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

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