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4-cyl. Diesel engine, Mechanics

For Polo

Original Volkswagen repair manual


14,65 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

3.137 KB

173 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Accelerator mechanism: Engine code AEF and Exhaust gas recirculation system: Engine codes AGD, AHG, AKU, ASX. Show more
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Repair manual Polo 4-cyl. Diesel 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
  • 1.4 Engine data
    2
  • 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
    7
  • 1.4 Notes on installing
    7
  • 1.5 Tightening torques
    8
  • 1.6 Assembly mountings
    9
  • Crankshaft group
    11
  • 1 Dismantling and assembling engine
    11
  • 1.1 Dismantling and assembling engine
    11
  • 1.2 Removing and installing ribbed belt
    23
  • 1.3 Checking semi-automatic toothed belt tensioning roller
    24
  • 1.4 Removing single part injection pump sprocket
    25
  • 2 Removing and installing sealing flange and flywheel
    27
  • 2.1 Removing and installing sealing flange and flywheel
    27
  • 2.2 Renewing crankshaft oil seal -pulley end
    31
  • 3 Removing and installing crankshaft
    34
  • 3.1 Removing and installing crankshaft
    34
  • 3.2 Crankshaft dimensions
    37
  • 4 Dismantling and assembling pistons and conrods
    38
  • 4.1 Dismantling and assembling pistons and conrods
    38
  • 4.2 Checking piston projection at TDC
    45
  • 4.3 Piston and cylinder dimensions
    47
  • Cylinder head, Valve gear
    48
  • 1 Removing and installing cylinder head
    48
  • 1.1 Removing and installing cylinder head
    48
  • 1.2 Removing and installing intake pipes
    55
  • 1.3 Removing, installing and tensioning toothed belt
    57
  • 1.4 Removing and installing cylinder head
    67
  • 1.5 Checking compression pressures
    70
  • 2 Servicing valve gear
    74
  • 2.1 Servicing valve gear
    74
  • 2.2 Reworking valve seats
    80
  • 2.3 Checking valve guides
    82
  • 2.4 Renewing valve guides
    84
  • 2.5 Renewing valve stem seals
    85
  • 2.6 Removing and installing camshaft
    88
  • 2.7 Checking hydraulic bucket tappets
    90
  • 2.8 Replacing swirl chambers
    91
  • Lubrication
    93
  • 1 Removing and installing parts of the lubrication system
    93
  • 1.1 Removing and installing parts of the lubrication system
    93
  • 1.2 Checking oil pressure and oil pressure switch
    101
  • Cooling system
    104
  • 1 Removing and installing parts of cooling system
    104
  • 1.1 Removing and installing parts of cooling system
    104
  • 1.2 Parts of cooling system body side
    105
  • 1.3 Parts of cooling system engine side
    108
  • 1.4 Removing and installing coolant pump and compact bracket
    112
  • 1.5 Draining and filling cooling system
    115
  • 1.6 Removing and installing radiator
    117
  • Fuel supply system
    119
  • 1 Removing and installing parts of fuel supply system
    119
  • 1.1 Removing and installing parts of fuel supply system
    119
  • 1.2 Removing and installing fuel tank with its attachments
    120
  • 1.3 Servicing fuel filter
    126
  • 1.4 Safety precautions when working on the fuel supply system
    128
  • 1.5 Rules for cleanliness
    129
  • 1.6 Removing and installing fuel tank
    129
  • 2 Accelerator mechanism: Engine code AEF
    131
  • 2.1 Accelerator mechanism: Engine code AEF
    131
  • 2.2 Servicing accelerator mechanism
    131
  • 3 Accelerator mechanism: > 09.99 (Engine codes AGD, AHG, AKU)
    134
  • 3.1 Accelerator mechanism: > 09.99 (Engine codes AGD, AHG, AKU)
    134
  • 3.2 Servicing accelerator mechanism
    134
  • 3.3 Checking accelerator pedal position sender adjustment
    136
  • 3.4 Checking accelerator pedal position sender
    138
  • 4 Accelerator mechanism: 10.99 > (Engine codes AGD, AKU, ASX)
    142
  • 4.1 Accelerator mechanism: 10.99 > (Engine codes AGD, AKU, ASX)
    142
  • 4.2 Servicing accelerator mechanism
    143
  • 4.3 Checking accelerator pedal position sender
    143
  • 4.4 Accelerator mechanism: 10.99 > (RHD vehicles)
    146
  • 4.5 Servicing accelerator mechanism
    146
  • 4.6 Checking accelerator pedal position sender
    147
  • 4.7 Adjusting pedal position sender
    150
  • 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
    151
  • 1.3 Silencer with mountings
    153
  • 2 Exhaust gas recirculation system: Engine code AEF
    155
  • 2.1 Exhaust gas recirculation system: Engine code AEF
    155
  • 2.2 Removing and installing parts of exhaust gas recirculation system
    156
  • 2.3 Checking exhaust gas recirculation
    157
  • 2.4 Checking exhaust gas recirculation valve (mechanical)
    159
  • 2.5 Checking EGR valve (electrical)
    159
  • 3 Exhaust gas recirculation system: Engine codes AGD, AHG, AKU, ASX
    160
  • 3.1 Exhaust gas recirculation system: Engine codes AGD, AHG, AKU, ASX
    160
  • 3.2 Removing and installing parts of exhaust gas recirculation system
    161
  • 3.3 Connection diagram for vacuum hoses
    163
  • 3.4 Checking exhaust gas recirculation valve (mechanical)
    164
  • 3.5 Checking EGR valve
    165
Manufacturer's designation 4-cyl. Diesel engine, Mechanics
Manufacturer Volkswagen
Suitable for Polo (1995 - 2002)
Suitable car types 6N
Engine code AGD, AHG, AKU, ASX
Category Reparaturanleitung

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