4-cylinder injection engine (1.4 l engine, BiFuel) Volkswagen R GmbH

Chapter overview

• Technical data
  1
• 1 Engine number
  1
• 2 Engine data
  2
• Self-diagnosis
  3
• 1 Reading fault memory for fuel system (LPG)
  3
• 1.1 Preparation to read fault memory
  3
• 1.2 Read fault memory
  3
• 1.3 Erasing fault memory
  4
• Removing and installing engine
  5
• 1 Removing and installing engine
  5
• 1.1 Removing engine
  7
• 1.2 Securing engine to assembly stand
  10
• 1.3 Installing engine
  10
• 1.4 Torque settings
  12
• 1.5 Assembly mountings
  13
• 1.6 Additional information and assembly work for vehicles with air conditioner
  14
• Crankshaft group
  15
• 1 Dismantling and assembling engine
  15
• 1.1 Assembly overview - parts l and ll
  15
• 1.2 Assembly overview - part I, belt drive
  17
• 1.3 Assembly overview - part II, cylinder block
  19
• 1.4 Removing and installing poly-V belt
  20
• 2 Cylinder block, sealing flange
  22
• 2.1 Assembly overview
  22
• 2.2 Renewing crankshaft oil seal - belt pulley end
  24
• 2.3 Poly V-belt pulley securing bolt tightening procedure
  25
• 2.4 Removing and installing drive plate
  26
• 2.6 Renewing crankshaft sealing flange - flywheel end ( assembly tool T10134 )
  29
• 2.7 Renewing crankshaft sealing flange - flywheel end ( assembly tool T10017 )
  37
• 2.8 Crankshaft dimensions
  44
• 3 Pistons and conrods
  46
• 3.1 Assembly overview
  46
• 3.2 Piston and cylinder dimensions
  49
• Cylinder head, valve gear
  50
• 1 Cylinder head
  50
• 1.1 Assembly overview
  50
• 1.2 Checking valve timing
  52
• 1.3 Removing, installing and tensioning toothed belt
  53
• 1.4 Checking semi-automatic toothed belt tensioner
  58
• 1.5 Removing and installing camshaft housing
  62
• 1.6 Removing and installing cylinder head
  64
• 1.7 Checking compression
  68
• 2 Valve gear
  70
• 2.1 Assembly overview
  70
• 2.2 Reworking valve seats
  73
• 2.3 Renewing camshaft oil seals
  74
• 2.4 Checking valve guides
  76
• 2.5 Renewing valve stem seals
  77
• Lubrication
  79
• 1 Parts of lubrication system
  79
• 1.1 Engine oil:
  79
• 1.2 Assembly overview
  79
• 1.3 Removing and installing oil sump
  81
• 1.4 Removing and installing oil pump
  83
• 1.5 Checking oil pressure and oil pressure switch
  86
• Cooling
  88
• 1 Parts of cooling system
  88
• 1.1 Assembly overview - parts of cooling system, body side
  88
• 1.2 Assembly overview - parts of cooling system, engine side
  90
• 1.3 Coolant hose connection diagram
  92
• 1.4 Draining and adding coolant
  93
• 1.5 Removing and installing radiator
  96
• 1.6 Removing and installing coolant pump
  98
• Fuel supply system
  100
• 1 Parts of fuel supply system
  100
• 1.1 Assembly overview - fuel tank with attachments
  100
• 1.2 Safety regulations for working on fuel supply
  103
• 1.3 Rules for cleanliness
  104
• 1.4 Removing and installing fuel delivery unit
  104
• 1.5 Removing and installing fuel gauge sender
  106
• 1.6 Removing and installing fuel tank
  106
• 1.7 Crash fuel shut-off
  108
• 1.8 Checking fuel pump
  108
• 1.9 Bleeding fuel system
  116
• 1.10 Parts of fuel supply system (LPG)
  119
• 2 Electronic power control (EPC)
  133
• 2.1 Assembly overview
  133
• 3 Activated charcoal filter system
  134
• 3.1 Assembly overview - parts of activated charcoal filter system
  134
• 3.2 Checking fuel tank breather
  135
• Mixture preparation - injection
  136
• 1 Injection system
  136
• 1.1 General notes on injection
  136
• 1.2 Assembly overview - parts of injection system
  136
• 1.3 Assembly overview - intake manifold
  139
• 1.4 Assembly overview - fuel rail with injectors
  140
• 1.5 Fuel rail, removing and installing gas rail
  140
• 1.6 Assembly overview - air filter
  141
• 1.7 Removing and installing air filter housing
  143
• 1.8 Cleaning throttle valve module J338
  144
• 1.9 Checking injectors
  144
• 1.10 Safety precautions
  146
• 1.11 Rules for cleanliness
  148
• 1.12 Technical data
  148
• 2 Engine control unit J623
  151
• 2.1 Removing and installing engine (motor) control unit J623
  151
• 2.2 Removing and installing anti-theft engine control unit J623
  151
• 2.3 Removing and installing anti-theft engine control unit J623
  153
• 3 Gas mode control unit J659
  155
• 3.1 Removing and installing gas mode control unit J659
  155
• 3.2 Removing holder for gas mode control unit J659
  155
• Exhaust system
  157
• 1 Parts of the exhaust system
  157
• 1.1 Assembly overview - front exhaust system with attachments
  157
• 1.2 Assembly overview - silencers with mountings
  159
• Ignition system
  160
• 1 Ignition system
  160
• 1.1 General notes on ignition system
  160
• 1.2 Assembly overview - parts of ignition system
  160
• 1.3 Safety precautions
  161
• 1.4 Test data, spark plugs
  162