Volkswagen 4-Cylinder Diesel Engine Workshop Manual

Volkswagen 4-Cylinder Diesel Engine Workshop Manual PDF

Volkswagen 4-Cylinder Diesel Engine Workshop Manual. The 4-Cyl. Diesel Engine is installed in the Volkswagen Fox 2004 ➤

  • Engine ID: ASY

CONTENTS:

Technical data

  • Technical data
  • Engine number
  • Engine features

Cylinders, engine block, support, protector

  • Engine – remove and install
  • Notes on removal
  • Fasten the engine on assembly stand
  • Notes on installation
  • Tightening torques
  • Supports for the power-drive group
  • Additional notes and installation works in vehicles with air conditioning

Crankshaft, pistons

  • Engine – disassemble and assemble
  • Poly-V belt – remove and install
  • Toothed belt semi-automatic tensioning pulley – check
  • Crankshaft and flywheel seal – remove and install
  • Crankshaft sealing (pulley side) – replace
  • Crankshaft flange (pulley side) – remove and install
  • Crankshaft – remove and install
  • Crankshaft measurements
  • Pistons and connecting rods – remove and install
  • Piston protrusion – check
  • Piston and cylinder dimensions

Cylinder head, valve control mechanism

  • Cylinder head – disassemble and assemble
  • Toothed belt – remove and install, adjust
  • Cylinder head – remove and install
  • Compression – check
  • Valve command – repair
  • Valve seat – grind
  • Valve guides – check
  • Valve stem seal – replace
  • Camshaft – remove and install
  • Hydraulic tappets – check

Lubrication system

  • Lubrication system components – remove and install
  • Crankcase – remove and install
  • Oil pressure and Oil pressure switch F1 – check

Cooling system

  • Cooling system components – remove and install
  • Cooling system components in the body
  • Cooling system components in the engine
  • Cooling hose connection diagram
  • Cooling system – drain and fill
  • Water pump – remove and install
  • Radiator – remove and install
  • Thermostat valve – remove and install

Supply system – Fuel tank, fuel pump

  • Fuel supply system components – remove and install
  • Fuel tank with accessories – remove and install
  • Fuel filter – repair
  • Safety measures when working in the supply system
  • Cleaning rules
  • Fuel tank – remove and install
  • Fuel level indicator sensor G
  • Fuel level meter – remove and install
  • Engine power electronic adjustment (electronic accelerator): check

Supply system – mechanical injection (diesel)

  • Direct diesel injection system – repair
  • Safety measures
  • Cleaning rules
  • Injector pump – repair
  • Intake manifold – remove and install
  • Injector pump – remove and install
  • Injectors – remove and install
  • Injectors – check
  • Sealing ring on the injection regulator cover – replace
  • Engine control unit J623
  • Engine control unit J623 – remove and install
  • Engine control unit J623 fault memory – read and clear
  • Functions and components – adapt

Exhaust system

  • Removing and installing exhaust system parts
  • Exhaust system – remove and install
  • Exhaust gas return system
  • Exhaust return system components – remove and instal
  • Connection plan for vacuum hoses
  • Check exhaust gas return valve

Chamber pre-heating system

  • Chamber pre-heating system – check
  • Pre-heating plugs – check

Edition 08.2010 (BRA5R007820)
Language: English
Format: PDF
Pages: 121
Size: 3.02 Mb
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