4-cylinder injection engine (1.4 l engine)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing
  4
• 1.2 Installing
  8
• 1.3 Specified torques
  10
• 1.4 Additional information and assembly work for vehicles with air conditioner
  11
• Crankshaft group
  12
• 1 Dismantling and assembling engine
  12
• 1.1 Part I: assembly overview - toothed belt drive
  13
• 1.2 Assembly overview - part II, cylinder block
  16
• 1.3 Removing and installing poly V-belt
  16
• 2 Cylinder block, sealing flange
  18
• 2.1 Assembly overview - aluminium cylinder block
  18
• 2.2 Renewing crankshaft oil seal - pulley end
  20
• 2.3 Poly V-belt pulley securing bolt tightening procedure
  21
• 2.4 Renewing crankshaft sealing flange - flywheel end
  22
• 2.5 Crankshaft dimensions
  29
• 3 Pistons and conrods
  31
• 3.1 Assembly overview
  31
• Cylinder head, valve gear
  35
• 1 Cylinder head
  35
• 1.1 Assembly overview
  35
• 1.2 Checking valve timing
  37
• 1.3 Removing, installing and tensioning toothed belt
  38
• 1.4 Checking semi-automatic toothed belt tensioning roller
  45
• 1.5 Removing and installing camshaft housing
  47
• 1.6 Removing and installing cylinder head
  51
• 1.7 Checking compression
  57
• 2 Valve gear
  59
• 2.1 Assembly overview
  59
• 2.2 Reworking valve seats
  62
• 2.3 Renewing camshaft oil seals
  63
• 2.4 Checking valve guides
  66
• 2.5 Renewing valve stem seals
  67
• Lubrication
  69
• 1 Parts of lubrication system
  69
• 1.1 Engine oil
  69
• 1.2 Assembly overview
  69
• 1.3 Assembly overview - oil filler neck, engine code BCA
  72
• 1.4 Removing and installing oil filler neck, engine code BCA
  72
• 1.5 Removing and installing oil sump
  73
• 1.6 Removing and installing oil pump
  75
• 1.7 Checking oil pressure and oil pressure switch
  77
• Cooling
  80
• 1 Parts of cooling system
  80
• 1.1 Assembly overview - parts of cooling system (radiator with two fans), body side
  80
• 1.2 Assembly overview - parts of cooling system (radiator with one fan), body side
  83
• 1.3 Assembly overview - parts of cooling system - thermostat side
  84
• 1.4 Assembly overview - parts of cooling system - coolant pump side
  85
• 1.5 Coolant hose schematic diagram
  86
• 1.6 Draining and filling coolant
  87
• 1.7 Removing and installing radiator fan V7 and radiator fan 2 V177
  91
• 1.8 Removing and installing radiator
  91
• 1.9 Removing and installing coolant pump
  93
• 1.10 Checking cooling system for leaks
  95
• Fuel supply system
  98
• 1 Parts of fuel supply system
  98
• 1.1 Assembly overview - dismantling and assembling fuel tank with add-on parts and fuel filter
  98
• 1.2 Safety precautions when working on fuel supply system
  101
• 1.3 Rules for cleanliness
  101
• 1.4 Emptying fuel tank
  101
• 1.5 Removing and installing fuel delivery unit
  104
• 1.6 Removing and installing fuel gauge sender G
  106
• 1.7 Removing and installing fuel tank
  106
• 1.8 Assembly overview - fuel filter with add-on parts (engine code BCA)
  108
• 1.9 Removing and installing fuel filter
  109
• 1.10 Crash fuel shut-off
  109
• 1.11 Checking fuel pump (vehicles ► model year 2006)
  110
• 1.12 Checking fuel pump (vehicles model year 2006 ►)
  117
• 1.13 Bleeding fuel system
  124
• 2 Electronic power control (EPC)
  128
• 2.1 Assembly overview
  128
• 2.2 Removing and installing accelerator module
  128
• 3 Activated charcoal filter system
  130
• 3.1 Assembly overview - activated charcoal filter system
  130
• 3.2 Checking fuel tank breather
  130
• Mixture preparation - injection
  132
• 1 Injection system
  132
• 1.1 General notes on injection
  132
• 1.2 Safety precautions
  133
• 1.3 Rules for cleanliness
  134
• 1.4 Assembly overview - intake manifold (engine code BCA)
  134
• 1.5 Assembly overview - intake manifold (engine codes BUD and CGGA)
  136
• 1.6 Assembly overview - fuel rail with injectors
  137
• 1.7 Assembly overview - air filter housing (engine code BCA)
  137
• 1.8 Assembly overview - air filter housing (engine codes BUD and CGGA)
  139
• 1.9 Removing and installing air filter housing (engine codes BUD and CGGA)
  140
• 1.10 Cleaning throttle valve module J338
  141
• 1.11 Removing and installing injectors
  142
• 2 Checking components
  144
• 2.1 Checking intake air preheater (only engine codes BCA)
  144
• 2.2 Checking injectors for leaks and quantity injected (vehicles ► model year 2006)
  144
• 2.3 Checking injectors for leaks and quantity injected (vehicles model year 2006 ►)
  147
• 2.4 Checking fuel pressure regulator and holding pressure
  150
• 3 Engine control unit J623
  153
• 3.2 Removing and installing anti-theft engine control unit J623 (Golf model year 2004 ► 2008)
  154
• 3.3 Removing and installing engine control unit J623 (Golf 2009 ►)
  157
• 3.4 Removing and installing anti-theft engine control unit J623 (Golf 2009 ►)
  158
• 3.5 Removing and installing engine control unit J623 (Golf Plus)
  160
• 3.6 Removing and installing anti-theft engine control unit J623 (Golf Plus)
  162
• Exhaust system
  165
• 1 Parts of the exhaust system
  165
• 1.1 Assembly overview - catalytic converters and add-on parts (engine code BCA)
  165
• 1.3 Assembly overview - silencers with mountings
  168
• 1.4 Separating front and rear silencers
  169
• 2 Exhaust gas recirculation system
  171
• 2.1 Assembly overview - exhaust gas recirculation system
  171
• Ignition system
  172
• 1 Ignition system
  172
• 1.1 General notes on ignition system
  172
• 1.2 Assembly overview - ignition system
  172
• 1.3 Removing and installing ignition coils with output stage
  173
• 1.4 Safety precautions
  175
• 1.5 Test data, spark plugs
  175