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  • Examplepage for repair manual 4-cylinder injection engine (1.6 l engine, BiFuel) Volkswagen R GmbH
  • Examplepage for repair manual 2 4-cylinder injection engine (1.6 l engine, BiFuel) Volkswagen R GmbH
  • Examplepage for repair manual 3 4-cylinder injection engine (1.6 l engine, BiFuel) Volkswagen R GmbH
  • Examplepage for repair manual 4-cylinder injection engine (1.6 l engine, BiFuel) Volkswagen R GmbH
  • Examplepage for repair manual 2 4-cylinder injection engine (1.6 l engine, BiFuel) Volkswagen R GmbH
  • Examplepage for repair manual 3 4-cylinder injection engine (1.6 l engine, BiFuel) Volkswagen R GmbH

4-cylinder injection engine (1.6 l engine, BiFuel) Volkswagen R GmbH

For Polo A05

Original Volkswagen repair manual


17,50 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

7.075 KB

212 Sites

Detailed technical data

Immediately readable

This repair manual contains: Read event memory, Removing and installing engine, Crankshaft, 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 A05 4-cylinder injection engine Volkswagen R GmbH 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
  • Self-diagnosis
    2
  • 1 Read event memory
    2
  • Removing and installing engine
    3
  • 1 Removing and installing engine
    3
  • 1.1 Removing
    4
  • 1.2 Installing
    7
  • 1.3 Specified torques
    8
  • 1.4 Additional information 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 Assembly overview - part I, belt drive
    13
  • 1.3 Assembly overview - part II, chain drive system
    14
  • 1.4 Removing and installing poly-V belt
    16
  • 1.5 Removing and installing valve timing housing (timing case)
    17
  • 1.6 Removing and installing bracket for ancillaries
    22
  • 2 Cylinder block, sealing flange
    24
  • 2.1 Assembly overview
    24
  • 2.2 Removing and installing engine speed sender G28
    25
  • 2.3 Renewing crankshaft oil seal, pulley end
    26
  • 2.4 Removing and installing crankshaft pulley
    28
  • 2.5 Renewing crankshaft sealing flange, flywheel end
    31
  • 3 Crankshaft
    40
  • 3.1 Assembly overview
    40
  • 3.2 Crankshaft dimensions
    41
  • 4 Pistons and conrods
    42
  • 4.1 Assembly overview
    42
  • 4.2 Checking piston
    43
  • 4.3 Checking cylinder bores
    44
  • 4.4 Piston and cylinder dimensions
    44
  • Cylinder head, valve gear
    45
  • 1 Cylinder head
    45
  • 1.1 Engine differences
    45
  • 1.2 Assembly overview - cylinder head
    46
  • 1.3 Checking valve timing
    50
  • 1.4 Adjusting valve timing
    55
  • 1.5 Removing and installing timing chain and chain drive for oil pump
    65
  • 1.6 Removing and installing camshaft housing
    72
  • 1.7 Removing and installing cylinder head
    78
  • 1.8 Checking compression
    83
  • 2 Valve gear
    85
  • 2.1 Assembly overview
    85
  • 2.2 Checking camshaft axial clearance
    87
  • 2.3 Reworking valve seats
    87
  • 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
    94
  • 1.4 Removing and installing oil pump
    96
  • 1.5 Checking oil pressure and oil pressure switch
    98
  • Cooling
    101
  • 1 Parts of cooling system
    101
  • 1.1 Assembly overview - parts of cooling system, body side
    101
  • 1.2 Assembly overview - parts of cooling system, engine side
    103
  • 1.3 Coolant hose connection diagram
    106
  • 1.4 Draining and adding coolant
    107
  • 1.5 Checking cooling system for leaks
    110
  • 1.6 Removing and installing cowling with radiator fan V7
    112
  • 1.7 Removing and installing radiator fan V7
    113
  • 1.8 Removing and installing radiator
    114
  • 1.9 Removing and installing coolant pump
    116
  • Fuel supply system
    120
  • 1 Parts of fuel supply system
    120
  • 1.1 Assembly overview - fuel tank with attachments
    120
  • 1.2 Safety regulations for working on fuel supply
    123
  • 1.3 Rules for cleanliness
    123
  • 1.4 Emptying fuel tank
    124
  • 1.5 Removing and installing fuel delivery unit
    128
  • 1.6 Removing and installing external fuel gauge sender G with 2 cable connections
    131
  • 1.7 Removing and installing interior fuel gauge sender G
    132
  • 1.8 Removing and installing fuel tank
    133
  • 1.9 Removing and installing fuel filter
    135
  • 1.10 Crash fuel shut-off
    136
  • 1.11 Checking fuel pump
    136
  • 1.12 Bleeding fuel system
    146
  • 1.13 Parts of fuel supply system (LPG)
    148
  • 2 Electronic power control (EPC)
    164
  • 2.1 Assembly overview
    164
  • 3 Activated charcoal filter system
    165
  • 3.1 Assembly overview
    165
  • 3.2 Checking fuel tank breather
    166
  • Mixture preparation - injection
    167
  • 1 Injection system
    167
  • 1.1 General notes on injection
    167
  • 1.2 Assembly overview - intake manifold
    167
  • 1.3 Assembly overview - fuel rail with injectors
    169
  • 1.4 Removing and installing injectors
    169
  • 1.5 Fuel rail, removing and installing gas rail
    170
  • 1.6 Removing and installing gas injectors
    171
  • 1.7 Removing and installing gas rail sensor G401
    172
  • 1.8 Assembly overview - air filter
    173
  • 1.9 Removing and installing air filter housing
    174
  • 1.10 Cleaning throttle valve module J338
    175
  • 1.11 Safety precautions
    176
  • 1.12 Rules for cleanliness
    177
  • 1.13 Technical data
    177
  • 1.14 Renewing filter for LPG system
    177
  • 2 Checking components
    190
  • 2.1 Checking injectors for leaks and quantity injected
    190
  • 3 Engine control unit J623
    193
  • 3.1 Removing and installing engine (motor) control unit J623
    193
  • 3.2 Vehicles with anti-theft secured engine control unit J623
    193
  • 4 Gas mode control unit J659
    195
  • 4.1 Removing and installing gas mode control unit J659
    195
  • 4.2 Removing holder for gas mode control unit J659
    195
  • Exhaust system
    197
  • 1 Parts of the exhaust system
    197
  • 1.1 Assembly overview - catalytic converters and attachments
    197
  • 1.2 Assembly overview - silencers with mountings, hatchback
    199
  • 1.3 Separating front and rear silencers
    199
  • Ignition system
    202
  • 1 Ignition system
    202
  • 1.1 Assembly overview - ignition system
    202
  • 1.2 Removing and installing ignition coils with output stage
    203
  • 1.3 Safety precautions
    205
  • 1.4 Test data, spark plugs
    206
Manufacturer's designation 4-cylinder injection engine (1.6 l engine, BiFuel) Volkswagen R GmbH
Manufacturer Volkswagen
Suitable for Polo A05 (2010)
Suitable car types 6R1
Engine code CNKA
Category Reparaturanleitung

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