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3-Zyl. Dieselmotor

For Polo

Original Volkswagen repair manual


15,82 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

5.307 KB

189 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Sealing flange and flywheel, Crankshaft, Pistons and conrods, Cylinder head, Engine oil, Charge air system with turbocharger, Repairing diesel direct injection system and Exhaust system. Show more
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Repair manual Polo 3-Zyl. Dieselmotor 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
  • Removing and installing engine
    3
  • 1 Removing and installing engine
    3
  • 1.1 Removing engine
    3
  • 1.2 Securing engine to assembly stand
    9
  • 1.3 Notes on installing
    10
  • 1.4 Assembly mountings
    11
  • 1.5 Additional information and assembly work for vehicles with air conditioner
    12
  • Crankshaft group
    13
  • 1 Dismantling and assembling engine
    13
  • 1.1 Assembly overview - toothed belt drive
    13
  • 1.2 Assembly overview - crankcase
    15
  • 1.3 Removing and installing poly V-belt
    16
  • 2 Sealing flange and flywheel
    20
  • 2.2 Assembly overview - sealing flange and flywheel, engine codes BMS, BWB
    22
  • 2.3 Renewing crankshaft oil seal - pulley end
    23
  • 2.4 Removing and installing sealing flange - pulley end
    24
  • 2.5 Renewing crankshaft sealing flange - flywheel end, engine codes BMS, BWB
    27
  • 3 Balancer shaft and retaining frame
    36
  • 3.1 Assembly overview - balancer shaft and retaining frame
    36
  • 3.2 Removing and installing balancer shaft
    38
  • 4 Crankshaft
    43
  • 4.1 Assembly overview - crankshaft
    43
  • 4.2 Crankshaft dimensions
    44
  • 5 Pistons and conrods
    46
  • 5.1 Assembly overview - pistons and conrods
    46
  • 5.2 Separating new conrods
    48
  • 5.3 Checking pistons, piston rings and cylinder bores
    48
  • 5.4 Checking piston projection at TDC
    50
  • 5.5 Piston and cylinder dimensions
    51
  • Cylinder head, valve gear
    52
  • 1 Cylinder head
    52
  • 1.1 Assembly overview - cylinder head
    52
  • 1.2 Removing, installing and tensioning toothed belt
    56
  • 1.3 Removing and installing cylinder head
    66
  • 1.4 Checking compression
    70
  • 2 Valve gear
    73
  • 2.1 Assembly overview - valve gear
    73
  • 2.2 Reworking valve seats
    76
  • 2.3 Checking valve guides
    78
  • 2.4 Renewing valve stem seals
    78
  • 2.5 Removing and installing camshaft
    80
  • 2.6 Removing and installing camshaft oil seal
    84
  • Lubrication
    87
  • 1 Engine oil
    87
  • 1.1 Oil capacities
    87
  • 1.2 Checking engine oil level
    87
  • 2 Parts of lubrication system
    88
  • 2.1 Assembly overview - parts of lubrication system
    88
  • 2.2 Assembly overview - oil filter bracket
    91
  • 2.3 Removing and installing oil sump
    92
  • 2.4 Checking oil pressure and oil pressure switch
    93
  • Cooling
    96
  • 1 Removing and installing parts of cooling system
    96
  • 1.1 Assembly overview - parts of cooling system, body side
    96
  • 1.2 Assembly overview - parts of cooling system, engine side
    98
  • 1.3 Coolant hose schematic diagram
    99
  • 1.4 Draining and filling coolant
    101
  • 1.5 Removing and installing radiator
    105
  • 1.6 Removing and installing coolant pump
    106
  • 1.7 Removing and installing thermostat
    108
  • 1.8 Checking cooling system for leaks
    109
  • 1.9 Checking engine oil cooler for leaks
    111
  • Fuel supply system
    114
  • 1 Removing and installing parts of fuel supply system
    114
  • 1.1 Safety precautions when working on fuel supply system
    115
  • 1.2 Rules for cleanliness
    115
  • 1.3 Assembly overview - fuel tank with attachments
    116
  • 1.4 Removing and installing fuel tank
    118
  • 1.5 Assembly overview - fuel filter
    119
  • 1.6 Removing and installing fuel cooler
    122
  • 1.7 Removing and installing fuel delivery unit
    122
  • 1.8 Removing and installing fuel gauge sender G
    124
  • 1.9 Checking fuel pump
    124
  • 1.10 Assembly overview - accelerator mechanism
    125
  • 1.11 Checking tandem pump
    126
  • 1.12 Removing and installing tandem pump
    130
  • Turbocharging/supercharging
    133
  • 1 Charge air system with turbocharger
    133
  • 1.1 Safety precautions
    133
  • 1.2 Rules for cleanliness
    134
  • 1.3 Installing hose connections with connector couplings
    134
  • 1.4 Hose connections with spring band ring
    135
  • 1.5 Assembly overview - turbocharger
    135
  • 1.6 Removing and installing turbocharger, engine codes BMS, BWB
    140
  • 1.7 Assembly overview - parts of charge air cooling
    142
  • 1.8 Checking charge air system for leaks
    144
  • Mixture preparation - injection
    147
  • 1 Repairing diesel direct injection system
    147
  • 1.1 Safety precautions
    147
  • 1.2 Rules for cleanliness
    148
  • 1.3 Assembly overview - intake manifold with intake manifold flap
    148
  • 1.4 Assembly overview - air filter
    152
  • 1.5 Assembly overview - unit injector
    152
  • 1.6 Removing and installing unit injector
    154
  • 1.7 Adjusting non-contact gap of unit injectors
    156
  • 1.8 Removing and installing O-rings for unit injector
    156
  • 2 Engine control unit
    159
  • 2.1 Removing and installing engine control unit
    159
  • 2.4 Reading and clearing engine control unit event memory
    162
  • 2.5 Adapting functions and components
    163
  • Exhaust system
    165
  • 1 Exhaust system
    165
  • 1.1 Assembly overview - front exhaust pipe with catalytic converter and silencer
    165
  • 1.2 Assembly overview - front exhaust pipe with particulate filter
    167
  • 1.3 Assembly overview - silencer, vehicles with particulate filter
    168
  • 1.4 Removing and installing front exhaust pipe with particulate filter
    169
  • 1.5 Aligning exhaust system free of stress
    170
  • 2 Exhaust gas recirculation system
    173
  • 2.1 Assembly overview - parts of exhaust gas recirculation system, engine code AMF
    173
  • 2.3 Assembly overview - parts of exhaust gas recirculation system, engine codes BMS, BWB
    175
  • 2.6 Vacuum hose assembly
    178
  • Glow plug system
    180
  • 1 Checking glow plug system
    180
  • 1.1 Removing, installing and checking glow plugs
    180
  • 1.2 Characteristics of ceramic glow plugs
    181
  • 1.3 Removing, installing and checking ceramic glow pin plugs
    181
Manufacturer's designation 3-Zyl. Dieselmotor
Manufacturer Volkswagen
Suitable for Polo (2005 - 2007)
Suitable car types 9N4
Engine code AMF
Category Reparaturanleitung

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