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

4-cylinder injection engine (1.6 l engine)

For Polo

Original Volkswagen repair manual


19,65 €7% VAT incl.

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  • English

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Language: English

Digital PDF file

29.600 KB

242 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Assembly mountings, Cylinder block (pulley end), Crankshaft, Pistons and conrods, Toothed belt drive, Valve gear, Sump, oil pump, Engine oil cooler, Oil filter, oil pressure switch, Coolant pump, regulation of cooling system, Lambda probe and Exhaust pipes, silencers. Show more
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Repair manual Polo 4-cylinder injection engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Identification
    1
  • 1.1 Engine number, engine data
    1
  • 2 Safety instructions
    2
  • 2.1 Safety precautions when working on fuel supply system
    2
  • 2.2 Safety precautions when working on vehicles with a Start/Stop system
    2
  • 2.4 Safety precautions when working on ignition system
    3
  • 2.5 Safety precautions when working on cooling system
    3
  • 3 Repair instructions
    4
  • 3.1 Rules for cleanliness
    4
  • 3.2 Foreign objects in engine
    4
  • 3.3 Contact corrosion
    4
  • 3.4 Routing and securing lines
    4
  • 3.5 Installing coolers, condensers and radiators
    5
  • Removing and installing engine
    6
  • 1 Removing and installing engine
    6
  • 1.1 Removing engine
    6
  • 1.2 Separating engine and gearbox
    14
  • 1.3 Securing engine on engine and gearbox support
    19
  • 1.4 Installing engine
    20
  • 2 Assembly mountings
    24
  • 2.1 Assembly overview - assembly mountings
    24
  • 2.2 Supporting engine in installation position
    29
  • 2.3 Removing and installing engine mountings
    32
  • 2.4 Removing and installing gearbox mounting
    34
  • 2.5 Removing and installing pendulum support
    35
  • Crankshaft group
    38
  • 1 Cylinder block (pulley end)
    38
  • 1.1 Assembly overview - poly V-belt drive
    38
  • 1.2 Removing and installing poly V-belt
    42
  • 1.3 Removing and installing tensioner for poly V-belt
    44
  • 1.4 Removing and installing vibration damper
    44
  • 1.5 Removing and installing engine support
    45
  • 1.6 Renewing crankshaft oil seal - belt pulley end
    48
  • 2 Cylinder block, gearbox end
    52
  • 2.1 Assembly overview - cylinder block, gearbox end
    52
  • 2.2 Removing and installing flywheel
    55
  • 2.3 Removing and installing drive plate
    56
  • 2.4 Removing and installing sealing flange on gearbox side
    58
  • 3 Crankshaft
    68
  • 3.1 Measuring axial clearance of crankshaft
    68
  • 4 Pistons and conrods
    70
  • 4.1 Assembly overview - pistons and conrods
    70
  • 4.2 Removing and installing pistons
    72
  • 4.3 Removing and installing oil spray jets
    73
  • 4.4 Checking pistons and cylinder bores
    74
  • 4.5 Separating new conrod
    75
  • 4.6 Checking radial clearance of conrods
    76
  • Cylinder head, valve gear
    77
  • 1 Cylinder head
    77
  • 1.1 Assembly overview - cylinder head
    77
  • 1.2 Assembly overview - camshaft housing
    79
  • 1.3 Removing and installing cylinder head
    80
  • 1.4 Removing and installing camshaft housing
    83
  • 1.5 Checking compression
    85
  • 2 Toothed belt drive
    88
  • 2.1 Assembly overview - toothed belt cover
    88
  • 2.2 Assembly overview - toothed belt
    89
  • 2.3 Checking valve timing
    90
  • 2.4 Removing toothed belt from camshaft
    94
  • 2.5 Removing and installing toothed belt
    107
  • 3 Valve gear
    122
  • 3.1 Assembly overview - valve gear
    122
  • 3.2 Removing and installing camshaft adjuster
    123
  • 3.3 Measuring axial play of camshaft
    123
  • 3.4 Removing and installing camshaft oil seal
    124
  • 3.5 Removing and installing inlet camshaft control valve 1 N205
    130
  • 3.6 Removing and installing valve stem seals
    130
  • 4 Inlet and exhaust valves
    138
  • 4.1 Checking valve guides
    138
  • 4.2 Checking valves
    138
  • 4.3 Valve dimensions
    139
  • Lubrication
    140
  • 1 Sump, oil pump
    140
  • 1.1 Assembly overview - sump and oil pump
    140
  • 1.2 Removing and installing lower part of sump
    143
  • 1.3 Removing and installing oil pump
    145
  • 1.4 Removing and installing upper part of sump
    147
  • 1.5 Engine oil
    150
  • 2 Engine oil cooler
    151
  • 2.1 Assembly overview - engine oil cooler
    151
  • 2.2 Removing and installing engine oil cooler
    151
  • 3 Crankcase breather
    153
  • 3.1 Assembly overview - crankcase breather system
    153
  • 3.2 Removing and installing oil separator
    154
  • 4 Oil filter, oil pressure switch
    156
  • 4.1 Assembly overview - oil filter/oil pressure switch
    156
  • 4.2 Removing and installing oil pressure switch F1
    156
  • 4.3 Checking oil pressure
    157
  • 4.4 Removing and installing oil filter housing
    159
  • Cooling
    160
  • 1 Cooling system, coolant
    160
  • 1.1 Coolant hose schematic diagram
    160
  • 1.2 Draining and filling coolant
    162
  • 1.3 Checking cooling system for leaks
    166
  • 2 Coolant pump, regulation of cooling system
    169
  • 2.1 Assembly overview - coolant pump, thermostat
    169
  • 2.2 Assembly overview - coolant temperature sender
    171
  • 2.3 Removing and installing coolant pump
    173
  • 2.4 Removing and installing toothed belt pulley for coolant pump
    176
  • 2.5 Removing and installing thermostat
    177
  • 2.6 Removing and installing coolant temperature sender G62
    180
  • 3 Coolant pipes
    183
  • 3.1 Assembly overview - coolant pipes
    183
  • 3.2 Removing and installing coolant pipes
    183
  • 4 Radiator and radiator fan
    186
  • 4.1 Assembly overview - radiator and radiator fan
    186
  • 4.2 Assembly overview - radiator cowl and radiator fan
    187
  • 4.3 Removing and installing radiator
    188
  • 4.4 Removing and installing radiator cowling
    191
  • 4.5 Removing and installing radiator fan
    192
  • Mixture preparation - injection
    193
  • 1 Injection system
    193
  • 1.1 Installation location overview - injection system
    193
  • 1.2 Assembly overview - fuel system
    197
  • 2 Air filter
    199
  • 2.1 Assembly overview - air filter housing
    199
  • 2.2 Removing and installing air filter housing
    199
  • 3 Intake manifold
    201
  • 3.1 Assembly overview - intake manifold
    201
  • 3.2 Removing and installing intake manifold
    202
  • 3.3 Removing and installing throttle valve module GX3
    204
  • 3.4 Cleaning throttle valve module GX3
    205
  • 4 Injectors
    206
  • 4.1 Assembly overview - fuel rail with injectors
    206
  • 4.2 Removing and installing fuel rail
    206
  • 4.3 Removing and installing injectors
    209
  • 4.4 Checking injectors
    209
  • 4.5 Cleaning injectors
    213
  • 5 Senders and sensors
    215
  • 5.1 Removing and installing intake manifold sender GX9
    215
  • 6 Lambda probe
    216
  • 6.1 Assembly overview - Lambda probe
    216
  • 7 Engine control unit
    219
  • 7.1 Removing and installing engine control unit J623
    219
  • 7.2 Removing and installing engine control unit J623 with protective housing
    220
  • Exhaust system
    222
  • 1 Exhaust pipes, silencers
    222
  • 1.1 Assembly overview - silencers
    222
  • 1.2 Removing and installing silencer
    223
  • 1.3 Separating exhaust pipes, silencers
    224
  • 1.4 Aligning exhaust system free of stress
    225
  • 1.5 Checking exhaust system for leaks
    226
  • 2 Emission control
    227
  • 2.1 Assembly overview - emission control
    227
  • 2.2 Removing and installing catalytic converter
    228
  • Ignition system
    230
  • 1 Ignition system
    230
  • 1.1 Assembly overview - ignition system
    230
  • 1.2 Test data, spark plugs
    231
  • 1.3 Removing and installing ignition coils with output stage
    231
  • 1.4 Removing and installing knock sensor
    233
  • 1.5 Removing and installing Hall sender
    234
  • 1.6 Removing and installing engine speed sender G28
    235
Manufacturer's designation 4-cylinder injection engine (1.6 l engine)
Manufacturer Volkswagen
Suitable for Polo (2014) / Polo (Russland) (2015 >)
Suitable car types 6C1, 614
Engine code CWVB
Category Reparaturanleitung

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