VW Golf Mk5 2004 6-cylinder injection engine VW Individual CBRA - Workshop Manual

1 Engine number......Page 7
2 Engine data......Page 8
1 Removing and installing engine......Page 9
1.1 Removing engine......Page 10
1.2 Securing engine on engine and gearbox support -VAS 6095-......Page 16
1.3 Installing engine......Page 17
1.4 Specified torques for assembly mounting......Page 19
1 Dismantling and assembling engine......Page 20
1.1 Part I: assembly overview - chain drive......Page 22
1.2 Part II: assembly overview - crankshaft group......Page 24
1.3 Removing and installing poly V-belt......Page 26
2.1 Assembly overview - sealing flange......Page 28
2.2 Removing and installing crankshaft seal on gearbox side......Page 29
2.3 Renewing crankshaft sealing flange -vibration damper side-......Page 31
2.4 Removing and installing flywheel......Page 32
2.5 Removing and installing drive plate......Page 34
3.1 Assembly overview - crankshaft......Page 36
3.2 Allocation of crankshaft bearing shells (classification)......Page 37
3.4 Pulling needle bearing out of and driving into crankshaft......Page 39
4.1 Assembly overview - pistons and conrods......Page 42
4.1.1 Separating new conrod......Page 43
4.2 Checking pistons, piston rings and cylinder bores......Page 44
4.3 Installing piston......Page 45
4.4 Piston and cylinder dimensions......Page 46
1 Cylinder head......Page 47
1.1 Assembly overview - cylinder head......Page 48
1.2 Removing and installing cylinder head......Page 50
1.2.1 Removing......Page 52
1.2.2 Installing......Page 56
1.2.3 Preparing cylinder head gasket for assembly......Page 57
1.3 Assembly overview - cover......Page 59
1.4 Checking valve timing......Page 60
1.5 Installing camshaft adjuster with timing chain for camshaft drive......Page 63
1.6 Installing timing chain for intermediate shaft drive and camshaft drive......Page 68
1.7 Removing and installing cylinder head cover......Page 73
1.8 Checking compression......Page 75
2.1 Assembly overview......Page 77
2.2 Removing and installing camshafts......Page 79
2.2.1 Removing......Page 80
2.3 Removing and installing camshaft control valves......Page 86
2.4 Valve stem oil seals......Page 89
2.4.1 Removing......Page 90
2.4.2 Installing......Page 91
2.5 Checking valve guides......Page 92
2.6 Reworking valve seats......Page 93
1.1 Engine oil......Page 95
1.2 Assembly overview - sump......Page 96
1.3 Removing and installing oil sump......Page 98
1.4 Assembly overview - oil filter bracket......Page 101
1.5 Removing and installing oil filter bracket......Page 102
1.6 Assembly overview - oil pump......Page 103
1.7 Checking oil pressure and oil pressure switch......Page 105
1.7.1 Checking oil pressure switch......Page 106
1.7.2 Checking oil pressure......Page 107
1 Removing and installing parts of cooling system......Page 109
1.1 Assembly overview - parts of cooling system, body side......Page 110
1.2 Assembly overview - cooling system, engine side......Page 112
1.3 Assembly overview - thermostat housing......Page 113
1.4 Coolant hose schematic diagram......Page 115
1.5 Draining and filling coolant......Page 116
1.6 Removing and installing fan support with fans......Page 119
1.7 Removing and installing radiator......Page 121
1.8 Checking continued coolant circulation pump......Page 122
1.9 Removing and installing coolant pump......Page 124
1.10 Removing and installing thermostat housing......Page 126
1.11 Removing and installing thermostat......Page 129
1.12 Removing and installing coolant pipe......Page 130
1.13 Checking cooling system for leaks......Page 132
1.13.1 Checking pressure relief valve in filler cap......Page 133
1 Safety precautions when working on fuel supply system......Page 134
2 Rules for cleanliness......Page 135
3.1 Assembly overview - fuel tank......Page 136
3.2 Emptying fuel tank......Page 138
3.2.1 Emptying fuel tank with fuel pump intact......Page 139
3.2.2 Emptying fuel tank if it is more than 3/4 full......Page 140
3.2.3 Emptying fuel tank if it is less than 3/4 full......Page 141
3.3.1 Removing fuel tank......Page 143
3.3.2 Installing fuel tank......Page 145
4.1 Removing and installing fuel delivery unit......Page 147
4.2 Removing and installing fuel gauge sender 2 -G169-......Page 150
4.4 Removing and installing fuel gauge sender -G-......Page 152
4.6 Removing and installing fuel filter......Page 154
4.7.1 Checking function and voltage supply......Page 156
4.7.2 Checking fuel delivery rate......Page 158
4.7.3 Checking current draw......Page 161
4.7.4 Checking non-return valve for fuel pump......Page 162
4.8 Bleeding fuel system......Page 163
5.2 Removing and installing accelerator module......Page 166
6.1 Assembly overview - activated charcoal filter system......Page 169
6.2 Checking fuel tank breather......Page 170
1.2 Technical data......Page 172
1.3 Assembly overview - intake manifold......Page 173
1.3.1 Assembly overview - vacuum system......Page 175
1.5 Removing and installing intake manifold......Page 176
1.6 Assembly overview - fuel rail......Page 179
1.7 Assembly overview - air filter......Page 180
1.9 Checking intake air preheating......Page 181
2.1 Checking vacuum unit for intake manifold flaps......Page 183
2.2.1 Checking for leaks......Page 185
2.2.2 Checking quantity injected......Page 186
2.3 Checking fuel pressure regulator and holding pressure......Page 187
3.2 Removing and installing anti-theft engine control unit......Page 191
1 Exhaust manifold, front exhaust pipe with catalytic converters and Lambda probes......Page 195
1.1 Assembly overview - exhaust manifold, front exhaust pipe with catalytic converters......Page 197
1.2 Removing and installing Lambda probe -G39- and Lambda probe 2 -G108-......Page 198
1.3 Removing and installing exhaust manifold......Page 200
1.4 Removing and installing front exhaust pipe with catalytic converters......Page 201
2.1 Assembly overview - silencers with mountings......Page 204
2.2 Checking exhaust flap......Page 205
2.3 Aligning exhaust system free of stress......Page 206
3.1 Function......Page 208
3.2 Assembly overview - secondary air system......Page 209
3.3 Removing and installing secondary air pump motor -V101-......Page 210
3.5 Removing and installing combination valve for secondary air system......Page 211
1.2 Safety precautions......Page 212
1.3 Assembly overview - parts of ignition system......Page 213
1.4 Removing and installing ignition coils with output stage......Page 214
1.5 Test data, spark plugs......Page 216