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  • Examplepage for repair manual 4-Cyl. injection engine (1.4 l)
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4-Cyl. injection engine (1.4 l)

For FOX

Original Volkswagen repair manual


15,82 €7% VAT incl.

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Language: English

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4.913 KB

189 Sites

Detailed technical data

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This repair manual contains: Engine - remove and install, Valve command - repair, Lubrication system components, Engine power electronic adjustment (electronic accelerator), Activated charcoal filter system and READINESS code. Show more
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Repair manual FOX 4-Cyl. injection engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical Data
    1
  • 1.1 Engine number
    1
  • 1.2 Engine characteristics
    1
  • Removing and installing engine
    3
  • 1 Engine - remove and install
    3
  • 1.1 Removal - recommendations
    6
  • 1.2 Engine - fasten to assembly stand
    9
  • 1.3 Installation notes
    10
  • 1.4 Tightening torque
    12
  • 1.5 Power-drive unit supports
    12
  • 1.6 Additional notes and installation works in vehicles with air conditioning
    14
  • Crankshaft group
    16
  • 1 Engine - assembly and disassembly
    16
  • 1.1 Seal lid - replace
    21
  • 1.2 Poly-V belt - remove and install
    21
  • 2 Crankshaft flanges - removal and installation
    26
  • 2.1 Flywheel - remove and install
    28
  • 2.2 Crankshaft seal (pulley side) - replace
    29
  • 2.3 Crankshaft flange (flywheel side) - replace
    31
  • 3 Crankshaft - remove and install
    44
  • 3.1 Identifying engine bearing shells
    45
  • 3.2 Crankshaft dimensions
    47
  • 4 Pistons and conrods - remove and install
    48
  • 4.1 Piston and cylinder specifications
    52
  • Cylinder head, valve gear
    53
  • 1 Cylinder head - assembly and disassembly
    53
  • 1.1 Toothed belt semi-automatic tensioning pulley - check
    56
  • 1.2 Toothed belt - remove and install, adjust
    57
  • 1.3 Cylinder head - remove and install
    63
  • 1.4 Compression - check
    69
  • 2 Valve command - repair
    73
  • 2.1 Camshaft - check axial clearance
    75
  • 2.2 Valve seat - trim
    77
  • 2.3 Camshaft seal - replace
    80
  • 2.4 Camshaft and cylinder head cover - remove and install
    82
  • 2.5 Valve guides - check
    86
  • 2.6 Valve stem sealant - replace
    87
  • Lubrication
    90
  • 1 Lubrication system components
    90
  • 1.1 Lubricating system components - assembly overview
    90
  • 1.2 Engine oil
    93
  • 1.3 Oil pan- remove and install
    93
  • 1.4 Oil filter - replace
    96
  • 1.5 Oil pump - remove and install
    98
  • 1.6 Oil pressure switch F1 - remove and install
    102
  • 1.7 Oil pressure and Oil pressure switch F1 - check
    103
  • Cooling
    105
  • 1 Cooling system components - remove and install
    105
  • 1.1 Cooling system components, body side
    105
  • 1.2 Cooling system components, engine side
    107
  • 1.3 Hose connection diagram for cooling system
    110
  • 1.4 Cooling system - drainage and replenishment
    110
  • 1.5 Cooling system - check air-tightness
    120
  • 1.6 Radiator - remove and install
    122
  • 1.7 Water pump - remove and install
    124
  • Fuel supply system
    127
  • 1 Fuel supply system components - removal and installation
    127
  • 1.1 Fuel tank components with accessories and fuel filter - removal and installation
    127
  • 1.2 Safety measures regarding work on the fuel supply
    130
  • 1.3 Cleanliness rules
    131
  • 1.4 Fuel pump (pre-supply pump) G6 - remove and install
    131
  • 1.5 Fuel gauge sensor G - remove and install
    134
  • 1.6 Fuel tank - remove and install
    134
  • 1.7 Fuel pump (pre-supply pump) G6 - check
    136
  • 2 Engine power electronic adjustment (electronic accelerator)
    146
  • 2.1 Operation
    146
  • 2.2 Engine power electronic adjustment (electronic accelerator) - check
    146
  • 3 Activated charcoal filter system
    148
  • 3.1 Operation
    148
  • 3.2 Activated charcoal filter system components - repair
    148
  • 3.3 Fuel tank ventilation - check
    149
  • Mixture preparation - injection
    151
  • 1 Injection system - repair
    151
  • 1.1 General instructions regarding the injection system
    151
  • 1.2 Component location
    151
  • 1.3 Injection components - remove and install
    153
  • 1.4 Intake manifold - remove and install
    156
  • 1.5 Fuel distributor with injectors - removal and installation
    158
  • 1.6 Air filter set - assemble and disassemble
    158
  • 1.7 Safety measures
    160
  • 1.8 Cleanliness rules
    161
  • 1.9 Technical Data
    162
  • 2 Component checks
    163
  • 2.1 Injection valves - check
    163
  • 2.2 Residual pressure and fuel pressure regulator - check
    165
  • 3 Engine control unit J623
    171
  • 3.1 Engine control unit J623 - remove and install
    171
  • 3.2 Adjust components
    172
  • 3.3 Check Engine control unit J623 fault memory and clear it
    172
  • 4 READINESS code
    175
  • 4.1 Creating and Interpreting the READINESS code
    175
  • Exhaust system
    176
  • 1 Exhaust system components - remove and install
    176
  • 1.1 Exhaust manifold, catalyst and front exhaust pipe with intermediate muffler
    176
  • 1.2 Rear muffler with supports
    178
  • Ignition system
    180
  • 1 Ignition system - repair
    180
  • 1.1 General instructions regarding the ignition system
    180
  • 1.2 Ignition system components - remove and install
    180
  • 1.3 Safety measures
    181
  • 1.4 Test data, spark plugs
    182
Manufacturer's designation 4-Cyl. injection engine (1.4 l)
Manufacturer Volkswagen
Suitable for FOX (2004 - 2010)
Suitable car types 5Z1
Engine code BKR
Category Reparaturanleitung

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