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  • Examplepage for repair manual 4-cyl. diesel engine, Mechanics
  • Examplepage for repair manual 2 4-cyl. diesel engine, Mechanics
  • Examplepage for repair manual 3 4-cyl. diesel engine, Mechanics

4-cyl. diesel engine, Mechanics

For Caddy Kasten/Kombi / Polo Classic / Polo Variant

Original Volkswagen repair manual


16,04 €7% VAT incl.

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Language: English

Digital PDF file

3.158 KB

192 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 1Y, AEY, AHB, AKW. Show more
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Repair manual Caddy Kasten/Kombi / Polo Classic / Polo Variant 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
  • Removing and installing engine
    3
  • 1 Removing and installing engine
    3
  • 1.1 Removing and installing engine
    3
  • 1.2 Notes on removing
    3
  • 1.3 Notes on installing
    5
  • 1.4 Tightening torques
    7
  • 1.5 Assembly mountings
    7
  • 1.6 Renewing engine carrier rubber mounting
    8
  • 1.7 Additional information and removal instructions for vehicles with air conditioner
    9
  • Crankshaft group
    11
  • 1 Dismantling and assembling engine
    11
  • 1.1 Dismantling and assembling engine
    11
  • 1.2 Removing and installing ribbed belt
    26
  • 1.3 Removing and installing toothed belt
    29
  • 1.4 Checking semi-automatic toothed belt tensioning roller
    35
  • 1.5 Removing single part injection pump sprocket
    36
  • 2 Removing and installing sealing flange and pressure plate/flywheel/drive plate
    37
  • 2.1 Removing and installing sealing flange and pressure plate/flywheel/drive plate
    37
  • 2.2 Renewing crankshaft oil seal - pulley end -
    40
  • 3 Removing and installing crankshaft
    42
  • 3.1 Removing and installing crankshaft
    42
  • 3.2 Crankshaft dimensions
    45
  • 4 Dismantling and assembling pistons and conrods
    46
  • 4.1 Dismantling and assembling pistons and conrods
    46
  • 4.2 Checking piston projection at TDC
    53
  • 4.3 Piston and cylinder dimensions
    54
  • Cylinder head, Valve gear
    55
  • 1 Removing and installing cylinder head
    55
  • 1.1 Removing and installing cylinder head
    55
  • 1.2 Removing and installing cylinder head
    60
  • 1.3 Checking compressions
    62
  • 2 Servicing valve gear
    65
  • 2.1 Servicing valve gear
    65
  • 2.2 Reworking valve seats
    71
  • 2.3 Checking valve guides
    73
  • 2.4 Renewing valve guides
    74
  • 2.5 Renewing valve stem seals
    74
  • 2.6 Removing and installing camshaft
    75
  • 2.7 Checking hydraulic bucket tappets
    77
  • 2.8 Replacing swirl chambers
    77
  • Lubrication
    79
  • 1 Removing and installing parts of the lubrication system
    79
  • 1.1 Removing and installing parts of the lubrication system
    79
  • 1.2 Checking oil pressure and oil pressure switch
    89
  • 1.3 Removing and installing oil sump cap
    90
  • Cooling system
    92
  • 1 Removing and installing parts of cooling system
    92
  • 1.1 Removing and installing parts of cooling system
    92
  • 1.2 Parts of cooling system body side
    93
  • 1.3 Parts of cooling system engine side
    97
  • 1.4 Dismantling and assembling coolant pump
    100
  • 1.5 Draining and filling cooling system
    101
  • 1.6 Removing and installing radiator and radiator fan
    103
  • Fuel supply system
    105
  • 1 Removing and installing parts of fuel supply system
    105
  • 1.1 Removing and installing parts of fuel supply system
    105
  • 1.2 Removing and installing fuel tank with its attachments, Polo Classic, Polo Estate
    106
  • 1.3 Removing and installing fuel tank with its attachments, Caddy
    110
  • 1.4 Servicing fuel filter
    115
  • 1.5 Safety precautions when working on the fuel supply system
    117
  • 1.6 Rules for cleanliness
    117
  • 1.7 Removing and installing fuel tank
    117
  • 1.8 Servicing accelerator mechanism
    119
  • 1.9 Checking accelerator position sender
    124
  • 1.10 Adjusting pedal position sender
    127
  • Charging
    129
  • 1 Charge air system with turbocharger
    129
  • 1.1 Charge air system with turbocharger
    129
  • 1.2 Safety precautions
    129
  • 1.3 Rules for cleanliness
    129
  • 1.4 Removing and installing turbocharger with attachments
    129
  • 1.5 Removing and installing parts of charge air cooling system
    138
  • 1.6 Exhaust gas turbocharger hose/pipe connections
    140
  • 1.7 Removing and installing turbocharger
    142
  • 2 Checking charge pressure system
    146
  • 2.1 Checking charge pressure system
    146
  • 2.2 Checking turbocharger
    146
  • 2.3 Checking pressure unit for charge pressure regulating valve
    148
  • 2.4 Removing and installing pressure unit for charge pressure regulating valve
    148
  • 2.5 Checking charge pressure control
    149
  • Exhaust system
    156
  • 1 Removing and installing parts of exhaust system
    156
  • 1.1 Removing and installing parts of exhaust system
    156
  • 1.2 Front exhaust pipe and catalyst with its attachments
    157
  • 1.3 Exhaust manifold, front exhaust pipe and catalyst with its attachments
    160
  • 1.4 Silencer with mountings Caddy
    162
  • 1.5 Silencer with mountings Polo Classic, Polo Estate
    165
  • 2 Exhaust gas recirculation system, engine codes 1Y, AEY, AHB, AKW
    167
  • 2.1 Exhaust gas recirculation system, engine codes 1Y, AEY, AHB, AKW
    167
  • 2.2 Removing and installing parts of exhaust gas recirculation system
    168
  • 2.3 Checking exhaust gas recirculation valve
    169
  • 2.4 Checking exhaust gas recirculation
    169
  • 2.5 Checking exhaust gas recirculation valve (N18)
    173
  • 3 Exhaust gas recirculation system, engine codes AFN, AHU, ALE
    174
  • 3.1 Exhaust gas recirculation system, engine codes AFN, AHU, ALE
    174
  • 3.2 Removing and installing parts of exhaust gas recirculation system
    175
  • 3.3 Vacuum hose connection diagram
    178
  • 3.4 Checking exhaust gas recirculation valve (mechanical)
    180
  • 3.5 Checking exhaust gas recirculation
    181
Manufacturer's designation 4-cyl. diesel engine, Mechanics
Manufacturer Volkswagen
Suitable for Caddy Kasten/Kombi (1996 - 2003) / Polo Classic / Polo Variant (1996 - 2002)
Suitable car types 9K, 6V
Engine code AFN, AHB, AHU, AKW, ALE
Category Reparaturanleitung

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