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  • Examplepage for repair manual 4 Cyl injection engine (2 valve), Mechanics
  • Examplepage for repair manual 2 4 Cyl injection engine (2 valve), Mechanics
  • Examplepage for repair manual 3 4 Cyl injection engine (2 valve), Mechanics

4 Cyl injection engine (2 valve), Mechanics

For Caddy Base / Caddy Club / Golf

Original Volkswagen repair manual


13,27 €7% VAT incl.

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  • English

Immediately available for download

Language: English

Digital PDF file

6.558 KB

154 Sites

Detailed technical data

Immediately readable

This repair manual contains: Engine removal and installation, Dismantling and assembling engine, Servicing valve gear, Throttle-mechanism and Checking exhaust gas recirculation (EGR) (engine code: JJ). Show more
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Repair manual Caddy Base / Caddy Club / Golf 4 Cyl injection engine , Mechanics PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technichal data
    1
  • 1.1 Technichal data
    1
  • 1.2 Engine number
    1
  • 1.3 Engine summary
    1
  • Removing and installing engine
    4
  • 1 Engine removal and installation
    4
  • 1.1 Engine removal and installation
    4
  • 1.2 Notes on engine removal
    4
  • 1.3 Notes on installation
    5
  • 1.4 Tightening torques
    6
  • 1.5 Additional installation procedures and notes for vehicles with air conditioning
    6
  • Crankshaft group
    8
  • 1 Dismantling and assembling engine
    8
  • 1.1 Dismantling and assembling engine
    8
  • 1.2 Installing toothed belt
    19
  • 1.3 Adjusting alternator V-belt tension
    21
  • 2 Dismantling and assembling cylinder block, crankshaft and flywheel
    22
  • 2.1 Dismantling and assembling cylinder block, crankshaft and flywheel
    22
  • 2.2 Installing release plate retaining ring
    29
  • 2.3 Renewing crankshaft oil seal -pulley end
    30
  • 2.4 Crankshaft dimensions
    31
  • 2.5 Installing drive plate
    32
  • 2.6 Marking flywheel with ignition timing notch
    32
  • 3 Dismantling and assembling pistons and conrods
    34
  • 3.1 Dismantling and assembling pistons and conrods
    34
  • 3.2 Piston and cylinder dimensions
    42
  • Cylinder head, Valve gear
    44
  • 1 Removing and installing cylinder head
    44
  • 1.1 Removing and installing cylinder head
    44
  • 1.2 Installing cylinder head
    48
  • 1.3 Testing compression
    49
  • 2 Servicing valve gear
    50
  • 2.1 Servicing valve gear
    50
  • 2.2 Reworking valve seats
    58
  • 2.3 Checking hydraulic tappets
    60
  • 2.4 Renewing camshaft oil seal
    61
  • 2.5 Removing and installing camshaft
    61
  • 2.6 Checking valve guides
    62
  • 2.7 Renewing valve guides
    63
  • 2.8 Renewing valve stem oil seal -with cylinder head installed
    63
  • 2.9 Checking and adjusting valve clearance
    64
  • Lubrication
    67
  • 1 Removing and installing lubrication system components
    67
  • 1.1 Removing and installing lubrication system components
    67
  • 1.2 Oil cooler
    74
  • 1.4 Checking oil pressure switch and oil pressure (engine code: EG)
    79
  • Cooling system
    81
  • 1 Removing and installing cooling system components
    81
  • 1.1 Removing and installing cooling system components
    81
  • 1.2 Draining and refilling with coolant
    89
  • 1.3 Fan run-on for cooling injectors
    90
  • 1.4 Repair air deflector installation
    90
  • Fuel supply system
    91
  • 1 Removing and installing fuel system components
    91
  • 1.1 Removing and installing fuel system components
    91
  • 1.6 Removing and installing fuel pump and fuel filter (engine code: 2H)
    107
  • 1.7 Rules of cleanliness
    108
  • 1.8 Connecting remote control V.A.G 1348/3A
    111
  • 1.9 Checking fuel pumps (engine codes: DX, EG, JH, JJ, KT)
    111
  • 1.10 Checking fuel pump (engine code: 2H)
    114
  • 1.11 Checking fuel pump non-return valve (engine codes: DX, EG, JH, JJ, KT)
    117
  • 1.12 Checking fuel pump relay (engine codes: DX, EG, JH, JJ, KT)
    118
  • 1.13 Checking fuel pump relay (engine code: 2H)
    119
  • 1.14 Retrotitting adapter plate for fuel pump relay (engine code: EG > 7/82)
    120
  • 1.15 Removal and installation of fuel gauge sender, fuel lift pump
    121
  • 1.17 Removing and installing fuel tank (> 1/84, 40- litre fuel tank)
    123
  • 1.18 Removing and installing fuel tank (2/84 >, 55- litre fuel tank)
    125
  • 1.19 Checking fuel system for leaks (> 1/84, 40-litre fuel tank)
    126
  • 2 Servicing activated charcoal filter unit
    128
  • 2.1 Servicing activated charcoal filter unit
    128
  • 2.2 Engine code: JH > 7/86
    128
  • 2.3 Engine code: JH 8/86 >
    130
  • 2.4 Engine code: 2H
    132
  • 3 Throttle-mechanism
    134
  • 3.1 Throttle-mechanism
    134
  • 3.2 Throttle cable adjustment, manual gearbox
    134
  • 3.3 Servicing throttle controls, automatic gearbox (engine codes: JH, 2H)
    135
  • 3.4 Adjusting throttle controls
    136
  • Exhaust system
    139
  • 1 Removing and installing exhaust system components
    139
  • 1.1 Removing and installing exhaust system components
    139
  • 1.2 Engine Codes: DX, EG JJ KT
    139
  • 1.3 Engine Code: JH
    142
  • 1.4 Engine Code: 2H
    145
  • 1.5 Removing and installing spring clips (engine codes: DX 8/83 >, JH, KT)
    148
  • 1.6 Tensioning and relaxing spring clips (engine codes: DX 8/83 >, JH, KT)
    148
  • 2 Checking exhaust gas recirculation (EGR) (engine code: JJ)
    149
  • 2.1 Checking exhaust gas recirculation (EGR) (engine code: JJ)
    149
Manufacturer's designation 4 Cyl injection engine (2 valve), Mechanics
Manufacturer Volkswagen
Suitable for Caddy Base / Caddy Club / Golf / Golf (USA/Canada) (1974 - 2007)
Suitable car types 17
Category Reparaturanleitung

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