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  • Examplepage for repair manual 4-cylinder injection engine (1.6 l roller rocker finger)
  • Examplepage for repair manual 2 4-cylinder injection engine (1.6 l roller rocker finger)
  • Examplepage for repair manual 3 4-cylinder injection engine (1.6 l roller rocker finger)

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

For Touran

Original Volkswagen repair manual


16,55 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

5.831 KB

199 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Sealing flange and flywheel or drive plate, Crankshaft, Pistons and conrods, Cylinder head, Fuel tank, Repairing fuel supply, Activated charcoal filter system, Checking components, Parts of the exhaust system and Exhaust gas recirculation system, engine code BGU. Show more
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Repair manual Touran 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
    2
  • 1 Removing and installing engine
    2
  • 1.1 Removing engine
    2
  • 1.2 Installing engine
    7
  • Crankshaft group
    11
  • 1 Dismantling and assembling engine
    11
  • 1.1 Assembly overview
    11
  • 1.2 Removing and installing poly V-belt
    16
  • 2 Sealing flange and flywheel or drive plate
    19
  • 2.1 Assembly overview - sealing flanges
    19
  • 2.2 Renewing crankshaft oil seal on pulley end
    20
  • 2.3 Removing and installing sealing flange - pulley end
    22
  • 2.4 Removing and installing crankshaft sealing flange - flywheel end
    25
  • 2.5 Removing and installing drive plate
    29
  • 3 Crankshaft
    31
  • 3.1 Assembly overview - crankshaft
    31
  • 3.2 Crankshaft dimensions
    33
  • 4 Pistons and conrods
    34
  • 4.1 Assembly overview - pistons and conrods
    34
  • 4.2 Checking pistons, piston rings and cylinder bores
    36
  • 4.3 Piston and cylinder dimensions
    38
  • Cylinder head, valve gear
    39
  • 1 Cylinder head
    39
  • 1.1 Assembly overview - cylinder head
    39
  • 1.2 Removing and installing cylinder head
    42
  • 1.3 Removing, installing and tensioning toothed belts
    46
  • 1.4 Checking semi-automatic toothed belt tensioning roller
    53
  • 1.5 Checking compression
    53
  • 2 Valve gear
    56
  • 2.1 Assembly overview - valve gear
    56
  • 2.2 Valve dimensions
    58
  • 2.3 Reworking valve seats
    58
  • 2.4 Checking valve guides
    59
  • 2.5 Renewing camshaft oil seal
    60
  • 2.6 Removing and installing camshaft
    63
  • 2.7 Renewing valve stem seals
    67
  • Lubrication
    70
  • 1 Parts of lubrication system
    70
  • 1.1 Engine oil
    70
  • 1.2 Assembly overview - parts of lubrication system
    71
  • 1.3 Removing and installing sump
    75
  • 1.4 Removing and installing oil pump
    76
  • 1.5 Checking oil pressure and oil pressure switch
    77
  • Cooling
    79
  • 1 Parts of cooling system
    79
  • 1.1 Assembly overview - parts of cooling system, engine side
    79
  • 1.2 Assembly overview - parts of cooling system, body side (radiator with two radiator fans)
    81
  • 1.4 Coolant hose schematic diagram
    83
  • 1.5 Draining and filling coolant
    84
  • 1.6 Removing and installing coolant pump
    87
  • 1.7 Removing and installing thermostat
    90
  • 1.8 Removing and installing radiator fan V7 and radiator fan 2 V177
    92
  • 1.9 Removing and installing radiator
    93
  • 1.10 Checking cooling system for leaks
    95
  • Fuel supply system
    98
  • 1 Fuel tank
    98
  • 1.1 Safety precautions when working on fuel supply system
    98
  • 1.2 Rules for cleanliness
    99
  • 1.3 Assembly overview - fuel tank
    99
  • 1.4 Emptying fuel tank
    101
  • 1.5 Removing and installing fuel tank
    107
  • 2 Repairing fuel supply
    110
  • 2.1 Safety precautions when working on fuel supply system
    110
  • 2.2 Rules for cleanliness
    111
  • 2.3 Removing and installing fuel delivery unit
    111
  • 2.4 Removing and installing fuel gauge sender G (up to November 2006)
    114
  • 2.5 Removing and installing fuel gauge sender G from November 2006
    114
  • 2.6 Assembly overview - fuel filter with attachments
    115
  • 2.7 Removing and installing fuel filter
    116
  • 2.8 Checking fuel pump
    117
  • 2.9 Bleeding fuel system
    130
  • 3 Electronic power control (EPC)
    133
  • 3.1 Function of EPC system
    133
  • 3.2 Assembly overview - accelerator pedal module
    133
  • 3.3 Removing and installing accelerator pedal module
    134
  • 4 Activated charcoal filter system
    137
  • 4.1 Function
    137
  • 4.2 Checking fuel tank breather
    137
  • Mixture preparation - injection
    139
  • 1 Injection system
    139
  • 1.1 General notes on injection
    139
  • 1.2 Safety precautions
    140
  • 1.3 Rules for cleanliness
    140
  • 1.4 Technical data
    141
  • 1.5 Assembly overview - intake manifold with attachments, engine code BGU
    141
  • 1.6 Assembly overview - intake manifold with attachments, engine codes BSE, BSF
    143
  • 1.7 Assembly overview - fuel rail with injectors
    144
  • 1.8 Assembly overview - air filter with attachments
    145
  • 1.9 Removing and installing lower part of intake manifold, engine code BGU
    145
  • 1.10 Removing and installing lower part of intake manifold, engine codes BSE, BSF
    148
  • 1.11 Removing and installing complete intake manifold, engine code BGU
    149
  • 1.12 Removing and installing complete intake manifold, engine codes BSE, BSF
    154
  • 1.13 Removing and installing injectors
    157
  • 2 Checking components
    159
  • 2.1 Checking injectors for leaks and quantity injected
    159
  • 2.2 Checking fuel pressure regulator and holding pressure
    165
  • 2.3 Checking intake manifold change-over
    168
  • 3 Engine control unit
    171
  • 3.1 Removing and installing engine control unit
    171
  • 3.2 Removing and installing anti-theft engine control unit
    172
  • Exhaust system
    174
  • 1 Parts of the exhaust system
    174
  • 1.1 Assembly overview - exhaust system
    174
  • 1.2 Separating centre and rear silencers
    177
  • 1.3 Removing and installing front exhaust pipe with catalytic converter
    178
  • 1.4 Removing and installing exhaust manifold
    179
  • 1.5 Aligning exhaust system free of stress
    181
  • 1.6 Removing and installing Lambda probe G39
    181
  • 1.7 Removing and installing Lambda probe after catalytic converter G130
    183
  • 2 Exhaust gas recirculation system, engine code BGU
    185
  • 2.1 Assembly overview - exhaust gas recirculation system
    185
  • 3 Secondary air system, engine codes BGU, BSE
    187
  • 3.1 Function
    187
  • 3.2 Assembly overview - secondary air system, engine code BGU
    187
  • 3.3 Assembly overview - secondary air system, engine code BSE
    189
  • 3.4 Checking combination valve
    189
  • Ignition system
    191
  • 1 Repairing ignition system
    191
  • 1.1 General notes on ignition system
    191
  • 1.2 Safety precautions
    191
  • 1.3 Assembly overview - ignition system
    191
  • 1.4 Test data, spark plugs
    192
Manufacturer's designation 4-cylinder injection engine (1.6 l roller rocker finger)
Manufacturer Volkswagen
Suitable for Touran (2003 - 2011)
Suitable car types 1T
Engine code BSE, BSF
Category Reparaturanleitung

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