VW Golf & Jetta 2005 4-cylinder injection engine BHY - Workshop Manual

1.2 Engine data......Page 7
1.1 Removing engine......Page 8
1.1.1 Securing engine to assembly stand......Page 13
1.2 Installing engine......Page 14
1 Dismantling and assembling engine......Page 17
1.1 Assembly overview......Page 18
1.1.1 Part I......Page 19
1.1.2 Part II......Page 20
1.2 Removing and installing poly V-belt......Page 21
1.2.2 Installing poly V-belt......Page 22
2.1 Assembly overview - Pistons and conrods......Page 24
2.1.1 Conventional conrods......Page 25
2.1.2 Industrially cracked conrods......Page 26
2.2 Checking pistons, piston rings and cylinder bores......Page 27
2.3 Piston and cylinder dimensions......Page 29
3 Removing and installing crankshaft......Page 30
3.2 Crankshaft dimensions......Page 31
1 Removing and installing cylinder head......Page 33
1.1 Removing, installing and tensioning toothed belt......Page 34
1.1.1 Removing......Page 35
1.1.2 Installing......Page 37
1.2 Checking semi-automatic toothed belt tensioning roller......Page 39
1.3 Removing and installing cylinder head......Page 40
1.3.1 Removing......Page 41
1.3.2 Installing......Page 43
1.4 Checking compression......Page 45
2 Repairing valve gear......Page 47
2.1 Reworking valve seats......Page 49
2.2.1 Removing......Page 52
2.2.2 Installing......Page 53
2.3.1 Removing......Page 54
2.3.2 Installing......Page 55
2.4 Checking hydraulic bucket tappets......Page 56
2.5 Checking valve guides......Page 57
2.6 Renewing valve guides......Page 58
2.7 Renewing valve stem seals......Page 59
1.1 Engine oil......Page 62
1.2 Assembly overview - Parts of lubrication system......Page 64
1.3 Assembly overview - Oil filter bracket......Page 65
1.4 Removing and installing sump......Page 66
1.4.2 Installing......Page 67
1.5 Checking oil pressure and oil pressure switch......Page 69
1 Removing and installing parts of cooling system......Page 71
1.1 Assembly overview - parts of cooling system - engine side......Page 72
1.2 Assembly overview - parts of cooling system - body side......Page 74
1.3.1 Draining coolant......Page 75
1.3.2 Filling with coolant......Page 77
1.4 Removing and installing coolant pump......Page 78
1.5 Removing and installing thermostat......Page 80
1.6 Removing and installing radiator fan -V7- and radiator fan 2 -V177-......Page 81
1.7 Removing and installing radiator......Page 82
1.8 Checking cooling system for leaks......Page 84
1.2 Rules for cleanliness......Page 86
1.3 Assembly overview - fuel tank......Page 87
1.4 Emptying fuel tank......Page 88
1.4.1 Emptying fuel tank if it is more than 3/4 full......Page 89
1.5 Removing and installing fuel tank......Page 90
2.2 Rules for cleanliness......Page 94
2.3.1 Removing......Page 95
2.3.2 Installing......Page 96
2.4 Removing and installing fuel gauge sender -G-......Page 97
2.5 Checking fuel pump......Page 98
2.5.1 Checking function and voltage supply......Page 99
2.5.2 Checking fuel pressure......Page 101
2.5.3 Checking residual pressure......Page 102
2.5.4 Checking delivery rate......Page 103
2.5.5 Checking current consumption......Page 106
3.1 Function of EPC system......Page 107
3.3 Removing and installing accelerator module......Page 108
4.1 Function......Page 110
4.3 Checking fuel tank breather......Page 111
1.1 General notes on injection......Page 113
1.3 Rules for cleanliness......Page 114
1.4 Technical data......Page 115
1.5 Dismantling and assembling intake manifold - upper part......Page 116
1.6 Dismantling and assembling intake manifold - lower part......Page 117
1.7 Fuel rail......Page 118
1.9 Removing and installing intake manifold......Page 119
1.10.1 Removing......Page 120
1.10.2 Installing......Page 121
1.11.1 Removing......Page 122
1.11.2 Installing......Page 123
1.12 Renewing Teflon seal on injector......Page 124
1.13 Cleaning throttle valve module -J338-......Page 126
2.1.1 Removing......Page 127
2.1.2 Installing......Page 128
2.2 Reading and erasing engine control unit fault memory......Page 129
1 Removing and installing parts of exhaust system......Page 130
1.1 Front exhaust pipe and catalytic converter with attachments......Page 131
1.3 Separating middle and rear silencers......Page 132
1.4 Aligning exhaust system stress free......Page 133
1.2 Safety precautions......Page 135
1.4 Spark plugs......Page 136