4-cylinder injection engine (1.6 l roller rocker finger)

Chapter overview

• Technical data
  1
• 1 Engine number
  1
• 2 Engine data
  2
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing engine
  4
• 1.2 Installing engine
  8
• Crankshaft group
  11
• 1 Dismantling and assembling engine
  11
• 1.1 Assembly overview
  11
• 1.2 Removing and installing poly-V belt
  16
• 2 Removing and installing sealing flanges and flywheel or drive plate
  19
• 2.1 Assembly overview - sealing flange
  19
• 2.2 Renewing crankshaft oil seal (belt pulley end)
  20
• 2.3 Removing and installing sealing flange (belt pulley end)
  23
• 2.4 Removing and installing crankshaft sealing flange (flywheel end)
  25
• 2.5 Removing and installing flywheel
  29
• 2.6 Removing and installing drive plate
  29
• 3 Crankshaft
  32
• 3.1 Assembly overview - crankshaft
  32
• 3.2 Crankshaft dimensions
  34
• 3.3 Renewing needle bearing in crankshaft
  34
• 4 Dismantling and assembling pistons and conrods
  37
• 4.1 Assembly overview - pistons and conrods
  37
• 4.2 Checking pistons, piston rings and cylinder bores
  39
• 4.3 Piston and cylinder dimensions
  40
• Cylinder head, valve gear
  41
• 1 Cylinder head
  41
• 1.1 Assembly overview - cylinder head
  41
• 1.2 Removing and installing cylinder head
  44
• 1.3 Removing, installing and tensioning toothed belt
  48
• 1.4 Checking semi-automatic toothed belt tensioner
  55
• 1.5 Compression test
  55
• 2 Repairing valve gear
  58
• 2.1 Assembly overview - valve gear
  58
• 2.2 Valve dimensions
  60
• 2.3 Reworking valve seats
  60
• 2.4 Checking valve guides
  62
• 2.5 Renewing camshaft oil seal
  62
• 2.6 Removing and installing camshaft
  65
• 2.7 Renewing valve stem seals
  70
• 2.8 Checking supporting elements with hydraulic clearance compensation
  73
• Lubrication
  74
• 1 Parts of lubrication system
  74
• 1.1 Engine oil:
  74
• 1.2 Assembly overview - parts of lubrication system
  75
• 1.3 Removing and installing sump
  80
• 1.4 Removing and installing oil pump
  81
• 1.5 Checking oil pressure and oil pressure switch
  82
• Cooling
  84
• 1 Removing and installing parts of cooling system
  84
• 1.1 Assembly overview - parts of cooling system, engine side, engine codes BGU, BSE, BSF
  84
• 1.5 Coolant hose schematic diagram - engine codes BGU, BSE and BSF
  90
• 1.6 Coolant hose schematic diagram - engine codes CCSA, CMXA
  91
• 1.7 Draining and adding coolant
  92
• 1.8 Removing and installing coolant pump
  97
• 1.9 Removing and installing thermostat
  99
• 1.10 Removing and installing radiator fan V7 and radiator fan 2 V177
  100
• 1.11 Removing and installing radiator
  102
• 1.12 Checking cooling system for leaks
  104
• 2 Assembly overview - engine preheating (engine codes CCSA, CMXA)
  107
• Fuel supply system
  108
• 1 Fuel
  108
• 1.1 Safety regulations for working on fuel supply
  108
• 1.2 Rules for cleanliness
  108
• 1.3 Assembly overview - fuel tank
  108
• 1.4 Emptying fuel tank
  110
• 1.5 Removing and installing fuel tank
  115
• 2 Repairing fuel supply
  118
• 2.1 Safety regulations for working on fuel supply
  118
• 2.2 Rules for cleanliness
  119
• 2.3 Removing and installing fuel delivery unit
  119
• 2.4 Removing and installing fuel gauge sender G
  122
• 2.5 Assembly overview - fuel filter with attachments
  123
• 2.6 Removing and installing fuel filter
  124
• 2.7 Checking fuel pump
  125
• 2.8 Bleeding fuel system
  138
• 3 Electronic power control (EPC)
  141
• 3.1 Function of the electronic throttle
  141
• 3.2 Assembly overview - accelerator module
  141
• 3.3 Removing and installing accelerator pedal module
  142
• 4 Activated charcoal filter system
  145
• 4.1 Function
  145
• 4.2 Assembly overview - activated charcoal filter system
  145
• 4.3 Checking fuel tank breather
  146
• Mixture preparation - injection
  148
• 1 Injection system
  148
• 1.1 General notes on injection
  148
• 1.2 Safety precautions
  149
• 1.3 Rules for cleanliness
  149
• 1.4 Technical data
  150
• 1.5 Assembly overview - intake manifold with attachments, engine code BGU
  150
• 1.7 Assembly overview - fuel rail with injectors
  154
• 1.8 Assembly overview - air filter with attachments
  155
• 1.9 Removing and installing lower part of intake manifold, engine code BGU
  155
• 1.11 Removing and installing complete intake manifold, engine code BGU
  159
• 1.13 Removing and installing injectors
  167
• 2 Checking components
  169
• 2.1 Checking injectors for leaks and quantity injected
  169
• 2.2 Checking fuel pressure regulator and holding pressure
  175
• 2.3 Checking intake manifold change-over
  178
• 3 Engine control unit J623 (Golf 2004 ►)
  181
• 3.1 Removing and installing engine control unit
  181
• 3.2 Removing and installing anti-theft engine control unit
  181
• 4 Engine control unit J623 (Golf Plus)
  184
• 4.1 Removing and installing engine control unit
  184
• 4.2 Removing and installing anti-theft engine control unit
  185
• 5 Engine control unit J623 (Golf 2009 ►)
  187
• 5.1 Removing and installing engine control unit
  187
• 5.2 Removing and installing anti-theft engine control unit
  188
• Exhaust system
  192
• 1 Exhaust system, engine codes BGU, BSE, BSF, CCSA
  192
• 1.1 Assembly overview - exhaust system
  192
• 1.2 Separating centre and rear silencers
  195
• 1.3 Removing and installing front exhaust pipe with catalytic converter
  196
• 1.4 Removing and installing exhaust manifold
  197
• 1.5 Aligning exhaust system free of stress
  199
• 1.6 Removing and installing Lambda probe G39
  200
• 1.7 Removing and installing Lambda probe after catalytic converter G130
  201
• 2 Exhaust system, engine code CMXA
  203
• 2.2 Assembly overview - exhaust system
  206
• 2.3 Separating centre and rear silencers
  206
• 2.4 Removing and installing front exhaust pipe with catalytic converter
  208
• 2.5 Removing and installing exhaust manifold
  210
• 2.6 Aligning exhaust system free of stress
  211
• 2.7 Removing and installing Lambda probe G39
  212
• 2.8 Removing and installing Lambda probe after catalytic converter G130
  213
• 3 Exhaust gas recirculation system, engine code BGU
  215
• 3.1 Assembly overview - exhaust gas recirculation system
  215
• 4 Secondary air system, engine codes BGU, BSE, CCSA, CMXA
  217
• 4.1 Function
  217
• 4.2 Assembly overview - secondary air system, engine code BGU
  217
• 4.4 Checking combination valve
  219
• Ignition system
  221
• 1 Repairing ignition
  221
• 1.1 General notes on ignition system
  221
• 1.2 Safety precautions
  221
• 1.3 Assembly overview - ignition system
  222
• 1.4 Test data, spark plugs
  223