4-cylinder injection engine (1.6 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 LPG system (Golf and Golf Plus ▶ 2010)
  3
• 1.1 Preparation for reading fault memory
  3
• 1.2 Reading fault memory
  3
• 1.3 Erasing fault memory
  4
• 2 Reading fault memory for LPG system (Golf and Golf Plus 2010 ▶)
  5
• 2.1 Preparation for reading fault memory
  5
• 2.2 Reading fault memory
  5
• Removing and installing engine
  7
• 1 Removing and installing engine
  7
• 1.1 Removing engine
  8
• 1.2 Installing engine
  12
• Crankshaft group
  15
• 1 Dismantling and assembling engine
  15
• 1.1 Assembly overview
  15
• 1.2 Removing and installing poly-V belt
  20
• 2 Removing and installing sealing flanges and flywheel or drive plate
  22
• 2.1 Assembly overview - sealing flange
  22
• 2.2 Renewing crankshaft oil seal (belt pulley end)
  23
• 2.3 Removing and installing sealing flange (belt pulley end)
  25
• 2.4 Removing and installing crankshaft sealing flange (flywheel end)
  28
• 2.5 Removing and installing flywheel
  32
• 3 Crankshaft
  33
• 3.1 Assembly overview - crankshaft
  33
• 3.2 Crankshaft dimensions
  35
• 4 Dismantling and assembling pistons and conrods
  36
• 4.1 Assembly overview - pistons and conrods
  36
• 4.2 Checking pistons, piston rings and cylinder bores
  38
• 4.3 Piston and cylinder dimensions
  39
• Cylinder head, valve gear
  40
• 1 Cylinder head
  40
• 1.1 Assembly overview - cylinder head
  40
• 1.2 Removing and installing cylinder head
  43
• 1.3 Removing, installing and tensioning toothed belt
  47
• 1.4 Checking semi-automatic toothed belt tensioner
  54
• 1.5 Compression test
  54
• 2 Repairing valve gear
  57
• 2.1 Assembly overview - valve gear
  57
• 2.2 Valve dimensions
  59
• 2.3 Reworking valve seats
  59
• 2.4 Checking valve guides
  60
• 2.5 Renewing camshaft oil seal
  61
• 2.6 Removing and installing camshaft
  64
• 2.7 Renewing valve stem seals
  69
• 2.8 Checking supporting elements with hydraulic clearance compensation
  72
• Lubrication
  73
• 1 Parts of lubrication system
  73
• 1.1 Engine oil:
  73
• 1.2 Assembly overview - parts of lubrication system
  74
• 1.3 Removing and installing oil sump
  77
• 1.4 Removing and installing oil pump
  78
• 1.5 Checking oil pressure and oil pressure switch
  79
• Cooling
  81
• 1 Removing and installing parts of cooling system
  81
• 1.1 Assembly overview - parts of cooling system, engine side
  81
• 1.2 Assembly overview - parts of cooling system, body side (radiator with two radiator fans)
  83
• 1.4 Coolant hose connection diagram
  85
• 1.5 Draining and adding coolant
  86
• 1.6 Removing and installing coolant pump
  91
• 1.7 Removing and installing thermostat
  93
• 1.8 Removing and installing radiator fan V7 and radiator fan 2 V177
  94
• 1.9 Removing and installing radiator
  96
• 1.10 Checking cooling system for leaks
  98
• Fuel supply system
  101
• 1 Fuel tank (petrol)
  101
• 1.1 Safety regulations for working on fuel supply
  101
• 1.2 Rules for cleanliness
  101
• 1.3 Assembly overview - fuel tank
  101
• 1.4 Emptying fuel tank
  104
• 1.5 Removing and installing fuel tank
  108
• 2 Fuel tank (LPG)
  111
• 2.1 Safety regulations for working on fuel supply
  111
• 2.2 Rules for cleanliness
  111
• 2.3 Assembly overview - emptying fuel tank (LPG)
  111
• 2.4 Emptying gas line
  116
• 2.5 Assembly overview - fuel tank (LPG)
  122
• 3 Repairing fuel and LPG supply systems
  127
• 3.1 Safety precautions when working on the fuel and LPG supply system
  127
• 3.2 Rules for cleanliness
  127
• 3.3 Removing and installing fuel delivery unit
  128
• 3.4 Removing and installing fuel gauge sender G
  131
• 3.5 Assembly overview - fuel filter with attachments
  132
• 3.6 Removing and installing fuel filter
  133
• 3.7 Renewing gas filter
  134
• 3.8 Checking fuel pump
  139
• 3.9 Bleeding fuel system
  148
• 4 Electronic power control (EPC)
  151
• 4.1 Function of the electronic throttle
  151
• 4.2 Assembly overview - accelerator module
  151
• 4.3 Removing and installing accelerator pedal module
  152
• 5 Activated charcoal filter system
  155
• 5.1 Function
  155
• 5.2 Assembly overview - activated charcoal filter system
  155
• 5.3 Checking fuel tank breather
  156
• Mixture preparation - injection
  158
• 1 Injection system
  158
• 1.1 General notes on injection
  158
• 1.2 Safety precautions
  159
• 1.3 Rules for cleanliness
  159
• 1.4 Technical data
  160
• 1.5 Assembly overview - intake manifold with attachments
  160
• 1.6 Assembly overview - fuel rail with injectors
  162
• 1.7 Assembly overview - air filter with attachments
  163
• 1.8 Removing and installing lower part of intake manifold
  163
• 1.9 Fuel rail, removing and installing gas rail
  165
• 1.10 Removing and installing complete intake manifold
  166
• 1.12 Removing and installing injectors
  172
• 1.13 Removing and installing gas injector
  173
• 2 Checking components
  174
• 2.1 Checking injectors for leaks and quantity injected
  174
• 2.2 Checking fuel pressure regulator and holding pressure
  178
• 2.3 Checking intake manifold change-over
  180
• 3 Engine control unit J623 Golf ► 2009
  183
• 3.1 Removing and installing engine control unit
  183
• 3.2 Removing and installing anti-theft engine control unit
  184
• 4 Engine control unit J623 Golf Plus
  188
• 4.1 Removing and installing engine control unit
  188
• 4.2 Removing and installing anti-theft engine control unit
  189
• Exhaust system
  191
• 1 Removing and installing parts of exhaust system
  191
• 1.1 Assembly overview - exhaust system
  191
• 1.2 Separating centre and rear silencers
  194
• 1.3 Removing and installing front exhaust pipe with catalytic converter
  195
• 1.4 Removing and installing exhaust manifold
  196
• 1.5 Aligning exhaust system free of stress
  197
• 1.6 Removing and installing Lambda probe G39
  198
• 1.7 Removing and installing Lambda probe after catalytic converter G130
  199
• 2 Secondary air system
  201
• 2.1 Function
  201
• 2.2 Assembly overview - secondary air system
  201
• 2.3 Checking combination valve
  202
• Ignition system
  204
• 1 Repairing ignition
  204
• 1.1 General notes on ignition system
  204
• 1.2 Safety precautions
  204
• 1.3 Assembly overview - ignition system
  205
• 1.4 Test data, spark plugs
  206