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VW Golf and Bora Haynes Service and Repair Manual. Zoltán Magyar. Uploaded by. Zoltán Magyar. Download with Google Download with Facebook. Free PDF Downloads for all Engine sizes and models for Volkswagen Bora. 1/ - Volkswagen Bora Workshop Manual PDF Download.
Note If the valve is to be renewed as part of a repair, use a new valve for the calculation. Deviation from nominal dimension max. Identification characteristics: When removing and installing the fuel gauge sender or fuel pump fuel delivery unit from a full or partly full fuel tank the following must be observed: The flow direction is marked on filter housing with arrows.
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Volkswagen Fox Workshop Manual. Volkswagen Fox — Self-study Programme Volkswagen EOS — Programme autodidactique Volkswagen Crafter Service Manual. Volkswagen Crafter Service Training. Note Observe that the contact surfaces of the poly V-belt sprocket, the securing bolt, the bearing bush and the crankshaft pulley sprocket must be free of oil and grease.
Ensure the camshaft housing does not cant when doing this.
Torque settings: Further installation is performed in the reverse order of removal. This deformation will cause a reduction of the bearing clearance. If the bearing cap bolts are loosened, the cylinder block must be replaced complete with the crankshaft. Removing and installing sealing flange and flywheel Installing Note Observe that the contact surfaces of the poly V-belt sprocket, the bolt, the bearing bush and the crankshaft pulley sprocket must be free of oil and grease. Collect leaking engine oil with a cloth.
Note Observe that all contact surfaces from the bolt for the poly V-belt sprocket - crankshaft up to the crankshaft pulley sprocket must be free of oil and grease. The bolt for the poly V-belt sprocket is spotted on the bolt head -arrow-. Always use a new bolt. Tighten cable tie tightly. Tightening torque: The position of the hole is not relevant for the later check. The marking must not be made on the washer otherwise it will not turn when turning further.
Turning further can be done in several stages. If both markings and align. In this way it is checked whether the chain sprocket has turned on the crankshaft when the bolt for the poly V-belt sprocket was tightened. If the markings and do not align. If the timing is not OK: Note First check whether the journal of the chain sprocket is still in the crankshaft groove. Replace a damaged chain sprocket. If the timing is OK: The crankshaft has been turned to the poly V-belt sprocket.
Continuation for all vehicles — Remove engine speed sender -G -arrow-. This support ring serves the function of a fitting sleeve and may not be removed prior to installation. Fitting appliance -TA - Clamping surface B - Hexagon nut C - Assembly bell housing D - Locating pin E - Hexagon socket head bolt F - Guide pin for diesel engines black knob G - Guide pin for petrol engines red knob A - Fit assembling seal with sender wheel on assembly appliance -T— Screw hexagon nut -B- to just before clamping surface -A- of threaded spindle.
Note The sender wheel must not be taken out of the sealing flange or twisted. Note Ensure sealing flange lies flat on assembly device. Note When installing sealing flange, ensure that sender wheel remains fixed in assembly device.
This ensures that the sender wheel reaches its final installation position. G and 24 mm insert -V. Note After hexagon nut is tightened to 35 Nm torque, a small air gap must be present between cylinder block and sealing flange. E - Checking sender wheel installation position on crankshaft — Screw hexagon nut -E- to end of threaded spindle. Is measurement -a- too small: F - Re-pressing sender wheel — Secure assembly tool -T to crankshaft flange using hexagon socket head bolts -A-. If dimension -a- is too small again: Note To avoid damaging the dual-mass flywheel during removal, the bolts -B- must not be removed using a pneumatic or impact driver.
The bolts -B- must be unscrewed by hand only. A - To tighten B - To loosen — Mark position of flywheel in relation to engine.
Installing Install in reverse order of removal. Dismantling and assembling pistons and conrods Deviation from nominal dimension max. Checking piston ring gap — Push ring squarely from above down to approx. Piston ring dimensions in mm new Wear limit 1st compression ring 0,04…0,08 0,15 2nd compression ring 0,02…0,06 0,15 Oil scraper ring Can not be measured 4. Cylinder head Wear protective glasses and protective gloves to avoid injuries and skin contact. Before loosening fuel pipes, wrap a cloth around the connection.
Then release pressure by carefully removing the hose. Note Lock the screwed connections on the high-pressure pump and on fuel rail when unbolting the union nuts with a spanner. Note The bolt -item 9- below the high-pressure pump remains in the camshaft housing. The retaining pins -arrows 1- must engage into the holes -arrows See hatched area on illustration.
Note Ensure no oil remnants drop on the sealing surfaces. Tighten to 10 Nm using torque wrench. Note Sealant must be left dry for approx. G Note To remove the cylinder head it is necessary to remove the engine with the gearbox. When working on the engine, the engine should be secured on the engine and gearbox support -VAS If the cylinder head must be dismantled, remove the following components: Note The thermostat is removed for a clearer illustration.
Damage will cause leakage. Ensure thereby that surfaces are not scored or scratched if abrasive paper is used, grade must not be less than The inscription Part No. Note the position of the dial gauge indicator. The holes -arrows- in the camshafts must stand as shown.
Then turn the crankshaft in engine D. To do this use counter-hold Note Centre bolt of the camshaft adjuster has a left-hand thread. To counterhold use counter-hold -T Note The camshafts must not be moved axially when turning.
Caution The camshaft clamp -T must not be used as counter-hold. Note If the crankshaft was turned more than 0. Note When tightening the camshaft bolts the crankshaft must not turn and the control chain must remain tensioned on both sides. If the camshaft clamp -T can not be fitted: If the camshaft clamp -T can be fitted: Note See relevant test unit operating instructions for instructions on how to use test unit. Compression pressures: If the fault memory was erased the readiness code must be generated.
Repairing valve gear Reworking cylinder head sealing surface Cylinder head reworking limit: Note When the sealing surface has been reworked, the valves must be set deeper by the same amount rework valve seats otherwise the valves will strike the pistons. Checking camshaft axial clearance Wear limit: Valve dimensions Note Valves must not be reworked. Only lapping-in is permitted. It is also necessary to check the valve guides for wear. If the reworking dimension is exceeded, hydraulic valve compensation can no longer be guaranteed and the cylinder head should be renewed.
The max. Note If the valve is to be renewed as part of a repair, use a new valve for the calculation. Minimum dimension: Inlet valve 7. Test procedure — Insert a new valve into the guide. The end of the valve stem must be flush with the guide. Due to slight differences in stem diameters, use only an inlet valve in inlet guide and an exhaust valve in exhaust guide.
Wear limit: When doing this, ensure that the roller rocker fingers are not interchanged. Installing — Place the plastic sleeve supplied on the appropriate valve stem.
To prevent this from causing further damage, perform the following repairs: Top up to max. Do not replenish with engine oil! Can be replenished with engine oil. Replenish with max. Removing and installing parts of lubrication system Loosen oil sump with light blows of a rubber headed hammer if necessary.
Sealant bead must be: Bolts M6: Only then fill engine oil. Note Do not remove bolt yet. Note Renew O-ring. Test procedure — Disconnect electrical wiring on oil pressure switch -Farrow-. LED must not light up. If LED does not light up: At higher engine speeds the oil pressure must not exceed 7. If necessary, release pressure before beginning repair work. In case of repair, only use spring-type clips.
G and adapter for cooling system tester -V. Removing and installing parts of cooling system Wear eye protection and protective clothing to prevent eye damage and scalding. Cover sealing cap with a cloth and open cap carefully.
Note Observe disposal regulations! Identification characteristics: Recommended mixture proportions: Without cooling system charging unit -VAS — Fill with coolant up to max. Models without auxiliary heating — Start engine and maintain an engine speed of about rpm for approx. Models with auxiliary heater Caution The auxiliary heater may only be switched on when the coolant circuit is filled as described in the following.
The coolant circuit of the auxiliary heater can be bled only this way correctly. Models without air conditioning system — Remove bolts from radiator mounting. Note The belt pulley - Coolant pump is removed via the wheel case.
To do this counterhold with modified water pump wrench -V. Note O-rings; Renew. The hole in the tappet for thermostat must show upwards.
If the pressure drops: Check pressure relief valve in sealing cap — Set cooling system tester -V. The fuel pump is activated when switching on the ignition and by the driver's door contact switch.
Therefore, for safety reasons, the fuel pump control unit -J must be pulled out of the cover and the electrical connection must be disconnected, before opening the fuel system, if the battery is not disconnected.
When removing and installing the fuel gauge sender or fuel pump fuel delivery unit from a full or partly full fuel tank the following must be observed: Wear fuel-resistant gloves! Use lint-free cloths only! Removing and installing parts of fuel supply system Do not use parts that have not been stored in their packing e.
Do not work with compressed air if this can be avoided. Do not move vehicle unless absolutely necessary. The tab on the fuel delivery unit must lie between the tongues and Note On the lower end of the filler neck there is a ball valve in the fuel tank which must not be damaged by the suction hose For this reason the hose must only be slid up to the applied mark -arrow-. Note Press locking ring inwards to release fuel lines. Note In vehicles with auxiliary heater, the connector for the metering pump -V must be disconnected additionally.
Installing Installation is carried out in reverse order of removal. To do this press securing ring in. The flow direction is marked on filter housing with arrows. Installation position The pin on the air filter housing must engage into the recess on the filter bracket guide G are recommended. When the door is opened the fuel pump is activated for 2 seconds to build-up fuel pressure. When opening the fuel system: Repairing fuel supply Installing Installation of the fuel delivery unit is carried out in the reverse order.
The -arrow- shows in direction of travel. Installing — Insert fuel gauge sender -G- in the guides on the fuel delivery unit and push up until it engages.
Note The fuel pump runs very quietly. G B- to the outer contacts of the connector with auxiliary cables from adapter set -V. G C-. LED does not light up briefly: LED lights up briefly voltage supply OK: If no open circuit can be found: G with the adapter -V. The lever then points in position -A-. If the specification is exceeded: If no fault is detected: If the specification is not obtained: G with adapter set -V. The handle points in direction of flow. Caution Close the cut-off tap only slowly.
At a fuel pressure of 8 bar, reopen the cut-off tap immediately to prevent damage to the pressure tester.
The pressure must rise to 6. When 6 bar have been reached, immediately reopen cut-off tap. If pressure has risen: Renew fuel filter. If pressure does not rise: After 10 minutes, pressure must not drop below 3.
If the pressure drops further: