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  • Examplepage for repair manual 4 - Cyl. diesel engine
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4 - Cyl. diesel engine

For FOX / Suran/Spacefox/SportV

Original Volkswagen repair manual


11,18 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

3.298 KB

125 Sites

Detailed technical data

Immediately readable

This repair manual contains: Engine - remove and install, Valve command - repair, Control unit of Diesel direct injection system J248 and Preheating system - check. Show more
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Repair manual FOX / Suran/Spacefox/SportV 4 - Cyl. diesel engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical data
    1
  • 1.1 Engine number
    1
  • 1.2 Engine characteristics
    1
  • Removing and installing engine
    2
  • 1 Engine - remove and install
    2
  • 1.1 Notes on removal
    3
  • 1.2 Engine - fasten to assembly stand
    6
  • 1.3 Notes on installation
    7
  • 1.4 Tightening torques
    8
  • 1.5 Power-drive unit supports
    8
  • 1.6 Additional notes and installation works in vehicles with air conditioning
    9
  • Crankshaft group
    11
  • 1 Engine - assembly and disassembly
    11
  • 1.1 Poly-V belt - remove and install
    15
  • 1.2 Toothed belt semi-automatic tensioning pulley - check
    17
  • 2 Crankshaft and flywheel seal - remove and install
    18
  • 2.1 Crankshaft seal (pulley side) - replace
    20
  • 2.2 Crankshaft flanges (flywheel side) - removal and installation
    22
  • 3 Crankshaft - remove and install
    26
  • 3.1 Crankshaft measurements
    27
  • 4 Pistons and connecting rods - removal and installation
    28
  • 4.1 Piston protrusion - check
    31
  • 4.2 Piston and cylinder dimensions
    32
  • Cylinder head, valve gear
    33
  • 1 Cylinder head - assembly and disassembly
    33
  • 1.1 Toothed belt - remove and install, adjust
    36
  • 1.2 Cylinder head - remove and install
    41
  • 1.3 Compression - check
    47
  • 2 Valve command - repair
    50
  • 2.1 Valve seat - trim
    52
  • 2.2 Valve guides - check
    54
  • 2.3 Valve rod sealant - replacement
    54
  • 2.4 Camshaft - remove and install
    56
  • 2.5 Hydraulic tappets - check
    59
  • Lubrication
    61
  • 1 Lubrication system components - remove and install
    61
  • 1.1 Crankcase - remove and install
    65
  • 1.2 Oil pump - remove and install
    67
  • 1.3 Oil pressure and Oil pressure switch F1 - check
    68
  • Cooling
    71
  • 1 Cooling system components - remove and install
    71
  • 1.1 Cooling system components, body
    71
  • 1.2 Cooling system components, engine
    73
  • 1.3 Cooling hose connection diagram
    74
  • 1.4 Cooling system - drain and fill
    75
  • 1.5 Water pump - remove and install
    78
  • 1.6 Radiator - remove and install
    80
  • 1.7 Thermostat valve - removal and installation
    82
  • Fuel supply system
    85
  • 1 Fuel supply system components - removal and installation
    85
  • 1.1 Fuel tank with accessories - remove and install
    85
  • 1.2 Fuel filter - repair
    89
  • 1.3 Safety measures when working on supply system
    91
  • 1.4 Cleaning rules
    91
  • 1.5 Fuel reservoir - remove and install
    92
  • 1.6 Fuel level indicator sensor G
    93
  • 1.7 Fuel level gauge - remove and install
    96
  • 1.8 Engine power electronic adjustment (electronic accelerator): check
    97
  • Mixture preparation - injection
    98
  • 1 Diesel direct injection system - repair
    98
  • 1.1 Safety measures
    98
  • 1.2 Cleaning rules
    98
  • 1.3 Injection pump - repair
    99
  • 1.4 Intake manifold - remove and install
    101
  • 1.5 Injection pump - remove and install
    102
  • 1.6 Nozzles - remove and install
    106
  • 1.7 Injectors - check
    108
  • 1.8 Sealing ring of the cap of injection adjuster - replace
    109
  • 2 Control unit of Diesel direct injection system J248
    110
  • 2.1 Control unit of Diesel direct injection system J248 - remove and install
    110
  • 2.3 Functions and components - adapt
    111
  • Exhaust system
    113
  • 1 Removing and installing exhaust system parts
    113
  • 1.1 Exhaust system - remove and install
    113
  • 2 Exhaust gas return system
    117
  • 2.1 Exhaust gas return system components - removal and installation
    117
  • 2.2 Vacuum hose connection diagram
    118
  • 2.3 Check the exhaust gas return valve
    118
  • Ignition system
    120
  • 1 Preheating system - check
    120
  • 1.1 Glow plugs - check
    120
Manufacturer's designation 4 - Cyl. diesel engine
Manufacturer Volkswagen
Suitable for FOX (2004 - 2010) / Suran/Spacefox/SportV (2006 - 2007) / FOX (2010)
Suitable car types 5Z1, 5Z7
Engine code ASY
Category Reparaturanleitung

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