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  • Examplepage for repair manual 4-Cyl. injection engine (1.6 l)
  • Examplepage for repair manual 2 4-Cyl. injection engine (1.6 l)
  • Examplepage for repair manual 3 4-Cyl. injection engine (1.6 l)

4-Cyl. injection engine (1.6 l)

For GOL BR / Voyage BR / Saveiro Cab. Dupla [BR] / Saveiro Cab. Sim. / Saveiro Cab. Est. / Voyage [BR] / Gol [BR]

Original Volkswagen repair manual


18,51 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

6.963 KB

226 Sites

Detailed technical data

Immediately readable

This repair manual contains: Engine - remove and install, Power-drive unit supports, Cylinder block (pulley side), Crankshaft, Toothed belt drive, Lubrication system components, Oil filter / Oil pressure switch F1, Radiator / Radiator fan, Fuel supply unit / fuel level sensor, Engine power electronic adjustment (electronic accelerator), Injection valves, Air cleaner, Intake manifold and READINESS code. Show more
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Repair manual 4-Cyl. injection engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 \--- Change history ---
    1
  • 2 Safety instructions
    2
  • 2.1 Safety measures regarding work on the fuel supply
    2
  • 2.2 Safety measures for working on the injection and ignition system
    2
  • 3 Repair instructions
    4
  • 3.1 Cleanliness rules
    4
  • 4 Technical Data
    5
  • 4.1 Engine number
    5
  • 4.2 Engine characteristics
    5
  • Removing and installing engine
    7
  • 1 Engine - remove and install
    7
  • 1.1 Engine - removal
    7
  • 1.2 Engine - fasten to assembly stand
    17
  • 1.3 Engine - installation
    18
  • 2 Power-drive unit supports
    21
  • 2.1 Power unit brackets - assembly overview
    21
  • 2.2 Drive train mountings - alignment
    23
  • Crankshaft group
    26
  • 1 Cylinder block (pulley side)
    26
  • 1.1 Poly-V belt drive (elastic) - assembly overview
    27
  • 1.2 Cylinder block (pulley side) - assembly overview
    29
  • 1.3 Seal lid - replace
    31
  • 1.4 Poly-V belt (elastic) - remove and install
    31
  • 1.5 Crankshaft pulley - removal and installation
    36
  • 1.6 Crankshaft seal (pulley side) - replace
    36
  • 2 Cylinder block, gearbox side
    40
  • 2.1 Crankshaft and flywheel flanges - assembly overview
    40
  • 2.2 Flywheel - remove and install
    42
  • 2.3 Crankshaft flange (flywheel side) with Engine speed sensor G28 rotor - replace
    43
  • 3 Crankshaft
    55
  • 3.1 Crankshaft - assembly overview
    55
  • 3.2 Identifying engine bearing shells
    56
  • 3.3 Colour codes
    58
  • 3.4 Crankshaft - dimensions
    58
  • 4 Pistons and conrods
    59
  • 4.1 Pistons and conrods - assembly overview
    59
  • 4.2 Pistons, rings, and cylinders - check
    61
  • 4.3 Piston and cylinder - dimensions
    64
  • Cylinder head, valve gear
    65
  • 1 Engine cylinder head
    65
  • 1.1 Engine cylinder head - assembly overview
    65
  • 1.2 Cylinder head - remove and install
    68
  • 1.3 Compression - check
    73
  • 2 Toothed belt drive
    76
  • 2.1 Toothed belt semi-automatic tensioning pulley - check
    76
  • 2.2 Toothed belt - remove and install, adjust
    77
  • 3 Camshaft
    84
  • 3.1 Camshaft - assembly overview
    84
  • 3.2 Camshaft - check axial clearance
    87
  • 3.3 Camshaft seal - replace
    89
  • 3.4 Camshaft and cylinder head cover - remove and install
    94
  • 3.5 Valve stem sealant - replace
    99
  • 4 Inlet and exhaust valves
    102
  • 4.1 Valve seat - trim
    102
  • 4.2 Valve guides - check
    104
  • Lubrication
    106
  • 1 Lubrication system components
    106
  • 1.1 Lubricating system components - assembly overview
    106
  • 1.2 Engine oil
    109
  • 1.3 Crankcase - remove and install
    110
  • 1.4 Oil pump - remove and install
    113
  • 2 Oil filter / Oil pressure switch F1
    118
  • 2.1 Oil pressure switch F1 - remove and install
    118
  • 2.2 Oil pressure and Oil pressure switch F1 - check
    118
  • 2.3 Oil filter - replace
    120
  • Cooling
    123
  • 1 Cooling system components
    123
  • 1.1 Hose connection diagram for cooling system
    123
  • 1.2 Cooling system - drainage and replenishment
    124
  • 1.3 Cooling system - check air-tightness
    133
  • 1.4 Coolant tank flap - check safety valve
    135
  • 2 Water pump / coolant adjustment
    137
  • 2.1 Water pump - assembly overview
    137
  • 2.2 Thermostat valve - assembly overview
    138
  • 2.3 Water pump - remove and install
    140
  • 3 Radiator / Radiator fan
    143
  • 3.1 Radiator / Radiator fan - assembly overview
    143
  • 3.2 Radiator - remove and install
    145
  • 3.3 Cowling with Radiator fan V7 - remove and install
    146
  • 3.4 Radiator fan V7 - remove and install
    147
  • Fuel supply system
    148
  • 1 Fuel supply system components
    148
  • 1.1 Fuel tank components with accessories and fuel filter - assembly overview
    148
  • 1.2 Cold start system components - remove and install
    154
  • 1.3 Fuel tank - remove and install
    155
  • 1.4 Fuel reservoir (EU5) - remove and install
    157
  • 2 Fuel supply unit / fuel level sensor
    161
  • 2.1 Fuel pump (pre-supply pump) G6 - remove and install
    161
  • 2.2 Fuel gauge sensor G - remove and install
    164
  • 3 Activated charcoal filter system
    165
  • 3.1 Operation
    165
  • 3.2 Activated charcoal filter system - assembly overview
    165
  • 3.3 Magnetic valve 1 for activated charcoal filter N80 - remove and install
    166
  • 3.4 Fuel tank ventilation - check
    167
  • 4 Engine power electronic adjustment (electronic accelerator)
    169
  • 4.1 Engine power electronic adjustment (electronic accelerator) - assembly overview
    169
  • 4.2 Electronic accelerator system operation
    169
  • 5 Fuel pump (pre-supply pump) G6
    171
  • 5.1 Voltage supply of the Fuel pump (pre-supply pump) G6 - check
    173
  • 5.2 Fuel supply system output - check
    175
  • 5.3 Current consumption - check
    180
  • 5.4 Fuel pump (pre-supply pump) G6 retention valve - check
    180
  • Mixture preparation - injection
    182
  • 1 Injection system
    182
  • 1.1 General instructions regarding the injection system
    182
  • 1.2 Injection system - assembly overview
    182
  • 1.3 Injection components - assembly overview
    184
  • 1.4 Technical Data
    187
  • 2 Injection valves
    188
  • 2.1 Fuel rail with injectors - assembly overview
    188
  • 2.2 Injection valves - check
    188
  • 2.3 Injection valves - clean
    193
  • 3 Air cleaner
    195
  • 3.1 Air filter - assembly overview
    195
  • 3.2 Air filter - remove and install
    196
  • 4 Intake manifold
    198
  • 4.1 Intake manifold - assembly overview
    198
  • 4.2 Throttle valve control unit J338 - clean
    199
  • 5 Component checks
    201
  • 5.1 Supply system pressure, fuel pressure gauge and residual pressure - check
    201
  • 6 READINESS code
    207
  • 6.1 Creating and Interpreting the READINESS code
    207
  • 7 Engine control unit J623
    208
  • 7.1 Engine control unit J623 - remove and install
    208
  • 7.2 Adjust components
    209
  • 7.3 Check the event memory in the Engine control unit J623 and delete it
    210
  • Exhaust system
    212
  • 1 Rear muffler
    212
  • 1.1 Rear muffler - assembly overview
    212
  • 1.2 Silencer/exhaust pipes - detach
    212
  • 1.3 Exhaust system - tension free alignment
    213
  • 1.4 Pipe clamp installation position
    214
  • Glow plug system
    218
  • 1 Ignition system
    218
  • 1.1 General instructions regarding the ignition system
    218
  • 1.2 Ignition system - assembly overview
    218
  • 1.3 Spark plugs Q - test data
    220
Manufacturer's designation 4-Cyl. injection engine (1.6 l)
Manufacturer Volkswagen
Suitable for GOL BR (2017) / Voyage BR (2017) / Saveiro Cab. Dupla [BR] (2017 >) / Saveiro Cab. Sim. (2017 >) / Saveiro Cab. Est. (2017 >) / Voyage [BR] (2019 >) / Gol [BR] (2019 >)
Suitable car types 5U5, 5UD, 5UF, 5UE, 5UG, 5U7
Engine code CFZA
Category Reparaturanleitung

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