Name: 4-cylinder injection engine (1.6 l engine)
Brand: Volkswagen
SKU: CDGc27eafdf9de0
Price: 19.65 EUR
Availability: InStock

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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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