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4-cyl engine

For Polo Vivo

Original Volkswagen repair manual


15,53 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

4.068 KB

185 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Pistons and conrods, Cylinder head, Parts of fuel supply system, Injection system, Checking components and Engine control unit J623. Show more
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Repair manual Polo Vivo 4-cyl engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical data
    1
  • 1.1 Engine number
    1
  • 1.2 Engine data
    1
  • Removing and installing engine
    2
  • 1 Removing and installing engine
    2
  • 1.1 Removing
    3
  • 1.2 Installing
    7
  • 1.3 Torque settings
    8
  • 1.4 Additional notes and assembly work for vehicles with air conditioner
    9
  • Crankshaft group
    11
  • 1 Dismantling and assembling engine
    11
  • 1.1 Assembly overview - parts l and ll
    11
  • 1.2 Part I Assembly overview - belt drive
    12
  • 1.3 Part II: Assembly overview - chain drive system
    13
  • 1.4 Removing and installing poly V-belt
    16
  • 1.5 Removing and installing valve timing housing
    17
  • 2 Cylinder block, sealing flange
    22
  • 2.1 Assembly overview
    22
  • 2.2 Renewing crankshaft oil seal - belt pulley end
    24
  • 2.3 Poly V-belt pulley securing bolt tightening procedure
    26
  • 2.4 Characteristics of the sealing flange and the assembly device T10134
    30
  • 2.5 Renewing crankshaft sealing flange - flywheel end (assembly tool T10134)
    31
  • 3 Removing and installing crankshaft
    42
  • 3.1 Exploded view crankshaft
    42
  • 3.2 Crankshaft bearings
    44
  • 3.3 Crankshaft dimensions
    44
  • 4 Pistons and conrods
    45
  • 4.1 Assembly overview
    45
  • 4.2 Checking piston
    47
  • 4.3 Checking cylinder bores
    48
  • 4.4 Piston and cylinder dimensions
    49
  • Cylinder head, valve gear
    50
  • 1 Cylinder head
    50
  • 1.1 Assembly overview
    50
  • 1.2 Checking valve timing
    52
  • 1.3 Adjusting valve timing
    55
  • 1.4 Removing and installing timing chain and chain drive for oil pump
    61
  • 1.5 Removing and installing camshaft housing
    70
  • 1.6 Removing and installing cylinder head
    76
  • 1.7 Checking compression
    80
  • 2 Valve gear
    83
  • 2.1 Assembly overview
    83
  • 2.2 Checking camshaft axial clearance
    86
  • 2.3 Reworking valve seats
    86
  • 2.4 Checking valve guides
    88
  • 2.5 Renewing valve stem seals
    89
  • Lubrication
    92
  • 1 Parts of lubrication system
    92
  • 1.1 Engine oil
    92
  • 1.2 Assembly overview
    92
  • 1.3 Removing and installing sump
    95
  • 1.4 Removing and installing oil pump
    97
  • 1.5 Checking oil pressure and oil pressure switch
    99
  • Cooling
    102
  • 1 Parts of cooling system
    102
  • 1.1 Assembly overview - parts of cooling system, body side
    102
  • 1.2 Assembly overview - parts of cooling system, engine side
    104
  • 1.3 Coolant hose schematic diagram
    106
  • 1.4 Draining and filling coolant
    107
  • 1.5 Removing and installing radiator
    116
  • 1.6 Removing and installing coolant pump
    118
  • Fuel supply system
    120
  • 1 Parts of fuel supply system
    120
  • 1.1 Assembly overview - fuel tank with attachments
    120
  • 1.2 Safety precautions when working on fuel supply system
    123
  • 1.3 Rules for cleanliness
    124
  • 1.4 Removing and installing fuel delivery unit
    124
  • 1.5 Removing and installing fuel gauge sender G
    126
  • 1.6 Removing and installing fuel tank
    127
  • 1.7 Assembly overview - fuel filter with attachments
    129
  • 1.8 Removing and installing fuel filter
    130
  • 1.9 Crash fuel shut-off
    132
  • 1.10 Checking fuel pump
    132
  • 1.11 Bleeding fuel system
    138
  • 2 Electronic power control (EPC)
    142
  • 2.1 Assembly overview
    142
  • 2.2 Removing and installing accelerator pedal module GX2
    142
  • 3 Activated charcoal filter system
    145
  • 3.1 Assembly overview
    145
  • 3.2 Checking fuel tank breather
    146
  • Mixture preparation - injection
    147
  • 1 Injection system
    147
  • 1.1 General notes on injection
    147
  • 1.2 Assembly overview - intake manifold
    147
  • 1.3 Removing and installing intake manifold
    148
  • 1.4 Assembly overview - fuel rail with injectors
    151
  • 1.5 Removing and installing injectors
    152
  • 1.6 Assembly overview - air filter
    154
  • 1.7 Removing and installing air filter housing
    156
  • 1.8 Cleaning throttle valve module J338
    157
  • 1.9 Safety precautions
    158
  • 1.10 Rules for cleanliness
    159
  • 1.11 Technical data
    160
  • 2 Checking components
    161
  • 2.1 Checking injectors for leaks and quantity injected
    161
  • 2.2 Checking fuel pressure regulator and holding pressure
    164
  • 3 Engine control unit J623
    168
  • 3.1 Removing and installing engine control unit J623
    168
  • 3.2 Vehicles with anti-theft secured engine control unit J623
    169
  • Exhaust system
    171
  • 1 Parts of the exhaust system
    171
  • 1.1 Assembly overview - catalytic converters and attachments
    171
  • 1.2 Assembly overview - silencers with mountings
    173
  • Ignition system
    175
  • 1 Ignition system
    175
  • 1.1 Assembly overview - ignition system
    175
  • 1.2 Removing and installing ignition coils with output stage
    176
  • 1.3 Safety precautions
    178
  • 1.4 Spark plug test data
    179
Manufacturer's designation 4-cyl engine
Manufacturer Volkswagen
Suitable for Polo Vivo (2018 >)
Suitable car types 6RS
Engine code CLPA, CLPB
Category Reparaturanleitung

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