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4 - Cyl. injection engine (1.6 l)

For Gol V / Sedan / Saveiro

Original Volkswagen repair manual


14,95 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

5.138 KB

177 Sites

Detailed technical data

Immediately readable

This repair manual contains: Engine - remove and install, Crankshaft and flywheel flanges - assembly overview, Lubrication system components, Engine power electronic adjustment (electronic accelerator) - check, Activated charcoal filter system and READINESS code. Show more
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Repair manual Gol V / Sedan / Saveiro 4 - Cyl. injection engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical Data
    1
  • 1.1 Engine number
    1
  • 1.2 Engine characteristics
    1
  • Removing and installing engine
    3
  • 1 Engine - remove and install
    3
  • 1.1 Removal - recommendations
    6
  • 1.2 Engine - fasten to assembly stand
    11
  • 1.3 Installation notes
    11
  • 1.4 Tightening torques
    12
  • 1.5 Engine and gearbox support set - align
    13
  • 1.6 Power-drive unit supports
    14
  • 1.7 Additional notes and installation works in vehicles with air conditioning
    15
  • Crankshaft group
    17
  • 1 Engine - assembly and disassembly
    17
  • 1.1 Seal lid - replace
    21
  • 1.2 Poly-V belt (elastic) - remove and install
    21
  • 2 Crankshaft and flywheel flanges - assembly overview
    25
  • 2.1 Flywheel - remove and install
    26
  • 2.2 Crankshaft seal (pulley side) - replace
    27
  • 2.3 Crankshaft flange (flywheel side) with Engine speed sensor G28 rotor - replace
    29
  • 3 Crankshaft - remove and install
    39
  • 3.1 Identifying engine bearing shells
    40
  • 3.2 Colour codes
    40
  • 3.3 Crankshaft - dimensions
    40
  • 4 Pistons and connecting rods - removal and installation
    42
  • 4.1 Piston and cylinder - dimensions
    45
  • Cylinder head, valve gear
    47
  • 1 Cylinder head - assembly and disassembly
    47
  • 1.1 Toothed belt semi-automatic tensioning pulley - check
    50
  • 1.2 Toothed belt - remove and install, adjust
    51
  • 1.3 Cylinder head - remove and install
    56
  • 1.4 Compression - check
    62
  • 2 Camshaft - assembly overview
    66
  • 2.1 Camshaft - check axial clearance
    69
  • 2.2 Valve seat - trim
    70
  • 2.3 Camshaft seal - replace
    72
  • 2.4 Camshaft and cylinder head cover - removal and installation
    75
  • 2.5 Valve guides - check
    78
  • 2.6 Valve stem sealant - replace
    79
  • Lubrication
    83
  • 1 Lubrication system components
    83
  • 1.1 Lubricating system components - assembly overview
    83
  • 1.2 Engine oil
    85
  • 1.3 Crankcase - remove and install
    86
  • 1.4 Oil filter - replace
    88
  • 1.5 Oil pump - remove and install
    90
  • 1.6 Oil pressure switch F1 - remove and install
    93
  • 1.7 Oil pressure and Oil pressure switch F1 - check
    94
  • Cooling
    97
  • 1 Cooling system components - remove and install
    97
  • 1.1 Cooling system components on the body side - assembly overview
    97
  • 1.2 Cooling system components on the engine side - assembly overview
    99
  • 1.3 Hose connection diagram for cooling system
    102
  • 1.4 Cooling system - drainage and replenishment
    103
  • 1.5 Cooling system - check air-tightness
    109
  • 1.6 Radiator - remove and install
    111
  • 1.7 Water pump - remove and install
    113
  • Fuel supply system
    116
  • 1 Fuel supply system components - removal and installation
    116
  • 1.1 Fuel tank components with accessories and fuel filter - removal and installation
    116
  • 1.2 Safety measures regarding work on the fuel supply systems
    119
  • 1.3 Cleaning rules
    120
  • 1.4 Cold start system components - remove and install
    120
  • 1.5 Fuel pump (pre-supply pump) G6 - remove and install
    122
  • 1.6 Fuel gauge sensor G - remove and install
    124
  • 1.7 Fuel reservoir - remove and install
    124
  • 1.8 Fuel pump (pre-supply pump) G6 - check
    126
  • 2 Engine power electronic adjustment (electronic accelerator) - check
    135
  • 2.1 Electronic accelerator system operation
    135
  • 3 Activated charcoal filter system
    137
  • 3.1 Operation
    137
  • 3.2 Activated charcoal filter system components - repair
    137
  • 3.3 Fuel tank ventilation - check
    138
  • Mixture preparation - injection
    140
  • 1 Injection system - repair
    140
  • 1.1 General instructions regarding the injection system
    140
  • 1.2 Component location
    140
  • 1.3 Injection components - remove and install
    143
  • 1.4 Intake manifold - remove and install
    146
  • 1.5 Fuel distributor with injectors - removal and installation
    147
  • 1.6 Air filter - disassembly and assembly
    147
  • 1.7 Air filter - remove and install
    148
  • 1.8 Safety measures
    149
  • 1.9 Cleaning rules
    150
  • 1.10 Technical Data
    150
  • 2 Component checks
    152
  • 2.1 Injection valves - check
    152
  • 2.2 Residual pressure and fuel pressure regulator - check
    154
  • 3 READINESS code
    159
  • 3.1 Creating and Interpreting the READINESS code
    159
  • 4 Engine control unit J623
    160
  • 4.1 Engine control unit J623 - remove and install
    160
  • 4.2 Adjust components
    161
  • 4.3 Event memory in Engine control unit J623 - reference and erase
    161
  • Exhaust system
    164
  • 1 Exhaust system components - remove and install
    164
  • 1.2 Rear muffler with supports
    166
  • Glow plug system
    168
  • 1 Ignition system: repair
    168
  • 1.1 General instructions regarding the ignition system
    168
  • 1.2 Ignition system components - remove and install
    168
  • 1.3 Safety measures
    170
  • 1.4 Test data, spark plugs
    170
Manufacturer's designation 4 - Cyl. injection engine (1.6 l)
Manufacturer Volkswagen
Suitable for Gol V (2009) / Sedan (2009) / Saveiro (2010)
Suitable car types 5U1, 5U8, 5U9
Engine code CFZA
Category Reparaturanleitung

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