Name: 4 - Cyl. injection engine (1.0 l)
Brand: Volkswagen
SKU: CDG93b636f9f5eb
Price: 16.84 EUR
Availability: InStock

Content
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Repair manual FOX 4 - Cyl. 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 characteristics
1
Removing and installing engine
3
1 Engine - remove and install
3
1.1 Removal - recommendations
6
1.2 Engine - fasten to assembly stand
11
1.3 Installation notes
12
1.4 Tightening torques
13
1.5 Engine and gearbox support set - align
14
1.6 Power-drive group supports (tightening torques)
15
1.7 Additional notes and installation works in vehicles with air conditioning
17
Crankshaft group
19
1 Engine - assembly and disassembly
19
1.1 Seal lid - replace
24
1.2 Poly-V belt - remove and install
24
1.3 Poly-V belt (elastic) - remove and install
28
2 Crankshaft and flywheel flanges - remove and install
32
2.1 Flywheel - remove and install
33
2.2 Crankshaft seal (pulley side) - replace
34
2.3 Crankshaft flange (flywheel side) - replace
36
3 Crankshaft - remove and install
47
3.1 Identifying engine bearing shells
48
3.2 Crankshaft - dimensions
48
4 Pistons and connecting rods - removal and installation
50
4.1 Pistons and cylinders - dimensions
54
Cylinder head, valve gear
55
1 Cylinder head - assembly and disassembly
55
1.1 Toothed belt semi-automatic tensioning pulley - check
58
1.2 Toothed belt - remove and install, adjust
59
1.3 Cylinder head - remove and install
64
1.4 Compression - check
70
2 Camshaft - repair
74
2.1 Camshaft - check axial clearance
76
2.2 Valve seat - trim
78
2.3 Camshaft seal - replace
79
2.4 Camshaft and cylinder head cover - removal and installation
82
2.5 Valve guides - check
86
2.6 Valve stem sealant - replace
86
Lubrication
90
1 Lubrication system components
90
1.1 Lubricating system components - assembly overview
90
1.2 Engine oil
92
1.3 Oil pan- remove and install
93
1.4 Oil filter - replace
94
1.5 Oil pump - remove and install
96
1.6 Oil pressure switch F1 - remove and install
100
1.7 Oil pressure and Oil pressure switch F1 - check
101
Cooling
103
1 Cooling system components - remove and install
103
1.1 Cooling system components, body side
103
1.2 Cooling system components, engine side
105
1.3 Hose connection diagram for cooling system
107
1.4 Cooling system - drainage and replenishment
110
1.5 Cooling system - check air-tightness
117
1.6 Radiator - remove and install
119
1.7 Water pump - remove and install
121
Fuel supply system
124
1 Fuel supply system components - removal and installation
124
1.1 Fuel tank components with accessories and fuel filter - removal and installation
124
1.2 Safety measures regarding work on the fuel supply systems
126
1.3 Cleaning rules
127
1.4 Quick connection “Pop Top” - disconnection and connection
127
1.5 Cold start system components - remove and install
129
1.6 Fuel pump (pre-supply pump) G6 - remove and install
137
1.7 Fuel gauge sensor G - remove and install
138
1.8 Fuel reservoir - remove and install
139
1.9 Fuel pump (pre-supply pump) G6 - check
141
2 Engine power electronic adjustment (electronic accelerator) - check
150
2.1 Electronic accelerator system operation
150
3 Activated charcoal filter system
152
3.1 Operation
152
3.2 Activated charcoal filter system components - repair
152
3.3 Fuel tank ventilation - check
153
Mixture preparation - injection
155
1 Injection system - repair
155
1.1 General instructions regarding the injection system
155
1.2 Component location
155
1.3 Injection components - remove and install
162
1.4 Intake manifold - remove and install
167
1.5 Fuel distributor with injectors - removal and installation
168
1.6 Air filter set - assemble and disassemble
169
1.7 Air filter assembly - remove and install
170
1.8 Safety measures
171
1.9 Cleaning rules
173
1.10 Technical Data
173
2 Component checks
174
2.1 Injection valves - check
174
2.2 Residual pressure and fuel pressure regulator - check
176
3 Engine control unit J623
181
3.1 Engine control unit J623 - remove and install
181
3.2 Engine control unit J623 (CPBA engine) - remove and install
181
3.3 Adjust components
182
3.4 Check Engine control unit J623 fault memory and clear it
183
4 READINESS code
186
4.1 Creating and Interpreting the READINESS code
186
Exhaust system
187
1 Exhaust system components - remove and install
187
1.2 Rear muffler with supports
190
Ignition system
192
1 Ignition system
192
1.1 General instructions regarding the ignition system
192
1.2 Ignition system components - remove and install
192
1.3 Safety measures
196
1.4 Spark plugs Q - test data
197

Manufacturer's designation	4 - Cyl. injection engine (1.0 l)
Manufacturer	Volkswagen
Suitable for	FOX (2004 - 2010) / FOX (2010) / FOX (2014)
Suitable car types	5Z1, 5Z4
Engine code	AQZ, BNX, CCNA, CPBA
Category	Reparaturanleitung

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