VW 4-Cylinder Injection Engine, 2005 Workshop Manual

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

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