4-Cyl. injection engine (2 valve, roller rocker finger), Mechanics

Kapitelübersicht

• Technical data
  1
• 1 Technical data
  1
• 1.1 Technical data
  1
• 1.2 Engine number
  1
• 1.3 Engine data
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing and installing engine
  3
• 1.2 Notes on removing
  4
• 1.3 Securing engine to assembly stand
  6
• 1.4 Notes on installing
  6
• 1.5 Tightening torques
  8
• 1.6 Assembly mounting
  8
• 1.7 Replacing engine carrier rubber mounting
  10
• 1.8 Additional information and removal instructions for vehicles with air conditioner
  11
• Crankshaft group
  13
• 1 Dismantling and assembling engine
  13
• 1.1 Dismantling and assembling engine
  13
• 1.2 Removing and installing ribbed belt
  21
• 1.3 Checking valve timing
  23
• 1.4 Removing and installing toothed belt
  24
• 1.5 Checking semi-automatic toothed belt tensioning roller
  26
• 2 Removing and installing cylinder block, sealing flange and flywheel
  27
• 2.1 Removing and installing cylinder block, sealing flange and flywheel
  27
• 2.2 Aluminium cylinder block
  28
• 2.3 Renewing crankshaft oil seal -belt pulley end
  31
• 2.4 Renewing crankshaft sealing flange -flywheel end-
  33
• 2.5 Crankshaft dimensions
  42
• 3 Dismantling and assembling pistons and conrods
  43
• 3.1 Dismantling and assembling pistons and conrods
  43
• 3.2 Piston and cylinder dimensions
  48
• Cylinder head, Valve gear
  50
• 1 Removing and installing cylinder head
  50
• 1.1 Removing and installing cylinder head
  50
• 1.2 Removing and installing cylinder head
  55
• 1.3 Checking compression pressures
  59
• 2 Servicing valve gear
  61
• 2.1 Servicing valve gear
  61
• 2.2 Reworking valve seats
  67
• 2.3 Replacing camshaft oil seal
  70
• 2.4 Removing and installing cylinder head cover and camshaft
  72
• 2.5 Checking valve guides
  75
• 2.6 Renewing valve stem seals
  76
• Lubrication
  79
• 1 Removing and installing parts of the lubrication system
  79
• 1.1 Removing and installing parts of the lubrication system
  79
• 1.2 Removing and installing oil sump
  85
• 1.3 Removing and installing oil pump
  87
• 1.4 Checking oil pressure and oil pressure switch
  90
• Cooling system
  93
• 1 Removing and installing parts of cooling system
  93
• 1.1 Removing and installing parts of cooling system
  93
• 1.2 Parts of cooling system body side
  94
• 1.3 Parts of cooling system engine side
  97
• 1.4 Coolant hose connection diagram
  102
• 1.5 Draining and filling cooling system
  103
• 1.6 Removing and installing radiator
  105
• 1.7 Removing and installing coolant pump
  107
• Fuel supply system
  109
• 1 Removing and installing parts of fuel supply system
  109
• 1.1 Removing and installing parts of fuel supply system
  109
• 1.2 Removing and installing fuel tank with its attachments, Polo Classic, Polo Estate
  110
• 1.3 Removing and installing fuel tank with its attachments, Caddy
  115
• 1.4 Safety precautions when working on the fuel supply system
  120
• 1.5 Rules for cleanliness
  120
• 1.6 Crash fuel shut-off
  121
• 1.7 Removing and installing fuel delivery unit
  121
• 1.8 Removing and installing fuel gauge sender
  122
• 1.9 Removing and installing fuel tank
  123
• 1.10 Checking fuel pump
  125
• 2 Electronic power control (EPC)
  131
• 2.1 Electronic power control (EPC)
  131
• 2.2 Function of EPC system
  131
• 2.3 Servicing parts of electronic power control (EPC)
  132
• 2.4 Checking EPC warning lamp
  135
• 2.5 Checking accelerator pedal position sender
  138
• 2.6 Adjusting pedal position sender
  142
• 3 Activated charcoal filter system
  143
• 3.1 Activated charcoal filter system
  143
• 3.2 Function
  143
• 3.3 Servicing parts of the activated charcoal filter system
  144
• 3.4 Checking activated charcoal filter solenoid valve 1
  146
• 3.5 Checking fuel tank breather
  148
• Exhaust system
  151
• 1 Removing and installing parts of exhaust system
  151
• 1.1 Removing and installing parts of exhaust system
  151
• 1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments
  152
• 1.3 Silencer with mountings
  156
• 1.4 Checking catalyst
  162