4-cyl. diesel engine, Mech. (without intermediate shaft)

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
  7
• 1.4 Notes on installing
  8
• 1.5 Tightening torques
  10
• 1.6 Assembly mountings
  10
• 1.7 Renewing bonded rubber bushes on subframe
  12
• 1.8 Additional information and removal instructions for vehicles with air conditioner
  13
• Crankshaft group
  15
• 1 Dismantling and assembling engine
  15
• 1.1 Dismantling and assembling engine
  15
• 1.2 Removing and installing ribbed belt
  25
• 2 Removing and installing sealing flange and pressure plate/flywheel/drive plate
  27
• 2.1 Removing and installing sealing flange and pressure plate/flywheel/drive plate
  27
• 2.2 Renewing crankshaft oil seal -pulley end
  32
• 2.3 Removing and installing front sealing flange
  35
• 3 Removing and installing crankshaft
  38
• 3.1 Removing and installing crankshaft
  38
• 3.2 Crankshaft dimensions
  41
• 4 Dismantling and assembling pistons and conrods
  42
• 4.1 Dismantling and assembling pistons and conrods
  42
• 4.2 Checking piston projection at TDC
  48
• 4.3 Piston and cylinder dimensions
  49
• Cylinder head, Valve gear
  50
• 1 Removing and installing cylinder head
  50
• 1.1 Removing and installing cylinder head
  50
• 1.2 Dismantling and assembling intake manifold
  55
• 1.3 Removing, installing and tensioning toothed belt
  60
• 1.4 Checking semi-automatic toothed belt tensioning roller
  66
• 1.5 Removing and installing cylinder head
  68
• 1.6 Checking compression pressures
  70
• 2 Servicing valve gear
  72
• 2.1 Servicing valve gear
  72
• 2.2 Reworking valve seats
  79
• 2.3 Checking valve guides
  80
• 2.4 Renewing valve guides
  81
• 2.5 Renewing valve stem seals
  82
• 2.6 Removing and installing camshaft
  85
• 2.7 Checking hydraulic bucket tappets
  89
• Lubrication
  91
• 1 Removing and installing parts of the lubrication system
  91
• 1.1 Removing and installing parts of the lubrication system
  91
• 1.2 Removing and installing sump
  102
• 1.3 Checking oil pressure and oil pressure switch
  105
• Cooling system
  107
• 1 Removing and installing parts of cooling system
  107
• 1.1 Removing and installing parts of cooling system
  107
• 1.2 Parts of cooling system body side
  108
• 1.3 Parts of cooling system engine side
  112
• 1.4 Draining and filling cooling system
  115
• 1.5 Removing and installing radiator
  118
• 1.6 Removing and installing coolant pump
  120
• 1.7 Removing and installing thermostat
  122
• Fuel supply system
  124
• 1 Removing and installing parts of fuel supply system
  124
• 1.1 Removing and installing parts of fuel supply system
  124
• 1.2 Removing and installing fuel tank with its attachments, Polo Classic, Polo Estate
  125
• 1.3 Removing and installing fuel tank with its attachments, Caddy
  130
• 1.4 Servicing fuel filter
  136
• 1.5 Safety precautions when working on the fuel supply system
  138
• 1.6 Rules for cleanliness
  139
• 1.7 Removing and installing fuel tank
  139
• 1.8 Servicing accelerator mechanism
  142
• 1.9 Checking accelerator pedal position sender
  144
• 1.10 Adjusting pedal position sender
  147
• Charging
  149
• 1 Charge air system with turbocharger
  149
• 1.1 Charge air system with turbocharger
  149
• 1.2 Safety precautions
  149
• 1.3 Rules for cleanliness
  149
• 1.4 Removing and installing turbocharger with attachments
  149
• 1.5 Removing and installing parts of charge air cooling
  160
• 1.6 Turbocharger hose/pipe connections
  163
• 2 Checking charge pressure system
  164
• 2.1 Checking charge pressure system
  164
• 2.2 Checking pressure unit for charge pressure regulating valve
  164
• 2.3 Removing and installing pressure unit for charge pressure regulating valve
  165
• 2.4 Checking charge pressure control
  166
• Exhaust system
  173
• 1 Removing and installing parts of exhaust system
  173
• 1.1 Removing and installing parts of exhaust system
  173
• 2 Exhaust gas recirculation system: Engine codes AGR, ALH, ASV
  177
• 2.1 Exhaust gas recirculation system: Engine codes AGR, ALH, ASV
  177
• 2.2 Removing and installing parts of exhaust gas recirculation system
  178
• 2.3 Vacuum hose connection diagram
  180
• 2.4 Checking exhaust gas recirculation valve (mechanical)
  180
• 2.5 Checking exhaust gas recirculation
  182
• 2.6 Checking EGR valve
  184
• 3 Exhaust gas recirculation system: Engine codes AGP, AQM, AYQ
  186
• 3.1 Exhaust gas recirculation system: Engine codes AGP, AQM, AYQ
  186
• 3.2 Removing and installing parts of exhaust gas recirculation system
  187
• 3.3 Vacuum hose connection diagram
  188
• 3.4 Checking exhaust gas recirculation valve (mechanical)
  189
• 3.5 Checking EGR valve
  190