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  • Examplepage for repair manual 4 - Cyl. injection engine (1.6 l)
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4 - Cyl. injection engine (1.6 l)

For FOX / Suran/Spacefox/SportV

Original Volkswagen repair manual


16,55 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

5.539 KB

199 Sites

Detailed technical data

Immediately readable

This repair manual contains: Engine - remove and install, Crankshaft and flywheel flanges - assembly overview, Lubrication system components, Engine power electronic adjustment (electronic accelerator) - check, Activated charcoal filter system and READINESS code. Show more
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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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