing urements ‘rankpins crankpins2 Basic dimensions. | 54.00 -0.022 ] 47.80 -0.022 20.042 0.082 Phase | 63.75 0.022 | 47.65 -0.022 20.042 0.082 Phase Il 53.50 0.022 | 47.30 -0.022 20.082 0.082 Phase Ill $3.25 0.022 | 47.05 _-0.022 20.082 20.082 30 Pop. 6x 13- Crankshaft aroun4 1. 2- 3- 4. 5 6 T Ss Inca 1995 > , Inca 2000 > aleve 4 cyl. diesel engine (1,9 it.), Mechanics - Edition 04.03, “=n Piston and piston rod: disassembly and assembly Piston rings A. Offset gaps by 120° Removing and fitting us- ing pliers adapted for piston rings a “TOP" faces towards piston crown 2 Check the play between the two ends of the pis- ton rings = page 32 Check ring to groove Clearance = page 32 Piston Mark the assembly po- sition and the cylinder correspondence 1 The-arrow- ofthe piston head should point in the direction of the pulley 2 Fitthe cylinger liner for the fiting of the piston rings A. Corresponding piston/ cylinder assembly posi- tion > page 33 Check the position in TDC = page 34 Piston pin Remove and fit using the -U-20008- tool 2 Ifthere is any play, heat this up to 60°C Pin diameter = 24 mm ‘Securing washer - Piston rod 2 Only renew as a set Mark the correspondence with the cylinders -arrows A- The marked -arrows B- must indicate towards the distribution Rod length = 150 mm + Lagerschale Note the fitfing position Do not interchange used bearing shells Ensure the correct positioning in the retainer Half bearing width = 19 mm Axial play, wear limit: 0.37 mm Check radial clearance with Plastigage. Wear limit: 0.08 mm linder block Check the cylinder bore = page 33, Piston and cylinder dimensions = page 33 a a a a a Do not rotate the crankshaft when checking the radial clearance = oy a a 4. Piston and piston od: csassambly and assembly 31Ss semy_ Inca 1995 > , Inca 2000 > mewn" 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 8 - Conrod/piston rod bearing caps The marked -arrows B- should point in the direction of the pulley 9 Centring caps Must be firmly inserted into the piston rod, not in the bearing cap 10- Oil injector @ For piston cooling 14-10Nm Q Fitusing -AMV 188 100 02- 12-30. m+" /g tum (90°) Replacement O Oilthe screw tread and the contact surface To carry out the measurement of radial play, use the old bolt Measurement of the play between the piston rings = Insert the ring from the top and push ring squarely from above down to approx. 15 mm from the edge of the cylinder. Piston ring New Wear limit 45'ring compression 0.20 ...0.40 1.20 [2nd ring compression 0.20 ... 0.40 0.60 [Oli seraper 0.25 ... 0.50 1.20 Checking ring to groove clearance Clean groove before checking. Piston ring New. Wear limit 418tring compression 0.09 ... 0.12 0.25 [2nd ring compression 0.05 ... 0.08 0.25 [Oil scraper 0.03 ... 0.06 0.15 32 Roo. 6x 13- Crankshaft group‘Checking cylinder bore diameters ‘Special tools and workshop equipment required © IInternal dial gauge 50 ... 100 mm - Measure across three different points from width wise -A- and lengthwise -B- . Difference with the nominal dimension: 0.10 max. (F) now Cylinder bore measurements should not be carried out when the engine block is attached to the assembly stand using an engine ‘support -AR-22044- , as this could result in erroneous measure- ments, Corresponding piston/cylinder assembly position Pistons in cylinders 1 and 2: Cased large for the inlet valve -arrows- towards the flywheel. Pistons in cylinders 3 and 4: Cased large for the inlet valve -errows- towards the pulley. (Eno Ss Inca 1995 > , Inca 2000 > aleve 4 cyl. diesel engine (1,9 it.), Mechanics - Edition 04.03, “=n * New pistons come with the number of the corresponding cy!- inders marked in colour on the piston head. ‘® Pistons for cylinders 1 and 2: Numbered ' /2 © Pistons for cylinders 3 and 4: Numbered 3 /4 41 Piston and cylinder dimensions Honing dimen- Piston @ Cylinder bore @ sions Basic dimen- mm] 79.48 79.51 sion Troning mm| 79.73 73.76 honing mm| 79.98 80.01 4. Piston and piston rod: csassambly and assembly 3Ssemy_ Inca 1995 > , Inca 2000 > mewn" 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 4.2 Position of the piston in the TDC: verifi- cation Special tools and workshop equipment required © Bracket -T20026- 720028 Checking process fw Note! To measure the position of the piston in the TDG, turn the engine Ina clockwise direction. When fitting new pistons or anewengine, always check the piston positions in the TDC, this test is necessary for deciding on the. type of cylinder head required, = Carry out the test using the tester and bracket tool -20026- Piston protrusion (mm) Notch/hole identification 0.66... 0.86 1 0.87... 0.90 2 09t... 1.02 3 4.2.1 Identification of the cylinder head gasket @ -Arrow 1-: Spare part number @ -Arrow 2. : Checking code (not to be taken into account) © -Arrow 3: Number of notches or holes fa Note! If the testing of the piston protrusion retums values that are mu- tually different, for the correct choice of gasket the largest value is.used. 34 op. 6x 13- Crankshaft groupInca 1995 > , Inca 2000 > en 4 cyl. diesel engine (1,9 Itr.), Mechanics - Edition 04.03 “=i Cylinder head, Valve gear 1 Cylinder head: disassembly and as- sembly CB) oes ¢ When a replacement cylinder head is fitted with the camshaft in place, all of the contact surfaces between te tappet and the iiction tracks of the cams before placing the cylinder head cover. © The plastic bases included for the protection of the open valves should only be removedimmediately before placing the cylinder head, + Aller replacement of the cylinder head, al! of the liquid coolant ‘must be changed. ‘Check the compression pressure = page 46 1A Assembly diagram 1- Expansive clip 2 - Upper protection cover of the notched belt 3 - Notched belt Before removing thie mark the rotation direc tion Check for wear Do not bend 2 Removing and fitting, tightening = page 41 4-45Nm 5 - Camshaft cogwheel 2 Remove from the cam- shaft cone by tapping once with a hammer and punch through the opening in the protec- tive cover for the notch- ed belt 6-10Nm 7 - Rear protection cover of the notched belt 8 - Cylinder head cover 9 - Cover I Replace the gasket if it is deteriorated 10 - Upper sealing washer Replace if damaged 8 91011 612131415 34 33 32 31 30 29 28 27 26 1. Culinderhoad: disassembly and assambly 35semy_ Inca 1995 > , Inca 2000 > mewrnin 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 11 - Washer 12-Cap 13 To the flexible suction tube 14- Clip 16 - Pressure regulator valve Cylinder block breather 16- Gasket Replace if demaged 17 - Cylinder head cover gasket Replace if damaged Insert the notches into the holes in the cylinder head 18 - Cylinder block breather 19 Cylinder head bolt Replacement Follow the correct order for loosening, tightening and the tightening torque = page 38 20- Attachment clip 24 - O-ring Replacement 22- Lower sealing cone 23 - Injection tubes, 25 Nm Remove and fit using the -U-40072- tool Always remove the complete set of tubes Do not moaity the curvature 24 Cylinder head Check for deformation = page 37 Removing and fitting = page 38 G Ifreplaced, renew all the coolant 25 - Injector G Removing and fitting: = Rep. Gr. 23; Direct injection diesel system 26 - Glow plug, 25 Nm Checking: = Rep. Gr. 28 ; Preheating system 27 Ring 28 - Cylinder head gasket Replacement Q Observe the identification = pace 37 O freplaced, renew all the coolant 29-20 Nm 30- Idler roller Q For other engine identification letters 31-25.Nm 32- Tension pulley Verification = page 46 36 op. Gx 19-yinderhead Valve gearSs Inca 1995 > , Inca 2000 > en 4 cyl. diesel engine (1,9 Itr.), Mechanics - Edition 04.03 “=i 33 - Off centre 34-45.Nm 20 Nm for a semi automatic tensioner ‘Checking cylinder head for distortion Maximum allowed distortion: 0.1 mm (F) no Diese! cylinder heads may not be flattened. Identification of the cylinder head gasket # -Arrow 1- : Spare part number 4 -Arrow 2- : Checking code (not to be taken into account) -Arrow 3- : Number of notches or holes: i) Note! If the testing of the piston protrusion returns values that are mu- tually different, for the correct choice of gasket the largest value is used, 1. Cylinder hoad: disassembly and assombly 37Ss seny_ Inca 1995 > , Inca 2000 > mln 4 oyl diesel engine (1,9 ir), Mechanics - Edition 04.03 1.2 Cylinder head: removal and installation Special tools and workshop equipment required © Torque spanners -SAT 801 Pliers -T20029- Centring guide -T20049- KIT -U-40020- ‘Spanner -U-40072- Drip tray -V.A.G 1306- SAT 8010 wees 1.2.1 Removing f Note! To carry out this work it is necessary to disconnect battery earth strap. The vehicle should be checked for a fitted radio. Ifneces- sary, obtain the anti-theft code for the radio first. = Draining the coolant = page 75 — Remove the air filter assembly, ~ Removing the sound proofing tray: = Rep. Gr. 80; Bodywork, ron = Remove the exhaust tube from the exhaust manifold = page 93 38 pep. Gr. 15- cyindr head. Valve gearSs Inca 1995 > , Inca 2000 > aleve 4 cyl. diesel engine (1,9 it.), Mechanics - Edition 04.03, “=n cylinder head. 1+ Ollpressure witch connector = Remove the follwing elements fom their atechments on the LN WR esx Kt 2- Multi connector support 3+ Liquid coolant hose 4+ Connector for the injector run sensor sender — Loosen and separate the injection tubes using the tool - s40072- Avoid making eny changes tothe ube configure- ion. A ewe — Remove the fuel return tube from its attachment to the injector. = Disconnect the ensemble of connections from the glow plug — Separate the hoses from their altachments on the liquid cool ant distributor -1-, use the pliers -T20029. . ~ Disconnect the temperature sender connection, - Remove the breathing tube from the engine crankcase “arrows — Remove the cylinder head cover, remove the gasket. = Unhook the attachment hooks -1- , remove the screw -2- and remove the upper protection from the notched belt. — Remove the notched belt = page 41 = Remove the wheel from the camshaft = page 54 — Remove the attachment bolts from the cylinder head following the established order. Use tool -U-40020- ~ Remove the cylinder head assembly. 1. Cylinder hoad: disassembly and assombly 3semy_ Inca 1995 > , Inca 2000 > mewn" 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 1.2.2 Fitting fo Note! @ Alnays replace the attachment bolts for the cylinder head. © Ifrepaired, carefully remove gasket remains from cylinder block and cylinder head. Avoid making scraiches or grooves. When using sandpaper, use a grain larger than 100. © Carefully remove all traces of abrasive particles. © Only remove the new cylinder head gasket from its packing immediately before inslaling. © Handle the new gasket with extreme care. If the layer of si- cone and the grooved area are damaged there is a possibilty of leakage. Before attaching the cylinder head, put the crankshaft into the TDC position, then turn it in the opposite direction to the engine rotation until the pistons are at the half way point and will net in- terfere with the valves. = To-centre correctly the gasket and the cylinder head, use the -T20049- tool and the guide pins screwed into the holes as shown in the diagram. — Fit a new cylinder head gasket. = Fit the gasket onto the guide pins correctly and then screw in by hand, the new cylinder head attachment bolts into the eight remaining holes. = Unscrew the guide pins using the tool -T20049- and remove them. = Fit the remaining two new attachment bolts With the engine cold. AO ep. Gr. 15-Cyinder head, Vavo goaSs Inca 1995 > , Inca 2000 > aleve 4 cyl. diesel engine (1,9 it.), Mechanics - Edition 04.03, “=n = Tighten the cylinder head in four stages using the following tightening sequence: 1 - Initial tightening with the torque wrench: -I pass = 40. Nm =I pass = 60 Nm. 2 Retighten using a fixed wrench: =Ill pass = 1/4 turn (90°) 14 turn (90°) — Fit the whee! to the camshaft = page 54 — After fiting the cylinder head, tum the camshaft wheel so that the cylinder 1 cams all face uniformly upwards. = Before fitting the notched belt, turn the crankshaft in the engine rotation direction until itis in the TDC position. fi) Note! itis not necessary to tighten the cylinder head bolts after repairs. - IV pass. For fitting, the operations are carried out in reverse order, taking the following into account: — Fitthe notched belt > page 41. — Charge the coolant = page 75 = Carry out a test drive and interrogate fault memory: = VAS 5051; Vehicle self-diagnosis 13 Notched belt: removing and fitting, stressing 1. Cylinder haad: disassembly and assambly 441Ss semy_ Inca 1995 > , Inca 2000 > severing cyl, diesel engine (1,9 Itr.), Mechanics - Edition 04.03 ‘Special tools and workshop equipment required @ Torque spanners -SAT SAT 8010 3010. Holding tool -T20018A- Adjustment tool -T20038- Holding tool -T20102- Spanner -U-20020- Turning tool -U-30009A- eee ee © Holding tool -720159- 720159 1.3.1. Removing (Bre To carry out this work itis necessary to disconnect battery earth strap. The vehicle should be checked for a fitted radio. Ifneces- sary, obtain the anti-theft code for the radio first. = Remove the air filter assembly. 42 ep. Gr. 15-Cyindr head, Vavo goaSs Inca 1995 > , Inca 2000 > one 4 cyl. diesel engine (1,9 Itr.), Mechanics - Edition 04.03 “=i = Unclip the hooks -1- from the upper protective cover of the notched belt = Remove the screw -2- and remove the upper protective cover from the notched belt. — Remove the Poly-Vtibbed belt = page 16 - Separate the tensioning pulley for the Poly-V bet. = Separate the oll sump ventilation tubes from the attachment to the intake manifold and the sump breather. = Remove the cylinder head cover and the gasket, — Remove the liquid coolant pump pulley by securing it with the -120159- tool, = Remove the pulley/Vibration damper from the crankshaft using the -T20018A- tool — Remove the lower protection cover of the notched belt = Remove the screw cap from the gearbox using the -U-20020- tool, - Tum the crankshaftto the TDC position of cylinder 1 and check that the mark on the engine fiywheel coincides with the mark made on the clutch housing -arrow- = Immobilise the camshaft using the adjustment tool -T20038- Centre the adjustment tool in the following way: — Tum the camshaft until one end of the adjustment tool reaches the limit of the cylinder head, Using a thickness gauge, meas- ure the existing play on the opposite end of the ruler. Tum the camshaft until the play measured previously had been divided equally between the two ends of the adjustment gauge. 1. Cylinder hoad: disassembly and assombly 43© inca 1995 nea 2000 = severing cyl, diesel engine (1,9 Itr.), Mechanics - Edition 04.03 ~ Immobilse the whee! of the injection pump using the -T20102- tool = Loosen the tensioning pulley. — Mark D.O.R. of notched bett. = Remove notched belt. 1.3.2 Fitting — Ensure that the TDC mark on the engine flywheel and the ref- erence mark on the clutch housing coincide -arrow- = Puta punch (2 6 mm) through the hole in the rear notched belt protection and remove the cogwheel of the camshaft from the ‘camshaft cone by tapping once using a plastic mass. = Fit the notched belt onto the crankshaft cogwheel, intermedi- ate shaft pulley, injection pump cogwheel and the tensioning pulley (observing the rotation direction). — Fit the notched belt onto the camshaft cogwheel and secure it with the attachment bolt without tightening. 44 kp. Gr. 15-Cyinder head, Vavo goaSs Inca 1995 > , Inca 2000 > aleve 4 cyl. diesel engine (1,9 t.), Mechanics - Edition 04.03 “rin = Stressing the notched belt, To do this, turn the -U-30009A- correctly until the notch and the bump -arrows- are facingeach other. = Stress the notched belt roller and tighten the bolt provided on the tensioning pulley. Tightening torque: 20 Nm (F) now If the off centre has been turned once too many, it will be neces- sary fo release the tensioning pulley and restress itt will not be sufficient to turn back the off centre by the amount by which it was fumed in excess. = Recheck the TDC mark on the engine flywheel = Tighten the screw attaching the camshaft cogwheel, immobil- ising it using the -T20018A- tool. Tightening forque: 45 Nm (Bre The -720038- adjustment tool must never be used to loosen and lighten the camshaft cogwheel. Always use the -T20018A- tool. — Remove the distribution adjustment tool -T20038- — Remove the tool -720102- to block the injection pump cog- wheel. — Tum the crankshaft in the engine direction of rotation and place itin TDC for cylinder one again. Verify that the following coincide: The flywheel TDC mark on the clutch housing The adjustment on the camshaft + The engagement pin -720102-on the injection pump cog. wheel The adjustment marks of the tensioning pulley — Ifthe notch and the bump do not coincide ~arrows- , stress the tensioning pulley more, attaching it with the -U-30009A. tool, remove the attachment bolt, turn the off-centre clockwise until the notch and the bump do coincide and the secure the ten- sioning pulley. Tightening torque: 20 Nm — Tum the crankshaft in the engine direction of rotation and place itin TDC for cylinder one again. - Repeat the check. — Fitthe lower protection cover of the notched belt. 1. Cylinder hoad: disassembly and assombly 45semy_ Inca 1995 > , Inca 2000 > mewn" 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 ~ Fitaand secure the crankshaft pulley/vibration damper using the -720018A- tool. Tightening torque: 25 Nm. = Fit the liquid coolant pump pulley and secure it while holding it with the -T20159- tool. Tightening torque: 25 Nm. - Fitand attach the tensioning pulley for the Poly-V belt. Tight- ening torque: 20 Nm — Verify the beginning of the injection cycle of the injection pump: = Rep. Gr, 23 ; Direct injection diesel system. Continue with the fiting following the disassembly operations in reverse order. 14 ‘Semi automatic tensioning pulley forthe notched belt: verification ‘Checking process To carry out this operation, the notched belt must be fitted and stressed, ~ Remove the upper protection, do this by releasing the hooks and the expansion ¢lip. = Ensure that the marks on the tensioning pulley coincide. — Press hard on the notched belt with a thumb, the tension marks should move. ~ Release the pressure on the belt, the tensioning pulley should return to its original position (the tension marks should coin- cide once more). 1.5 AG op. Ge. 15-Cyindr head, Vavo goaSs Inca 1995 > , Inca 2000 > aleve 4 cyl. diesel engine (1,9 it.), Mechanics - Edition 04.03, “=n ‘Special tools and workshop ‘equipment required @ Spanner -U-40082- SAT 8010 * Torque spanners -SAT a 8010- CO ost © Adapter -V.AG 1361/12. # Compression tester - VAG 1763- CMD Cy VAG 138112 —<—1—r 8B Test conditions + Engine oil temperature should be at least 30 *C + Battery should be in good condition ‘Checking process - Disconnect the ten pin connector for the fuel cut off valve - N109- and the connector as far as the injection pump doser setvomechanism: > Rep. Gr. 23; Direct injection ceselsys- ~ Extract the connections of the glow plugs. — Separate all of the glow plugs using the -U-40082- tool 1. Cylinder hoad: disassembly and assambly 47Ss semy_ Inca 1995 > , Inca 2000 > mewn" 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 ~ Apply the compression tester -V.A.G 1381- or -V.AG 1763- into the glow plug allotment, to do this itis necessary to fit the -V.AG 1381/12- adapter in place of the glow plugs. - Run the starter motor until the compression tester indicates no more increase in pressure. Compression pressure: Engine New (bar) Wear limit (bar) 1¥. 25.3 19 The difference between cylinders should be no more than 5 bar. ~ Fitthe alow plugs using the -U-40082 too! Tightening torque: 15Nm. — Reconnect al of the elements that were previously discon- nected. a) Note! Once the pressure has been tested and all ofthe elements re- connected, it wil be necessary to check and to erase the fautt ‘memory. Disconnection of the elements will cause errors to be recorded. = Interrogate fault memory: > Rep. Gr. 01 ; Fault memory AB sp. 6e. 15-Cyindr head, Vavo goaSs Inca 1995 > , Ince 2000 > Jnr 4 cyl. diesel engine (1,9 it), Mechanics - Edition 04.03 “=~ 2 Accelerator control: disassembly and assembly (F) naes Cylinder head presenting fissures between the valve seats can stil be used, however the useful life is reduced. The fissures ‘should be ne more than 0.5 mm in diameter maximum. 24 Assembly diagram 1- Bearing cap Installation position = page 50 O Fitting position 2-20Nm 3 - Camshaft 2 Check axial play = page 50 3 Removing and fiting > page Wear limit: 0.14 mm a 2 Off centre: max. 0.01 mm) a Distribution timing iden- tification = 4-- Hydraulic cam follower 2 Do not interchange With hydraulic valve clearance compensa- tion 2 Verification > page St 2 Place with contact eur- face downwards Before fitting, check the axial play of the cam- shaft = page 50 2 Oilsliding surface 5 - Valve cotters 6 - Valve spring plate Ni5-0025 7 - Exterior valve spring 2 Removing and fiting = page 62 8 - Interior valve spring 2 Removing and fitting = page 62 9- Valve stem seal Replace = page 62 2, Accelerator conto: disassembly and assambly 49Ss semy_ Inca 1995 > , Inca 2000 > mewn" 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 10- Lower valve spring plate 11- Valve guide Q Verification = page 59 O Replace = page 60 @ The replacement vaive guides are fitted with a collaret 12- Oil seal Removing and fiting = pace 58 13 Cylinder head Rectification is not possible Rework valve seats = page 53 14-Valves 1D Valve dimensions = page 51 15- Turbulence chamber Renew if damaged O Replace = page 63 16- Inside gasket Check the camshaft axial play Wear limit: maximum 0.15 mm, Carry out the measurement with the hydraulic pushers removed ‘and with the first and lat bearing caps in place. Assembly position for the bearing caps of the camshaft Note the ee¢éntricity. Befre Mounting the camshaft, fit the bear- Ing caps and establish the assembly position. 50 pep. 15- yin head, Vavo goaSs Inca 1995 > , Inca 2000 > aleve 4 cyl. diesel engine (1,9 it.), Mechanics - Edition 04.03, “=n Valve dimensions i) Note! Rectification of the valves is not permitted, only polishing. [Dimension Inlet valve Exhaust valve (mm) a mm 36.00 3 31.00 8 mm 797 27.95 ce mm 95.00 95.00 a é S S ‘Camshaft identification, distribution timing Identification Basic diameter of the cams: a = © 38 mm. Identification using the numbers stamped between the inlet and exhaust came: [Cylinder 14 -arrow A- Ww [Cylinder 2 -arrow B- 028D Distribution time for 1 mm of valve moverent Inlet open after TOC. S Inlet closed after BDC 20° Exhaust open before BDC 25.5° Exhaust closed before TDC 65° 22 Hydraulic pushers: verification ‘Special tools and workshop equipment required Lever -U-30800- Thickness gauge fw Note! The pushers must be replaced entirely, they cannot be aqjus- ted or revised. © The slight noise produced by the valves upon starting the en- gine is normal. 2, Accelerator conto: dlsassombly and assambly 541semy_ Inca 1995 > , Inca 2000 > mewn" 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 Checking process — Start the engine and run it until the electric ventilator is turned on. — Run the engine at 25000 RPM for 2 minutes. Ifthe pushers still produce noise, carry out the following sequence of operations to find the defective pusher: = Switch ignition off = Remove the cylinder head cover. ~ Turn the crankshatt clockwise (when looking from the cog- wheel end), until the cams of the pushers to be tested are up. ‘Then measure any play between the cams and the pushers. = Ifthe measurement is any more than 0.1 mm then replace the pusher. Ifthe measurement is less than 0.1 mm, continue the test Press the pusher all the way down using the -U-30800- tool, If there is movement of more than 0.1 mm before the opening of the valve, replace the pusher. 23 Hydraulic pushers: replacement ‘Special tools and workshop equipment required Extractor -T20120- 52 pep. Gr. 15-yindr head, Vavo goaSs Inca 1995 > , Inca 2000 > aleve 4 cyl. diesel engine (1,9 it.), Mechanics - Edition 04.03, “=n Valve spring box -U-10083- y-10083, ey y Ny 2.3.1. Removing = Remove the camshaft = pace 54 = Extract the pushers using the -T20120- too (Brow To avoid accidentally mixing up the pushers before fitting, attach them in order to the -U-10083- base is such a way that the cam rction surface is downwards. 2.3.2 Fitting For fiting, the operations are carried out in reverse order, taking the following into account: = Oilthe friction surfaces. = Carry out fitting conserving the placement order before re- moval fi) Note! Afier fing the new pushers, the engine must not be started for at least 30 min. (The valves can press on the piston. 24 Valve seating: revision ‘Special tools and workshop equipment required # Depth gauge + Valve seat refacing too! 2, Accserator conto: clsassombly and assambly 93fw Note! © When repairing engines with valves that are not airtight, it wall, not be enough to revise or replace the valve seats and vaives. It’s particularly important on high mileage engines to check the valve guides for wear. © The valve seats should only be reworked just enough to pro- duce @ perfect seating pattern. The maximum permissible reworking dimension must be calculated before reworking commences. Ifthe reworking dimension is exceeded, the func- tion of the hydraulic tappets can no longer be guaranteed and the cylinder head should be renewed. Calculate the max. permissible reworking dimension. = Insert valve and press firmly against seat fa Note! Ifthe valve is to be renewed as part of a repair, use a new valve for the calculation. = Measure the distance -a- between the top of the rod and the top edge of the cylinder head. Calculate the maximum reworking dimension starting from the distance measured -a- and the minimum dimension. Minimum dimensions: Inlet valve 36.8 mm Exhaust valve 36.1 mm Distance measured -a- minus the minimum measurement = max- imum reworking dimension, Example: ~ Measured distance 36.5mm Minimum dimension 35.8mm ‘Maximum permissible reworking di 0.7 mm mension Reworking the valve seats Dim: ‘Admission valves seat | Exhaust valves seat loam 37.20 33.20" m ab om 34.80 30.40 m lcm 2.70 2.05 m a5" valve seating angle 30" correction angle 1) Max. diameter ofthe miling citar 25 Camshaft: removing and fitting 54 ep. Gr. 15-Cyindr head, Vavo goaSs Inca 1995 > , Inca 2000 > aleve 4 cyl. diesel engine (1,9 it.), Mechanics - Edition 04.03, “=n ‘Special tools and workshop ‘equipment required Torque spanners SAT 8010- Holding tool -T200184- Adjustment tool -T20038- Holding too! -720102- Spanner -U-20020- Tuming too! -U-30008A- Thickness gauge toe eee TiS-0105 2.5.1 Removing To carry out this work itis necessary to disconnect battery earth strap. The vehicle should be checked for a fitted radio. ifneces- sary, obiain the anti-theft code for the radio frst. = Remove the air fiter assembly. = Unolip the hooks -1- from the upper protective cover of the notched belt — Remove the screw -2- and remove the upper protective cover from the notched bett. — Remove the screw cap from the gearbox using the -U-20020- tool, 2, Accelerator conto: lsassombly and assambly 95Ss semy_ Inca 1995 > , Inca 2000 > severing cyl, diesel engine (1,9 Itr.), Mechanics - Edition 04.03 ~ Turnthe crankshattto the TDC position of cylinder 1 and check that the mark on the engine flywheel coincides with the mark made on the clutch housing -arrow= — Immobilse the camshaft using the adjustment tool -T20038- . Centre the adjustment tool in the following way: = Turnthe camshaft until one end of the adjustment tool reaches the limit of the cylinder head. Using a thickness gauge, meas- ure the existing play on the opposite end of the ruler. Turn the camshaft until the play measured previously had been divided equally between the two ends of the adjustment gauge. ~|mmobilse the wheel of he injection pump Using the -T20102+ tool = Loosen the tensioning pulley nut and, using the -U-30009A- tool turn towards the left. = Mark D.O.R. of notched belt. — Remove partially the notched belt. = Puta punch (2 6 mm) through the hole in the rear notched belt protection and remove the cogwheel of the camshaft from the ‘camshaft cone by tapping once using a plastic mass. = Remove the bolt and separate the cogwheel from the cam. shaft = Remove the bearing caps 5, 1 and 3 alternately. — Then remove the bearing caps 2 and 4, = Remove the camshaft. 56 pep. Gr. 15-Cyindr head, Vavo goaSs Inca 1995 > , Inca 2000 > aleve 4 cyl. diesel engine (1,9 it.), Mechanics - Edition 04.03, “=n 2.5.2 Fitting w Note! © When fiting the camshaft, the cams for the cylinder 1 must face upwards. ¢ When fitting the bearing caps, note the off centring of the space. Before fitting, position the bearing caps and determine the correct position. = Lubricate the friction surfaces of the camshaft. — Fitthe camshaft ~ Fitthe bearing caps 2 and four and tighten alternatively cross- ways. Tightening torque: 20 Nm = Fit the bearing caps 5, 1 and 3 and tighten also crossways. Tightening torque: 20 Nm — Fitthe camshaft cogwheel and tighten the bolt by hand. = Ensure that the TOG mark on the engine flywheel coincide with reference mark on the clutch bell = Ensure that the camshaft is in the TDC position, to do this make sure that the adjustment tool -720038- is correctly posi- tioned and the -720102- tool is blocking the injection pump cogwheel. = Once allofthe distribution marks are lined up, fitthe cogwheel. Note the direction of rotation. — Remove the tool -720102- blocking the injection pump cog- wheel 2, Accelerator conto: lsassombly and assambly 97Ss semy_ Inca 1995 > , Inca 2000 > severing cyl, diesel engine (1,9 Itr.), Mechanics - Edition 04.03 = Using the -U-30009- or -U-30009A- tool, turn the tensioning pulley correctly unti the noich and the rise coincide -arrows- = Tighten the nut attaching the tensioning pulley. Tightening tor- que: 20 Nm — Attach the camshaft cogwheel using the -T20018A'T20018- tool. Tightening torque: 45 Nm — Remove the adjustment tool -T20038- and tum the crankshaft twice then recheck the distribution marks. — Fit the gasket and the cylinder head cover. — Fit the notched belt protection, — Verify the beginning of the injection cycle of the injection pump: = Rep. Gr. 23 ; Direct injection diesel system fw Note! Following fitting of the camshaft, the engine should not be started for at least 30 min. The hydraulic compensation elements need time to sit properly (the valves may touch the piston). 2.6 Oil seal for the camshaft: replacement ‘Special tools and workshop equipment required © Torque spanners -SAT SAT 8010 8010- © Guide sleeve -7200818- 58 pep. Ge 15-cyindr head, Vavo goaSs Inca 1995 > , Inca 2000 > aleve 4 cyl. diesel engine (1,9 it.), Mechanics - Edition 04.03, “=n © Extractor -T20143- 2.6.1 Removing = Remove the cogwheel from the camshaft > page 54 = Attach the oil seal extractor -T20143/2- , as shown in the dia- gram, inserting the end of the tool between the axle and the Seal and searching for the supporting point for the other end, Put force on the lever until the Seal is freed, be careful not to damage the axle. 26.2 Fitting (F) now Progressive insertion of the PTFE seals (characteristics: no re- taining spring, larger sealing lig). The sealing lip of these seals cannot be olled or greased. A radial bearing seal for the axles of the type used previously (retaining spring) may be replaced by a PTFE seal, but not vice versa. = Remove the remains of any oil from the camshaft pivot using a clean cloth. — Cover the groove in the camshaft cone (for example using cellophane). = Position the seal in the -T20081B/3- tool, and introduce the ensemble onto the camshaft. Insert the oil seal until the limit using the pressure element of, the -T20081B/1- or -T20081- controlled by the bolt. Fit the cogwheel to the camshaft => page 54 27 Valve guides verification ‘Special tools and workshop equipment required 2, Accelerator conto: clsassombly and assambly 5semy_ Inca 1995 > , Inca 2000 > mewn" 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 © Bracket -T20020- # Dial gauge Checking process When testing play or even identifying the affected elements to be replaced, proceed as follows: = Insert the valve into the valve guide; the end of the valve rod should be level with the guide. — Dus to the different valve rod diameters, only use the inlet valve and the exhaust valve in the exhaust valve guide. — Always clean thoroughly the elements to be tested before the test ~ Measure the play using the universal dial gauge support - 720020- anda tester. Looseness: maximum 4.3 mm. If the measured values Were superior, proceed with the replace- ment of the valve guides. 28 Valve guides: replacement Special tools and workshop equipment required Valve guide installer -T20035- 720020 720035 60 ep. Gr 15-Cyindr head, Vavo goaSs Inca 1995 > , Inca 2000 > aleve 4 cyl. diesel engine (1,9 it.), Mechanics - Edition 04.03, “=n Valve guide reamer -T20066- 720066 * Talacrina (cutting ol) 2.8.1 Removing (Bre Note that the cylinder head whose valve seating rings cannot be further rectified or eylinder heads that have reached tolerance level are inadequate for valve guide substitution. — Remove the valve guides by the camshaft side using the valve ‘guide installation tool -T20035- ‘The valve guide with a collaret (for replacement) are removed by the combustion chamber. 28.2 Fitting = Oilthe new guides, insert them as far es the collarets from the camshaft side using the valve guide installation tool -T20035- while the cylinder head is cool (Bre Once the collaret of the vaive guide is pressed, the insertion pres- sure should not exceed 1.0 Tn. Ifso the collaret may rupture. — Ream the valve guides with the valve guide reamer -T20066- Use the punch very carefully. — Rework valve seats = page 53 — Polish the valves if they are not being replaced. 2, Accelerator conto: dlsassombly and assambly 641Ss semy_ Inca 1995 > , Inca 2000 > severing cyl, diesel engine (1,9 Itr.), Mechanics - Edition 04.03 29 Valve rod seals: replacement Special tools and workshop equipment required © Valve installation tool - 7200348- @ Extractor -720058- # Plunger -T20039- 2.9.1 Removing These operations are carried out with the cylinder head in place = Remove the camshaft = page 54 = Remove the hydraulie pushers = page 52 — Bring the piston in the cylinder to TDC. 62 ep. Gr. 15-Cyinder head, Vavo goaSs Inca 1995 > , Inca 2000 > one 4 cyl. diesel engine (1,9 Itr.), Mechanics - Edition 04.03 “=i = Position the -T20034B- tool on the cylinder head so that the upper plate of the valve spring needs to be compressed. w@ Note! + Never use an magnetic object to seperate the semi-cones, this may affect the correct operation of the hydraulic pushers. The valves press on the piston head. = Turn the tool until the valve spring is compressed and separate the semi-cones, — Ones the cones are separated, remove the upper spring along, with the valve spring = Remove the valve rod seals using the -T20058- tool 2.9.2 Fitting — Oilthe seal before fiting = To avoid deterioration ofthe seals, attach the plastic cap onto the valve rod (this cap is included withthe spare) and slide the seal on — Put the seal into position with the -720038- tool. Continue with the fiting following the disassembly operations in reverse order. 2.10 Turbulence chamber ‘Special tools and workshop equipment required 2, Accelerator conto: clsassombly and assambly 63semy_ Inca 1995 > , Inca 2000 > mewn" 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 © Bracket -T20026- # Dial gauge @ Spanner -U-40082- 2.10.1 Removing + Cylinder head removed — Remove the injectors: > Rep. Gr. 23 ; Direct injection diesel system — Separate all of the glow plugs using the -U-40082- glow plug socket spanner. ~ Expel the turbulence chamber by tapping through the injector placement using a hammer. = Remove the combustion residue from the contact surfaces of the cylinder head turbulence chamber. — Fit a new turbulence chamber; the assembly position will be determined by the groove and the guide tab, Insert the turbulence chamber by using a plastic mass. Measure the protrusion of the turbulence chamber: Theoreti- cal value: 0.07 mm maximum If the specification is exceeded: — Replace the cylinder head = page 38 64 ep. Gr. 15-Cyindr head, Vavo goaInca 1995 > , Inca 2000 > en 4 cyl diesel engine (1,9 ltr), Mechanics - Edition 04.03 “== ira ubrication 1 Lubrication system: disassembly and assembly CB) oes + If during engine repairs, significant quantities of metal shav- ings and particles separated by abrasion or erosion due to inretion damage, for example from the bed plate bearings or the piston rod, are discovered in the ol, to avoid damage caused by this particularty, apart from a minute cleaning of the ol condurts, the oil radiator must be replaced. © The oil love! must not be above the max. mark= danger of damaging catalytic converter! Check the oil pressure = page 68 Oil capacity With oil fiter 4.3 Litre Without oil fter 4.8 Litre Engine oil specifications ‘Only use engine oil complying to the -VW'S05- 00 or VW 505-04 standard. 14 Assembly diagram 1. Lubrication system: disassembly and assamblySs seny_ Inca 1995 > , Inca 2000 > mln 4 oyl diesel engine (1,9 ir), Mechanics - Edition 04.03 1- Cover 2- Gasket Replace if damaged 3- Dipstick O Verification = page 68 4 - Dipstick tube Remove this for siphon- ing the oil 5 - Oil pressure switch -F22- , 25Nm O 0.3 bar switch Brown colour Verification a Ifthe sealing rings leak- ing, nip open and re- place the o-ring 6 - Seal bolt, 25 Nm 1D For other engine ident- fication letters 7- O-ring Replacement 8 - To the turbocompressor from the exhaust gases 1 Forother engine identi- fication letters 9- Oil pressure switch F'1-,25 0.9 bar switch Grey Yellow cable Verification = page 68 Ifthe sealing ring is leaking, nip open and replace the o-ring 10- Oilfiter bracket 11-25Nm 12- Gasket Replacement 13 - O-ring Replacement 414- Oil cooler O To remove, first take away the oil iter = Item 16 (page 66) Lubricate the contact surfaces with the oil iter support outside of the join ring using -AMV 188 100 02- Ensure that there is enough space to the outer components 15-25Nm 16- Oilfiter For seperation, use the oil fter spanner -U-30043- Follow the fitting instructions printed on the fier For fiting, tighten by hand oooog 66 ep. Gr. 17- LubricationSs Inca 1995 > , Inca 2000 > one 4 cyl. diesel engine (1,9 Itr.), Mechanics - Edition 04.03 “=i 17 - Oil pump pinions Removing = Remove the oil sump = Item 20 (page 67) = Remove the bolts = Item 19 (page 67) attaching the oll pump Check the play between gear teeth flanks = page 68 A Check axial play = pace 68 18 - Oil pump cover Opening pressure: 5.7 ... 6.7 bar Pressure regulator valve included 19-10 Nm 20-Sump a. Removing — Removing the sound proofing tray: > Rep. Gr. 50; Bodywork, front = Remove the lower clutch housing protection — Remove the bolts attaching the sump to the gearbox using the -U-40051A- or -U-40051+/14/2- tool = Remove the bolts = Item 22 (page 67) Clean sealing surface before installing 21 - Oil purge bolt, 30 Nm 22-20Nm 23 - Oil sump gasket For other engine identification letters a Replacement 24 - Baffle plate Removing - Remove the oil sump = Item 20(page 67) — Remove the suction pipe = Item 25 (page 67) 25 - Suction pipe 2 Clean fiter if soiled 28 - Baffle plate 2 With gasket Replace the gasket if itis deteriorated 27-10 Nm Fit using -AMV 188 100 02- 28 - Oil injector For piston cooling 1. Lubrication system: asassombly and assombly 7semy_ Inca 1995 > , Inca 2000 > mewn" 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 Check the play between the gear teeth flanks To carry out the test of the play between flanks, the oil pump has to separated from the engine. Remove the bolts attaching the cover to the pump carcass. Use a thickness gauge to measure the play between the gear teeth flanks. New pump: 0.05 mm Wear limit: 0.20 mm. oe Check the axial play of the oil pump To carry out the test of the axial play, the oll pump has to sepa- rated from the engine = Remove the bolts attaching the cover tothe pump carcass. ~ Check the axial play using a thickness Gauge and a precision ruler, © Wear limit: 0.15 mm Ifthe axial play exceeds the wear limit, proceed in the following manner: — Measure the width of the pinion. this should be equal fo 36 mm; if the measurement i then replace the pinion. = Ifthe measurement of the pinion is equal to 36 mm, replace the carcass of the oil pump. Checking the oil level Test conditions ‘+ The oil level should only be checked when the engine is hot (oll temperature more than 60 °C) + When measuring the oil level the vehicle should be horizontal. ‘Once engine is switched off, wait a few minutes so that the oll can return to the sump Checking process ~ Remove the cil dipstick, clean with a clean rag and replace fully. = Next, remove the dipstick and read the level: 1-Max. mark 2- Min, mark. 2 - Area between the upper border of the engraved area and the Max. mark: Do not add oil 'b- The level is in the engraved area: oil can be added. Level between the Min. mark and the lower border of the en- graved area: Fill with a maximum of 0.5 Litres of ol The oll level should not be over the Max. mark. 12 Oil pressure and the oll pressure switch: 68 pep. Gr. 17- Lubrication4 cyl. diesel engi ‘Special tools and workshop ‘equipment required Oil pressure tester - VAG 1942 VAG 1342- Voltmeter -V.AG 15278- Auxiliary measurement tool set -V.AG 15944- or - VAG 15840- VAG 1594, il pressure switches: verification w Note! The test for the oil pressure switches is done using the - V.A.G 1342- equipment and the voltmeter -V.A.G 1527B-; the auxiliary tool set -V.A.G 1594C- may also be used to make the ‘connections. Inca 1985 > Ince 2000> = ine (1,9 itr.), Mechanics - Edition 04.03 “= V.A.G 1827 B 1. Lubrication system: asassambly and assombly GQsemy_ Inca 1995 > , Inca 2000 > mewn" 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 ~ Remove the 0.3 bar switch whichis coloured brown and screw into the -V.A.G 1342- tester. = Screw in the adaptor for the equipment pressure measure- ment into the allotment for the 0.3 bar switch — Connect the brown cable of the equipment to the earth, ~ Connect the voltmeter -V.A.G 15278- between the positive terminal of the battery and the terminal of the 0.3 bar switch on the equipment. = The LED must light-up. — Start the engine and increase siowly the revolution speed ‘At 0.16 + 0.45 bar of positive pressure, The LED must turn off. = Ifnot then replace the 0.3 bar pressure switch. — Disconnect the diode from the 0.3 bar switch A and connect it to the 0.9 bar switch 8. Between 0.75 and 1.05 bar the diode should light up. = Ifnot replace the 0.9 bar switch, Engine oil pressure: verification ‘The oll pressure testis caried out using the -V.AG 1342- equip- ment = Connect the equipment (mentioned in the previous paragraph) and increase the revolution speed of the engine. ‘At 2000 RPM and an cil temperature of 80 °C, the cil pressure should be at least 2.0 bar minimum. To make the connections, the auxiliary cable set -V.AG 1594C- may be used. At higher engine speeds, the oil pressure should not exceed 7.0 bar. If necessary, replace the oil pump cover with the pressure release valve, 70 Rep. Gr. 17- LubricationInca 1995 > , Inca 2000 > one 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 “== Cooling system 1 Cooling system: disassembly and as- sembly CB) oes When the engine is hot the cooling system is under pressure. ifnecessary release pressure before commencing repair work. + Hose comections are secured with spring-type clips. When repairing, only use spring-type clips. © When fitting the clos, the use of the pliers -T20028- is recom- mended. The coolant flexible tubes must be under no strain when they are connected, they should not come into contact with any other components (note the indicative mark at the contact be- tween the liquid coolant and the flexible tube) Cooling system components, bodywork side = p868.71. Cooling system components, engine side = page 73) Cooling system components, pump side = page 74 ‘Cooling liquid: evacuation and charging = page 75 Notes on coolant mixture ratios = page 76 Removing and fitting the liquid coolant pump > page 79. Verification of the coolant system airticht seal = pace 81 1A Cooling system, bodywork side: disassembly and assembly 1. Coating systom: disassombly and assambly 71E, inca 1995 > , nca 2000 > mln 4 oyl diesel engine (1,9 ir), Mechanics - Edition 04.03 1- Radiator Removing and fiting = page 77 @ After replacing, renew all coolant 2 Trapezoidal drive belt 2 Depending on different versions 3 - Ventilator ring 1D Note the fitting position This is atteched to the lock carrier plate by clips = Item 6 (page 72, 4 - Ventilator for coolant -V7- 5 - Additional fan Depending on different versions 6 - Lock carrier plate 7 = Upper flexible tube To the liquid coolant dis- tributor 8 - Interior flexible tubing To the liquid coolant pump 9-10 Nm 10 Connector 11 - Protection 12 Expansion tank Verification of the cook. ant system airtight seal = page 81 13 To liquid coolant tube = Item 14 (page 73) 414 - To the junetion hose = tem 3 (page 73, 416 - Expansion tank cap O Test pressure 1.4... 1.6 bar O Verification = page 81 416 - Thermal switch -F18-, 35 Nm G For the electric ventilator Switching temperatures Speed 1 connection: 92 ... 97 °C and disconnection: 84 ... $1 °C ‘Speed 2 connection: 99 ... 105 °C and disconnection: 91 ... 98 °C 72 Rep. Gr. 19- Cooking systemSs Inca 1995 > , Inca 2000 > en 4 cyl. diesel engine (1,9 it), Mechanics - Edition 04.03 “=~ 1.2 Cooling system, engine side: disassembly and assembly 4- O-ring Replacement 2-10.Nm 3 - From expansion tank @ = Item 14 (page 72) 4 Securing clip 5 - Liquid coolant temperature ‘sender -G62- or engine tem- perature sender -G27- 2 With liquid coolant tem- perature sender -G2- 6 - To heat exchanger 7- Thermal switch for speed 3 of the electric ventilator -F165- 2 Switching temperature: To. 115 Cand dis- connection: 105. 110 ca 8 - From heat exchanger ‘9 - From expansion tank 2 = Item 13 (page 72) 10 Support 11 - Liquid coolant rigid tube 12 - Oil cooler 13 From internal flexible tube of radiator Q = Item 8ipage 72) 14 - 20 Nm + 1/4 turn. (90°) 45 - Support For Poly-V belt without tensioning pulley 16-30Nm 17 - Poly-V belt Removing end fiting = page 18 18 - Coolant pump: 1 Verify correct operation Removing and fiting = page 79 19 - To the upper flexible tubing of the radiator 2 = Item 7 (page 72) 1. Cooling system: disassembly and assombly 73Ss seny_ Inca 1995 > , Inca 2000 > mln 4 oyl diesel engine (1,9 ir), Mechanics - Edition 04.03 13 Cooling system, pump side: disassembly and assembly 1-25Nm 2-Pulley Poly-V belt version 3 Coolant pump O Verity correct operation D There are no repairs 4- Gasket Replacement 5 - Coolant thermostat O Verification: heat the thermostat in water Opening commences approx. 87 °C, maxi= mum open: 102°C = Opening range 7 mm 6 - Connection hose 7 = O-ring Replacement 8 - Securing clip 9-10Nm 10- Thermostat cover 11- Pulley Version for trapezoidal drive belt Vig-0564 74. Rep. Gr. 19- Cooking systemSs Inca 1995 > , Inca 2000 > 4 cyl. diesel engine (1,9 Itr.), Mechanics - Edition 04.03 “=i 14 Cooling liquid: evacuation and charging Special tools and workshop ‘equipment required @ Measurement tool - SAT 8010 T10007- Pliers -T20029- Drip tray -V.AG 1306- Torque spanners SAT Ct, 8010- T2029 VAG 1306 1.4.1 Evacuation A Caution ‘Steam can be released when removing the cap from the ex. pansion tank. The cap should be covered with a cloth and opened carefully — Remove the cap from the expansion tank ~ Removing the sound proofing tray: = Rep. Gr. 50; Bodywork, font = Place the drip tray -V.A.G 1306- underneath the engine com- partment. 1. Coating systom: disassombly and assombly 75semy_ Inca 1995 > , Inca 2000 > mewn" 4 cyl. diesel engine (1,9 ltr), Mechanics - Edition 04.03 ~ Remove the attachment hook -3- and separate the hose -2- from the thermostat cover -4- = Disconnect the flexible tube -1-, separating the elastic bracket using the -T200289- pliers. (0) nas Observe disposal regulations! 1.4.2 Filling (Ena © Only use antifreeze additive G 12 according to specification TL -VW 774 F-. Identification: purple colour. © The purple G 12 (conforming to the TL -VW 774 F- standard) gan be mixed with he addive G 12 which wes being used afore. © ifthe fluid in expansion tank is brown, G 12 has been mixed with other anti-freeze additives, In this case the coolant must be changed, © The G 12nd the ant freeze with the indication “according to TL -VW774. F” avoid damage due to corrosion, freezing or lime sedimentation. They also increase the boiling tempera- ture of the liquid coolant. For this reason the system must be filed al year round with an-reeze and corrosion profection adkitives, # Because of its high boiling point, the coolant improves engine reliability under heavy workloads, particularly in countries with tropical climates. @ The anti-freeze protection should be guaranteed to approx. -25 °C (for countries with an artic climate prox -35 °C). © Coolant concentration must not be reduced by adding water, even in warmer seasons or in warmer countries. The percent- age of antifreeze should be about 40 %, If for climatic reasons, a better antifreeze protection is re- quired. the percentage of G 12 can be increased but only up 10 60 % (antifreeze protection up to -40 °C). With a greater concentration engine cooling and anti-freeze properties are diminished. © radiator, heat exchanger, cylinder head or eylinder head gasket has been replaced, do not reuse old coolant. Recommended mixture ratios: Frost protection | _ Antifreeze Giz | Water to amount. “25°C 40% 26ltre | 3.9 litre “35°C 50% 3:25 litre | 3.25 litre 2, The aunty of uid coolant may vary according tothe eausment itd inthe 76 Rep. Gx. 19- Coating system