4-cylinder injection engine (1.6 l engine, BiFuel) Volkswagen R GmbH

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Self-diagnosis
  2
• 1 Read event memory
  2
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing
  4
• 1.2 Installing
  7
• 1.3 Specified torques
  8
• 1.4 Additional information and assembly work for vehicles with air conditioner
  9
• Crankshaft group
  11
• 1 Dismantling and assembling engine
  11
• 1.1 Assembly overview - parts l and ll
  11
• 1.2 Assembly overview - part I, belt drive
  13
• 1.3 Assembly overview - part II, chain drive system
  14
• 1.4 Removing and installing poly-V belt
  16
• 1.5 Removing and installing valve timing housing (timing case)
  17
• 1.6 Removing and installing bracket for ancillaries
  22
• 2 Cylinder block, sealing flange
  24
• 2.1 Assembly overview
  24
• 2.2 Removing and installing engine speed sender G28
  25
• 2.3 Renewing crankshaft oil seal, pulley end
  26
• 2.4 Removing and installing crankshaft pulley
  28
• 2.5 Renewing crankshaft sealing flange, flywheel end
  31
• 3 Crankshaft
  40
• 3.1 Assembly overview
  40
• 3.2 Crankshaft dimensions
  41
• 4 Pistons and conrods
  42
• 4.1 Assembly overview
  42
• 4.2 Checking piston
  43
• 4.3 Checking cylinder bores
  44
• 4.4 Piston and cylinder dimensions
  44
• Cylinder head, valve gear
  45
• 1 Cylinder head
  45
• 1.1 Engine differences
  45
• 1.2 Assembly overview - cylinder head
  46
• 1.3 Checking valve timing
  50
• 1.4 Adjusting valve timing
  55
• 1.5 Removing and installing timing chain and chain drive for oil pump
  65
• 1.6 Removing and installing camshaft housing
  72
• 1.7 Removing and installing cylinder head
  78
• 1.8 Checking compression
  83
• 2 Valve gear
  85
• 2.1 Assembly overview
  85
• 2.2 Checking camshaft axial clearance
  87
• 2.3 Reworking valve seats
  87
• 2.4 Checking valve guides
  88
• 2.5 Renewing valve stem seals
  89
• Lubrication
  92
• 1 Parts of lubrication system
  92
• 1.1 Engine oil:
  92
• 1.2 Assembly overview
  92
• 1.3 Removing and installing sump
  94
• 1.4 Removing and installing oil pump
  96
• 1.5 Checking oil pressure and oil pressure switch
  98
• Cooling
  101
• 1 Parts of cooling system
  101
• 1.1 Assembly overview - parts of cooling system, body side
  101
• 1.2 Assembly overview - parts of cooling system, engine side
  103
• 1.3 Coolant hose connection diagram
  106
• 1.4 Draining and adding coolant
  107
• 1.5 Checking cooling system for leaks
  110
• 1.6 Removing and installing cowling with radiator fan V7
  112
• 1.7 Removing and installing radiator fan V7
  113
• 1.8 Removing and installing radiator
  114
• 1.9 Removing and installing coolant pump
  116
• Fuel supply system
  120
• 1 Parts of fuel supply system
  120
• 1.1 Assembly overview - fuel tank with attachments
  120
• 1.2 Safety regulations for working on fuel supply
  123
• 1.3 Rules for cleanliness
  123
• 1.4 Emptying fuel tank
  124
• 1.5 Removing and installing fuel delivery unit
  128
• 1.6 Removing and installing external fuel gauge sender G with 2 cable connections
  131
• 1.7 Removing and installing interior fuel gauge sender G
  132
• 1.8 Removing and installing fuel tank
  133
• 1.9 Removing and installing fuel filter
  135
• 1.10 Crash fuel shut-off
  136
• 1.11 Checking fuel pump
  136
• 1.12 Bleeding fuel system
  146
• 1.13 Parts of fuel supply system (LPG)
  148
• 2 Electronic power control (EPC)
  164
• 2.1 Assembly overview
  164
• 3 Activated charcoal filter system
  165
• 3.1 Assembly overview
  165
• 3.2 Checking fuel tank breather
  166
• Mixture preparation - injection
  167
• 1 Injection system
  167
• 1.1 General notes on injection
  167
• 1.2 Assembly overview - intake manifold
  167
• 1.3 Assembly overview - fuel rail with injectors
  169
• 1.4 Removing and installing injectors
  169
• 1.5 Fuel rail, removing and installing gas rail
  170
• 1.6 Removing and installing gas injectors
  171
• 1.7 Removing and installing gas rail sensor G401
  172
• 1.8 Assembly overview - air filter
  173
• 1.9 Removing and installing air filter housing
  174
• 1.10 Cleaning throttle valve module J338
  175
• 1.11 Safety precautions
  176
• 1.12 Rules for cleanliness
  177
• 1.13 Technical data
  177
• 1.14 Renewing filter for LPG system
  177
• 2 Checking components
  190
• 2.1 Checking injectors for leaks and quantity injected
  190
• 3 Engine control unit J623
  193
• 3.1 Removing and installing engine (motor) control unit J623
  193
• 3.2 Vehicles with anti-theft secured engine control unit J623
  193
• 4 Gas mode control unit J659
  195
• 4.1 Removing and installing gas mode control unit J659
  195
• 4.2 Removing holder for gas mode control unit J659
  195
• Exhaust system
  197
• 1 Parts of the exhaust system
  197
• 1.1 Assembly overview - catalytic converters and attachments
  197
• 1.2 Assembly overview - silencers with mountings, hatchback
  199
• 1.3 Separating front and rear silencers
  199
• Ignition system
  202
• 1 Ignition system
  202
• 1.1 Assembly overview - ignition system
  202
• 1.2 Removing and installing ignition coils with output stage
  203
• 1.3 Safety precautions
  205
• 1.4 Test data, spark plugs
  206