6 cyl. Injection engine, Mechanics

Kapitelübersicht

• Technical data
  1
• 1 Engine technical data
  1
• 1.1 Engine technical data
  1
• 1.2 Engine number
  1
• 1.3 Engine data
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing and installing engine
  3
• 1.2 Notes on removing
  4
• 1.3 Securing engine to assembly stand
  8
• 1.4 Notes on installing
  9
• 1.5 Tightening torques
  11
• 1.6 Aligning engine and gearbox mountings
  11
• 1.7 Assembly mountings
  13
• 1.8 Additional information and removal instructions for vehicles with air conditioner
  14
• Crankshaft group
  15
• 1 Dismantling and assembling engine
  15
• 1.1 Dismantling and assembling engine
  15
• 1.2 Characteristics of the New Beetle RSi
  15
• 1.3 Dismantling and assembling engine
  17
• 1.4 Removing and installing ribbed belt
  33
• 2 Removing and installing sealing flanges and two-part flywheel
  35
• 2.1 Removing and installing sealing flanges and two-part flywheel
  35
• 2.2 Removing and installing drive plate
  39
• 2.3 Renewing crankshaft oil seal -vibration damper end-
  41
• 3 Removing and installing crankshaft
  44
• 3.1 Removing and installing crankshaft
  44
• 4 Dismantling and assembling piston and conrod
  48
• 4.1 Dismantling and assembling piston and conrod
  48
• 4.2 Characteristics of the New Beetle RSi
  48
• 4.3 Dismantling and assembling pistons and conrods
  49
• 4.4 Piston and cylinder dimensions
  55
• Cylinder head, Valve gear
  56
• 1 Removing and installing cylinder head
  56
• 1.1 Removing and installing cylinder head
  56
• 1.2 Characteristics of the New Beetle RSi
  56
• 1.3 Removing and installing cylinder head for engine codes AQP and AUE
  57
• 1.4 Removing and installing cylinder head
  66
• 1.5 Checking valve timing
  73
• 1.6 Adjusting valve timing
  75
• 1.7 Removing and installing cylinder head cover
  81
• 1.8 Checking compression pressures
  86
• 2 Servicing valve gear
  88
• 2.1 Servicing valve gear
  88
• 2.2 Characteristics of the New Beetle RSi
  88
• 2.3 Servicing valve gear for engine codes AQP and AUE
  90
• 2.4 Removing and installing camshafts
  98
• 2.5 Checking camshaft adjustment
  107
• 2.6 Renewing valve stem seals
  110
• 2.7 Checking valve guides
  114
• 2.8 Reworking valve seats
  115
• Lubrication
  118
• 1 Removing and installing parts of the lubrication system
  118
• 1.1 Removing and installing parts of the lubrication system
  118
• 1.2 Characteristics of the New Beetle RSi
  118
• 1.3 Dismantling and assembling oil filter housing
  125
• 1.4 Checking oil pressure sender (G10)
  128
• 1.5 Dismantling and assembling oil pump
  129
• 1.6 Removing and installing oil sump
  132
• 1.7 Checking oil pressure and oil pressure switch
  134
• Cooling system
  138
• 1 Removing and installing parts of cooling system
  138
• 1.1 Removing and installing parts of cooling system
  138
• 1.2 Characteristics of the New Beetle RSi
  138
• 1.3 Parts of coolant system, body side
  139
• 1.4 Parts of coolant system, engine side
  141
• 1.5 Supplementary radiator
  147
• 1.6 Removing and installing supplementary radiator
  148
• 1.7 Coolant hose connection diagram
  150
• 1.8 Checking continued coolant circulation pump
  151
• 1.9 Checking radiator fan
  154
• 1.10 Removing and installing coolant pump
  155
• 1.11 Dismantling and assembling coolant thermostat housing
  158
• 1.12 Draining and filling cooling system
  161
• 1.13 Removing and installing radiator
  164
• Fuel supply system
  166
• 1 Removing and installing parts of fuel supply system
  166
• 1.1 Removing and installing parts of fuel supply system
  166
• 1.2 Removing and installing fuel tank with its attachments and fuel filter
  167
• 1.3 Removing and installing fuel tank with its attachments and fuel filter
  174
• 1.4 Safety precautions when working on the fuel supply system
  179
• 1.5 Rules for cleanliness
  179
• 1.6 Removing and installing suction jet pump
  179
• 1.7 Removing and installing fuel delivery unit
  182
• 1.8 Removing and installing fuel gauge sender
  184
• 1.9 Removing and installing fuel tank
  185
• 1.10 Crash fuel shut-off
  187
• 1.11 Checking fuel pump
  187
• 2 Electronic power control (EPC)
  194
• 2.1 Electronic power control (EPC)
  194
• 2.2 Function of EPC system
  194
• 2.3 Servicing parts of electronic power control (EPC)
  195
• 2.4 Checking accelerator pedal position sender
  197
• 3 Activated charcoal filter system
  201
• 3.1 Activated charcoal filter system
  201
• 3.2 Function
  201
• 3.3 Servicing parts of the activated charcoal canister system
  202
• 3.4 Checking activated charcoal filter system solenoid valve 1
  205
• 3.5 Checking fuel tank breather
  206
• Exhaust system
  212
• 1 Removing and installing parts of exhaust system
  212
• 1.1 Removing and installing parts of exhaust system
  212
• 1.2 Silencer with mountings
  212
• 1.3 Exhaust gas flap
  215
• 1.4 Checking vacuum actuating element for exhaust flap
  218
• 1.5 Removing and installing parts of exhaust system
  219
• 1.6 Exhaust manifold, front exhaust pipe with double catalyst and attachments
  220
• 1.7 Silencer with mountings
  225
• 2 Secondary air system
  228
• 2.1 Secondary air system
  228
• 2.2 Function
  228
• 2.3 Removing and installing parts of the secondary air system
  229
• 2.4 Checking combi-valve
  233