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  • Examplepage for repair manual 4-cyl. diesel engine, Mech. (without intermediate shaft)
  • Examplepage for repair manual 2 4-cyl. diesel engine, Mech. (without intermediate shaft)
  • Examplepage for repair manual 3 4-cyl. diesel engine, Mech. (without intermediate shaft)
  • Examplepage for repair manual 4-cyl. diesel engine, Mech. (without intermediate shaft)
  • Examplepage for repair manual 2 4-cyl. diesel engine, Mech. (without intermediate shaft)
  • Examplepage for repair manual 3 4-cyl. diesel engine, Mech. (without intermediate shaft)

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

For Caddy Kasten/Kombi / Polo Classic / Polo Variant

Original Volkswagen repair manual


16,33 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

3.308 KB

196 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Charge air system with turbocharger and Exhaust gas recirculation system: Engine codes AGR, ALH, ASV. Show more
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Repair manual Caddy Kasten/Kombi / Polo Classic / Polo Variant 4-cyl. diesel engine, Mech. 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
    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
Manufacturer's designation 4-cyl. diesel engine, Mech. (without intermediate shaft)
Manufacturer Volkswagen
Suitable for Caddy Kasten/Kombi (1996 - 2003) / Polo Classic / Polo Variant (1996 - 2002)
Suitable car types 9K, 6V
Engine code AGR, ALH, AQM, ASV, AYQ
Category Reparaturanleitung

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