THE CAR REPAIR SHOP
0
Home » Manuals » 5-cyl. injection engine (4-valve)
  • Examplepage for repair manual 5-cyl. injection engine (4-valve)
  • Examplepage for repair manual 2 5-cyl. injection engine (4-valve)
  • Examplepage for repair manual 3 5-cyl. injection engine (4-valve)
  • Examplepage for repair manual 5-cyl. injection engine (4-valve)
  • Examplepage for repair manual 2 5-cyl. injection engine (4-valve)
  • Examplepage for repair manual 3 5-cyl. injection engine (4-valve)

5-cyl. injection engine (4-valve)

For Bora / Bora Variant / Golf / Golf Variant

Original Volkswagen repair manual


14,43 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

5.621 KB

170 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Checking electronic power control (EPC) and Activated charcoal filter system. Show more
Secure Payment via PayPal, credit card, direct debit and more
PayPal Logo SEPA Lastschrift Logo Giropay Logo Sofort Überweisung Logo

Repair manual Bora / Bora Variant / Golf / Golf Variant 5-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 data
    1
  • Removing and installing engine
    3
  • 1 Removing and installing engine
    3
  • 1.1 Notes on removing
    4
  • 1.2 Securing engine to assembly stand
    8
  • 1.3 Notes on installing
    9
  • 1.4 Aligning engine and gearbox mountings
    11
  • 1.5 Torque settings
    12
  • 1.6 Additional information and removal instructions for vehicles with air conditioner
    13
  • Crankshaft group
    14
  • 1 Dismantling and assembling engine
    14
  • 1.1 Parts l and ll - Assembly overview
    14
  • 1.2 Part I: Assembly overview - Chain drive
    16
  • 1.3 Part II: Crankshaft drive
    18
  • 1.4 Removing and installing poly V-belt
    20
  • 2 Removing and installing sealing flange and dual mass flywheel/drive plate
    22
  • 2.1 Assembly overview
    22
  • 2.2 Renewing crankshaft oil seal, vibration damper end
    24
  • 2.3 Removing and installing drive plate
    25
  • 2.4 Removing and installing oil seal, flywheel end
    27
  • 3 Removing and installing crankshaft
    29
  • 3.1 Assembly overview
    29
  • 4 Dismantling and assembling pistons and conrods
    32
  • 4.1 Assembly overview
    32
  • 4.2 Piston and cylinder dimensions
    35
  • Cylinder head, valve gear
    36
  • 1 Removing and installing cylinder head
    36
  • 1.1 Assembly overview
    36
  • 1.2 Assembly overview - Cover part
    39
  • 1.3 Removing and installing cylinder head cover
    42
  • 1.4 Removing and installing cylinder head
    46
  • 1.5 Checking valve timing
    52
  • 1.6 Adjusting valve timing
    53
  • 1.7 Checking compression
    58
  • 2 Repairing valve gear
    61
  • 2.1 Assembly overview
    61
  • 2.2 Reworking valve seats
    65
  • 2.3 Removing and installing camshafts
    67
  • 2.4 Checking valve guides
    73
  • 2.5 Renewing valve stem seals
    74
  • Lubrication
    77
  • 1 Removing and installing parts of lubrication system
    77
  • 1.1 Engine oil
    77
  • 1.2 Assembly overview
    77
  • 1.3 Assembly overview - Oil filter housing
    80
  • 1.4 Assembly overview - Oil pump
    81
  • 1.5 Removing and installing sump
    82
  • 1.6 Checking oil pressure and oil pressure switch
    84
  • Cooling
    87
  • 1 Removing and installing parts of cooling system
    87
  • 1.1 Assembly overview - Parts of cooling system, body side
    87
  • 1.2 Assembly overview - Parts of cooling system, engine side
    89
  • 1.3 Coolant hose schematic diagram
    91
  • 1.4 Assembly overview - Thermostat housing
    91
  • 1.5 Draining and filling coolant
    93
  • 1.6 Removing and installing radiator and fan
    96
  • 1.7 Removing and installing coolant pump
    98
  • 1.8 Checking continued coolant circulation pump V51
    99
  • 1.9 Checking radiator fan
    101
  • Fuel supply system
    103
  • 1 Removing and installing parts of fuel supply system
    103
  • 1.1 Assembly overview - Fuel tank with attachments and fuel filter
    103
  • 1.2 Safety precautions when working on fuel supply system
    109
  • 1.3 Rules for cleanliness
    110
  • 1.4 Removing, installing and checking suction jet pump: vehicles with four-wheel drive
    110
  • 1.5 Crash fuel shut-off
    113
  • 1.6 Removing and installing fuel delivery unit
    113
  • 1.7 Removing and installing fuel gauge sender G
    116
  • 1.8 Removing and installing fuel tank
    116
  • 1.9 Checking fuel pump
    118
  • 2 Checking electronic power control (EPC)
    125
  • 2.1 Function of EPC system
    125
  • 2.2 Assembly overview
    125
  • 3 Activated charcoal filter system
    127
  • 3.1 Function
    127
  • 3.2 Assembly overview
    127
  • 3.3 Checking fuel tank breather
    128
  • Mixture preparation - injection
    131
  • 1 Repairing injection system
    131
  • 1.1 Fitting locations overview
    131
  • 1.2 General notes on injection
    133
  • 1.3 Assembly overview - Parts of injection system
    134
  • 1.4 Assembly overview - Intake manifold
    137
  • 1.5 Assembly overview - Fuel rail
    138
  • 1.6 Assembly overview - Air cleaner
    139
  • 1.7 Safety precautions
    140
  • 1.8 Rules for cleanliness
    141
  • 1.9 Technical data
    141
  • 2 Checking components
    142
  • 2.1 Checking injectors
    142
  • 2.2 Checking fuel pressure regulator and holding pressure
    144
  • 3 Engine control unit
    148
  • 3.1 Removing and installing engine control unit
    148
  • 3.2 Adapting components
    148
  • 3.3 Reading and erasing engine control unit fault memory
    149
  • Exhaust system
    151
  • 1 Removing and installing parts of exhaust system
    151
  • 1.3 Assembly overview - Silencer with mountings: vehicles with front-wheel drive
    155
  • 1.4 Assembly overview - Silencer with mountings: vehicles with four-wheel drive
    157
  • 2 Secondary air system
    158
  • 2.1 Function
    158
  • 2.2 Assembly overview - Parts of secondary air system
    158
  • 2.3 Checking combination valve
    160
  • Ignition system
    162
  • 1 Repairing ignition system
    162
  • 1.1 Assembly overview - Parts of ignition system
    162
  • 1.2 Safety precautions
    163
  • 1.3 Test data, spark plugs
    164
Manufacturer's designation 5-cyl. injection engine (4-valve)
Manufacturer Volkswagen
Suitable for Bora / Bora Variant / Golf / Golf Variant (1998 - 2006)
Suitable car types 1J
Engine code AQN
Category Reparaturanleitung

There are no reviews for this product at the moment.

Similar repair manuals

5-speed automatic gearbox 09A self-diagnosis

Examplepage for repair manual 5-speed automatic gearbox 09A self-diagnosis

For Bora / Bora Variant / Golf / Golf Variant (1998 - 2006)

5,89 € Details

5-speed manual gearbox 02K

Examplepage for repair manual 5-speed manual gearbox 02K

For Bora / Bora Variant / Golf / Golf Variant (1998 - 2006)

11,18 € Details

5-speed manual gearbox 02T

Examplepage for repair manual 5-speed manual gearbox 02T

For Bora / Bora Variant / Golf / Golf Variant (1998 - 2006)

14,07 € Details

5 and 6-speed manual gearbox 02M

Examplepage for repair manual 5 and 6-speed manual gearbox 02M

For Bora / Bora Variant / Golf / Golf Variant (1998 - 2006)

16,40 € Details

4cyl. Injection Engine, (2.0 ltr. Engine) (Mexico)

Examplepage for repair manual 4cyl. Injection Engine, (2.0 ltr. Engine) (Mexico)

For Bora / Bora Variant / Golf / Golf Variant (1998 - 2006)

17,93 € Details

5-speed automatic gearbox 09A

Examplepage for repair manual 5-speed automatic gearbox 09A

For Bora / Bora Variant / Golf / Golf Variant (1998 - 2006)

10,68 € Details

Automatic gearbox 01M

Examplepage for repair manual Automatic gearbox 01M

For Bora / Bora Variant / Golf / Golf Variant (1998 - 2006)

20,01 € Details

5-speed manual gearbox 02C four-wheel drive

Examplepage for repair manual 5-speed manual gearbox 02C four-wheel drive

For Bora / Bora Variant / Golf / Golf Variant (1998 - 2006)

30,13 € Details

Body self-diagnosis

Examplepage for repair manual Body self-diagnosis

For Bora / Bora Variant / Golf / Golf Variant (1998 - 2006)

12,61 € Details

Maintenance

Examplepage for repair manual Maintenance

For Bora / Bora Variant / Golf / Golf Variant (1998 - 2006)

15,82 € Details

Our Best Sellers

Did you know? We also offer original spare parts.

car part 1Y0035411M Tieftoener

1Y0035411M

Tieftoener

55,49 €

Details
car part 7N0122101P Schlauch

7N0122101P

Schlauch

79,92 €

Details
car part 8S0827990 Adapter

8S0827990

Adapter

67,54 €

Details
car part 059121113N Kuehlregle

059121113N

Kuehlregle

61,17 €

Details
car part 06D103469N Zyl.Kopfha

06D103469N

Zyl.Kopfha

257,96 €

Details

4-Zyl.-Dieselmotor (1,5- und 1,6 l-Motor) 068.2 / 068.5 / 068.A / ADK

Examplepage for repair manual 4-Zyl.-Dieselmotor (1,5- und 1,6 l-Motor) 068.2 / 068.5 / 068.A / ADK

For Industriemotoren - Industrial Engines ()

8,15 € Details

Nr. 547: Der 2,0l-176kW-TDI-Biturbo-Motor der Dieselmotoren-Baureihe EA288

Examplepage for repair manual Nr. 547: Der 2,0l-176kW-TDI-Biturbo-Motor der Dieselmotoren-Baureihe EA288

5,89 € Details

1AV Einspritz- und Zündanlage

Examplepage for repair manual 1AV Einspritz- und Zündanlage

For Golf / Golf Variant / Vento (1992 - 1999)

8,28 € Details

image/svg+xml About Clonck

Original repair manuals und spare parts

Our repair manuals are original, come directly from Volkswagen and meet the highest quality standards.

In our original parts shop we sell high-quality original spare parts from car manufacturers. Use the search function to enter the desired part number (OE number) and order the required spare part quickly and easily.

Highest quality standards

At Clonck, we want to make car mechanics and car professionals happy. That's why you will only find professional and high-quality repair manuals at Clonck that will help you to repair your vehicle professionally.

Our partners

Autohaus Schmidt GmbH
Automag GmbH Filiale Laim
KFZ-VERLAG GmbH
Zimpel und Franke GmbH

Clonck: The car repair shop - also as app!

Clonck App Logo Play Store

Clonck: Fitting car parts for your car repair

4,5 90

With Clonck you can order the right original spare parts in no time.

  • Add your car model
  • Select assembly group
  • Enter vehicle identification number (VIN)
  • Access to over 5,000 original repair manuals
Start app now
Clonck App Preview Car Mobilephone Carparts