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  • Examplepage for repair manual 4-cylinder fuel injection engine
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  • Examplepage for repair manual 3 4-cylinder fuel injection engine
  • Examplepage for repair manual 4-cylinder fuel injection engine
  • Examplepage for repair manual 2 4-cylinder fuel injection engine
  • Examplepage for repair manual 3 4-cylinder fuel injection engine

4-cylinder fuel injection engine

For FOX

Original Volkswagen repair manual


14,80 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

5.322 KB

175 Sites

Detailed technical data

Immediately readable

This repair manual contains: Engine - remove and install, Servicing camshaft - replace, Engine power electronic regulation (electronic throttle) - check, Activated charcoal filter system, Component check, READINESS Code and Ignition system: Repair. Show more
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Repair manual FOX 4-cylinder fuel 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
  • Cylinders, engine block, support, cover
    3
  • 1 Engine - remove and install
    3
  • 1.1 Removal
    4
  • 1.2 Engine - fix on the assembly support
    9
  • 1.3 Installation
    9
  • 1.4 Tightening torque
    11
  • 1.5 Engine and transmission bracket set - align
    12
  • 1.6 Drive train supports (torques)
    13
  • 1.7 Additional indications related to installation
    15
  • Crankshaft, pistons
    16
  • 1 Engine - disassemble and assemble
    16
  • 1.1 Seal cover - replace
    21
  • 1.2 Poly-V belt - remove and install
    21
  • 1.3 Poly-V belt (elastic) - remove and install
    23
  • 2 Sealing flanges and flywheel - Remove and install
    27
  • 2.1 Crankshaft sealant (pulley side) - replace
    28
  • 2.2 Crankshaft flange (flywheel side) - replace
    31
  • 3 Crankshaft - remove and install
    39
  • 3.1 Identification of engine bearing shells
    40
  • 3.2 Color codes
    40
  • 3.3 Crankshaft dimensions
    41
  • 4 Pistons and rods - remove and install
    42
  • 4.1 Piston and cylinder dimensions
    45
  • Cylinder head, ?Valve gear
    47
  • 1 Cylinder head - disassemble and assemble
    47
  • 1.1 Semi-automatic tensioner pulley of the toothed belt - check
    49
  • 1.2 Tooth belt - remove, install, and adjust
    52
  • 1.3 Cylinder head - remove and install
    57
  • 1.4 Compression - check
    62
  • 2 Servicing camshaft - replace
    65
  • 2.1 Camshaft - check axial clearance
    67
  • 2.2 Valve seat - rework
    68
  • 2.3 Camshaft seal - replace
    70
  • 2.4 Head and camshaft cover - remove and install
    72
  • 2.5 Valve guides - check
    74
  • 2.6 Valve stem seal - replace
    76
  • Lubrication system
    78
  • 1 Lubrication system components - remove and install
    78
  • 1.1 Oil sump - remove and install
    81
  • 1.2 Oil pump - remove and install
    84
  • 1.3 Oil pressure and Oil pressure switch F1 - Check
    87
  • Cooling system
    89
  • 1 Cooling system components - remove and install
    89
  • 1.1 Cooling system components on the body side
    90
  • 1.2 Cooling system components on the engine side
    91
  • 1.3 Cooling system hose connections diagram
    93
  • 1.4 Cooling system - drain and fill
    96
  • 1.5 Radiator - remove and install
    100
  • 1.6 Water pump - remove and install
    102
  • Fuel supply system
    104
  • 1 Fuel supply system components - remove and install
    104
  • 1.1 Fuel tank components with accessories and fuel filter - remove and install
    105
  • 1.2 Safety measures for work on the fuel supply
    106
  • 1.3 Rules for cleanliness
    107
  • 1.4 Quick connection “Pop Top” - Disconnect and connect
    107
  • 1.5 Fuel pump for cold start V263 - Remove and install
    109
  • 1.6 Fuel system pressurization pump G6 - Remove and install
    114
  • 1.7 Fuel level sensor G - Remove and install
    116
  • 1.8 Fuel tank - remove and install
    117
  • 1.9 Fuel system pressurization pump G6 - Check
    120
  • 2 Engine power electronic regulation (electronic throttle) - check
    127
  • 2.1 Electronic throttle system operation
    127
  • 3 Activated charcoal filter system
    129
  • 3.1 Function
    129
  • 3.2 Activated charcoal filter system components - repair
    130
  • 3.3 Fuel tank ventilation - check
    130
  • Fuel supply - injection system
    132
  • 1 Injection system - repair
    132
  • 1.1 General indications about injection
    132
  • 1.2 Component location
    132
  • 1.3 Injection components - remove and install
    136
  • 1.4 Intake manifold - remove and install
    141
  • 1.5 Fuel distributor with injectors - remove and install
    142
  • 1.6 Air filter - disassemble and assemble
    142
  • 1.7 Safety measures
    146
  • 1.8 Rules for cleanliness
    147
  • 1.9 Technical data
    147
  • 2 Component check
    149
  • 2.1 Injection valves - check
    149
  • 2.2 Fuel pressure regulator and remaining pressure - check
    152
  • 3 READINESS Code
    156
  • 3.1 Read and generate READINESS code
    156
  • 4 Engine control unit J623
    157
  • 4.1 Engine control unit J623 - remove and install
    157
  • 4.2 Fasten components
    158
  • 4.3 Consult fault memory of the Engine control unit J623 and erase
    158
  • Exhaust system
    161
  • 1 Removal and installation of the exhaust system parts
    161
  • 1.1 Exhaust manifold, front exhaust pipe with catalyst and attachments
    161
  • 1.2 Muffler with supports
    164
  • Ignition system
    166
  • 1 Ignition system: Repair
    166
  • 1.1 General indications about the ignition system
    166
  • 1.2 Injection system components - remove and install
    166
  • 1.3 Safety measures
    168
  • 1.4 Test data, spark plugs
    168
Manufacturer's designation 4-cylinder fuel injection engine
Manufacturer Volkswagen
Suitable for FOX (2010)
Suitable car types 5Z7
Engine code BJA, BPA, BLH, CCRA, CFZA
Category Reparaturanleitung

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