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

4-cylinder injection engine (2-valve, roller rocker finger)

For Lupo

Original Volkswagen repair manual


11,68 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

2.581 KB

132 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Electronic power control (EPC), Activated charcoal filter system and Checking components. Show more
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Repair manual Lupo 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 Notes on removing
    3
  • 1.2 Securing engine to assembly stand
    5
  • 1.3 Notes on installing
    5
  • 1.4 Specified torques
    7
  • 1.5 Assembly mountings
    7
  • 1.6 Additional information and assembly work for vehicles with air conditioner
    8
  • Crankshaft group
    9
  • 1 Dismantling and assembling engine
    9
  • 1.1 Part I: assembly overview - toothed belt drive
    10
  • 1.2 Part II: assembly overview - cylinder block
    11
  • 1.3 Removing and installing poly V-belt
    12
  • 2 Removing and installing cylinder block, sealing flange and flywheel
    15
  • 2.1 Assembly overview - aluminium cylinder block
    15
  • 2.2 Renewing crankshaft oil seal - belt pulley end
    17
  • 2.3 Renewing crankshaft sealing flange - flywheel end
    18
  • 2.4 Crankshaft dimensions
    26
  • 3 Dismantling and assembling pistons and conrods
    28
  • 3.1 Assembly overview
    28
  • 3.2 Piston and cylinder dimensions
    31
  • Cylinder head, valve gear
    32
  • 1 Dismantling and assembling cylinder head
    32
  • 1.1 Assembly overview
    32
  • 1.2 Removing, installing and tensioning toothed belt
    35
  • 1.3 Checking semi-automatic toothed belt tensioning roller
    37
  • 1.4 Removing and installing cylinder head
    39
  • 1.5 Checking compression
    44
  • 2 Repairing valve gear
    47
  • 2.1 Assembly overview
    47
  • 2.2 Reworking valve seats
    49
  • 2.3 Renewing camshaft oil seal
    51
  • 2.4 Removing and installing cylinder head cover and camshaft
    52
  • 2.5 Checking valve guides
    55
  • 2.6 Renewing valve stem seals
    56
  • Lubrication
    59
  • 1 Removing and installing parts of lubrication system
    59
  • 1.1 Engine oil
    59
  • 1.2 Assembly overview
    59
  • 1.3 Removing and installing oil sump
    61
  • 1.4 Removing and installing oil pump
    63
  • 1.5 Checking oil pressure and oil pressure switch
    66
  • Cooling
    69
  • 1 Removing and installing parts of cooling system
    69
  • 1.1 Assembly overview - parts of cooling system, body side
    69
  • 1.2 Assembly overview - parts of cooling system, engine side
    71
  • 1.3 Coolant hose schematic diagram
    73
  • 1.4 Draining and filling coolant
    74
  • 1.5 Removing and installing radiator
    76
  • 1.6 Checking cooling system for leaks
    77
  • Fuel supply system
    79
  • 1 Removing and installing parts of fuel supply system
    79
  • 1.2 Safety precautions when working on fuel supply system
    81
  • 1.3 Rules for cleanliness
    82
  • 1.4 Crash fuel shut-off
    82
  • 1.5 Removing and installing fuel delivery unit
    82
  • 1.6 Removing and installing fuel tank
    84
  • 1.7 Checking fuel pump
    85
  • 2 Electronic power control (EPC)
    92
  • 2.1 Assembly overview
    92
  • 2.2 Function of EPC system
    92
  • 3 Activated charcoal filter system
    94
  • 3.1 Function
    94
  • 3.2 Assembly overview - repairing activated charcoal filter system components
    94
  • 3.3 Checking fuel tank breather
    95
  • Mixture preparation - injection
    98
  • 1 Repairing injection system
    98
  • 1.1 General notes on injection
    98
  • 1.2 Safety precautions
    98
  • 1.3 Rules for cleanliness
    99
  • 1.4 Technical data
    100
  • 1.5 Assembly overview - dismantling and assembling intake manifold
    100
  • 1.6 Assembly overview - dismantling and assembling fuel rail with injectors
    102
  • 1.7 Assembly overview - dismantling and assembling air filter housing
    102
  • 1.8 Cleaning throttle valve module J338
    104
  • 2 Checking components
    106
  • 2.1 Checking intake air preheating
    106
  • 2.2 Check injectors for spray pattern and leakage
    106
  • 2.3 Checking injection rate of injectors
    109
  • 2.4 Checking fuel pressure regulator and holding pressure
    112
  • 2.5 Checking vacuum valve
    115
  • 3 Engine control unit
    117
  • 3.1 Removing and installing engine control unit
    117
  • 3.2 Adapting function and components
    117
  • 3.3 Reading and erasing engine control unit fault memory
    118
  • Exhaust system
    120
  • 1 Removing and installing parts of exhaust system
    120
  • 1.2 Assembly overview - silencer with mountings
    122
  • 2 Exhaust gas recirculation system
    123
  • 2.1 Assembly overview - repairing parts of exhaust gas recirculation system
    123
  • Ignition system
    124
  • 1 Repairing ignition system
    124
  • 1.1 General notes on ignition system
    124
  • 1.2 Assembly overview - ignition system components
    124
  • 1.3 Safety precautions
    125
  • 1.4 Test data, spark plugs
    126
Manufacturer's designation 4-cylinder injection engine (2-valve, roller rocker finger)
Manufacturer Volkswagen
Suitable for Lupo (1998 - 2006)
Suitable car types 6X
Engine code ANV, AUC, AUD
Category Reparaturanleitung

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