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4-Cyl. injection engine (1.4 l)

For Polo [BR] / Virtus [BR] / T-Cross [BR]

Original Volkswagen repair manual


32,48 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

42.987 KB

440 Sites

Detailed technical data

Immediately readable

This repair manual contains: Engine - remove and install, Assembly mountings, Cylinder block - belt pulley side, Crankshaft, Piston and connecting rod, Toothed belt drive, Valve gear, Oil filter/Oil pressure switch, Cooling system/coolant, Radiator/Radiator fan, Fuel tank, Fuel supply unit/Fuel level sensor, Activated charcoal system, Accelerator activation, Turbocharger, Intake manifold, Lambda probe and Silencer/exhaust pipes. Show more
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Repair manual Polo [BR] / Virtus [BR] / T-Cross [BR] 4-Cyl. injection engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 \--- Change history ---
    1
  • 2 Identification
    2
  • 2.1 Engine number/engine characteristics
    2
  • 3 Safety indications
    4
  • 3.1 Safety measures for working on fuel supply system
    4
  • 3.2 Safety measures for work in vehicles with Start-Stop system
    4
  • 3.3 Safety measures for test drives with testing and measuring equipment
    4
  • 3.4 Safety measures when working on the cooling system
    5
  • 3.5 Safety measures when working on the ignition system
    5
  • 4 Repair instructions
    6
  • 4.1 Cleanliness rules
    6
  • 4.2 Foreign bodies on the engine
    6
  • 4.3 Contact corrosion
    6
  • 4.4 Cable routing and fastening
    6
  • 4.5 Radiators and condensers - assembly
    7
  • Removing and installing engine
    8
  • 1 Engine - remove and install
    8
  • 1.1 Engine - removal
    8
  • 1.2 Engine and gearbox - separate
    21
  • 1.3 Engine in the gearbox and engine support - secure
    25
  • 1.4 Engine - install
    26
  • 2 Assembly mountings
    30
  • 2.1 Assembly mountings - assembly overview
    30
  • 2.2 Hold the engine in assembly position
    35
  • 2.3 Engine bracket - remove and install
    40
  • 2.4 Gearbox bracket - remove and install
    42
  • 2.5 Pendulum support (torque limiter) - remove and install
    44
  • 2.6 Assembly mountings adjustment - check
    45
  • 2.7 Assembly mountings - adjust
    46
  • Crankshaft group
    49
  • 1 Cylinder block - belt pulley side
    49
  • 1.1 Poly-V belt drive - assembly overview
    49
  • 1.2 Pulley side sealing flange - assembly overview
    51
  • 1.3 Poly-V belt - remove and install
    53
  • 1.4 Poly-V belt tensioner - remove and install
    55
  • 1.5 Pulley (vibration damper) - remove and install
    56
  • 1.6 Engine console - remove and install
    57
  • 1.7 Crankshaft seal on the pulley side - replace
    62
  • 1.8 Sealing flange on the belt pulley side - remove and install
    64
  • 2 Cylinder block, gearbox side
    68
  • 2.1 Cylinder block (gearbox side) - assembly overview
    68
  • 2.2 Clutch Disk - removal and installation
    70
  • 2.3 Sealing flange on the gearbox side - remove and install
    73
  • 3 Crankshaft
    86
  • 3.1 Crankshaft - dimensions
    86
  • 3.2 Crankshaft axial clearance - measure
    86
  • 4 Piston and connecting rod
    88
  • 4.1 Piston and connecting rod - assembly overview
    88
  • 4.2 Pistons - remove and install
    92
  • 4.3 Oil injectors - remove and install
    93
  • 4.4 Piston and cylinder - test
    94
  • 4.5 Conrod radial clearance - check
    96
  • Cylinder head, valve gear
    98
  • 1 Toothed belt drive
    98
  • 1.1 Toothed belt cover - assembly overview
    98
  • 1.2 Toothed belt - assembly overview
    99
  • 1.3 Toothed belt guard - remove and install
    101
  • 1.4 Valve timing - check
    102
  • 1.5 Remove the camshaft toothed belt
    108
  • 1.6 Valve timing - adjust
    115
  • 1.7 Toothed belt - remove and install
    123
  • 2 Engine cylinder head
    130
  • 2.1 Engine cylinder head - assembly overview
    130
  • 2.2 Cylinder head cover with camshafts - assembly overview
    132
  • 2.3 Engine cylinder head - remove and install
    135
  • 2.4 Cylinder head cover with camshafts - remove and install
    140
  • 2.5 Compression pressure - check
    145
  • 3 Valve gear
    147
  • 3.1 Valve gear - assembly overview
    147
  • 3.2 Camshaft adjustment valve 1 N205 - remove and install
    149
  • 3.3 Exhaust camshaft adjustment valve 1 N318 - remove and install
    149
  • 3.4 Camshaft control shaft adjuster - remove and install
    150
  • 3.5 Camshaft axial clearance - measure
    151
  • 3.6 Camshaft seal - remove and install
    152
  • 3.7 Valve stem sealant - remove and install
    158
  • 4 Inlet and exhaust valves
    169
  • 4.1 Valve guides - check
    169
  • 4.2 Valves - check
    170
  • 4.3 Valve dimensions
    170
  • Lubrication
    171
  • 1 Crankcase/oil pump
    171
  • 1.1 Crankcase/oil pump - assembly overview
    171
  • 1.2 Sump (bottom section) - remove and install
    175
  • 1.3 Oil pump - remove and install
    180
  • 1.4 Sump (top section) - remove and install
    182
  • 1.5 Engine oil
    188
  • 2 Engine oil cooler
    189
  • 2.1 Engine oil cooler - assembly overview
    189
  • 2.2 Engine oil cooler - remove and install
    189
  • 3 Crankcase breather
    191
  • 3.1 Crankcase breather - assembly overview
    191
  • 3.2 Oil separator - remove and install
    192
  • 4 Oil filter/Oil pressure switch
    195
  • 4.1 Oil filter/Oil pressure switch - assembly overview
    195
  • 4.2 Oil pressure switch F1 - remove and install
    196
  • 4.3 Oil pressure switch F378 – remove and install
    197
  • 4.4 Oil pressure control valve N428 - remove and install
    198
  • 4.5 Oil pressure - check
    199
  • Cooling
    202
  • 1 Cooling system/coolant
    202
  • 1.1 Coolant lines - connection diagram
    202
  • 1.2 Coolant - drain and fill
    204
  • 1.3 Cooling system - check tightness
    211
  • 2 Coolant pump/coolant thermostat
    214
  • 2.1 Coolant pump/coolant thermostat - assembly overview
    214
  • 2.2 Air intake cooling pump - assembly overview
    217
  • 2.3 Coolant temperature sensor - assembly overview
    218
  • 2.4 Coolant pump - remove and install
    219
  • 2.5 Coolant pump toothed belt roller - remove and install
    225
  • 2.6 Coolant thermostat - remove and install
    226
  • 2.7 Air intake cooling pump - remove and install
    230
  • 2.8 Coolant temperature sensor G62 - remove and install
    232
  • 2.9 radiator outlet coolant temperature sender G83 remove and install
    233
  • 3 Coolant lines
    235
  • 3.1 Coolant lines - assembly overview
    235
  • 3.2 Coolant lines - remove and install
    235
  • 4 Radiator/Radiator fan
    240
  • 4.1 Radiator - assembly overview
    240
  • 4.2 Fan cowl and radiator fan - assembly overview
    242
  • 4.3 Radiator - remove and install
    243
  • 4.4 Fan housing - remove and install
    245
  • 4.5 Radiator fan V7 - remove and install
    246
  • 4.6 Charge air cooling system radiator - remove and install
    247
  • Fuel supply system
    251
  • 1 Fuel tank
    251
  • 1.1 Fuel tank - assembly overview
    251
  • 1.2 Fuel tank - remove and install
    253
  • 1.3 Fuel tank - drain
    260
  • 2 Fuel supply unit/Fuel level sensor
    271
  • 2.1 Fuel pump (pre-supply pump) G6/Fuel gauge sensor G - assembly overview
    271
  • 2.2 Fuel pump (pre-supply pump) G6/Fuel gauge sensor G - remove and install
    273
  • 2.3 Fuel gauge sensor G - remove and install
    278
  • 2.4 Installation opening cover - remove and install
    279
  • 3 Plug-in connectors
    281
  • 3.1 Plug-in connectors - disconnect
    281
  • 4 Fuel filter
    287
  • 4.1 Fuel filter - remove and install
    287
  • 5 Activated charcoal system
    289
  • 5.1 Activated charcoal filter system - assembly overview
    289
  • 5.2 Activated charcoal filter - remove and install
    290
  • 5.3 Fuel tank ventilation - check
    291
  • 6 Accelerator activation
    298
  • 6.1 Accelerator pedal module - assembly overview
    298
  • 6.2 Accelerator pedal module GX2 - remove and install
    298
  • 7 Fuel system pressurisation pump G6
    300
  • 7.1 Fuel system pressurisation pump G6 - check
    300
  • 7.2 Fuel pump control unit J538 - remove and install
    319
  • 8 Fuel lines
    321
  • 8.1 Fuel lines - remove and install
    321
  • Turbocharging/supercharging
    326
  • 1 Turbocharger
    326
  • 1.1 Turbocharger - assembly overview
    326
  • 1.2 Turbocharger - remove and install
    330
  • 1.3 Load pressure control V465 - remove and install
    334
  • 1.4 Turbocharger inlet nozzle - remove and install
    336
  • 2 Supercharging air system
    338
  • 2.1 Supercharging air system - assembly overview
    338
  • 2.2 Load pressure sensor GX26 - remove and install
    341
  • 2.3 Intercooler - remove and install
    342
  • 2.4 Charge air system - check air-tightness
    345
  • 2.5 Air duct - remove and install
    347
  • Mixture preparation - injection
    350
  • 1 Injection system
    350
  • 1.1 Injection system - assembly overview
    350
  • 1.2 High fuel pressure - relieve
    354
  • 2 Air cleaner
    356
  • 2.1 Air filter - assembly overview
    356
  • 2.2 Air filter - remove and install
    358
  • 2.3 Air duct - remove and install
    359
  • 3 Intake manifold
    361
  • 3.1 Intake manifold - assembly overview
    361
  • 3.2 Intake manifold - remove and install
    364
  • 3.3 Throttle butterfly valve control unit GX3 - remove and install
    366
  • 3.4 Throttle valve control unit GX3 - clean
    367
  • 4 Injection valves
    369
  • 4.1 Fuel rail with injection valves - assembly overview
    369
  • 4.2 Fuel distributor - removal and installation
    371
  • 4.3 Injection valves - remove and install
    372
  • 4.4 Injectors - clean
    378
  • 5 Transmitters and sensors
    380
  • 5.1 Intake manifold sensor GX9 - remove and install
    380
  • 5.2 Fuel pressure sensor G247 - remove and install
    381
  • 5.3 Fuel pressure sensor G247 - check
    382
  • 5.4 Ethanol concentration sensor G708
    384
  • 5.5 Control unit and actuator for structure-borne sound – assembly overview
    388
  • 6 High pressure pump
    390
  • 6.1 High pressure pump - assembly overview
    390
  • 6.2 High pressure pump - remove and install
    391
  • 6.3 Rigid high pressure line - remove and install
    392
  • 7 Lambda probe
    395
  • 7.1 Lambda probe - assembly overview
    395
  • 7.2 Lambda probe - remove and install
    396
  • 8 Engine control unit
    400
  • 8.1 Engine control unit J623 - remove and install
    400
  • Exhaust system
    402
  • 1 Silencer/exhaust pipes
    402
  • 1.1 Silencer - assembly overview
    402
  • 1.2 Silencer/exhaust pipes - detach
    404
  • 1.3 Centre silencer with rear silencer - remove and install
    406
  • 1.4 Centre silencer - remove and install
    410
  • 1.5 Rear silencer - remove and install
    412
  • 1.6 Exhaust system - tension free alignment
    413
  • 1.7 Exhaust tail pipe - align
    413
  • 1.8 Exhaust system - check tightness
    414
  • 1.9 Pipe clamp installation position
    414
  • 2 Emission control
    416
  • 2.1 Emission control - assembly overview
    416
  • 2.2 Catalytic converter - remove and install
    419
  • Ignition system
    424
  • 1 Ignition system
    424
  • 1.1 Ignition system - assembly overview
    424
  • 1.2 Test data, spark plugs
    426
  • 1.3 Ignition coil with final power stage - remove and install
    426
  • 1.4 Knock sensor 1 G61 - remove and install
    429
  • 1.5 Hall Sensor - remove and install
    430
  • 1.6 Engine speed sensor G28 - remove and install
    431
Manufacturer's designation 4-Cyl. injection engine (1.4 l)
Manufacturer Volkswagen
Suitable for Polo [BR] (2018 >) / Virtus [BR] (2018 >) / T-Cross [BR] (2020 >)
Suitable car types BZ1, BF1
Engine code DSJA
Category Reparaturanleitung

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