Name: 4 - Cyl. injection engine (1.6 l)
Brand: Volkswagen
SKU: CDGab5b0ad1ce2e
Price: 16.55 EUR
Availability: InStock

Content
Details
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Repair manual FOX / Suran/Spacefox/SportV 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, (torque)
16
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 - assembly overview
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 Colour codes
48
3.3 Crankshaft - dimensions
48
4 Pistons and connecting rods - removal and installation
50
4.1 Piston and cylinder - dimensions
53
Cylinder head, valve gear
55
1 Cylinder head - assembly overview
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
69
2 Camshaft - assembly overview
73
2.1 Camshaft - check axial clearance
75
2.2 Valve seat - trim
76
2.3 Camshaft seal - replace
78
2.4 Camshaft and cylinder head cover - removal and installation
81
2.5 Valve guides - check
85
2.6 Valve stem sealant - replace
85
Lubrication
89
1 Lubrication system components
89
1.1 Lubricating system components - assembly overview
89
1.2 Engine oil
91
1.3 Oil pan- remove and install
92
1.4 Oil filter - replace
94
1.5 Oil pump - remove and install
96
1.6 Oil pressure switch F1 - remove and install
99
1.7 Oil pressure and Oil pressure switch F1 - check
100
Cooling
103
1 Cooling system components - remove and install
103
1.1 Cooling system components on the body side - assembly overview
103
1.2 Cooling system components on the engine side - assembly overview
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
122
Fuel supply system
125
1 Fuel supply system components - removal and installation
125
1.1 Fuel tank components with accessories and fuel filter - assembly overview
125
1.2 Safety measures regarding work on the fuel supply systems
128
1.3 Cleaning rules
129
1.4 Quick connection “Pop Top” - disconnection and connection
129
1.5 Fuel pump for cold start V263 - removal and installation
131
1.6 Fuel pump (pre-supply pump) G6 - remove and install
135
1.7 Fuel gauge sensor G - remove and install
138
1.8 Fuel reservoir - remove and install
138
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
159
1.4 Intake manifold - remove and install
165
1.5 Fuel distributor with injectors - removal and installation
166
1.6 Air filter - disassembly and assembly
166
1.7 Safety measures
170
1.8 Cleaning rules
171
1.9 Technical Data
171
2 Component checks
173
2.1 Injection valves - check
173
2.2 Residual pressure and fuel pressure regulator - check
175
3 READINESS code
180
3.1 Creating and Interpreting the READINESS code
180
4 Engine control unit J623
181
4.1 Engine control unit J623 - remove and install
181
4.2 Components - adjust
182
4.3 Event memory in Engine control unit J623 - reference and erase
182
Exhaust system
185
1 Removing and installing exhaust system parts
185
1.1 Intake manifold, front exhaust tube with catalytic converter and installation parts
185
1.2 Muffler with supports
188
Ignition system
190
1 Ignition system: repair
190
1.1 General instructions regarding the ignition system
190
1.2 Ignition system components - remove and install
190
1.3 Safety measures
191
1.4 Test data, spark plugs
192

Manufacturer's designation	4 - Cyl. injection engine (1.6 l)
Manufacturer	Volkswagen
Suitable for	FOX (2004 - 2010) / Suran/Spacefox/SportV (2006 - 2007) / FOX (2010) / FOX (2014)
Suitable car types	5Z1, 5Z3, 5Z7, 5Z4
Engine code	BJA, BPA, BLH, CCRA, CFZA
Category	Reparaturanleitung

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