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4-Cyl. injection engine (1.6 l)

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

Original Volkswagen repair manual


30,85 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

38.949 KB

412 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, Oil filter/Oil pressure switch F1, Cooling system/coolant, Radiator, Fuel tank, Fuel supply unit/Fuel level sensor, Activated charcoal system, Accelerator activation, Injection valves, Air cleaner, Intake manifold and Front exhaust pipe with catalytic converters. 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 Identification
    2
  • 2.1 Engine number/engine characteristics
    2
  • 3 Safety instructions
    4
  • 3.1 Safety measures regarding work on the fuel supply
    4
  • 3.2 Safety measures in test drives using testing and measurement devices
    5
  • 3.3 Safety measures when working on the ignition system
    6
  • 3.4 Safety measures when working on the exhaust system
    6
  • 3.5 Safety measures when working on the cooling system
    6
  • 4 Repair instructions
    8
  • 4.1 Cleanliness rules
    8
  • 4.2 General Notes
    8
  • 4.3 General repair instructions
    8
  • 4.4 Foreign bodies on the engine
    9
  • 4.5 Contact corrosion
    9
  • 4.6 Connection installation and fastening
    9
  • 4.7 Radiator and capacitor installation
    9
  • Removing and installing engine
    10
  • 1 Engine - remove and install
    10
  • 1.1 Engine - removal
    10
  • 1.2 Engine - separate gearbox
    21
  • 1.3 Engine - secure to engine and gearbox support
    25
  • 1.4 Engine - installation
    27
  • 1.5 Engine - remove and install, summarized instructions
    31
  • 2 Power-drive unit supports
    34
  • 2.1 Power unit brackets - assembly overview
    34
  • 2.2 Power unit bracket (engine side) - remove and install
    37
  • 2.3 Drive-train mounting (gearbox side) - remove and install
    38
  • 2.4 Pendulum support (torque limiter) - remove and install
    41
  • 2.5 Support the engine in assembly position
    42
  • 2.6 Drive train mountings - adjust
    46
  • 2.7 Drive train mounting adjustment - check
    47
  • Crankshaft group
    49
  • 1 Cylinder block (pulley side)
    49
  • 1.1 Poly-V belt - assembly overview
    49
  • 1.2 Poly-V belt - remove and install
    51
  • 1.3 Poly-V belt tensioner - remove and install
    53
  • 1.4 Crankshaft pulley (vibration damper) - remove and install
    54
  • 1.5 Engine console - remove and install
    55
  • 1.6 Crankshaft seal (pulley side) - replace
    59
  • 2 Cylinder block (gearbox side)
    63
  • 2.1 Cylinder block (gearbox side) - assembly overview
    63
  • 2.2 Flywheel - remove and install
    67
  • 2.3 Clutch Disk - removal and installation
    68
  • 2.4 Crankshaft flange (flywheel side) - replace
    71
  • 3 Crankshaft
    85
  • 3.1 Crankshaft - dimensions
    85
  • 3.2 Crankshaft - check axial clearance
    85
  • 4 Pistons and conrods - remove and install
    87
  • 4.1 Pistons and conrods - assembly overview
    87
  • 4.2 Pistons - remove and install
    91
  • 4.3 Pistons, rings, and cylinders - check
    92
  • 4.4 Pistons, rings, and cylinders - check
    95
  • 4.5 Connecting rod (radial clearance) - check
    97
  • 4.6 New conrod - separate
    97
  • 4.7 Oil injectors - remove and install
    98
  • Cylinder head, valve gear
    100
  • 1 Engine cylinder head
    100
  • 1.1 Engine cylinder head - assembly overview
    100
  • 1.2 Cylinder head cover - assembly overview
    102
  • 1.3 Engine cylinder head - remove and install
    105
  • 1.4 Cylinder head - remove and install, summarized instructions
    112
  • 1.5 Cylinder head cover with exhaust and inlet camshafts - remove and install
    114
  • 1.6 Compression - check
    117
  • 2 Toothed belt drive
    122
  • 2.2 Toothed belt - assembly overview
    122
  • 2.3 Valve timing - check
    124
  • 2.4 Remove the toothed belt from the camshafts
    129
  • 2.5 Toothed belt - remove and install
    138
  • 3 Camshaft mechanism - repair
    147
  • 3.1 Camshaft mechanism - assembly overview
    147
  • 3.2 Inlet camshaft regulator - remove and install
    149
  • 3.3 Exhaust camshaft sprocket - remove and install
    155
  • 3.4 Crankshaft - check axial clearance
    159
  • 3.5 Crankshaft seal - replace
    160
  • 3.6 Camshaft adjustment valve 1 N205 - remove and install
    167
  • 3.7 Valve stem sealant - replace
    168
  • 4 Inlet and exhaust valves
    179
  • 4.1 Valve guides - check
    179
  • 4.2 Valves - check
    180
  • 4.3 Valves - dimensions
    180
  • Lubrication
    181
  • 1 Crankcase/oil pump
    181
  • 1.1 Crankcase/oil pump - assembly overview
    181
  • 1.2 Lower sump - remove and install
    185
  • 1.3 Upper crankcase - remove and install
    190
  • 1.4 Oil pump - remove and install
    194
  • 1.5 Engine oil
    197
  • 2 Engine oil cooler
    198
  • 2.1 Engine oil cooler - assembly overview
    198
  • 2.2 Engine oil cooler - remove and install
    198
  • 3 Engine crankcase ventilation
    200
  • 3.1 Engine crankcase ventilation - assembly overview
    200
  • 3.2 Crankcase ventilation device - remove and install
    201
  • 4 Oil filter/Oil pressure switch F1
    204
  • 4.1 Oil filter/Oil pressure switch F1 - assembly overview
    204
  • 4.2 Oil pressure switch 0.3...0.6 bar F1 - remove and install
    204
  • 4.3 Oil pressure and Oil pressure switch F1 - check
    206
  • 4.4 Oil filter - remove and install
    208
  • Cooling
    210
  • 1 Cooling system/coolant
    210
  • 1.1 Hose connection diagram for cooling system
    210
  • 1.2 Cooling system - check air-tightness
    211
  • 1.3 Coolant tank flap - check safety valve
    214
  • 1.4 Cooling system - drainage and replenishment
    216
  • 2 Coolant/cooling system water pump
    224
  • 2.1 Water pump - assembly overview
    224
  • 2.2 Coolant temperature sensor - assembly overview
    227
  • 2.3 Water pump - remove and install
    228
  • 2.4 Water pump sprocket - remove and install
    234
  • 2.5 Thermostat valve - remove and install
    235
  • 2.6 Water pump toothed belt - remove and install
    243
  • 2.7 Coolant temperature sensor G62 - remove and install
    246
  • 3 Cooling system piping
    250
  • 3.1 Coolant system piping - Assembly overview
    250
  • 3.2 Cooling system piping - remove and install
    250
  • 4 Radiator
    253
  • 4.1 Radiator - assembly overview
    253
  • 4.2 Cowling with Radiator fan V7 - assembly overview
    254
  • 4.3 Radiator - remove and install
    255
  • 4.4 Cowling with Radiator fan V7 - remove and install
    259
  • 4.5 Radiator fan V7 - remove and install
    260
  • Fuel supply system
    262
  • 1 Fuel tank
    262
  • 1.1 Fuel tank - assembly overview
    262
  • 1.2 Fuel tank - remove and install
    264
  • 1.3 Fuel tank - drain
    271
  • 2 Fuel supply unit/Fuel level sensor
    282
  • 2.1 Fuel pump (pre-supply pump) G6/Fuel gauge sensor G - assembly overview
    282
  • 2.2 Fuel pump (pre-supply pump) G6/Fuel gauge sensor G - remove and install
    284
  • 2.3 Fuel gauge sensor G - remove and install
    289
  • 2.4 Installation opening cover - remove and install
    290
  • 3 Plug-in connectors
    292
  • 3.1 Plug-in connectors - disconnect
    292
  • 4 Fuel filter
    298
  • 4.1 Fuel filter - remove and install
    298
  • 5 Activated charcoal system
    300
  • 5.1 Activated charcoal filter system - assembly overview
    300
  • 5.2 Activated charcoal filter - remove and install
    302
  • 5.3 Fuel tank ventilation - check
    303
  • 6 Accelerator activation
    310
  • 6.1 Accelerator pedal module - assembly overview
    310
  • 6.2 Accelerator pedal module GX2 - remove and install
    310
  • 7 Fuel system pressurisation pump G6
    312
  • 7.1 Fuel system pressurisation pump G6 - check
    312
  • 8 Fuel lines
    331
  • 8.1 Fuel lines - remove and install
    331
  • Mixture preparation - injection
    336
  • 1 Injection system
    336
  • 1.1 Injection system - assembly overview
    336
  • 1.2 Combustion system - assembly overview
    340
  • 2 Injection valves
    343
  • 2.1 Fuel rail with injection valves - assembly overview
    343
  • 2.2 Fuel rail with injection valves - assembly overview
    345
  • 2.3 Fuel distributor - removal and installation
    346
  • 2.4 Injection valves - remove and install
    349
  • 2.5 Injection valves - check
    350
  • 2.6 Injection valves - clean
    354
  • 3 Air cleaner
    356
  • 3.1 Air filter - assembly overview
    356
  • 3.2 Air filter - remove and install
    357
  • 4 Intake manifold
    359
  • 4.1 Intake manifold - assembly overview
    359
  • 4.2 Intake manifold - remove and install
    361
  • 4.3 Throttle butterfly valve control unit J338 - remove and install
    364
  • 4.4 Throttle valve control unit J338 - clean
    365
  • 5 Transmitters and sensors
    367
  • 6 Engine control unit J623
    369
  • 6.1 Engine control unit J623 - remove and install
    369
  • 7 Lambda probe
    371
  • 7.1 Lambda probe - assembly overview
    371
  • 7.2 Lambda probe - remove and install
    372
  • Exhaust system
    376
  • 1 Silencer/exhaust pipes
    376
  • 1.1 Silencer - assembly overview
    376
  • 1.2 Silencer/exhaust pipes - detach
    377
  • 1.3 Centre silencer with rear silencer - remove and install
    379
  • 1.4 Centre silencer - remove and install
    383
  • 1.5 Rear silencer - remove and install
    385
  • 1.6 Exhaust system - tension free alignment
    386
  • 1.7 Exhaust system - check tightness
    387
  • 1.8 Pipe clamp installation position
    387
  • 2 Front exhaust pipe with catalytic converters
    389
  • 2.1 Front exhaust pipe with catalytic converters - assembly overview
    389
  • 2.2 Catalytic converter - remove and install
    392
  • Ignition system
    395
  • 1 Ignition system
    395
  • 1.1 Ignition system - assembly overview
    395
  • 1.2 Ignition coils with final power stage - assembly overview
    397
  • 1.3 Test data, spark plugs
    398
  • 1.4 Ignition coil with final power stage - remove and install
    398
  • 1.5 Knock sensor 1 G61 - remove and install
    402
  • 1.6 Hall Sensor G40 - remove and install
    403
  • 1.7 Engine speed sensor G28 - remove and install
    404
  • 1.8 Heater control unit J65 - remove and install
    405
Manufacturer's designation 4-Cyl. injection engine (1.6 l)
Manufacturer Volkswagen
Suitable for Polo [BR] (2018 >) / Virtus [BR] (2018 >) / T-Cross [BR] (2020 >) / Nivus [BR] (2020 >)
Suitable car types BZ1, BF1, CH1
Engine code CWSA
Category Reparaturanleitung

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