VW Golf 2004. Workshop Manual (Edition 10.2009). 6-cylinder injection engine VW Individual

VW Golf 2004. Workshop Manual (Edition 10.2009). 6-cylinder injection engine VW Individual PDF free online

Engine ID: CBRA

CONTENTS

00 – Technical data

• 1 Engine number
• 2 Engine data

10 – Removing and installing engine

• 1 Removing and installing engine
  • 1.1 Removing engine
  • 1.2 Securing engine on engine and gearbox support VAS 6095
  • 1.3 Installing engine
  • 1.4 Specified torques for assembly mounting

13 – Crankshaft group

• 1 Dismantling and assembling engine
  • 1.1 Part I: assembly overview – chain drive
  • 1.2 Part II: assembly overview – crankshaft group
  • 1.3 Removing and installing poly V-belt
• 2 Sealing flanges and flywheel
  • 2.1 Assembly overview – sealing flange
  • 2.2 Removing and installing crankshaft seal on gearbox side
  • 2.3 Renewing crankshaft sealing flange -vibration damper side
  • 2.4 Removing and installing flywheel
  • 2.5 Removing and installing drive plate
• 3 Crankshaft
  • 3.1 Assembly overview – crankshaft
  • 3.2 Allocation of crankshaft bearing shells (classification)
  • 3.3 Fitting sender wheel to crankshaft
  • 3.4 Pulling needle bearing out of and driving into crankshaft
• 4 Pistons and conrods
  • 4.1 Assembly overview – pistons and conrods
  • 4.2 Checking pistons, piston rings and cylinder bores
  • 4.3 Installing piston
  • 4.4 Piston and cylinder dimensions

15 – Cylinder head, valve gear

• 1 Cylinder head
  • 1.1 Assembly overview – cylinder head
  • 1.2 Removing and installing cylinder head
  • 1.3 Assembly overview – cover
  • 1.4 Checking valve timing
  • 1.5 Installing camshaft adjuster with timing chain for camshaft drive
  • 1.6 Installing timing chain for intermediate shaft drive and camshaft drive
  • 1.7 Removing and installing cylinder head cover
  • 1.8 Checking compression
• 2 Valve gear
  • 2.1 Assembly overview
  • 2.2 Removing and installing camshafts
  • 2.3 Removing and installing camshaft control valves
  • 2.4 Valve stem oil seals
  • 2.5 Checking valve guides
  • 2.6 Reworking valve seats

17 – Lubrication

• 1 Parts of lubrication system
  • 1.1 Engine oil
  • 1.2 Assembly overview – sump
  • 1.3 Removing and installing oil sump
  • 1.4 Assembly overview – oil filter bracket
  • 1.5 Removing and installing oil filter bracket
  • 1.6 Assembly overview – oil pump
  • 1.7 Checking oil pressure and oil pressure switch

19 – Cooling

• 1 Removing and installing parts of cooling system
  • 1.1 Assembly overview – parts of cooling system, body side
  • 1.2 Assembly overview – cooling system, engine side
  • 1.3 Assembly overview – thermostat housing
  • 1.4 Coolant hose schematic diagram
  • 1.5 Draining and filling coolant
  • 1.6 Removing and installing fan support with fans
  • 1.7 Removing and installing radiator
  • 1.8 Checking continued coolant circulation pump
  • 1.9 Removing and installing coolant pump
  • 1.10 Removing and installing thermostat housing
  • 1.11 Removing and installing thermostat
  • 1.12 Removing and installing coolant pipe
  • 1.13 Checking cooling system for leaks

20 – Fuel supply system

• 1 Safety precautions when working on fuel supply system
• 2 Rules for cleanliness
• 3 Fuel tank
  • 3.1 Assembly overview – fuel tank
  • 3.2 Emptying fuel tank
  • 3.3 Removing and installing fuel tank
• 4 Repairing fuel supply
  • 4.1 Removing and installing fuel delivery unit
  • 4.2 Removing and installing fuel gauge sender 2 G169
  • 4.3 Removing and installing suction-jet pump
  • 4.4 Removing and installing fuel gauge sender G
  • 4.5 Assembly overview – fuel filter with attachments
  • 4.6 Removing and installing fuel filter
  • 4.7 Checking fuel pump
  • 4.8 Bleeding fuel system
• 5 Electronic power control (EPC)
  • 5.1 Assembly overview – accelerator module
  • 5.2 Removing and installing accelerator module
• 6 Activated charcoal filter system
  • 6.1 Assembly overview – activated charcoal filter system
  • 6.2 Checking fuel tank breather

24 – Mixture preparation – injection

• 1 Repairing injection system
  • 1.1 General notes on the injection system
  • 1.2 Technical data
  • 1.3 Assembly overview – intake manifold
  • 1.4 Removing and installing throttle valve module J338
  • 1.5 Removing and installing intake manifold
  • 1.6 Assembly overview – fuel rail
  • 1.7 Assembly overview – air filter
  • 1.8 Assembly overview – resonator with resonance air pipe
  • 1.9 Checking intake air preheating
• 2 Checking components
  • 2.1 Checking vacuum unit for intake manifold flaps
  • 2.2 Checking injectors for leaks and quantity injected
  • 2.3 Checking fuel pressure regulator and holding pressure
• 3 Engine control unit
  • 3.1 Removing and installing engine control unit
  • 3.2 Removing and installing anti-theft engine control unit

26 – Exhaust system

• 1 Exhaust manifold, front exhaust pipe with catalytic converters and Lambda probes
  • 1.1 Assembly overview – exhaust manifold, front exhaust pipe with catalytic converters
  • 1.2 Removing and installing Lambda probe G39 and Lambda probe 2 G108
  • 1.3 Removing and installing exhaust manifold
  • 1.4 Removing and installing front exhaust pipe with catalytic converters
• 2 Silencer with mountings
  • 2.1 Assembly overview – silencers with mountings
  • 2.2 Checking exhaust flap
  • 2.3 Aligning exhaust system free of stress
• 3 Secondary air system
  • 3.1 Function
  • 3.2 Assembly overview – secondary air system
  • 3.3 Removing and installing secondary air pump motor V101
  • 3.4 Checking combination valve for secondary air system
  • 3.5 Removing and installing combination valve for secondary air system

28 – Ignition system

• 1 Ignition system
  • 1.1 General notes on ignition system
  • 1.2 Safety precautions
  • 1.3 Assembly overview – parts of ignition system
  • 1.4 Removing and installing ignition coils with output stage
  • 1.5 Test data, spark plugs

Language: English
Format: PDF
Pages: 217

Golf 2004. Workshop Manual (Edition 10.2009). 6-cylinder injection engine VW Individual PDF free online