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  • Examplepage for repair manual 4-cylinder injection engine (1.4 l engine)
  • Examplepage for repair manual 2 4-cylinder injection engine (1.4 l engine)
  • Examplepage for repair manual 3 4-cylinder injection engine (1.4 l engine)

4-cylinder injection engine (1.4 l engine)

For Golf / Golf Plus

Original Volkswagen repair manual


15,24 €7% VAT incl.

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Language: English

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4.967 KB

181 Sites

Detailed technical data

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This repair manual contains: Removing and installing engine, Pistons and conrods, Cylinder head, Parts of fuel supply system, Injection system, Checking components and Engine control unit J623. Show more
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Repair manual Golf / Golf Plus 4-cylinder 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 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
Manufacturer's designation 4-cylinder injection engine (1.4 l engine)
Manufacturer Volkswagen
Suitable for Golf (2004 - 2007) / Golf Plus (2005 - 2007) / Golf (2009) / Golf Plus (2009)
Suitable car types 1K1, 5K1, 521
Engine code CGGA, BCA
Category Reparaturanleitung

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