4-cylinder injection engine (5-valve, turbocharger) Volkswagen R GmbH

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 Securing engine to assembly stand
  6
• 1.3 Installing engine
  8
• 1.4 Assembly mountings
  10
• Crankshaft group
  11
• 1 Dismantling and assembling engine
  11
• 1.1 Assembly overview
  11
• 1.2 Removing and installing poly V-belt
  15
• 2 Sealing flange and flywheel
  17
• 2.1 Renewing crankshaft oil seal - pulley end
  18
• 2.2 Removing and installing sealing flange - pulley end
  20
• 2.3 Removing and installing flywheel
  22
• 2.4 Removing and installing crankshaft sealing flange - flywheel end
  23
• 3 Crankshaft
  25
• 3.1 Assembly overview - crankshaft
  25
• 3.2 Crankshaft dimensions
  26
• 4 Pistons and conrods
  28
• 4.1 Assembly overview - pistons and conrods
  28
• 4.2 Checking pistons, piston rings and cylinder bores
  29
• 4.3 Piston and cylinder dimensions
  31
• Cylinder head, valve gear
  32
• 1 Cylinder head
  32
• 1.1 Assembly overview - cylinder head
  32
• 1.2 Removing, installing and tensioning toothed belt
  34
• 1.3 Removing and installing cylinder head
  39
• 1.4 Checking compression
  43
• 2.1 Assembly overview - valve gear
  47
• 2.2 Valve dimensions
  49
• 2.3 Reworking valve seats
  49
• 2.4 Renewing camshaft oil seals
  51
• 2.5 Checking hydraulic bucket tappets
  55
• 2.6 Removing and installing camshafts
  55
• 2.7 Checking valve guides
  60
• 2.8 Renewing valve stem seals
  60
• Lubrication
  63
• 1 Parts of lubrication system
  63
• 1.1 Engine oil
  63
• 1.2 Assembly overview - parts of lubrication system
  63
• 1.3 Assembly overview - oil filter bracket
  65
• 1.4 Removing and installing oil sump
  66
• 1.5 Checking oil pressure and oil pressure switch
  69
• Cooling
  72
• 1 Parts of cooling system
  72
• 1.1 Parts of cooling system - body side
  72
• 1.2 Parts of cooling system - engine side
  73
• 1.3 Coolant hose schematic diagram
  76
• 1.4 Draining and filling coolant
  77
• 1.5 Removing and installing radiator
  80
• 1.6 Removing and installing coolant pump
  82
• 1.7 Removing and installing thermostat
  83
• Fuel supply system
  85
• 1 Fuel tank
  85
• 1.1 Safety precautions when working on fuel supply system
  85
• 1.2 Rules for cleanliness
  85
• 1.3 Assembly overview - fuel tank with attachments
  86
• 1.4 Removing and installing fuel tank
  88
• 2 Repairing fuel supply system
  91
• 2.1 Safety precautions when working on fuel supply system
  91
• 2.2 Rules for cleanliness
  91
• 2.3 Assembly overview - fuel delivery unit
  92
• 2.4 Removing and installing fuel delivery unit
  92
• 2.5 Removing and installing fuel gauge sender G
  94
• 2.6 Checking fuel pump
  94
• 3 Electronic power control (EPC)
  102
• 3.1 Assembly overview
  102
• 4 Activated charcoal filter system
  104
• 4.1 Function
  104
• 4.2 Assembly overview - parts of activated charcoal filter system
  104
• 4.3 Overview of activated charcoal filter system
  106
• 4.4 Checking fuel tank breather
  106
• Turbocharging/supercharging
  108
• 1 Turbocharger
  108
• 1.1 Rules for cleanliness
  108
• 1.2 Assembly overview part 1 - turbocharger
  109
• 1.3 Assembly overview part 2 - turbocharger
  111
• 1.4 Removing and installing turbocharger
  111
• 2 Charge air system
  117
• 2.1 Assembly overview - charge air cooler
  117
• 2.2 Schematic diagram of turbocharging system
  118
• 2.3 Checking vacuum unit for charge pressure control valve
  118
• 2.4 Checking overrun shut-off valve
  119
• 2.5 Checking charge air system for leaks
  120
• Mixture preparation - injection
  122
• 1 Injection system
  122
• 1.1 General notes on injection
  122
• 1.2 Safety precautions
  122
• 1.3 Rules for cleanliness
  123
• 1.4 Technical data
  123
• 1.5 Assembly overview - intake manifold
  124
• 1.6 Assembly overview - fuel rail with injectors
  125
• 1.7 Assembly overview - air filter
  126
• 1.8 Removing and installing intake manifold
  126
• 2 Checking components
  128
• 2.1 Checking injectors
  128
• 2.2 Checking fuel pressure regulator and holding pressure
  130
• 3 Engine control unit
  134
• 3.1 Removing and installing engine control unit
  134
• 3.2 Removing and installing anti-theft engine control unit
  134
• Exhaust system
  137
• 1 Parts of exhaust system
  137
• 1.1 Assembly overview - exhaust system
  137
• 1.2 Separating centre and rear silencers
  139
• 1.3 Removing and installing front exhaust pipe with catalytic converter
  140
• 2 Secondary air system
  142
• 2.1 Function
  142
• 2.2 Assembly overview - secondary air system
  142
• 2.3 Removing and installing secondary air pump motor V101
  143
• 2.4 Checking combination valve
  143
• Ignition system
  145
• 1 Repairing ignition system
  145
• 1.1 General notes on ignition system
  145
• 1.2 Safety precautions
  145
• 1.3 Assembly overview - parts of the ignition
  145
• 1.4 Removing and installing ignition coils with output stage
  147
• 1.5 Test data, spark plugs
  148