VW 4-Cylinder Injection Engine, 2005 Workshop Manual

VW 4-Cylinder Injection Engine, 2005 ➤ Workshop Manual PDF free online

The 4-Cylinder Injection Engine, 2005 ➤ is installed in the Volkswagen Golf – Jetta 2005 ➤

Engine ID: BHY

List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups

Repair Group
00 – Technical data
10 – Removing and installing engine
13 – Crankshaft group
15 – Cylinder head, Valve gear
17 – Lubrication
19 – Cooling system
20 – Fuel supply system
24 – Mixture preparation, Injection
26 – Exhaust system
28 – Ignition system

CONTENTS

  • 00 – Technical data
    • Technical data
    • Engine number
    • Engine data
  • 10 – Removing and installing engine
    • Removing and installing engine
    • Removing engine
    • Installing engine
  • 13 – Crankshaft group
    • Dismantling and assembling engine
    • Assembly overview
    • Removing and installing poly V-belt
    • Dismantling and assembling pistons and conrods
    • Assembly overview – Pistons and conrods
    • Checking pistons, piston rings and cylinder bores
    • Piston and cylinder dimensions
    • Removing and installing crankshaft
    • Colour identification
    • Crankshaft dimensions
  • 15 – Cylinder head, Valve gear
    • Removing and installing cylinder head
    • Removing, installing and tensioning toothed belt
    • Checking semi-automatic toothed belt tensioning roller
    • Removing and installing cylinder head
    • Checking compression
    • Repairing valve gear
    • Reworking valve seats
    • Renewing camshaft oil seal
    • Removing and installing camshaft
    • Checking hydraulic bucket tappets
    • Checking valve guides
    • Renewing valve guides
    • Renewing valve stem seals
  • 17 – Lubrication
    • Removing and installing parts of the lubrication system
    • Engine oil
    • Assembly overview – Parts of lubrication system
    • Assembly overview – Oil filter bracket
    • Removing and installing sump
    • Checking oil pressure and oil pressure switch
  • 19 – Cooling system
    • Removing and installing parts of cooling system
    • Assembly overview – parts of cooling system – engine side
    • Assembly overview – parts of cooling system – body side
    • Draining and filling coolant
    • Removing and installing coolant pump
    • Removing and installing thermostat
    • Removing and installing radiator fan V7 and radiator fan 2 V177
    • Removing and installing radiator
    • Checking cooling system for leaks
  • 20 – Fuel supply system
    • Fuel tank
    • Safety precautions when working on the fuel supply system
    • Rules for cleanliness
    • Assembly overview – fuel tank
    • Emptying fuel tank
    • Removing and installing fuel tank
    • Repairing fuel supply
    • Safety precautions when working on the fuel supply system
    • Rules for cleanliness
    • Removing and installing fuel delivery unit
    • Removing and installing fuel gauge sender G
    • Checking fuel pump
    • Checking electronic power control (EPC)
    • Function of EPC system
    • Assembly overview – accelerator pedal module
    • Removing and installing accelerator module
    • Active charcoal filter system
    • Function
    • Assembly overview – active charcoal filter system
    • Checking fuel tank breather
  • 24 – Mixture preparation, Injection
    • Repairing injection system
    • General notes on injection
    • Safety precautions
    • Rules for cleanliness
    • Technical data
    • Dismantling and assembling intake manifold – upper part
    • Dismantling and assembling intake manifold – lower part
    • Fuel rail
    • Dismantling and assembling air cleaner
    • Removing and installing intake manifold
    • Removing and installing fuel rail with intake manifold flaps
    • Removing and installing injectors
    • Renewing Teflon seal on injector
    • Cleaning throttle valve module J338
    • Engine control unit
    • Removing and installing anti-theft engine control unit
    • Reading and erasing engine control unit fault memory
  • 26 – Exhaust system
    • Removing and installing parts of exhaust system
    • Front exhaust pipe and catalytic converter with attachments
    • Silencer with mountings
    • Separating middle and rear silencers
    • Aligning exhaust system stress free
  • 28 – Ignition system
    • Repairing ignition system
    • General notes on ignition system
    • Safety precautions
    • Assembly overview – ignition system
    • Spark plugs

Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

Edition: 09.2005 (SAR5R025020)
Language: English
Format: PDF
Pages: 136

VW 4-Cylinder Injection Engine, 2005 ➤ Workshop Manual PDF free online

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