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  • Examplepage for repair manual 4-Cyl. injection engine (4 valve), Mechanics
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  • Examplepage for repair manual 4-Cyl. injection engine (4 valve), Mechanics
  • Examplepage for repair manual 2 4-Cyl. injection engine (4 valve), Mechanics
  • Examplepage for repair manual 3 4-Cyl. injection engine (4 valve), Mechanics

4-Cyl. injection engine (4 valve), Mechanics

For Caddy Kasten/Kombi / Polo Classic / Polo Variant

Original Volkswagen repair manual


13,85 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

4.012 KB

162 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Checking electronic power control (EPC) and Activated charcoal filter system. Show more
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Repair manual Caddy Kasten/Kombi / Polo Classic / Polo Variant 4-Cyl. injection engine , Mechanics PDF download has the following content:

Chapter overview

  • 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
    7
  • 1.6 Assembly mountings
    8
  • 1.7 Replacing engine carrier rubber mounting
    9
  • 1.8 Additional information and removal instructions for vehicles with air conditioner
    10
  • Crankshaft group
    12
  • 1 Dismantling and assembling engine
    12
  • 1.1 Dismantling and assembling engine
    12
  • 1.2 Removing and installing ribbed belt
    21
  • 1.3 Checking valve timing
    22
  • 1.4 Removing, installing and tensioning toothed belts
    24
  • 1.5 Checking semi-automatic toothed belt tensioning roller
    30
  • 2 Removing and installing cylinder block, sealing flange and flywheel
    33
  • 2.1 Removing and installing cylinder block, sealing flange and flywheel
    33
  • 2.2 Aluminium cylinder block
    34
  • 2.3 Renewing crankshaft oil seal -belt pulley end-
    37
  • 2.4 Renewing crankshaft sealing flange -flywheel end-
    39
  • 2.5 Crankshaft dimensions
    48
  • 3 Dismantling and assembling pistons and conrods
    49
  • 3.1 Dismantling and assembling pistons and conrods
    49
  • 3.2 Piston and cylinder dimensions
    55
  • Cylinder head, Valve gear
    56
  • 1 Removing and installing cylinder head
    56
  • 1.1 Removing and installing cylinder head
    56
  • 1.2 Removing and installing camshaft housing
    60
  • 1.3 Removing and installing cylinder head
    63
  • 1.4 Checking compression pressures
    67
  • 2 Servicing valve gear
    69
  • 2.1 Servicing valve gear
    69
  • 2.2 Reworking valve seats
    77
  • 2.3 Replacing camshaft oil seals
    79
  • 2.4 Checking valve guides
    81
  • 2.5 Renewing valve guides
    81
  • 2.6 Renewing valve stem seals
    82
  • Lubrication
    85
  • 1 Removing and installing parts of the lubrication system
    85
  • 1.1 Removing and installing parts of the lubrication system
    85
  • 1.2 Removing and installing oil sump
    90
  • 1.3 Removing and installing oil pump
    92
  • 1.4 Checking oil pressure and oil pressure switch
    95
  • Cooling system
    97
  • 1 Removing and installing parts of cooling system
    97
  • 1.1 Removing and installing parts of cooling system
    97
  • 1.2 Parts of cooling system body side
    98
  • 1.3 Parts of cooling system engine side
    101
  • 1.4 Coolant hose connection diagram
    106
  • 1.5 Draining and filling cooling system
    107
  • 1.6 Removing and installing radiator
    109
  • 1.7 Removing and installing coolant pump
    111
  • Fuel supply system
    113
  • 1 Removing and installing parts of fuel supply system
    113
  • 1.1 Removing and installing parts of fuel supply system
    113
  • 1.2 Removing and installing fuel tank with its attachments, Polo Classic, Polo Estate
    114
  • 1.3 Removing and installing fuel tank with its attachments, Caddy
    119
  • 1.4 Safety precautions when working on the fuel supply system
    124
  • 1.5 Rules for cleanliness
    124
  • 1.6 Removing and installing fuel delivery unit
    125
  • 1.7 Removing and installing fuel gauge sender
    126
  • 1.8 Removing and installing fuel tank
    126
  • 1.9 Crash fuel shut-off
    128
  • 1.10 Checking fuel pump
    129
  • 2 Checking electronic power control (EPC)
    136
  • 2.1 Checking electronic power control (EPC)
    136
  • 2.2 Function of EPC system
    138
  • 2.3 Checking accelerator pedal position sender
    139
  • 3 Activated charcoal filter system
    142
  • 3.1 Activated charcoal filter system
    142
  • 3.2 Function
    142
  • 3.3 Servicing parts of the activated charcoal filter system
    143
  • 3.4 Checking fuel tank breather
    145
  • Exhaust system
    147
  • 1 Removing and installing parts of exhaust system
    147
  • 1.1 Removing and installing parts of exhaust system
    147
  • 1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments
    148
  • 1.3 Silencer with mountings
    151
  • 2 Exhaust gas recirculation system
    153
  • 2.1 Exhaust gas recirculation system
    153
  • 2.2 Servicing parts of exhaust gas recirculation system
    154
  • 2.3 Checking potentiometer for exhaust gas recirculation (G212)
    156
Manufacturer's designation 4-Cyl. injection engine (4 valve), Mechanics
Manufacturer Volkswagen
Suitable for Caddy Kasten/Kombi (1996 - 2003) / Polo Classic / Polo Variant (1996 - 2002)
Suitable car types 9K, 6V
Engine code AUA
Category Reparaturanleitung

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