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.
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Under this brand in , 5 million 20 thousand cars were sold. 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: The lever then points in direction -B-. If the pressure drops again: If pressure does not drop any further: If no fault in the fuel line is detected: Connect pressure tester -V. If the pressure does not drop: G with connector -V.
The lever then points in position -B-. Hold container over free connection of pressure tester. The lever then points in the through flow direction -A-. At the same time slowly close shut-off tap until pressure gauge shows 4 bar. From this point on do not move position of shut-off tap.
Therefore connect multimeter -V.
G C- to vehicle battery. During the test a voltage of As the voltage at the pump is approx. If the minimum delivery rate is not attained: If the minimum delivery rate is now attained: If the minimum delivery rate is again not attained: Only when up to now no fault has been detected: G or the vehicle diagnosis, testing and information system -VAS to the cable -B- to contact 1 of the 5-pin connector.
Note If the fuel system malfunction is intermittent, the check can be performed during a road test, but a 2nd person is necessary. If the current draw is exceeded: Then release pressure by carefully removing the line. Note Collect leaking fuel with a cloth. Tightening torque of the securing bolt of the cable guide: There is no mechanical connection between accelerator and throttle valve.
The position of the accelerator pedal is transmitted to the engine control unit by two accelerator pedal position senders variable resistors together in one housing connected to the accelerator pedal. The position of the accelerator pedal driver's requirement is a main input value for the engine control unit.
The throttle valve is operated over the complete engine speed and load range by an electric motor throttle valve positioner in the throttle valve module. The throttle valve is operated by the throttle valve positioner which is controlled by the engine control unit. That is, when the accelerator is depressed halfway, the throttle valve positioner opens the throttle valve by the same amount. The throttle is then approximately half open. This means that the throttle valve can already be completely open even though the accelerator pedal is depressed half way.
This has the advantage of preventing throttling losses at the throttle valve. After evaluating the torque requirements of various components e. Servicing electronic power control EPC Removing — Remove cover for steering column -arrows-. Installing — Fit connector to the accelerator pedal module and slide the rubber grommet onto the connector again. The active charcoal filter system prevents these HC emissions escaping to the atmosphere.
The activated charcoal stores these vapours like a sponge. The opening period depends on the input signals. Intake manifold vacuum draws fresh air through the vent opening on the underside of the activated charcoal filter during the purging procedure regenerating the activated charcoal.
The pressure retention valve prevents fuel vapours from being drawn from the tank when the solenoid valve is open and intake manifold vacuum is present. When there is no electrical signal i. The activated charcoal filter will not be purged.
Activated charcoal filter system Test procedure — Pull off breather line press locking ring in. If vacuum a builds-up: If no vacuum builds up: A vacuum must build up. Before carrying out repairs and fault finding the fault memory must be interrogated. Also the vacuum hoses and connections must be checked unmetered air.
The use of clamp or screw-type clips is not permissible. It reduces the danger of a fire in a crash as the fuel pump is switched off by the fuel pump relay. Then release pressure by carefully loosening the banjo bolts. Observe following if test and measuring instruments are required during a test drive: Repairing injection system Removing — Unclip air intake hose on the upper part and on the side of the air ducting -arrows-.
To do this press release buttons. Note Renew O-rings and seals.
Note Otherwise the charging flaps between the fuel rail and the cylinder head may jam, so that it will not be possible anymore to operate them when installed. Ensure that the hooks of the puller engage in the injector recesses -arrows-.
Note The seal must not be oiled. Note The injector must easily be fitted, if necessary wait until the seal shrinks. Do not use compressed air when cleaning the throttle valve. Test procedure — Remove vacuum hose -arrow- from intake manifold flap valve -N to intake manifold on intake manifold.
Checking components If the pressure remains at 0. The vacuum reservoir in the intake manifold is OK. If the vacuum drops. Note When the intake manifold is removed, the function of the intake manifold flap can be checked simultaneously.
Note The function of the thermoelement can be checked easily by spraying with commercial chilling agent. Only when engine does not start: Select operating mode: Select vehicle system: The display shows the control unit identification and coding as well as the chassis number and the identification number of the immobilizer centre part.
Note A print-out can be made if needed. Select diagnostic function: Removing — Switch off ignition. Engine control unit Installing — Connect rear connector to engine control unit and lock it. Note Apply locking fluid to the shear bolts thread.
By heating up the shear head bolts with the hot air blower the inhibitation of the locking fluid is reduced.
Caution Cover lines, connectors and control units in the near area of the engine control unit to avoid damages by burns. Perform hot air blower adjustments as follows: The procedure for the second shear head bolt is the same.
If necessary, loosen double and single clamps and align silencer and pre-catalytic converter so that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded. Removing and installing parts of exhaust system Take bracket off. Note Renew seals and self-locking nuts. Torque settings Component Nm Exhaust manifold to cylinder head 25 6 Warm air collector plate to exhaust manifold 10 Pre-catalytic converter to exhaust manifold 40 6 Pre-catalytic converter to cylinder block 23 Bracket for exhaust manifold to gearbox 60 6 Renew 1.
Torque settings Component Nm Pre-catalytic converter to cylinder block 23 Pre-catalytic converter to main catalytic converter 25 7 Pre-catalytic converter to exhaust manifold 40 7 Exhaust system bracket to subframe 25 Warm air collector plate to exhaust manifold 10 7 Renew 1. Connect Note A second mechanic is required to tighten the repair clamp-type clip.
Front socket remains fitted loosely on the pipes. The -arrow- points forwards. Exhaust gas recirculation system When doing this swivel out of intake manifold upwards.
Before tightening all bolts screw in hand-tight. Therefore after completing all checks and repairs the fault memory must be interrogated and if necessary erased.
In this case, the control unit must be adapted. Repairing ignition system Installing — Fit puller -T on the ignition coil with final output stage. If we helped you at all - could you consider donating to keep us online?
Toggle navigation. Removing and installing sealing flange and flywheel 37 Page 44 P r o t e c t e d b y c o p y r i g h t. Removing and installing sealing flange and flywheel 39 Page 46 P r o t e c t e d b y c o p y r i g h t.
Removing and installing sealing flange and flywheel 41 Page 48 P r o t e c t e d b y c o p y r i g h t. Removing and installing sealing flange and flywheel 43 Page 50 P r o t e c t e d b y c o p y r i g h t. Removing and installing sealing flange and flywheel 45 Page 52 P r o t e c t e d b y c o p y r i g h t. Removing and installing sealing flange and flywheel 47 Page 54 P r o t e c t e d b y c o p y r i g h t. Removing and installing sealing flange and flywheel 49 Page 56 P r o t e c t e d b y c o p y r i g h t.
Removing and installing sealing flange and flywheel 51 Page 58 P r o t e c t e d b y c o p y r i g h t. Dismantling and assembling pistons and conrods 53 Page 60 P r o t e c t e d b y c o p y r i g h t. Dismantling and assembling pistons and conrods 55 Page 62 P r o t e c t e d b y c o p y r i g h t.
Removing and installing parts of lubrication system 83 Page 90 P r o t e c t e d b y c o p y r i g h t. Removing and installing parts of lubrication system 85 Page 92 P r o t e c t e d b y c o p y r i g h t. Removing and installing parts of lubrication system 87 Page 94 P r o t e c t e d b y c o p y r i g h t.
Removing and installing parts of lubrication system 89 Page 96 P r o t e c t e d b y c o p y r i g h t. Removing and installing parts of lubrication system 91 Page 98 P r o t e c t e d b y c o p y r i g h t. Removing and installing parts of lubrication system 93 Page P r o t e c t e d b y c o p y r i g h t. Removing and installing parts of lubrication system 95 Page P r o t e c t e d b y c o p y r i g h t.
Removing and installing parts of cooling system 97 Page P r o t e c t e d b y c o p y r i g h t. Removing and installing parts of cooling system 99 Page P r o t e c t e d b y c o p y r i g h t. Removing and installing parts of cooling system Page P r o t e c t e d b y c o p y r i g h t. Removing and installing parts of fuel supply system Page P r o t e c t e d b y c o p y r i g h t. Removing and installing parts of exhaust system Page P r o t e c t e d b y c o p y r i g h t.